CA3229456A1 - Reservoir for a refilling device, device and method for refilling an article of an aerosol provision system, nozzle for fluid dispensing, and refillable article for an electronic aerosol provision syste - Google Patents

Abstract

A reservoir for use in a refilling device comprises: a fluid storage volume bounded by one or more side walls and an end wall; an outlet orifice in or near the end wall, configured to form, or engage with, a fluid conduit engagable with an inlet orifice of an article of an aerosol provision system to provide a fluid flow path from the fluid storage volume to a storage area in the article when the reservoir and the article are installed in the refilling device; and a moveable wall disposed opposite to the end wall to close the fluid storage volume, the movable wall configured to slide towards the end wall, and engagable with a pushing element of the refilling device operable to push the moveable wall towards the end wall in order to reduce a capacity of the fluid storage volume such that fluid in the fluid storage volume is moved through the outlet orifice to the fluid flow path in order to fill the storage area of the article.

Description

RESERVOIR FOR A REFILLING DEVICE, DEVICE AND METHOD FOR REFILLING AN
ARTICLE OF AN AEROSOL PROVISION SYSTEM, NOZZLE FOR FLUID DISPENSING, AND REFILLABLE ARTICLE FOR AN ELECTRONIC AEROSOL PROVISION SYSTEM
Technical Field The present disclosure relates to a reservoir for a refilling device, a device and method for refilling an article of an aerosol provision system, a nozzle for fluid dispensing, and a refillable article for an electronic aerosol provision system.
Background Electronic aerosol provision systems, which are often configured as so-called electronic cigarettes, can have a unitary format with all elements of the system in a common housing, or a multi-component format in which elements are distributed between two or more housings which can be coupled together to form the system. A common example of the latter format is a two-component system comprising a device and an article. The device typically contains an electrical power source for the system, such as a battery, and control electronics for operating elements in order to generate aerosol. The article, also referred to by terms including cartridge, cartomiser, consumable and clearomiser, typically contains a storage volume or area for holding a supply of aerosolisable material from which the aerosol is generated, plus an aerosol generator such as a heater operable to vaporise the aerosolisable material. A similar three-component system may include a separate mouthpiece that attaches to the article. In many designs, the article is designed to be disposable, in that it is intended to be detached from the device and thrown away when the aerosolisable material has been consumed. The user obtains a new article which has been prefilled with aerosolisable material by a manufacturer and attaches it to the device for use.
The device, in contrast, is intended to be used with multiple consecutive articles, with a capability to recharge the battery to allow prolonged operation.
While disposable articles, which may be called consumables, are convenient for the user, they may be considered wasteful of natural resources and hence detrimental to the environment. An alternative design of article is therefore known which is configured to be refilled with aerosolisable material by the user. This reduces waste, and can reduce the cost of electronic cigarette usage for the user. The aerosolisable material may be provided in a bottle, for example, from which the user squeezes or drips a quantity of material into the article via a refilling orifice on the article. However, the act of refilling can be awkward and inconvenient, since the items are small and the volume of material involved is typically low.
Alignment of the juncture between bottle and article can be difficult, with inaccuracies leading to spillage of the material. This is not only wasteful, but may also be dangerous.
Aerosolisable material frequently contains liquid nicotine, which can be poisonous if it makes contact with the skin.

Therefore, refilling units or devices have been proposed, which are configured to receive a bottle or other reservoir of aerosolisable material plus a refillable cartridge, and to automate the transfer of the material from the former to the latter.
Alternative, improved or enhanced features and designs for such refilling devices are therefore of interest.
Summary According to a first aspect of some embodiments described herein, there is provided a reservoir for use in a refilling device, the reservoir comprising: a fluid storage volume bounded by one or more side walls and an end wall; an outlet orifice in or near the end wall, configured to form, or engage with, a fluid conduit engagable with an inlet orifice of an article of an aerosol provision system to provide a fluid flow path from the fluid storage volume to a storage area in the article when the reservoir and the article are installed in the refilling device; and a moveable wall disposed opposite to the end wall to close the fluid storage volume, the movable wall configured to slide towards the end wall, and engagable with a pushing element of the refilling device operable to push the moveable wall towards the end wall in order to reduce a capacity of the fluid storage volume such that fluid in the fluid storage volume is moved through the outlet orifice to the fluid flow path in order to fill the storage area of the article.
According to a second aspect of some embodiments described herein, there is provided a refilling device configured for refilling of an article of an aerosol provision system received in the refilling device with aerosol generating material from a reservoir, the refilling device comprising a reservoir according to the first aspect.
According to a third aspect of some embodiments described herein, there is provided a method of refilling a storage area with fluid, the method comprising:
dispensing fluid from a reservoir according to the first aspect into the storage area.
According to a fourth aspect of some embodiments described herein, there is provided a refilling device for refilling an article from a reservoir, comprising: a reservoir interface for receiving a reservoir containing fluid, the reservoir having a moveable wall configured to be inwardly pushable to reduce a capacity of the reservoir and move fluid in the reservoir out of an outlet orifice of the reservoir; an article interface for receiving an article of an aerosol provision system having a storage area for fluid, such that a fluid flow path is formed between the outlet orifice of the reservoir and the storage area of the article; a motor; a plunger configured to be driven by the motor to provide linear movement comprising advancement of the plunger from a retracted position to engage with and inwardly push the moveable wall of a received reservoir, and retraction of the plunger away from the moveable wall; and a controller configured to control the motor to drive the plunger.
According to a fifth aspect of some embodiments described herein, there is provided a method of refilling an article from a reservoir, comprising: forming a fluid flow path between

2 an outlet orifice of the reservoir and an inlet orifice of the article, wherein the reservoir has a moveable wall configured to be inwardly pushable to reduce a capacity of the reservoir and move fluid out of the outlet orifice, and the article is an article of a vapour provision system having a storage area in fluid communication with the inlet orifice; and controlling a motor-driven plunger to inwardly push the moveable wall of the reservoir to move fluid out of the outlet orifice, along the fluid flow path and into the inlet orifice in order to fill the storage area of the article with fluid from the reservoir.
According to a sixth aspect of some embodiments described herein, there is provided a kit comprising: a refilling device according to the fourth aspect; and an aerosol provision system comprising an article having a storage area for aerosol generating material and a device to which the article can be coupled to form the aerosol provision system, wherein the article is configured to be received in the article interface of the refilling device.
According to a seventh aspect of some embodiments described herein, there is provided a nozzle for dispensing fluid, comprising: a tubular outer wall extending between a proximal end and a distal end and surrounding a nozzle volume; an inner wall dividing the nozzle volume into a fluid channel for the flow of fluid from the proximal end to the distal end, and a venting channel for the flow of air from the distal end towards the proximal end; the inner wall and the outer wall configured such that, at the distal end, the fluid channel extends beyond the venting channel.
According to a eighth aspect of some embodiments described herein, there is provided a reservoir for storing fluid, the reservoir comprising a nozzle according to the seventh aspect for dispensing fluid from the reservoir.
According to a ninth aspect of some embodiments described herein, there is provided a refilling device configured for refilling an article of an aerosol provision system received in the refilling device with aerosol-generating material from a reservoir, the refilling device comprising a reservoir according to the eighth aspect.
According to a tenth aspect of some embodiments described herein, there is provided a nozzle for dispensing fluid, comprising: a tubular inner wall defining a fluid channel for the flow of fluid from a first end to a second end of the nozzle;
and a tubular outer wall surrounding the inner wall and defining a venting channel for the flow of air from the second end towards the first end of the nozzle, the venting channel defined by an inner surface of the outer wall and an outer surface of the inner wall; wherein the inner wall is eccentrically located within the outer wall.
According to a eleventh aspect of some embodiments described herein, there is provided a reservoir for storing fluid, the reservoir comprising a nozzle according to the tenth aspect for dispensing fluid from the reservoir. The reservoir may further comprise aerosol-generating material stored in the reservoir.

3 According to a twelfth aspect of some embodiments described herein, there is provided a refilling device configured for refilling an article of an aerosol provision system received in the refilling device with aerosol-generating material from a reservoir, the refilling device comprising a reservoir according to the eleventh aspect.
According to a thirteenth aspect of some embodiments described herein, there is provided a method of refilling a storage area with fluid, the method comprising: using a nozzle according to the seventh aspect or the tenth aspect to transfer fluid from a reservoir into the storage area.
According to a fourteenth aspect of some embodiments described herein, there is provided an article for an aerosol provision system, comprising: an outer housing comprising one or more walls including an inlet wall; a storage area for aerosol-generating material defined within the outer housing; an inlet orifice in fluid communication with an interior of the storage area by which aerosol-generating material can be added into the storage area; and a valve closing the inlet orifice; wherein the inlet orifice is located in the inlet wall of the outer housing and the valve is integrally formed with inlet orifice and the inlet wall.
According to a fifteenth aspect of some embodiments described herein, there is provided an aerosol provision system comprising an article according to the fourteenth aspect.
According to a sixteenth aspect of some embodiments described herein, there is provided a wall for an article for an aerosol provision system, the wall configured to define at least part of an outer housing of the article, and comprising: an inlet orifice by which aerosol-generating material can be added into a storage area of the article; and a valve closing the inlet orifice; wherein the wall, the inlet orifice and the valve are integrally formed.
These and further aspects of the certain embodiments are set out in the appended independent and dependent claims. It will be appreciated that features of the dependent claims may be combined with each other and features of the independent claims in combinations other than those explicitly set out in the claims. Furthermore, the approach described herein is not restricted to specific embodiments such as set out below, but includes and contemplates any appropriate combinations of features presented herein. For example, a reservoir, a refilling device, or related methods, may be provided in accordance with approaches described herein which includes any one or more of the various features described below as appropriate.
Brief Description of the Drawings Various embodiments of the invention will now be described in detail by way of example only with reference to the following drawings in which:
Figure 1 shows a simplified schematic cross-section through an example electronic aerosol provision system to which embodiments of the present disclosure are applicable;

4 Figure 2 shows a simplified schematic representation of a refilling device in which embodiments of the present disclosure can be implemented;
Figure 3 shows a simplified schematic cross-sectional view of a reservoir refilling an article of an aerosol provision system according to examples of the disclosure;
Figure 4 shows a schematic cross-sectional view of an example reservoir according to a first-described invention of the disclosure, and for use in a refilling device according to an example of a second-described invention of the disclosure;
Figure 4A shows a schematic cross-sectional partial view of another example reservoir according to a first-described invention of the disclosure having a different sealing arrangement than the Figure 4 example;
Figures 5A and 5B respectively show schematic views of a refilling device in which a reservoir according to an example of a first-described invention of the disclosure is installed, prior to and after the refilling of an article from the reservoir, also being a further example refilling device according to a second-described invention of the disclosure, prior to and after the refilling of an article from a reservoir when both are installed in the refilling device;
Figure 6 shows a schematic cross-sectional view of a further example reservoir according to a first-described invention of the disclosure, additionally comprising a socket for an article to be refilled;
Figure 7 shows a schematic cross-sectional view of the example reservoir of Figure 6 with an article inserted into the socket;
Figure 8 shows a schematic cross-sectional view of a first example of an end wall and outlet orifice nozzle for a reservoir, according to a first-described invention of the disclosure the disclosure;
Figure 9 shows a schematic cross-sectional view of a second example of an end wall and outlet orifice nozzle for a reservoir, according to a first-described invention of the disclosure Figures 10A, 10B and 10C show simplified schematic representations of a first example motor-driven plunger fluid transfer mechanism suitable for use in a refilling device according to a second-described invention of the present disclosure, for different positions of the plunger;
Figure 11 shows a simplified schematic representations of a second example motor-driven plunger fluid transfer mechanism suitable for use in a refilling device according to a second-described invention of the present disclosure;
Figure 12 shows a simplified schematic side view of an example article interface suitable for use in a refilling device according to a second-described invention of the present disclosure;

5 Figure 13 shows a simplified schematic front view of an example refilling device according to a second-described invention of the present disclosure;
Figure 14 shows a flow chart of steps in a first example method for refilling an article from a reservoir according to a second-described invention of the present disclosure;
Figure 15 shows a flow chart of steps in a second example method for refilling an article from a reservoir according to a second-described invention of the present disclosure;
Figure 16 shows a flow chart of steps in a third example method for refilling an article from a reservoir according to a second-described invention of the present disclosure;
Figures 17A and 17B respectively show simplified longitudinal and transverse cross-sectional views of a first example nozzle according to a third-described invention of the present disclosure;
Figures 18A and 18B respectively show simplified longitudinal and transverse cross-sectional views of a second example nozzle according to a third-described invention of the present disclosure;
Figure 19 shows a simplified transverse cross-sectional view of a third example nozzle according to a third-described invention of the present disclosure;
Figure 20 shows a simplified transverse cross-sectional view of a fourth example nozzle according to a third-described invention of the present disclosure;
Figures 21A and 21B show simplified transverse cross-sectional views of a fifth and sixth example nozzles according to a third-described invention of the present disclosure;
Figure 22 shows a bar chart of experimental measurements of pressures measured during refilling of an article using a nozzle according to an example of a third-described invention of the disclosure;
Figure 23 shows a scatter graph of experimental measurements of pressures measured during refilling of an article using a nozzle according to an example of a third-described invention of the disclosure.
Figure 24 shows a simplified schematic cross-sectional view of a first example article according to a further-described invention of the present disclosure;
Figures 25A and 25B respectively show simplified schematic cross-sectional views of a second example article according to a fourth-described invention of the present disclosure, immediately prior to refilling with a refilling device, and during refilling with a refilling device;
Figure 26 shows a simplified schematic cross-sectional view of a third example article according to a fourth-described invention of the present disclosure;
Figure 27 shows a simplified schematic cross-sectional view of a fourth example article according to a fourth-described invention of the present disclosure;
Figure 28 shows a photographic image of an example refilling inlet wall for an article according to a fourth-described invention of the present disclosure;

6 Figure 29 shows a perspective external view of a partial outer housing of an example article having a location feature according to a fourth-described invention of the present disclosure; and Figure 30 shows a transverse cross-sectional view of an example outer housing for an article have location features according to a fourth-described invention of the present disclosure.
Detailed Description Aspects and features of certain examples and embodiments are discussed /
described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed / described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.
As described above, the present disclosure relates to (but is not limited to) electronic aerosol or vapour provision systems, such as e-cigarettes. Throughout the following description the terms "e-cigarette" and "electronic cigarette" may sometimes be used;
however, it will be appreciated these terms may be used interchangeably with aerosol (vapour) provision system or device. The systems are intended to generate an inhalable aerosol by vaporisation of a substrate (aerosol-generating material) in the form of a liquid or gel which may or may not contain nicotine. Additionally, hybrid systems may comprise a liquid or gel substrate plus a solid substrate which is also heated. The solid substrate may be for example tobacco or other non-tobacco products, which may or may not contain nicotine.
The terms "aerosol-generating material" and "aerosolisable material" as used herein are intended to refer to materials which can form an aerosol, either through the application of heat or some other means. The term "aerosol" may be used interchangeably with "vapour".
As used herein, the terms "system" and "delivery system" are intended to encompass systems that deliver a substance to a user, and include non-combustible aerosol provision systems that release compounds from an aerosolisable material without combusting the aerosolisable material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolisable materials, and articles comprising aerosolisable material and configured to be used within one of these non-combustible aerosol provision systems. According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery to a user. In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an

7 electronic cigarette, also known as a vaping device or electronic nicotine delivery (END) system, although it is noted that the presence of nicotine in the aerosol generating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosolisable materials, one or a plurality of which may be heated. Each of the aerosolisable materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and an article (consumable) for use with the non-combustible aerosol provision device. However, it is envisaged that articles which themselves comprise a means for powering an aerosol generator or aerosol generating component may themselves form the non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision device may comprise a power source and a controller. The power source may, for example, be an electric power source. In some embodiments, the article for use with the non-combustible aerosol provision device may comprise an aerosol generating material, an aerosol generating component (aerosol generator), an aerosol generating area, a mouthpiece, and/or an area for receiving and holding aerosol generating material.
In some systems the aerosol generating component or aerosol generator comprises a heater capable of interacting with the aerosolisable material so as to release one or more volatiles from the aerosolisable material to form an aerosol. However, the disclosure is not limited in this regard, and applies also to systems that use other approaches to form aerosol, such as a vibrating mesh.
In some embodiments, the article for use with the non-combustible aerosol provision device may comprise aerosolisable material or an area for receiving aerosolisable material.
In some embodiments, the article for use with the non-combustible aerosol provision device may comprise a mouthpiece. The area for receiving aerosolisable material may be a storage area for storing aerosolisable material. For example, the storage area may be a reservoir. In some embodiments, the area for receiving aerosolisable material may be separate from, or combined with, an aerosol generating area.
As used herein, the term "component" may be used to refer to a part, section, unit, module, assembly or similar of an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an exterior housing or wall. An aerosol provision system such as an electronic cigarette may be formed or built from one or more such components, such as an article and a device, and the components may be removably

8 or separably connectable to one another, or may be permanently joined together during manufacture to define the whole system. The present disclosure is applicable to (but not limited to) systems comprising two components separably connectable to one another and configured, for example, as an article in the form of an aerosolisable material carrying component holding liquid or another aerosolisable material (alternatively referred to as a cartridge, cartomiser, pod or consumable), and a device having a battery or other power source for providing electrical power to operate an aerosol generating component or aerosol generator for creating vapour/aerosol from the aerosolisable material. A
component may include more or fewer parts than those included in the examples.
In some examples, the present disclosure relates to aerosol provision systems and components thereof that utilise aerosolisable material in the form of a liquid or a gel which is held in a storage area such as a reservoir, tank, container or other receptacle comprised in the system, or absorbed onto a carrier substrate. An arrangement for delivering the material from the reservoir for the purpose of providing it to an aerosol generator for vapour / aerosol generation is included. The terms "liquid", "gel", "fluid", "source liquid", "source gel", "source fluid" and the like may be used interchangeably with terms such as "aerosol-generating material", "aerosolisable substrate material" and "substrate material" to refer to material that has a form capable of being stored and delivered in accordance with examples of the present disclosure.
Figure 1 is a highly schematic diagram (not to scale) of a generic example electronic aerosol/vapour provision system such as an e-cigarette 10, presented for the purpose of showing the relationship between the various parts of a typical system and explaining the general principles of operation. Note that the present disclosure is not limited to a system configured in this way, and features may be modified in accordance with the various alternatives and definitions described above and/or apparent to the skilled person. The e-cigarette 10 has a generally elongate shape in this example, extending along a longitudinal axis indicated by a dashed line, and comprises two main components, namely a device 20 (control or power component, section or unit), and an article or consumable 30 (cartridge assembly or section, sometimes referred to as a cartomiser, clearomiser or pod) carrying aerosol-generating material and operating to generate vapour/aerosol.
The article 30 includes a storage area such as a reservoir 3 for containing a source liquid or other aerosol-generating material comprising a formulation such as liquid or gel from which an aerosol is to be generated, for example containing nicotine. As an example, the source liquid may comprise around 1% to 3% nicotine and 50% glycerol, with the remainder comprising roughly equal measures of water and propylene glycol, and possibly also comprising other components, such as flavourings. Nicotine-free source liquid may also be used, such as to deliver flavouring. A solid substrate (not illustrated), such as a portion of

9 tobacco or other flavour element through which vapour generated from the liquid is passed, may also be included. The reservoir 3 may have the form of a storage tank, being a container or receptacle in which source liquid can be stored such that the liquid is free to move and flow within the confines of the tank. In other examples, the storage area may comprise absorbent material (either inside a tank or similar, or positioned within the outer housing of the article) that holds the aerosol generating material. For a consumable article, the reservoir 3 may be sealed after filling during manufacture so as to be disposable after the source liquid is consumed. However, the present disclosure is relevant to refillable articles that have an inlet port, orifice or other opening (not shown in Figure 1) through which new source liquid can be added to enable reuse of the article 30. The article 30 also comprises an aerosol generator 5, comprising in this example an aerosol generating component, which may have the form of an electrically powered heating element or heater 4 and an aerosol-generating material transfer component 6. The heater 4 is located externally of the reservoir 3 and is operable to generate the aerosol by vaporisation of the source liquid by heating. The aerosol-generating material transfer component 6 is a transfer or delivery arrangement configured to deliver aerosol-generating material from the reservoir 3 to the heater 4. In some examples, it may have the form of a wick or other porous element. A wick 6 may have one or more parts located inside the reservoir 3, or otherwise be in fluid communication with liquid in the reservoir 3, so as to be able to absorb source liquid and transfer it by wicking or capillary action to other parts of the wick 6 that are adjacent or in contact with the heater 4. This liquid is thereby heated and vaporised, and replacement liquid drawn, via continuous capillary action, from the reservoir 3 for transfer to the heater 4 by the wick 6. The wick may be thought of as a conduit between the reservoir 3 and the heater 4 that delivers or transfers liquid from the reservoir to the heater.
In some designs, the heater 4 and the aerosol-generating material transfer component 6 are unitary or monolithic, and formed from a same material that is able to be used for both liquid transfer and heating, such as a material which is both porous and conductive. In still other cases, the aerosol-generating material transfer component may operate other than by capillary action, such as by comprising an arrangement of one or more valves by which liquid may exit the reservoir 3 and be passed onto the heater 4.
A heater and wick (or similar) combination, referred to herein as an aerosol generator 5, may sometimes be termed an atomiser or atomiser assembly, and the reservoir with its source liquid plus the atomiser may be collectively referred to as an aerosol source. Various designs are possible, in which the parts may be differently arranged compared with the highly schematic representation of Figure 1. For example, and as mentioned above, the wick 6 may be an entirely separate element from the heater 4, or the heater 4 may be configured to be porous and able to perform at least part of the wicking function directly (a metallic mesh, for example). In the present example, the system is an electronic system, and the heater 4 may comprise one or more electrical heating elements that operate by ohmic/resistive (Joule) heating, although inductive heating may also be used, in which case the heater comprises a susceptor in an induction heating arrangement. A heater of this type could be configured in line with the examples and embodiments described in more detail below. In general, therefore, an atomiser or aerosol generator, in the present context, can be considered as one or more elements that implement the functionality of a vapour-generating element able to generate vapour by heating source liquid (or other aerosol-generating material) delivered to it, and a liquid transport or delivery element able to deliver or transport liquid from a reservoir or similar liquid store to the vapour-generating element by a wicking action / capillary force or otherwise. An aerosol generator is typically housed in an article 30 of an aerosol generating system, as in Figure 1, but in some examples, at least the heater part may be housed in the device 20. Embodiments of the disclosure are applicable to all and any such configurations which are consistent with the examples and description herein.
Returning to Figure 1, the article 30 also includes a mouthpiece or mouthpiece portion 35 having an opening or air outlet through which a user may inhale the aerosol generated by the heater 4.
The device 20 includes a power source such as cell or battery 7 (referred to hereinafter as a battery, and which may or may not be re-chargeable) to provide electrical power for electrical components of the e-cigarette 10, in particular to operate the heater 4.
Additionally, there is a controller 8 such as a printed circuit board and/or other electronics or circuitry for generally controlling the e-cigarette. The controller may include a processor programmed with software, which may be modifiable by a user of the system. The control electronics/circuitry 8 operates the heater 4 using power from the battery 7 when vapour is required. At this time, the user inhales on the system 10 via the mouthpiece 35, and air A
enters through one or more air inlets 9 in the wall of the device 20 (air inlets may alternatively or additionally be located in the article 30). When the heater 4 is operated, it vaporises source liquid delivered from the reservoir 3 by the aerosol-generating material transfer component 6 to generate the aerosol by entrainment of the vapour into the air flowing through the system, and this is then inhaled by the user through the opening in the mouthpiece 35. The aerosol is carried from the aerosol generator 5 to the mouthpiece 35 along one or more air channels (not shown) that connect the air inlets 9 to the aerosol generator 5 to the air outlet when a user inhales on the mouthpiece 35.
More generally, the controller 8 is suitably configured / programmed to control the operation of the aerosol provision system to provide functionality in accordance with embodiments and examples of the disclosure as described further herein, as well as for providing conventional operating functions of the aerosol provision system in line with established techniques for controlling such devices. The controller 8 may be considered to logically comprise various sub-units / circuitry elements associated with different aspects of the aerosol provision system's operation in accordance with the principles described herein and other conventional operating aspects of aerosol provision systems, such as display driving circuitry for systems that may include a user display (such as an screen or indicator) and user input detections via one or more user actuable controls 12. It will be appreciated that the functionality of the controller 8 can be provided in various different ways, for example using one or more suitably programmed programmable computers and/or one or more suitably configured application-specific integrated circuits / circuitry / chips / chipsets configured to provide the desired functionality.
The device 20 and the article 30 are separate connectable parts detachable from one another by separation in a direction parallel to the longitudinal axis, as indicated by the double-headed arrows in Figure 1. The components 20, 30 are joined together when the system 10 is in use by cooperating engagement elements 21, 31 (for example, a screw or bayonet fitting) which provide mechanical and in some cases electrical connectivity between the device 20 and the article 30. Electrical connectivity is required if the heater 4 operates by ohmic heating, so that current can be passed through the heater 4 when it is connected to the battery 5. In systems that use inductive heating, electrical connectivity can be omitted if no parts requiring electrical power are located in the article 30. An inductive work coil can be housed in the device 20 and supplied with power from the battery 5, and the article 30 and the device 20 shaped so that when they are connected, there is an appropriate exposure of the heater 4 to flux generated by the coil for the purpose of generating current flow in the material of the heater. The Figure 1 design is merely an example arrangement, and the various parts and features may be differently distributed between the device 20 and the article 30, and other components and elements may be included. The two sections may connect together end-to-end in a longitudinal configuration as in Figure 1, or in a different configuration such as a parallel, side-by-side arrangement. The system may or may not be generally cylindrical and/or have a generally longitudinal shape. Either or both sections or components may be intended to be disposed of and replaced when exhausted, or be intended for multiple uses enabled by actions such as refilling the reservoir and recharging the battery. In other examples, the system 10 may be unitary, in that the parts of the device 20 and the article 30 are comprised in a single housing and cannot be separated.
Embodiments and examples of the present disclosure are applicable to any of these configurations and other configurations of which the skilled person will be aware.
The present disclosure relates to the refilling of a storage area for aerosol generating material in an aerosol provision system, whereby a user is enabled to conveniently provide a system with fresh aerosol generating material when a previous stored quantity has been used up. It is proposed that this be done automatically, by provision of apparatus which is termed herein a refilling device, refilling unit, refilling station, or simply dock. The refilling device is configured to receive an aerosol provision system, or more conveniently, the article from an aerosol provision system having a storage area which is empty or only partly full, plus a larger reservoir holding aerosol generating material. A fluid communication flow path is established between the reservoir and the storage area, and a controller in the refilling device controls a transfer mechanism or arrangement operable to move aerosol generating material along the flow path from the reservoir to the storage area. The transfer mechanism can be activated in response to user input of a refill request to the refilling device, or activation may be automatic in response to a particular state or condition of the refilling device detected by the controller. For example, if both an article and a reservoir are correctly positioned inside the refilling unit, refilling may be carried out. Once the storage area is replenished with a desired quantity of aerosol generating material (the storage area is filled or a user specified quantity of material has been transferred to the article, for example), the transfer mechanism is deactivated, and transfer ceases. Alternatively, the transfer mechanism may be configured to automatically dispense a fixed quantity of aerosol generating material in response to activation by the controller, such as the fixed quantity matching the capacity of the storage area.
Figure 2 shows a highly schematic representation of an example refilling device. The refilling device is shown in a simplified form only, to illustrate various elements and their relationship to one another. More particular features of one or more of the elements with which the present disclosure is concerned will be described in more detail below.
The refilling device 50 may be referred to hereinafter for convenience as a "dock".
This term is applicable since a reservoir and an article are received or "docked" in the refilling device during use. The dock 50 comprises an outer housing 52. The dock 50 is expected to be useful for refilling of articles in the home or workplace (rather than being a portable device or a commercial device, although these options are not excluded).
Therefore, the outer housing, made for example from metal, plastics or glass, may be designed to have an pleasing outward appearance such as to make it suitable for permanent and convenient access, such as on a shelf, desk, table or counter. It may be any size suitable for accommodating the various elements described herein, such as having dimensions between about 10 cm and 20 cm, although smaller or larger sizes may be preferred. Inside the housing 50 are defined two cavities or ports 54, 56. A
first port 54 is shaped and dimensioned to receive and interface with a reservoir 40. The first or reservoir port 54 is configured to enable an interface between the reservoir 40 and the dock 50, so might alternatively be termed a reservoir interface. Primarily, the reservoir interface is for moving aerosol generating material out of the reservoir 40, but in some cases the interface may enable additional functions, such as electrical contacts and sensing capabilities for communication between the reservoir 40 and the dock 50 and determining characteristics and features of the reservoir 40.
The reservoir 40 comprises a wall or housing 41 that defines a storage space for holding aerosol generating material 42. The volume of the storage space is large enough to accommodate many or several times the storage area of an article intended to be refilled in the dock 50. A user can therefore purchase a filled reservoir of their preferred aerosol generating material (flavour, strength, brand, etc.), and use it to refill an article multiple times. A user could acquire several reservoirs 40 of different aerosol generating materials, so as to have a convenient choice available when refilling an article. The reservoir 40 includes an outlet orifice or opening 44 by which the aerosol generating material 42 can pass out of the reservoir 40. In the current context, the aerosol generating material 42 has a liquid form or a gel form, so may be considered as aerosol generating fluid. The term "fluid" may be used herein for convenience to refer to either a liquid or a gel material;
where the term "liquid" is used herein, it should be similarly understood as referring to a liquid or a gel material, unless the context makes it clear that only liquid is intended.
A second port 56 defined inside the housing is shaped and dimensioned to receive and interface with an article 30. The second or article port 54 is configured to enable an interface between the article 30 and the dock 50, so might alternatively be termed an article interface. Primarily, the article interface is for receiving aerosol generating material into the article 30, but in some cases the interface may enable additional functions, such as electrical contacts and sensing capabilities for communication between the article 30 and the dock 50 and determining characteristics and features of the reservoir 30.
The article 30 itself comprises a wall or housing 31 that has within it (but possibly not occupying all the space within the wall 31) a storage area 3 for holding aerosol generating material. The volume of the storage area 3 is many or several times smaller than the volume of the reservoir 40, so that the article 30 can be refilled multiple times from a single reservoir 40. The article also includes an inlet orifice or opening 32 by which aerosol generating material can enter the storage area 3. Various other elements may be included within the article, as discussed above with regard to Figure 1. For convenience, the article 30 may be referred to hereinafter as a pod 30.
The refilling device housing 52 also accommodates a fluid conduit 58, being a passage or flow path by which the reservoir 40 and the storage area 3 of the article 30 are placed in fluid communication, so that aerosol generating material can move from the reservoir 40 to the article 30 when both the reservoir 40 and the article 30 are correctly positioned in the dock 50. Placement of the reservoir 40 and the article 30 into the dock 30 locates and engages them such that the fluid conduit 58 is connected between the outlet orifice 44 of the reservoir 40 and the inlet orifice 32 of the article 30.
Note that in some examples, all or part of the fluid conduit 58 may be formed by parts of the reservoir 40 and the article 30, so that the fluid conduit is created and defined only when the reservoir 40 and/or the article 30 are placed in the dock 30. In other cases, the fluid conduit 58 may be flow path defined within a body of the dock 52, to each end of which the respective orifices are engaged.
Access to the reservoir port 54 and the article port 56 can be by any convenient means. Apertures may be provided in the housing 52 of the dock 50, through which the reservoir 40 and the article 30 can be placed or pushed. Doors or the like may be included to cover the apertures, which might be required to be placed in a closed state to allow refilling to take place. Doors, hatches and other hinged coverings, or sliding access elements such as drawers or trays might include shaped tracks, slots or recesses to receive and hold the reservoir 40 or the article 30, which bring the reservoir 40 or the article 30 into proper alignment inside the housing when the door etc. is closed. These and other alternatives will be apparent to the skilled person, and do not affect the scope of the present disclosure.
The dock 50 also includes an aerosol generating material ("liquid" or "fluid") transfer mechanism, arrangement, apparatus or means 53, operable to move or cause the movement of fluid out of the reservoir 40, along the conduit 58 and into the article 30.
Various options are contemplated for the transfer mechanism 53.
A controller 55 is also included in the dock 50, which is operable to control components of the dock 50, in particular to generate and send control signals to operate the transfer mechanism. As noted, this may be in response to a user input, such as actuation of a button or switch (not shown) on the housing 52, or automatically in response to both the reservoir 40 and the article 30 being detected as present inside their respective ports 54, 56.
The controller 55 may therefore be communication with contacts and/or sensors (not shown) at the ports 54, 56 in order to obtain data from the ports and/or the reservoir 40 and article that can be used in the generation of control signals for operating the transfer mechanism 3. The controller 55 may comprise a microcontroller, a microprocessor, or any configuration of circuitry, hardware, firmware or software as preferred; various options will be apparent to 30 the skilled person.
Finally, the dock 50 includes a power source 57 to provide electrical power for the controller 53, and any other electrical components that may be included in the dock, such as sensors, user inputs such as switches, buttons or touch panels, and display elements such as light emitting diodes and display screens to convey information about the dock's operation and status to the user. Also, the transfer mechanism may be electrically powered.
In particular, electrical power may be provided to the transfer mechanism when it is required to operate. Since the dock may be for permanent location in a house or office, the power source 57 may comprise a socket for connection of an electrical mains cable to the dock 50, so that the dock 50 may be "plugged in". Alternatively, the power source may comprise one or more batteries, which might be replicable or rechargeable, in which case a socket connection for a charging cable is included.
While the example of Figure 2 relates to the refilling of an article which has been separated from its aerosol generating system device, other examples may be configured such that the whole of an aerosol generating system can be received in the refilling device for refilling of its aerosol generating material storage area.
RESERVOIR FOR A REFILLING DEVICE
A reservoir for a refilling device is described with reference to Figures 1 and 2 mentioned above and Figures 3- 9 mentioned below.
Further details relating to the reservoir will now be described.
Figure 3 shows a schematic representation of an article arranged for refilling from a reservoir, where both the reservoir and the article are received in appropriate interfaces in a refilling dock (not shown). A reservoir 40 containing aerosol-generating fluid 42 has a nozzle 60 arranged as its outlet orifice. The nozzle 60 acts as the fluid conduit shown in Figure 2. In this example, the nozzle has a tubular elongate shape, and extends from the first end 61 to a second or distal end 62, remote from the reservoir 40, which acts as the fluid dispensing point or fluid outlet of the nozzle. Fluid is retained in the reservoir by, for example a valve (not shown) at or near the proximal end 61, which is opened when fluid transfer to the article commences. In other cases, surface tension may be sufficient to retain the fluid, for example if the bore of the nozzle is sufficiently small. The distal end 62 is inserted into the inlet orifice 32 of the article 30, and in this example extends directly into the storage area 3 of the article 30. In other examples, there may be tubing, pipework or some other fluid flow path connecting the inlet orifice 32 to the interior of the storage area 3. In use, aerosol-generating material 42 is moved out of the reservoir 40 using the fluid transfer mechanism of the dock, along a fluid channel defined by the nozzle 60 (acting as the fluid conduit) from the proximal end 61 to the distal end 62, where it reaches the fluid outlet of the nozzle and flows into the storage area 3, in order to refill the article 30 with aerosol generating material.
Figure 3 shows an example arrangement only, and the outlet orifice of the reservoir may be configured other than as a nozzle, and as noted, the fluid conduit that allows refilling of the article using the refilling dock may or may not comprise parts of the reservoir and the article. In general, however, the outlet orifice of the reservoir is configured to act as, or for engagement with, the fluid conduit so that fluid from the reservoir can be ejected from the fluid conduit and into the storage area of the article. Engagement with the fluid conduit or direct engagement with the article, depending on the arrangement used, may be achieved by relative movement between the reservoir and the end of the fluid conduit, or between the reservoir and the article once the article has been inserted into the article port of the refilling dock. Placement of the reservoir and the article in the dock brings them into suitable alignment such that relative movement towards one another engages and creates the required fluid flow path between the two.
An option for removing fluid from the reservoir for transfer to the article is to pull the fluid out of the reservoir. Pulling can be achieved by a pumping arrangement associated with the outlet orifice, through which fluid is pulled. A peristaltic pump might be used, for example.
However, pumping arrangements can be vulnerable to leakage. Typically a number of components are coupled together along and within the flow channel for the pumped fluid, so there can be several joints, and corresponding multiple potential weak points where leaks may arise. Also, the small scale of a typical article, and the corresponding only somewhat larger scale of a suitable reservoir (since a very large store of aerosol generating material may be undesirable for reasons including safety and shelf-life) can make a pump awkward to implement. An overall size for a refilling unit required to accommodate a pumping arrangement may be undesirably large.
Accordingly, the present disclosure proposes instead to push fluid from the reservoir.
This can be implemented by configuring the reservoir to have a movable wall that slides inwardly into the reservoir's internal volume in order to reduce that volume and increase the pressure on fluid in the volume so that fluid is forced out of the reservoir's outlet orifice as the system attempts to equalise the internal pressure. The refilling device is provided with a pushing device, element or apparatus that can act on the moveable wall of a reservoir installed in the reservoir port of the refilling device to provide the required inward pushing when fluid dispensing to refill an article is required.
Figure 4 shows a schematic simplified cross-sectional view through a first example reservoir configured in this way. The reservoir 40 comprises a housing having the form of one or more side walls 41, and an end wall 43 which closes one end of the space bounded by the side walls 41. The side wall(s) 41 and the end wall 43 thereby define a fluid storage volume 45, having a capacity within for storing fluid, in this case aerosol generating material 42. The side wall(s) 41 may be considered as a single side wall if the transverse cross-sectional shape (section through the side wall(s) parallel to the end wall) is circular or oval, or generally curved and lacking corners. If other shapes are used, such as square or rectangular, the side wall(s) might be considered to be multiple side walls, each flat and connected to neighbouring walls at the corners/edges of the reservoir 40.
Regardless of shape, the side wall(s) and the end wall may be conveniently formed as a single piece; this can avoid the risk of leaks that may arise if separate parts are joined together. A single piece construction can also be stronger and more sturdy, so better suited to withstand the fluid pressure increases during fluid dispensing. This part of the reservoir 40 (side and end walls 41, 43, bounding the fluid storage volume) can be formed from plastics materials, such as by moulding or three-dimensional printing, although other materials and fabrication techniques are not excluded.
The reservoir 40 further comprises a moveable wall 63 which engages within the side walls 41 in order to close the fluid storage volume 45. The moveable wall 63 is configured to lie in a plane orthogonal to a longitudinal axis of the tubular shape formed by the side walls 41 (so, parallel to the transverse cross-section of the side wall(s) 41), and has a size and shape matching the internal cross-section of the side wall(s) 41 so as to fit closely, while being able to move within the side wall(s) 41 along the direction of the longitudinal axis.
During movement, the edge(s) or perimeter of the moveable wall 63 slide over the inner surface of the side wall(s), maintaining contact therewith. The side wall(s) 41 therefore are parallel along the length of the reservoir 40. In order to reduce leakage of fluid 42 from out of the storage volume 45, the moveable wall 63 is configured for sealing around its perimeter.
In the Figure 4 example, this is achieved by forming one or more flanges 64 (in this case two flanges) that protrude from the moveable wall edges and are compressed against the side wall(s) when the moveable wall 63 is installed. The moveable wall may be formed from a suitable compressible material such as natural or synthetic rubber, or a plastics material with similar properties, for example. This will allow the flanges 64 to be integrally formed with the moveable wall 63, such as by moulding or three-dimensional printing, for ease of fabrication.
Note that in regard to providing a high quality seal between the moveable wall 63 and the side wall(s), a circular cross-section may be most suitable, with a corresponding circular moveable wall 63.
An outlet orifice 44 is provided for the reservoir 40, by which fluid can exit the storage volume 45. In this example, the outlet orifice 44 is located in the end wall 43, but in general it should be remote from the movable wall in order to maximise the usable capacity of the storage volume 45, in other words, the capacity from which fluid can be expelled through the outlet orifice 44 by movement of the moveable wall 63. Accordingly, the outlet orifice could be located merely near to the end wall 43, such as in the side wall(s) 41 adjacent to the end wall 43.
The outlet orifice 44 is configured so as to be able to connect to or engage with the fluid conduit in a refilling device when the reservoir 40 is installed in the refilling device. In some cases, the outlet orifice itself can form the entirety of the fluid conduit, by being engagable directly with the inlet orifice of an article also installed in the refiling device. In other cases, the outlet orifice can connect to a tubing or pipework included within the refilling device that acts as the fluid conduit, and to which the outlet orifice of the article is also connectable. In any of these arrangements, when the outlet orifice and the inlet orifice are joined in this way, a fluid flow path is established from the storage volume of the reservoir to the storage area in the article, along which fluid can be moved in order to allow refilling of the article when its storage area has become depleted of aerosol generating material.
In Figure 4, the outlet orifice 44 is represented simply as a small opening with a surrounding collar; in general the collar portion can be sized and shaped as appropriate for either connection to a separate fluid conduit or to provide the fluid conduit itself, such as an elongated collar portion formed as a nozzle.
For the dispensing of fluid from the reservoir 40, the refilling device is configured to act on the moveable wall by providing a pressure or pushing force P directed towards the end wall 43 and the outlet orifice 44. This moves the moveable 63 wall inwardly by sliding over the inside of the side wall(s) 41, in other words towards the end wall 43. This reduces the size of the storage volume 45, so that fluid is pushed out of the outlet orifice 44. Fluid can then flow along the flow path of the fluid conduit and into the storage area of the connected article.
In order to achieve this, the refilling device comprises a fluid transfer mechanism 53 as discussed with regard to Figure 2. The transfer mechanism 53 can comprise a plunger, piston or similar pressure-applying or force-applying element that bears against the moveable wall externally to the storage volume to push the moveable wall in the desired direction towards the end wall. Depending on the construction of the transfer mechanism, the moveable wall 63 may have an outer surface (the surface facing outwardly, away from the storage volume 45) which is shaped to receive and/or engage or cooperate with an end part of the transfer mechanism. In other cases, a planar surface may be adequate, and avoids any need for alignment between the reservoir and the fluid transfer mechanism.
Figure 4A shows a schematic cross-sectional view of an edge part of the moveable wall according to another example. In this case, sealing between the moveable wall 63 and the side wall(s) 41 is provided by use of a separate seal or sealing element 65 provided for the moveable wall 63, in place of the integrally formed seal provided by the flanges in Figure 4. For example, the seal 65 may comprise an 0-ring of rubber or plastics material secured around the perimeter of the moveable wall. This arrangement allows the moveable wall and the seal to be formed from different materials, which may be useful if a flexible material is not preferred for the whole of the moveable wall. For example, flexing of the moveable wall which may occur under the force applied by the transfer mechanism may be undesirable, such as if it causes the sealing properties of an integral flange to be compromised.
Figure 5A shows a schematic representation of an example refiling device 50, set up for a refilling action, but prior to the act of refilling. A reservoir 40 has been installed in the refilling device 50 by being placed by a user into the reservoir port 54. The reservoir 40 has a vertical orientation, with the moveable wall at the top and the outlet orifice in the end wall at the bottom. This allows gravity to assist with the movement of fluid out of the reservoir.

When the reservoir is in this position, a plunger 53a of the fluid transfer mechanism 53 can be moved into contact with the moveable wall 63 of the reservoir 40. The plunger 53a can be driven by a motor, for example, configured to move the plunger 53a along the vertical direction such that it can be advanced towards and retracted away from the moveable wall 63, and also push the moveable wall 63 towards the end wall of the reservoir.
In this example, the outlet orifice of the reservoir 40 has the form of a nozzle 60 and comprises the whole of the fluid conduit. This can be beneficial because there is no residual aerosol generating material left in the refilling device 50 when the reservoir is removed, as might occur for a fluid conduit comprised within the refilling device 50 to which the reservoir 40 is coupled. Hence, cross-contamination between different types of aerosol-generating material that might be held in consecutive reservoirs is avoided. The nozzle 60 is located centrally within the end wall of the reservoir; this can facilitate alignment of the nozzle 60 with the article 30. When a user requires the refilling of an article, the article 30 is placed by the user into the article port 56 of the refilling device 50. The article port 56 holds the article 30 such that the inlet orifice 32 of the article, which may be covered by a valve (not shown), is aligned with the distal end of the nozzle 60. The fluid flow path from reservoir 40 to article 30 is completed by relative movement between the article 30 and the reservoir 40, which inserts the distal end of the nozzle 60 into the inlet orifice 32, causing the valve to open. The movement, effected by movement of the article port 56 and/or the reservoir port 54, can be automatically provided by the refilling unit 50, electrically by use of one or more motors under control of the controller 55 in response to insertion of the article 30 into the article port 56, or mechanically by suitable hinging, folding and/or sliding parts that operate in conjunction with opening and closing of the door, tray or similar of the article port 56.
Otherwise, a lever or similar operable by the user may be provided. The article 30 may be moved upwards towards the reservoir 40, the reservoir 40 may be moved downwards towards the article 30, or the reservoir 40 and the article 30 may both be moved. The refilling device is now ready to commence filling of the article 30.
Figure 5B shows the refilling device 50 after a portion of aerosol generating material 42 has been dispensed into the article 30. Once the refilling device 50 is configured for refilling as in Figure 5A, the controller 55 generates control signal in order to operate the fluid transfer mechanism 53. In the present example, this is by the control of a motor such as a stepper motor (not shown) coupled to the plunger 53a, to move the plunger 53 downwards to push on and move the moveable wall 63, as shown by the arrow. This pushes some of the fluid 42 into and along the nozzle 60, from which it is expelled into the storage area 3 of the article 30. Once a desired quantity of fluid 42 has been transferred from the reservoir 40 to the article 30, the controller 55 ceases controlling the plunger to advance downwards, there is no further pushing on and movement of the moveable wall, and fluid transfer ceases. The transfer may be halted after the plunger has travelled a predetermined distance known to correspond to the capacity of the article's storage area 3, for example.
Alternatively, the amount of fluid which has been moved can be detected or deduced from measurements made on the article or the reservoir by the controller, so that the transfer can be stopped once enough fluid has been moved, such as when the article's storage area is determined to be full.
Next, the relative movement between the article 30 and the reservoir 40 is reversed to uncouple the article from the fluid conduit. In this case, the nozzle 60 is withdrawn from the inlet aperture 32, the valve of which then closes to seal the storage area 3 against leaks.
The user can then remove the refilled article 30 from article port 56, for reuse in an aerosol provision system. The reservoir 40 can be retained in the refilling device 50 for use in the next refilling action. If it has been emptied of aerosol generating material 42 by refilling the article 30, it can be removed and replace with a new full reservoir.
Alternatively, it can be swapped with a reservoir holding a different type of aerosol generating material if the user likes to consume more than one type.
Figure 6 shows a schematic longitudinal cross-sectional view of a further example reservoir. As in the example shown in Figures 5A and 5B, the reservoir 40 has a nozzle 60 as the outlet orifice. In this example, however, the nozzle 60 is offset from the centre of the end wall 43, towards one side of the end wall 43. This can align with a similarly offset inlet orifice in an article, which may be required to accommodate the inlet orifice among other parts of the article, for example. Otherwise the reservoir 40 is similar to those in Figures 4, 5A and 5B, and like parts will not be described again. A difference, however, is that the reservoir in Figure 6 additionally comprises a socket 48 formed at the outlet orifice end of the reservoir 40. The socket 48 is a cavity or recess which has as its base or closed end the exterior surface of the end wall 43. It is formed by one or more socket wall portions 46 which extend from the end wall 43 in a direction outwardly therefore away the moveable wall 63, and form a socket wall around the nozzle 60 (or other format of outlet orifice). The socket wall portions 46 may be continuous (and hence be a single portion) or may comprise more than one spaced-apart portion, to create a gapped socket wall. In this example, the socket wall portions 46 extend inline with the side wall(s) 41 of the reservoir 40 (they are extensions of the side wall(s)) so that the exterior of the reservoir is smooth and continuous; the reservoir has a constant width. This may make the reservoir port in the refilling dock less complex, for example. In other cases, part or all of the socket wall may inset from the edge of the end wall 43, to give a stepped profile for the reservoir.
A function of the socket 48 is to provide some protection for the outlet orifice 44, particularly when it is formed as a nozzle 60. The nozzle will typically have small diameter, required by the typical scale of an article, such as 2 mm or less. Hence, it can be relatively delicate and easily damaged, and is vulnerable as it protrudes out of the end wall 43. Any damage could render it inoperable, or make alignment with the article difficult such as if it becomes bent. The socket 48 can afford protection from accidental bumps and knocks. This can be enhanced if the socket wall 46 extends further than the nozzle 60, so the nozzle 60 does not protrude out of the socket 48.
The socket 48 may additionally provide a function of receiving at least part of an article which is brought together with the reservoir 40 for refilling in the refilling device. The relative movement between the article and the reservoir to form the fluid flow path will insert the part of the article closest to the reservoir 40 into the socket 48. The presence of the socket wall 46 can guide the article towards the reservoir 40, to give and maintain correct alignment between the inlet orifice of the article and the outlet orifice of the reservoir 40.
Also, it can inhibit the use of inappropriate or unauthorised pairings of reservoirs and articles, for improved safety. For these functions, the inner profile of the socket should correspond to the outer profile of the intended article. This can prevent an incorrectly shaped or sized article or improperly oriented article from being received into the socket, while a correctly shaped and/or sized and/or oriented article will be received and guided towards the position at which it is coupled for fluid transfer, in this example by insertion of the nozzle 60 into an inlet orifice of an article. To achieve this, the socket walls 46 may be inset from the side walls 41, for example if the article is narrower than the reservoir. Alternatively or additionally, the socket walls may have a different transverse cross-section of their inner and outer surfaces.
The outwardly facing surface of the socket wall portions 46 may be inline with the outer surface of the side walls 41 to give a smooth exterior for the reservoir, while the inwardly facing surface of the socket wall portions 46 matches the cross section of the article. Also, the inner surface of the socket wall portions may slope outwardly with distance from the end wall so the socket 48 is wider at its mouth or open end. This can also aid in receiving the article and guiding it into alignment for connection to the fluid conduit.
Additionally, the inner surface of the socket wall portions 46 may be shaped to define one or more guiding elements which are configured to cooperate with shaping on an outer surface of the article. This can also assist in guiding the article into engagement with the fluid conduit during its insertion into the socket.
Figure 7 shows the reservoir 40 of Figure 6 with an article 30, held in the article port 56, inserted into the socket 48 of the reservoir 40 and coupled with the nozzle 60 of the reservoir ready for refilling. The reservoir 40 is similarly held in the reservoir port (not shown). The article 30 has been inserted into the socket 48 by movement of the article port 56 upwards to carry the article 30 towards the reservoir 40.
The reservoir 40 of Figures 6 and 7 further comprises a window 47, being a transparent portion provided in the side wall 41 of the reservoir (although it could be positioned elsewhere). This allows the user to see into the storage volume 45 of the reservoir 40 to see how much aerosol generating material remains. Thus, a time at which the reservoir will need to be replaced can be ascertained. Alternatively, at least the side wall(s) 41 of the reservoir 40 can be wholly fabricated from transparent material to allow ease of observation of the interior of the storage volume 45. This option may allow simpler manufacturing, but a window design might be preferred in some cases as allowing a non-transparent portion of the external surface of the reservoir for labelling (use instructions or branding, for example) and colouring.
As a further optional feature, a reservoir with a nozzle may comprise a moveable mount 49 on which the nozzle is supported. Operation of the moveable mount extends and retracts the nozzle along the direction of its length or longitudinal axis as indicated by the dotted arrow in Figure 6, so that the nozzle can be inserted into and retracted out of the inlet orifice of an article. This provides an alternative to the various approaches for achieving the relative movement of the article and reservoir for coupling and creation of the fluid flow path.
The mount 48 may operated under the control of the controller in the refilling device, by means in the reservoir or means in the refilling device.
The addition of fluid into the article during the refilling process can increase the pressure within the storage area of the article, pending the release, or venting, of air which is displaced by the added fluid. A dedicated venting path may be provided within the article itself, but it is proposed herein according to some examples, that where the reservoir includes a nozzle as the outlet orifice, venting is provided via the nozzle.
This allows the single inlet orifice of the article to be used for both the ingress of fluid and the egress of air.
To enable this, the nozzle can be configured to have two channels, both having an end at the distal end of the nozzle that reaches into the storage area of the article. The channels comprise a first channel, being a fluid channel that communicates with the interior of the storage volume of the reservoir to collect fluid and deliver it into the article, and a second channel, being a venting channel or air flow channel that collects air forced out of the storage area of the article by the incoming fluid and includes an air outlet for this air to escape or vent into the surrounding environment. This is typically the interior of the refilling device.
While the nozzle can be held in a dedicated mount attached to the end wall of the reservoir, it may instead conveniently be mounted within the end wall itself.
The end wall can be formed to have a passage passing through it, in which the nozzle can be held. This allows the end wall to also be used to form part of the venting path provided by the venting channel of the nozzle.
Figure 8 shows a schematic cross-section through an example of a reservoir end wall and mounted nozzle. The end wall 43 has a passage 43a passing through it between the storage volume 45 and the exterior. Held in the passage 43a is a nozzle 60 configured for dual flow of fluid and air. The bore of the nozzle 60 is divided into two channels. A fluid channel 66 for the outward flow of fluid F runs from the storage volume 45 to a distal end (not shown) of the nozzle 60, and a venting channel 67 for the inward flow of air A runs from the distal end of the nozzle 60 towards the reservoir. The two channels are indicated merely schematically in Figure 8 as running side-by-side; their exact configuration is unimportant to the present example. Formed within the end wall 43 is a venting chamber 68, which is a hollow or void within the material from which the end wall 43 is formed, contiguous with the nozzle passage 43a. The venting channel 67 has an outlet 67a, which is positioned for air flow communication with the venting chamber 68, so that air A forced up the venting channel 67 can be discharged into the venting chamber 68. The venting chamber 68 is provided with an outlet or exit 68a in the side of the end wall 43, but may be otherwise located. Hence, air pushed out of the storage area in an article being filled can be vented to the exterior, thereby reducing pressure increases inside the storage area. This is important for enabling efficient refilling. If the pressure inside the storage area rises, the inflow of fluid will be impeded which slows the refilling process.
A consequence of venting the article's storage area in this way is that fluid F can enter the venting channel 67 along with air A. The flow of air A can carry any such fluid along the length of the venting channel 67 until it is discharged through the outlet 67a into the venting chamber 68. Discharged fluid can collect around or near the outlet 67a as droplets or a deposit D, and cause partial or complete blockage of the outlet 67a. This can impede the venting, and cause a pressure increase within the article's storage area.
Figure 9 shows a schematic cross-section through a second example of a reservoir end wall modified compared to the Figure 8 example to address the issue of fluid in the venting chamber. Compared with the end wall of Figure 8, the Figure 9 example comprises a venting chamber 68 which has a floor that is angled downwardly away from the outlet 67a of the venting channel 67 (in the depicted orientation in which the reservoir would be vertical as in Figure 4, with the end wall at the bottom, or lowermost, and the moveable wall at the top).
More generally, the venting chamber 68 can be described as being shaped in order that any fluid which arrives into the venting chamber 68 via the venting channel 67 and its outlet 67a flows away from the outlet 67a, owing to gravity. This allows any droplets D
to move away from the outlet 67a so that it does not become blocked with fluid. Figure 9 shows additionally a upwardly extending lip 70 at the base of the venting chamber outlet 68a which interrupts the downward slope of the floor 69, and hence blocks the droplets D from flowing out of the venting chamber altogether. In this way, any fluid drawn out of the article's storage area can be collected in the venting chamber 68 remotely from the venting channel outlet 67a to avoid blockages, and also kept out of the interior of the refilling device.

DEVICE AND METHOD FOR REFILLING AN ARTICLE OF AN AEROSOL PROVISION
SYSTEM
A device and method for refilling and article of an aerosol provision system is described with reference to Figures 1 and 2 mentioned above and Figures 3, 4, 5A, 5B and 10A-16 mentioned below.
Figure 3 shows a schematic representation of an article arranged for refilling from a reservoir, where both the reservoir and the article are received in appropriate interfaces in a refilling dock (not shown). A reservoir 40 containing aerosol-generating fluid 42 has a nozzle 60 arranged as its outlet orifice. The nozzle 60 acts as the fluid conduit shown in Figure 2. In this example, the nozzle has a tubular elongate shape, and extends from the first end 61 to a second or distal end 62, remote from the reservoir 40, which acts as the fluid dispensing point or fluid outlet of the nozzle. Fluid is retained in the reservoir by, for example a valve (not shown) at or near the proximal end 61, which is opened when fluid transfer to the article commences. In other cases, surface tension may be sufficient to retain the fluid, for example if the bore of the nozzle is sufficiently small. The distal end 62 is inserted into the inlet orifice 32 of the article 30, and in this example extends directly into the storage area 3 of the article 30. In other examples, there may be tubing, pipework or some other fluid flow path connecting the inlet orifice 32 to the interior of the storage area 3. In use, aerosol-generating material 42 is moved out of the reservoir 40 using the fluid transfer mechanism of the dock, along a fluid channel defined by the nozzle 60 (acting as the fluid conduit) from the proximal end 61 to the distal end 62, where it reaches the fluid outlet of the nozzle and flows into the storage area 3, in order to refill the article 30 with aerosol generating material.
Figure 3 shows an example arrangement only, and the outlet orifice of the reservoir may be configured other than as a nozzle, and as noted, the fluid conduit that allows refilling of the article using the refilling dock may or may not comprise parts of the reservoir and the article. In general, however, the outlet orifice of the reservoir is configured to act as, or for engagement with, the fluid conduit so that fluid from the reservoir can be ejected from the fluid conduit and into the storage area of the article. Engagement with the fluid conduit or direct engagement with the article, depending on the arrangement used, may be achieved by relative movement between the reservoir and the end of the fluid conduit, or between the reservoir and the article once the article has been inserted into the article port of the refilling dock. Placement of the reservoir and the article in the dock brings them into suitable alignment such that relative movement towards one another engages and creates the required fluid flow path between the two. The refilling dock may be configured to sense when a reservoir and an article are in place and correctly installed ready for refilling.
An option for removing fluid from the reservoir for transfer to the article is to pull the fluid out of the reservoir. Pulling can be achieved by a pumping arrangement associated with the outlet orifice, through which fluid is pulled. A peristaltic pump might be used, for example.
However, pumping arrangements can be vulnerable to leakage. Typically a number of components are coupled together along and within the flow channel for the pumped fluid, so there can be several joints, and corresponding multiple potential weak points where leaks may arise. Also, the small scale of a typical article, and the corresponding only somewhat larger scale of a suitable reservoir (since a very large store of aerosol generating material may be undesirable for reasons including safety and shelf-life) can make a pump awkward to implement. An overall size for a refilling unit required to accommodate a pumping arrangement may be undesirably large.
Accordingly, the present disclosure proposes instead to push fluid from the reservoir.
This can be implemented by configuring the reservoir to have a movable wall that slides inwardly into the reservoir's internal volume in order to reduce that volume and increase the pressure on fluid in the volume so that fluid is forced out of the reservoir's outlet orifice as the system attempts to equalise the internal pressure. The transfer mechanism of the refilling device is configured with a pushing device, element or apparatus that can act on the moveable wall of a reservoir installed in the reservoir port of the refilling device to provide the required inward pushing when fluid dispensing to refill an article is required.
Figure 4 shows a schematic simplified cross-sectional view through an example reservoir configured in this way. The reservoir 40 comprises a housing having the form of one or more side walls 41, and an end wall 43 which closes one end of the space bounded by the side walls 41 so that the side wall(s) 41 and the end wall 43 define a fluid storage volume 45 for storing aerosol generating material 42. The reservoir 40 further comprises a moveable wall 63 which engages within the side walls 41 in order to close the fluid storage volume 45. The moveable wall 63 is configured to lie in a plane orthogonal to a longitudinal axis of the tubular shape formed by the side walls 41 (so, parallel to the transverse cross-section of the side wall(s) 41), and has a size and shape matching the internal cross-section of the side wall(s) 41 so as to fit closely, while being able to move within the side wall(s) 41 along the direction of the longitudinal axis. During movement, the edge(s) or perimeter of the moveable wall 63 slide over the inner surface of the side wall(s), maintaining contact therewith. The side wall(s) 41 therefore are parallel along the length of the reservoir 40. In order to reduce leakage of fluid 42 from out of the storage volume 45, the moveable wall 63 is configured for sealing around its perimeter; one or more flanges 64 protrude from the moveable wall edges and are compressed against the side wall(s) when the moveable wall 63 is installed. An outlet orifice 44, such as the nozzle in the Figure 3 example, is located in the end wall 43 by which fluid can exit the storage volume 45.
For the dispensing of fluid from the reservoir 40, the refilling device is configured to act on the moveable wall by providing a pressure or pushing force P directed towards the end wall 43 and the outlet orifice 44. This moves the moveable 63 wall inwardly by sliding over the inside of the side wall(s) 41, in other words towards the end wall 43. This reduces the size of the storage volume 45, so that fluid is pushed out of the outlet orifice 44. Fluid can then flow along the flow path of the fluid conduit and into the storage area of the connected article.
In order to achieve this, the refilling device comprises a fluid transfer mechanism 53 as discussed with regard to Figure 2. The transfer mechanism 53 can comprise a plunger, piston or similar pressure-applying or force-applying element that bears against the moveable wall externally to the storage volume to push the moveable wall in the desired direction towards the end wall. Depending on the construction of the transfer mechanism, the moveable wall 63 may have an outer surface (the surface facing outwardly, away from the storage volume 45) which is shaped to receive and/or engage or cooperate with an end part of the transfer mechanism. In other cases, a planar surface may be adequate, and avoids any need for precise alignment between the reservoir and the fluid transfer mechanism.
Figure 5A shows a schematic representation of an example refiling device 50, set up for a refilling action, but prior to the act of refilling. A reservoir 40 has been installed in the refilling device 50 by being placed by a user into the reservoir port 54. The reservoir 40 has a vertical orientation, with the moveable wall at the top and the outlet orifice in the end wall at the bottom. This allows gravity to assist with the movement of fluid out of the reservoir.
When the reservoir is in this position, a plunger 53a of the fluid transfer mechanism 53 can be moved into contact with the moveable wall 63 of the reservoir 40, as shown.
The plunger 53a is driven by a motor (not shown here but described further later) configured to move the plunger 53a along the vertical direction such that it can be advanced towards and retracted away from the moveable wall 63, and also push the moveable wall 63 towards the end wall of the reservoir 40.
In this example, the outlet orifice of the reservoir 40 has the form of a nozzle 60 and comprises the whole of the fluid conduit. When a user requires the refilling of an article, the article 30 is placed by the user into the article port 56 of the refilling device 50. The article port 56 holds the article 30 such that the inlet orifice 32 of the article, which may be covered by a valve (not shown), is aligned with the distal end of the nozzle 60. The fluid flow path from reservoir 40 to article 30 is completed by relative movement between the article 30 and the reservoir 40, which inserts the distal end of the nozzle 60 into the inlet orifice 32, causing the valve to open. The movement, effected by movement of the article port 56 and/or the reservoir port 54, can be automatically provided by the refilling unit 50, electrically by use of one or more motors under control of the controller 55 in response to insertion of the article 30 into the article port 56, or mechanically by suitable hinging, folding and/or sliding parts that operate in conjunction with opening and closing of the door, tray or similar of the article port 56. Otherwise, a lever or similar operable by the user may be provided.
The article 30 may be moved upwards towards the reservoir 40, the reservoir 40 may be moved downwards towards the article 30, or the reservoir 40 and the article 30 may both be moved.
The refilling device is now ready to commence filling of the article 30.
Figure 5B shows the refilling device 50 after a portion of aerosol generating material 42 has been dispensed into the article 30. Once the refilling device 50 is configured for refilling as in Figure 5A, the controller 55 generates control signals in order to operate the fluid transfer mechanism 53, in order to control of a motor such as a stepper motor (not shown) coupled to the plunger 53a, to move the plunger 53 downwards to push on and move the moveable wall 63, as shown by the arrow. This pushes some of the fluid 42 into and along the nozzle 60, from which it is expelled into the storage area 3 of the article 30.
Once a desired quantity of fluid 42 has been transferred from the reservoir 40 to the article 30, the controller 55 ceases controlling the plunger to advance downwards, there is no further pushing on and movement of the moveable wall, and fluid transfer ceases. The transfer may be halted after the plunger has travelled a predetermined distance known to correspond to the capacity of the article's storage area 3, for example.
Alternatively, the amount of fluid which has been moved can be detected or deduced from measurements made on the article or the reservoir by the controller, so that the transfer can be stopped once enough fluid has been moved, such as when the article's storage area is determined to be full.
Next, the relative movement between the article 30 and the reservoir 40 is reversed to uncouple the article from the fluid conduit. In this case, the nozzle 60 is withdrawn from the inlet aperture 32, the valve of which then closes to seal the storage area 3 against leaks.
The user can then remove the refilled article 30 from article port 56, for reuse in an aerosol provision system. The reservoir 40 can be retained in the refilling device 50 for use in the next refilling action. If it has been emptied of aerosol generating material 42 by refilling the article 30, it can be removed and replace with a new full reservoir.
Alternatively, it can be swapped with a reservoir holding a different type of aerosol generating material if the user likes to consume more than one type.
Further details relating to the refilling device and the transfer mechanism will now be described.
The transfer mechanism of the refilling device comprises a plunger for pushing the moveable wall of a reservoir installed in the refilling device. The plunger is driven by an electric motor, which is under control of the controller of the refilling device, and receives power from the power source in the refilling device. The controller acts to control the motor to move the plunger to engage with the moveable wall, push against the moveable wall to dispense fluid from the reservoir in a series of refilling actions, each being the refilling of an empty or partially empty article, and retract the plunger away from the removable wall after use. This is achieved by linear movement of the plunger, along a direction substantially orthogonal to the plane of the moveable wall, and parallel to the side walls of the reservoir in order to slide the moveable wall smoothly over the inner surface of the reservoir, towards the outlet orifice.
An example of an electric motor which may be used to produce the required linear motion of the plunger is a stepper motor, since these are available in a compact size suitable for incorporation into a refilling unit of the type described herein. A
stepper motor is a brushless DC motor comprising a series of electromagnets arranged around a toothed rotor that can engage with the electromagnets as they are energised in turn, according to control signals from the controller of the refilling unit in the present case. The rotor is coupled to or configured as a lead screw, so that driving the motor turns the rotor and also the lead screw.
This rotational movement can be converted to linear movement by use of a lead screw nut wound onto the threads of the lead screw. If the lead screw nut is coupled to a non-rotatable item, the turning of the lead screw causes the lead screw nut to wind up or down the lead screw as it follows the threads, thereby pulling or pushing the coupled item.
In the present case, the coupled item comprises the plunger. Operation of the motor thereby can extend and retract the plunger towards or away from the moveable wall of the reservoir depending on the direction of rotation of the lead screw and rotor, which is governed by the order in which the electromagnetics are energised. Benefits of a stepper motor for the present purpose are that the degree of rotation and hence the amount of linear motion can be controlled very precisely, both by appropriate switching of the electromagnetics and by gearing of coupling between the rotor, the lead screw and the lead screw nut, and also that the components remain in position when the motor is switched off, so that the plunger can be retained in a retracted or extended position between uses. This can save time for repositioning that would be needed if the plunger was withdrawn from the reservoir after each refilling action, for example.
Figure 10A shows a simplified schematic representation of an example of a motor-driven plunger transfer mechanism. The transfer mechanism 53 comprises, in line with the above description, a plunger 53a which is coupled (in this example directly) to a lead screw nut 71 engaged on a lead screw 170. The lead screw 170 is rotated by being driven with a stepper motor, to the rotor of which the lead screw 170 is coupled, under the control of a controller in the refilling device which sends control signals to the stepper motor when movement of the plunger is needed (see Fig. 5A). The motor and the function of the control by the controller is generally indicated as 72. The plunger 53a is arranged in the refilling device (not shown) so as to be aligned with the moveable wall 63 of a reservoir 40 received in the reservoir interface of the refilling device for pushing parallel to the reservoir walls as described. In the depicted orientation, the reservoir 40 is positioned vertically with the moveable wall 63 uppermost, and the plunger 53a is located above the reservoir 40. Linear motion of the plunger 53a produced by operation of the motor is therefore towards and away from the moveable wall (extension and retraction of the plunger 53a). The reservoir 40, the plunger 53a and its coupling to the lead screw 170 via the lead screw nut 71 are positioned relative to one another such that the plunger 53a and the lead screw are in line with one another. The direction of motion of the plunger 53a is coaxial with the longitudinal axis of the lead screw 170. This allows for a simple coupling between the lead screw nut 71 and the plunger 53a. In order to reduce the amount of space required along this direction, and therefore reduce the height of the refilling unit, the plunger 53a is configured to be hollow, as shown in Figure 10A, and surrounds and fits over the lead screw 170, which is inserted into the hollow core of the plunger 53a. This is not essential however, and the plunger 53a may be simply arranged below the lead screw 170.
Figure 10A shows the plunger in a retracted position, at which the transfer mechanism is effectively at rest and unengaged with a reservoir. The plunger 53a is withdrawn or retracted from a position at which it is ready to push a reservoir moveable wall for fluid dispensing. This allows the user to insert a reservoir into the reservoir interface of the refilling device, or to remove a reservoir from the reservoir interface, unencumbered by the presence of the plunger 53a. In Figure 10A, a reservoir 40 is installed in the refilling device ready for use, and the plunger 53a is in the retracted position in which it is spaced apart from the moveable wall 63.
Figure 10B shows the same components as Figure 10A, but with the plunger 53a in a next position, comprising an engaged position. In this position, the plunger 53a is engaged with the moveable wall 63, ready for pushing. The controller can control the motor to move the plunger 53a from the retracted position into the engaged position after the reservoir 40 has been inserted into the refilling device, for example. This avoids delay when a refilling action is required, since the plunger can start to push for dispensing of fluid immediately, with no need to move from the retracted position to the engaged position.
Alternatively, movement into the engaged position from the retracted position by extending the plunger can be effected as a first stage in a first refilling action after the reservoir is installed, if the additional time added to the duration of the refilling action is acceptable.
In the engaged position, the end of the plunger 53a is in contact with or in close proximity to the moveable wall 63, so that further extension causes inward movement of the moveable wall 63 for pushing fluid out of the reservoir 40. Any contact with the moveable wall 63 should be light and minimal so that fluid in the reservoir 40 is not put under pressure, which could force fluid from the reservoir 40 outside of a refiling action, causing a leak. The moveable wall 63 may be shaped for cooperation with the end of the plunger 53a, such as by having a recess or socket formed on its outer surface into which the plunger end is inserted.
Alternatively, the outer surface may substantially plane, flat or featureless in this regard.
When an article is inserted into the refiling device, the controller recognises that refilling is required. This can be by the use of sensors or detectors in the refilling unit, such as in the article interface, that can detect the presence of a correctly inserted article and communicate this to the controller, for example. More simply, the refilling device may comprise a switch, button or other user control or interface that the user actuates after inserting the article in the refilling device to indicate that a refilling action is wanted. In response, the controller sends one or more control signals to the motor to advance or extend the plunger 53a in the inward pushing direction to move fluid out of the reservoir 40 and into the article. This extending movement of the plunger 53a is continued until the controller recognises that a required amount of fluid has been transferred into the article. This may be by the use of a sensor or detector in the article or in the article interface that can detect when the amount of fluid in the article reaches or exceeds a threshold or target level, for example corresponding to the article's storage area being full. The output of the sensor or detector is communicated to the controller, which responds by ceasing advancement of the plunger 53a. Determination of the fluid volume or level, and comparison with the threshold can be carried out locally by the sensor or detector or a chip in the article interface, which send a "stop" signal to the controller. Alternatively, the sensor or detector reading can be sent to the controller which performs the processing and determines when to stop moving the plunger 53a. These are useful arrangements that allow the user to refill an already partially full article. A less complex arrangement is one in which the controller is configured to cause the plunger 53a to move by a pre-set fixed extension amount, to dispense a fixed amount of fluid, which may correspond to the capacity of the article's storage area, for example. Once this pre-set movement is accomplished, the controller recognises the refilling should stop, and ceases to advance the plunger 53a. Assuming that the motor is able to advance the plunger 53a at a fixed speed over its full range of travel, this can be achieved by the controller operating the motor for a fixed amount of time, for example. Other methods for stopping and starting the pushing of the moveable wall are not excluded, however.
At the end of a refilling action, the plunger 53a can usefully be left in its current extended position, engaged with the moveable wall 63. This places the plunger 53a in a new engaged position, immediately ready for a next refilling action, and saves time delays that would result if the plunger 53a was returned to its retracted position after every refilling action. However, it can be useful to retract the plunger 53a very slightly at the end of the pushing movement to achieve the new engaged position. This reduces pressure on the fluid in the reservoir that could otherwise result from a continued small force of the plunger 53a on the moveable wall 63 (if the moveable wall 63 is flexible, for example), and can cause any drips at the reservoir outlet orifice to be drawn back into the reservoir.
This can reduce leakage.
Figure 10C against shows the same components, but with the plunger 53a in an intermediate extended position which it has reached after several consecutive refilling actions, during each of which it is advanced further from the retracted position, pushing the moveable wall progressively inwards and reducing the capacity of the reservoir 40 more each time to dispense fluid. As depicted, roughly half of the original amount of fluid in the reservoir 40 has been dispensed. Successive forward advancement of the plunger 53a can continue in successive refilling actions until the moveable wall reaches the base of the reservoir, the capacity of the reservoir has been reduced to zero or nearly zero, and the reservoir has been emptied, nearly emptied or substantially emptied. This position of the moveable wall 63 is shown in phantom in Figure 10C. The controller is configured to recognise when the reservoir 40 has become empty, and in response, controls the motor in the reverse direction in order to pull the plunger 53a away from the moveable wall, and back to its retracted position (Fig. 10A). The empty reservoir 40 is thereby disengaged from the plunger, and is able to be removed from the refilling device, and replaced with a fresh full or partially full reservoir when desired by the user. The refilling device can be configured to communicate the empty reservoir condition to the user, for example via a message on a user display or the illumination of a light on the exterior of the refilling unit.
The empty state of the reservoir may be determined in any convenient manner.
For example, sensors or detectors in the reservoir interface or the reservoir itself may detect the level or volume of fluid in the reservoir and communicate this to the controller, from which an empty or near empty state can be calculated, in a similar manner to that proposed above for detecting liquid level in the article. Additionally, a threshold for approaching depletion of the reservoir, such as 25%, 20% or 10% of full reservoir capacity, can be monitored for, and used to trigger presentation of a user alert that a new reservoir will be needed soon. A
sensor or detector may be operable to detect the height of the moveable wall 63 within the reservoir 40, so that an empty state is notified when the moveable wall reaches the base of the reservoir. In a further alternative, the lead screw, lead screw nut and plunger may be configured so that a maximum attainable extension of the plunger is provided which corresponds to an empty or near empty reservoir. For example there is a physical barrier to block the lead screw or the plunger from moving further, or the thread on the lead screw runs out. The motor will produce a current spike when the maximum extension is reached, as it attempts to drive the plunger past the end of the allowable movement; this can be detected by the controller and recognised at the empty reservoir state. Alternatively, the end wall 43 of the reservoir 40 may be used as the physical barrier, if pushing of the moveable wall against the end wall by the plunger is acceptable (for example, it will not disturb the position of the reservoir in its reservoir interface).
Figure 11 shows a simplified schematic representation of a further example of a motor-driven plunger transfer mechanism. The various components shown in the Figures 10A-10C example are included, and will not be described in further detail. The components are differently arranged relative to one another, however. In particular, the reservoir 40 is not received in the refilling device directly under and in line with the lead screw 170, but offset to one side. The plunger 53a is aligned with and acts on the moveable wall 63 of the reservoir 40 as before, but in order to be properly aligned it is also offset sideways from the lead screw 170. The plunger 53a is arranged so that the direction of its linear motion (up and down in the depicted orientation) along the line P is parallel to the longitudinal axis L of the lead screw 170, in contrast to the in-line coaxial arrangement of Figure 10A.
To achieve this, the plunger 53a is coupled to the lead screw nut 71 via an arm or plate 73 which extends sideways from the lead screw nut, orthogonally to the lead screw axis L. This enables the plunger 53a to be displaced from the lead screw 70 to give the required parallel configuration. The arm 73 may be a separate element connected to the lead screw nut 71 and the plunger 53a, or the lead screw nut 71 itself may be shaped to provide the arm 73 as an integral part.
The parallel arrangement of Figure 11, which allows the lead screw 170 and the plunger 53a plus the reservoir 40 to be arranged side-by-side, can be useful in reducing the overall height required for the components as a whole, which in turn can reduce the total external size required for the refilling device.
Also shown in Figure 11 is an additional optional feature of the reservoir 40, which comprises a fixed external wall 146 that extends between the side walls 41 to close the reservoir 40 externally of the moveable wall 63. The fixed wall 146 has an aperture 147 therein through which the plunger 53a passes to engage with the moveable wall 63. The fixed wall 146 therefore largely covers the moveable wall 53a, and can protect it from accidental pushing (and to some extent, deliberate tampering, depending on the size of the aperture 147) that may occur in transit or as the user handles the reservoir 40 and which might cause fluid to be unintentionally expelled from the reservoir's outlet orifice. Leakage and spillage is thereby reduced.
Figure 12 shows a schematic side view of an example article interface that may be included in a refilling device as disclosed herein. The article interface 56 has the form of a sliding drawer or tray 80 that is slidably mounted in a suitable opening in the refilling device (not shown). The drawer 80 has a front wall 81 which closes the opening the refilling device when the drawer 80 is in a closed position, pushed into the refilling device.
The front wall 81 is provided with a handle portion 82 by which the user can grip the drawer 80 for the purposes of pulling it into an open position extended from the refilling device and pushing it into its closed positon inside the refilling device, indicated by the double arrow in Figure 12.
The handle portion 82 can take any usable format apparent to the skilled person, including a protrusion, a recess or an aperture. Mounted in the drawer 80 is a cavity 84, in the form of a cup or recess into which an article 30 is inserted by the user when the article 30 requires refilling. The cavity 84 is defined by a boundary wall 83 upstanding from the base of the drawer 81, the interior surface of which conforms to the external size and shape of the article 30 so that the article is held firmly and securely when inserted. This aids alignment and guiding of the article 30 with the fluid conduit when the article 30 and reservoir are brought together in the refilling device to form the fluid flow path for refilling. In order to facilitate insertion and removal of the article 30 into and out of the close fit of the cavity 84, cut-out portions 85 are provided in the boundary wall 83, extending downwards from the upper edge or rim 83a of the cavity 84. The user can reach their fingers through the cut-out portions 85 in order to grip and hold the article 30 when inserting or removing it from the article interface 56. Conveniently, a pair of cut-out portions 85 are provided (only one is shown), arranged on opposite sides of the cavity 84, for ease of gripping the article with a thumb and forefinger.
The provision of cut-out portions 85 allows the cavity 84 to be sufficiently deep in order to receive the article 30 such that its upper surface 33 is flush with the rim 83a of the cavity 84 when fully inserted, or alternatively sits below the rim 83a, or extends only a small way above it, as depicted. This helps to hold the article 30, which is typically a relatively small item, more firmly.
In use, the user uses the handle portion 82 to slide the drawer 80 open, which brings the cavity 84 into access, and allows the user to insert the article 30 into the cavity. The user than pushes the drawer 80 to its closed position, which places the article 30 in a position in or from which it can be coupled into the fluid flow path for refilling.
In this example the article interface also has associated with it at least one sensor or detector 86 which is in communication with the controller of the refilling device. A sensor or detector 86 may be configured to detect that an article 30 is present in the article interface 80, and optionally additionally that the article is correctly inserted (in a required orientation, for example), and/or that the drawer 80 has been returned to the closed position. The controller can determine from the output of the detector 86 that these conditions are met, accordingly recognise that an article is present and ready for refilling, and in response initiate processes required for producing a refilling action. In particular, the controller controls the transfer mechanism, which in the present examples is the control of the motor to advance the plunger to push the moveable wall and dispense fluid from the reservoir.
Additionally other actions may be undertaken by the controller, such as the control of any movements needed to create the fluid conduit, such as bringing the reservoir and the article together for the insertion of a reservoir nozzle into the inlet orifice of the article.
Additionally or alternatively, one or more sensors or detectors 86 can be provided to monitor or measure the level or volume of fluid in the article, in order to enhance control of the refilling action by the controller, such as appropriate timing of the end of a refilling action when the article's storage area is full, as described above. Options for sensing or determining fluid level or volume include detecting the weight of the article, which will depend on the amount of fluid present, and optical detection involving directing a beam of light into the storage area and detecting transmitted or reflected light, which will vary according to the height of the fluid surface. A further option is to measure the capacitance across the article or the storage area. The capacitance will depend on how much fluid, or the presence/absence of fluid, is in the measurement region.
Figure 13 shows a schematic external front view of a further example refilling device 50. The refilling device has an article interface 56 and a reservoir interface 54 as before. The article interface comprises a sliding drawer with a front wall 81 having a handle portion 82 as in the Figure 12 example. The reservoir interface 54 is similarly configured as a sliding drawer, with a front wall 91 and a handle portion 92. Once open, the drawer allows access to a cavity, recess or similar into which the user can place or insert the reservoir before closing the drawer to position the reservoir with the refilling device. Additionally, the front wall 91 of the reservoir interface includes an observation aperture 93, through which the user can look to see the level of fluid which is present in the reservoir. To enable this, the reservoir should comprise a transparent portion or window in its side wall to allow visual inspection of the interior of the reservoir, or the entire side wall(s) can be fabricated from transparent material.
The observation aperture 93 may be an opening in the front wall 91 glazed with a transparent material such as glass or plastic, or may be a simple open hole.
Also, it may be located elsewhere on the housing 52 of the refilling device; any location that is conveniently accessible to the user and which gives a line of sight to the appropriate part of the reservoir can be used. Also, the observation aperture 93 can be used for the user to quickly ascertain if a reservoir is currently installed in the refilling device. This functionality does not require any transparent portion in the reservoir. Both observation functions can be used to supplement other automated processes for conveying the same information to the user, such as messages or symbols on a user display or the illumination of indicator lights in response to detector outputs received by the controller. Alternatively, the enablement of visual inspection in this way may be used in place of automated display of such information in order to simply the refilling apparatus.
Note that any of the various features of the refilling device described with respect to Figures 12 and 13 can be included separately in any refilling device, or in any combination of two or more features. They may also be used in refilling devices that have a transfer mechanism other than the described motor-driven plunger, so as a pump arrangement to pull fluid out of the reservoir rather than pushing it out with a plunger. The features pertaining to the article interface and the reservoir interface may also be implemented in interface configurations other than the sliding drawer arrangements described.
In general terms, the present disclosure provides a method of refilling an article by controlling a motor-driven plunger to move fluid from reservoir with an inwardly moveable wall to a storage area in an article coupled to the reservoir by a fluid flow path. Some more particular details of example of methods of this type will now be described.
Figure 14 shows a flow chart of steps in a first example method. In a first step S1, the user inserts a reservoir with a movable wall in a dock or refilling device. A
controller of the refilling device performs an automated check to determine that the reservoir has been inserted and is present and available for refilling, in a second step S2.
Having recognised that the reservoir is present, the controller sends appropriate control signals to the motor to control the motor such that it moves the plunger in an advancing direction in order to engage the plunger with the moveable wall of the reservoir. The refilling device is now in a condition in which it is immediately ready to refill an article that is inserted into it. While the plunger is in the engaged position, the controller monitors a state of an access door, hatch, or the like that gives access to the reservoir interface in which the reservoir is held inside the refilling device. In a next step S4, the controller determines at any given time whether the access door has been opened. If no, the door has remained closed, and the refilling device can be considered to be still in a state of readiness for refilling. The method proceeds to step S5, in which the controller controls the motor to advance the plunger one or more times to perform one or more refilling actions in response to empty articles being inserted into the refilling device. The refilling actions can proceed until all the fluid in the reservoir is used up. Then in step S6, the controller detects that the reservoir is empty, and no longer available for refilling actions. In response, the controller controls the motor to retract the plunger so that it is disengaged from the moveable wall of the reservoir, and the reservoir itself, by being moved in a reverse direction back to its original retracted position. Then, the user is able to remove the reservoir from the dock in step S8, by opening the access door to reach the empty reservoir.
However, if in step S4 the controller detects that the reservoir access door has been opened, this state is recognised as a likelihood that the user wants to remove the reservoir, for example to replace it with a reservoir holding different fluid, or to check some characteristic of the reservoir. If the user was to attempt removal of the reservoir while the plunger is engaged with it, the plunger and/or the reservoir could be damaged.
To avoid this, the controller acts in response to the opened access door by retracting the plunger to the retract position, so the method proceeds directly to step S7. The user may then safely remove the reservoir in step S8.
The user may open the reservoir access door at any time during the lifetime of the reservoir, so the method can loop back from step S5 to step S4, so that the controller checks for opening of the access door over the time period during which refilling actions can be performed before the reservoir becomes empty.
Figure 15 shows a flow chart of steps in a second example method. This method includes more possible details about the refilling actions of step S5 in the Figure 14 method.
In a first step S10, an article or pod is inserted into a refilling device or dock which is ready to perform refilling actions (such as by steps S1-S3 of the Figure 14 method having been performed). The controller of the refilling device performs an automated check to determine that the article is present and has been correctly inserted for refilling, in a second step S11.
Having recognised that the article is present, the controller sends appropriate control signals to relevant portions of the refilling device to engage the article and reservoir for formation of the required fluid flow path between them, in step S12. The article is then appropriately positioned for refilling, and the reservoir and plunger are primed for a refilling action. In a next step S3, the controller sends control signals to the motor to control the motor such that it moves the plunger in an advancing direction in order to push the moveable wall of the reservoir inwardly to dispense fluid from the reservoir into the article to effect a refilling action. While the dispensing in step S13 is being carried out, the controller monitors an amount of fluid in the article in step S14, where the amount is increasing over the course of the refilling action. In a next step S15, the controller tests if the article is full, such as by comparing the current amount of fluid determined in step S14 with a pre-set maximum or target amount. If the controller determines that no, the article is not full, the method returns to step S14 for continued dispensing of fluid. If the controller determines in step S15 that yes, the article is full, the method passes to step S16, in which the controller controls the motor to stop advancement of the plunger. In a next optional step S17, the controller controls the motor to retract the plunger slightly, to ease the fluid pressure inside the reservoir so that any droplets of fluid at the reservoir outlet are drawn back into the reservoir. In step S18, the article is disengaged from the reservoir, in a reversal of step S12. Finally, the user can remove the article from the refilling device in step S19.
Figure 16 shows a flow chart of steps in a third example method, which provides a simplified refilling action that may be carried out in a refilling device with fewer components and actions. As in the Figure 15 method, the method starts with a user inserting an article or pod into a refilling device or dock in step S20. In step S21, the article and the reservoir are engaged together for formation of the required fluid flow path between them, the result of which is that the article is appropriately positioned for refilling. In a next step S22, the controller sends control signals to the motor to control the motor such that it moves the plunger in an advancing direction in order to push the moveable wall of the reservoir inwardly to dispense fluid from the reservoir into the article to effect a refilling action. In step S23, the dispensing is continued until a required amount of fluid has been dispensed into the article. This may be by detection of the fluid in the article having reached a particular level, for example corresponding to the storage area being full, in response to which a "stop" signal is sent to the controller by a detector or sensor. Alternatively, it may be by operating the plunger for a specified time or over a specified distance known to match a required amount of fluid being dispensed from the reservoir, such as an amount matching the article's storage area capacity. Then in step S24, the plunger is stopped from further advancement in order to cease dispensing of the fluid. In step S25, the article and reservoir are disengaged, in a reversal of step S21. Finally, the user can remove the article from the refilling device in step S26.
Stepper motors have been described in detail herein as being suitable for driving a plunger in a refilling unit. However, other types of motor might be used instead, which are able to produce linear motion of the plunger either directly or by gearing and the like.
While a refilling device according to the present disclosure may be made available to the consumer separately from one or more models of aerosol provision system having aerosol generating material storage areas able to be filled using the refilling device, it may be convenient to make a complete refillable system available as a single group of items.
Hence, a kit may be provided that includes a refilling device and an aerosol provision system with a refillable article of the appropriate format to fit into the refilling device. In an alternative arrangement, the aerosol provision system itself might be receivable into the refilling device for refilling of the storage area. The kit may also include one or more reservoirs pre-filled with aerosol generating material, although the reservoirs should also be available separately to increase longevity of the refilling system as a whole, and in order for the consumer to select between different types of aerosol generating material.
NOZZLE FOR FLUID DISPENSING
A nozzle for fluid dispensing is described with reference to Figures 1 and 2 mentioned above and Figures 3 and 17A- 23 mentioned below.
Further details relating to the fluid conduit will now be described. As noted above, the fluid conduit may be wholly or partly formed by parts of the reservoir 40 and the article 30. In particular, an example arrangement for the fluid conduit 58 is a nozzle by which fluid aerosol generating material is dispensed from the reservoir 40. The nozzle may be provided as an element of the dock, such that the outlet orifice of the reservoir is coupled to a first end of the nozzle when the reservoir is installed in the dock. Alternatively, the nozzle may be embodied as an integral part of the reservoir, to provide the outlet orifice. This associates the nozzle only with the particular reservoir and its contents, thereby avoiding any cross-contamination that may arise from using reservoirs of different aerosol-generating materials with the same nozzle. The nozzle is engaged into the inlet orifice of the article in order to enable fluid transfer from the reservoir into the article. The engagement may be achieved by movement of the article towards the reservoir, or vice versa, for example, when both have been installed in the dock.
Figure 3 shows a schematic representation of a nozzle arranged for use as a fluid conduit. A reservoir 40 containing aerosol-generating fluid 42 has a nozzle 60 arranged as its outlet orifice, a first end or proximal end 61 of the nozzle 60 being adjacent the reservoir 40. The nozzle may be integrally formed with the reservoir by moulding of a plastics material or 3D printing, for example. This ensures a leak-free juncture between the nozzle 60 and the housing 41 of the reservoir 40. Alternatively, the two parts may be formed separately and joined together afterwards, such as by welding, adhesive, a screw-thread or push-fit coupling, or other approach. The nozzle has a tubular elongate shape, and extends from the first end 61 to a second or distal end 62, remote from the reservoir 40, which acts as the fluid dispensing point. Fluid is retained in the reservoir by, for example a valve (not shown) at or near the proximal end 61, which is opened when fluid transfer to the article commences. In other cases, surface tension may be sufficient to retain the fluid, for example if the bore of the nozzle is sufficiently small. The distal end 62 is inserted into the inlet orifice 32 of the article 30, and in this example extends directly into the storage area 3 of the article 30. In other examples, there may be tubing, pipework or some other fluid flow path connecting the inlet orifice 32 to the interior of the storage area 3. In use, aerosol-generating material 42 is moved out of the reservoir 40 using the fluid transfer mechanism of the dock, along a fluid channel defined by the nozzle 60 (acting as the fluid conduit) from the proximal end 61 to the distal end 62, where it reaches a fluid outlet of the nozzle and flows into the storage area 3, in order to refill the article 30 with aerosol generating material.
During this act of refilling, fluid enters the empty or partly empty storage area and displaces the air therein. To avoid or reduce a pressure increase inside the storage area, the air should be allowed to escape. This is known as venting. It is undesirable for a large pressure increase to arise in the storage area, since the pressure can force fluid out of the storage area via the aerosol-generating material transfer component (wick or similar) towards the vapour generator, causing internal leakage within the article.
This may be addressed by providing a vent in the wall of the storage area, but this will become a further point vulnerable to leakage.
Accordingly, the present disclosure proposes to allow both fluid in and air out via the article's inlet orifice and additionally via the nozzle. To achieve this, the nozzle is configured such that its outer wall, having a tubular shape and extending between the proximal end and the distal end, encloses two channels, a first channel being a fluid channel to carry fluid flowing from the reservoir, into the proximal end of the nozzle and out of the distal end of the nozzle into the article. The air displaced by the fluid in the storage area enters a second channel in the nozzle, the second channel being a venting channel to carry the air away from the article from the distal end of the nozzle towards the proximal end. In this way, pressure increases inside the storage area of the article can be reduced or avoided.
This dual nozzle arrangement of two channels, one for fluid flow and one for air flow, is implemented by dividing the volume inside an outer tube or wall (overall nozzle volume) into two channels by use of a dividing, inner, wall inside the outer wall.
Various configurations of the inner wall are contemplated; some non-limiting examples are discussed below. The inner wall similarly extends between the proximal and distal ends of the nozzle, providing the flow channel and the venting channel as two parallel channels extending along the longitudinal direction of the nozzle.
Figure 17A shows a schematic longitudinal cross section through a first example dual nozzle 60. As previously noted, the nozzle 60 has a proximal end (reservoir end) 61 and a distal end (article end) 62. The proximal end 61 is integral with or coupled to a reservoir (not shown) by any suitable means, including intermediate coupling elements (not shown). The nozzle 60 comprises an outer wall 163, which is tubular, and in this example has a circular transverse cross-sectional shape. The interior space bounded by the outer wall 163, which can be though of as the nozzle volume, contains within it an inner wall 164, which in this example is also tubular with a circular transverse cross-section. The inner wall 164 is arranged within the outer wall 163 so as to be positioned concentrically with the outer wall 163. In other words, the longitudinal axes of the two tubular walls 163, 164 are coincident.
More generally, the inner wall 164 is coaxial with the outer wall 163. The space inside the inner wall 164, bounded by the inner surface of the inner wall 164, provides the fluid flow channel 166, along which fluid F flows from the proximal end 61 to the distal end 62, where it is ejected from the nozzle 60 into the storage area of an article (not shown).
The space between the inner wall 164 and the outer wall 163, bounded by the inner surface of the outer wall 163 and the outer surface of the inner wall 164, provides the venting channel 165. Air A
enters the venting channel 165 at the distal end, and flows along it towards the proximal end.
The fluid channel 166 is arranged to extend beyond the venting channel 165, at the distal end 62. There is a length X, being the length by which the fluid channel 166 exceeds the length of the venting channel 165. In this example, this extension of the fluid channel 166 is achieved by configuring the inner wall 164 to be longer than the outer wall 163 at the distal end 62, so that the distal end of the inner wall 164 protrudes out of the distal end of the outer wall 163. The purpose of this arrangement is to spatially separate the fluid outlet from the air inlet. This reduces the chance of fluid entering or being drawn into the venting channel 165 and blocking or partially blocking it. Such a blockage impedes the venting capability of the nozzle 60, and allow pressure increases inside the article.
Figure 17B shows a schematic representation of the nozzle of Figure 17A in transverse cross-section. The coaxial position of the inner wall 164 inside the outer wall 163 can be seen, together with the circular cross-sections of the walls 163, 164.
The venting channel 165 comprises the annular spaced formed between the inner wall 164 and the outer wall 163.
The nozzle has a transverse width W, being the exterior width (diameter in this case) of the outer wall 163. While this may be any size, as appropriate depending on the intended use of the nozzle 60, in the context of a refilling dock for e-cigarette pods, a width of up to about 2 mm is envisaged as being practical given the typical size of a pod, and feasible or desirable dimensions of a fluid inlet orifice for a pod. As a concrete example, W may have a value of 1.6 mm or 1.8 mm, for example. Accordingly, the nozzle width might be in the range of 1.5 mm to 2 mm. Wider nozzles are of course possible, for example in the range 1.5 mm to 2.5 mm or 1.5 mm to 3 mm.
Figure 18A shows a schematic longitudinal cross-section of a further example dual nozzle 60. This example differs from the Figure 17A example by the position of the inner wall 164. As in the Figure 17A example, both the inner wall 164 and the outer wall 163 have a circular cross-section. However, the inner wall 164 is not coaxial with the outer wall 163, but rather it is offset from the central longitudinal axis, indicated by the dotted line, of the outer wall 163 (and hence of the nozzle 60 overall). This arrangement may be termed eccentric, in contrast to the concentric arrangement in Figures 17A and 17B. Figure 18B
shows a transverse cross-sectional view of the nozzle 60. The inner wall 164 is placed at one side of the outer wall 164, so as to be in contact with the inner surface of the outer wall 164. This gives the venting channel 165, again defined between the inner and outer walls 163, 164, a crescent shape instead of the previous annular shape.
A purpose of this arrangement is to increase transverse dimensions of the venting channel, which reduces the chance of blockage if fluid enters the venting channel. For the same inner width of the outer wall and outer width of the inner wall, the venting channel is made wider as its widest point, compared to the width of the annular venting channel which would be formed by a concentric position.
Figure 19 shows a transverse cross-sectional view of another example dual nozzle having an eccentrically positioned inner wall 164. In this case, the inner wall 164 is offset from the central longitudinal axis of the nozzle 60, as in the Figures 18A and 18B example, but is still separated from the inside surface of the outer wall 163. Its position is intermediate between that in the Figures 17B and 18B examples. The venting channel 165 therefore has an irregular annular shape, of non-constant width, but nevertheless, somewhat increased with respect to a concentric arrangement.
In nozzle designs comprising a tubular inner wall inside a tubular outer wall, any position of the inner wall relative to the outer wall may be used. An eccentric arrangement can be used to widen the venting channel and reduce the likelihood of blockage. A
concentric arrangement may be preferred owing to its symmetry, which may ease alignment of the nozzle with the inlet orifice of an article.
Also, the nozzle need not be formed only from tubes or tubular walls of circular cross-sectional shape. Other shapes may be used as preferred, and the two walls need not be of the same shape. Curved shapes may be generally preferred as providing smoother fluid flow, but are not essential.
Figure 20 shows a transverse cross-sectional view of a further example dual nozzle defined by two tubular walls. In this case, the outer wall 163 has an oval or ellipse shape, and the inner wall 164 is circular. This configuration can also be used to increase the width of the venting channel 165 to reduce blockage. Other shapes are not excluded, however.
The inner wall may divide the nozzle volume into the two required channels in other ways than by being configured as a second tubular shaped, however. The volume may be partitioned simply by an inner wall that extends across the interior of the outer wall, attached at two different points around the inner perimeter of the outer wall.
Figure 21A shows a transverse cross-sectional view of a first example nozzle having a partitioning inner wall. The nozzle 60 comprises an outer wall 163 of circular cross-section, and an inner wall 164 which is straight, and extends across the nozzle volume without passing through the central axis. In effect, the inner wall 164 is a chord of the circle defined by the outer wall 163, and divides the nozzle volume into two segments, one on either side of the inner wall 164. Hence the two channels 165, 166 are provided, each bounded by one side of the inner wall 164, and part of the inner surface of the outer wall 163. The inner wall 163 is offset from the centre, so the channels 165, 166 have different sizes.
The larger channel 165 can be allocated as the venting channel, since its larger width will help to reduce blockages, as described above. The position of the inner wall 164 may be chosen to set the relative sizes of the channels 165, 166 as desired. In some cases, it may be desirable for the straight inner wall 164 to be aligned along the diameter (or other midway dividing line of the outer wall 163 if it is not circular) of the outer wall 163 to give two channels of equal cross-sectional area.
A partitioning inner wall need not be straight or flat, however; other shapes may be used to divide the nozzle volume as desired.
Figure 21B shows a transverse cross-sectional view of a second example nozzle having a partitioning inner wall. The nozzle 60 comprises an outer wall 163 of circular cross-section, and an inner wall 164 which is curved between the two points at which it contacts the inner surface of the outer wall 163. The amount of curvature can be chosen as desired; a relatively tight curvature as in Figure 21B will create a cross-sectional space inside the curve which approximates a circle, similar to the eccentric inner tubular wall of Figure 17B. This might be preferred for smoother fluid flow in the fluid channel 166. As in previous examples, the inner wall may be shaped and positioned in order to divide the nozzle volume into two unequally sized channels, where the larger one can be allocated as the venting channel 165.
While substantially equally sized flow and venting channels may be used, and may be suitable or preferred in some circumstances, a larger venting channel can be used to reduce blockage, as explained above. The sizes of the channels can be defined in terms of their transverse cross-sectional area. For a larger or wider venting channel, the transverse cross-sectional area of the venting channel is therefore larger than that of the fluid channel.
Experiment has determined that a useful ratio is about 2:1, in other words, the cross-sectional area of the venting channel is about twice the cross-sectional area of the fluid channel. Considering the nozzle volume as a whole, the fluid channel and the venting channel respectively occupy about one-third and two-thirds of the volume and the total cross-sectional area. Values near this proportion may also be useful, for example so that the cross-sectional area of the venting channel may be in the range of about 1.5 to 2.5 times the cross-sectional area of the fluid channel. Other values are not excluded, however, and may be appropriate in some cases. The examples values given are useful for nozzles of the width noted above, of about 2 mm or less, for example.
The nozzle may be substantially straight, in that the cross-sectional shape and size remains constant along the length of the nozzle. Also, the ratio of the areas of the two channels may remain constant with length. Other arrangements may be used, however, such as a flaring nozzle shape which is wider at the proximal end and narrower at the distal end. The ratio between the channels might vary. For example, a proportionately larger venting channel at the distal end may aid in reducing blocking if any fluid is drawn in, while a proportionately larger fluid channel at the proximal end may aid in feeding fluid into the fluid channel from the reservoir.
In order for the air to escape from the venting channel, one or more apertures may be formed in the outer wall of the nozzle, that are in fluid communication with the venting channel. If the one or more apertures are positioned outside the article when the nozzle is inserted into the inlet orifice for refilling, the air is simply vented into the interior of the refilling dock. Depending on the connection or juncture configuration at the proximal end of the nozzle, a chamber may be provided in fluid communication with the venting channel (either by an aperture or by termination of the outer wall while the inner wall extends further) to receive the air, formed for example within a bung or socket that holds the proximal end within the reservoir. The chamber may then have an outlet.
As noted above, the fluid channel is configured to extend beyond the venting channel at the distal end of the nozzle. Experiments have been conducted to test the efficacy of different lengths of the extending part (this length being a length differential between the two channels). As discussed, the purpose of the extra length is to separate the fluid outlet and the air inlet to minimise blockage of the venting channel with fluid. This can be tested by measuring the pressure inside a space to which the fluid is dispensed, such as the storage area in an article. If the venting channel is fully effective, no pressure increase is observed.
However, if the venting channel becomes obstructed, such as by fluid intake, the flow of air along the venting channel is impeded or stopped, and the pressure in the space increases as more incoming fluid is unable to displace air from the space.
Figure 22 shows a bar chart of some experimental measurements performed to test this feature. Nozzles with variety of length differentials were fabricated, having a concentric circular configuration as in Figure 17B and an outer diameter between 1.5 and 2 mm. The length differential is the extension X of the fluid channel beyond the venting channel, as shown in Figure 17A. Nozzles with a zero length differential (X = 0) experienced blockage sufficient to cause a significant pressure increase, of around 1kPa, as shown in Figure 22. A
value for X of 3mm significantly reduced the observed pressure increase, to about 0.3 kPa, indicating that an extension of this size is highly beneficial. A further increase in length up to X = 4.5 mm produced no measurable pressure increase, a result also noted at still longer lengths (7 mm and 12 mm). Accordingly, it is concluded that a length differential is beneficial is improving performance of the venting channel. A length of 3 mm or more provides a useful effect, and a length of 4.5 mm or more can reduce or eliminate a pressure increase.
Figure 23 show a graph of further experimental measurements of pressure during refilling. In this case, the nozzle had a length differential, and was configured with an eccentrically located inner wall as in Figure 18B. The outer diameter was between 1.5 and 2 mm. As can be seen from the graph, the pressure increase remained substantially at zero throughout the refilling, indicating good venting performance through the venting channel.
In applications where small nozzle sizes are required or desirable, such as the example dimensions given above, a dual nozzle in accordance with the disclosure may conveniently be fabricated using three-dimensional printing. This may also be used for larger scale nozzles, but in such designs other fabrication techniques may be more straightforward than at smaller sizes, such as moulding of plastics materials, or assembly of separate parts for the inner and outer walls.
Although the refilling of aerosol generating material storage areas of aerosol provision system and articles for aerosol provision systems have been cited as a particular use of nozzles as disclosed herein, including use in refilling devices, the concept is not so limited. Nozzles in accordance with the disclosure can be used in any circumstance where liquid is to be transferred into a substantially closed or airtight space so that air needs to be vented in order to avoid or reduce pressure increases.
REFILLABLE ARTICLE FOR AN ELECTRONIC AEROSOL PROVISION SYSTEM
A refillable article for an electronic aerosol provision system is described with reference to Figures 1 and 2 mentioned above and Figures 3 and 24-30 mentioned below.
Further details relating to the article will now be described.
Figure 3 shows a schematic representation of an article arranged for refilling from a reservoir, where both the reservoir and the article are received in appropriate interfaces in a refilling dock (not shown). A reservoir 40 containing aerosol-generating fluid 42 has a nozzle 60 arranged as its outlet orifice. The nozzle 60 acts as the fluid conduit shown in Figure 2. In this example, the nozzle has a tubular elongate shape, and extends from the first end 61 to a second or distal end 62, remote from the reservoir 40, which acts as the fluid dispensing point. Fluid is retained in the reservoir by, for example a valve (not shown) at or near the proximal end 61, which is opened when fluid transfer to the article commences.
In other cases, surface tension may be sufficient to retain the fluid, for example if the bore of the nozzle is sufficiently small. The distal end 62 is inserted into the inlet orifice 32 of the article 30, and in this example extends directly into the storage area 3 of the article 30. In other examples, there may be tubing, pipework or some other fluid flow path connecting the inlet orifice 32 to the interior of the storage area 3. In use, aerosol-generating material 42 is moved out of the reservoir 40 using the fluid transfer mechanism of the dock, along a fluid channel defined by the nozzle 60 (acting as the fluid conduit) from the proximal end 61 to the distal end 62, where it reaches a fluid outlet of the nozzle and flows into the storage area 3, in order to refill the article 30 with aerosol generating material.
Figure 3 shows an example arrangement only, and the outlet orifice of the reservoir may be configured other than as a nozzle, and as noted, the fluid conduit that allows refilling of the article using the refilling dock may or may not comprise parts of the reservoir and the article. In general, however, the inlet orifice of the article is configured for engagement with the fluid conduit so that fluid from the reservoir can be ejected from the fluid conduit and into the storage area of the article. Engagement with the fluid conduit may be achieved by relative movement between the article and the end of the fluid conduit (such as the distal end of a nozzle) once the article has been inserted into the article port of the refilling dock.
Once the article has been filled or refilled with aerosol-generating material, it is important that the fluid be retained within the storage area other than the intended egress to feed the vapour generator of the aerosol provision system. Accordingly, the storage area should be configured for the minimisation of leakage. According to the present disclosure, this is addressed by the use of a valve for the inlet orifice of the article.
Figure 24 shows a schematic cross-sectional view of an example article (not to scale). The article 30 is bounded by an outer housing 31 that defines the external shape of the article 30 and forms an interior space for accommodating various elements and parts of the article 30 such as were discussed above with reference to Figure 1. Of relevance to the present concept, there is shown a storage area 3 for holding fluid aerosol-generating material 42. Other parts not relevant to the concept are not shown for simplicity. The storage area 3 is represented as a simple cylindrical or cuboidal tank, but again this is for simplicity, and the storage area 3 may have any shape in reality, according to the nature of the other parts within the article and the size and shape of the article.
The outer housing 31 is formed from one or more walls, where the number of walls used to assemble the outer housing will be dictated by the design of the article. The article 30 has a somewhat elongate shape, with one end being a mouthpiece end 36. This outer housing slopes inwardly towards the mouthpiece end in order to form a comfortable shape for the mouthpiece. Side walls extend from the mouthpiece end towards a second end of the article 30, opposite to the mouthpiece end 36. Towards the second end, the side walls have a recessed portion 37 for insertion into a receiving socket at an end of a corresponding device in order to create an aerosol generating system. This is an example only, however, and the outer housing may be otherwise shaped.
The article 30 is closed at the second end by a wall 33. This wall 33 includes an inlet orifice 32 by which aerosol-generating material can be added to the storage area for refilling of the article 30. Hence, this wall can be considered as an inlet wall 22. The inlet orifice 32 is closed or covered by a valve 34 that inhibits the flow of fluid out of the storage area 3, and thus reduces leakage from the article 30. Note that in this example, the inlet orifice 32 is in the form of an aperture in the inlet wall 33. The valve 34 covers the aperture. Also, the valve 34 opens directly into the interior of the storage area 3.
Note also that in this example, the inlet wall 33 is at an opposite end of the article 30 to the mouthpiece end 36. To allow refilling, the mouthpiece end can be held in an article port in a refilling device, leaving the inlet wall exposed for connection with the fluid conduit.
For example, the article port may receive the article with the mouthpiece end oriented downwardly, as in Fig. 24, so that the inlet wall faces upwardly for refilling. This can be useful for some internal configurations of article, such as particular vapour generators, or vapour generator and storage area combinations. Also, placement of the inlet orifice in the article wall opposite the mouthpiece will, in general, enable it to be covered when the article is coupled to a device. It is therefore protected from tampering or accidental ingress of contaminants into the storage area. The concept is not limited in this way, however, and the inlet orifice and associated inlet wall can be otherwise located as part of the outer housing 31.
Also shown are electrical contacts 35 for electrical connection of the article 30 to a device with which the article forms an aerosol provision system. Contacts will typically pass through the end wall of the outer housing 31, where in this case the end wall is also the inlet wall 33.
In this example, the inlet wall 33 comprises only the end wall of the outer housing 31.
In such an arrangement, the remainder of the outer housing 31, namely the wall or surface at the mouthpiece end, and the side wall or walls or surfaces, might be formed as a single part, and the inlet wall used to close the article 30 once all required elements are installed in the article's interior. In other cases, the rest of the outer housing 31 might be formed from more than one separate wall or walls, which are joined together by welding, adhesive, snap-fit or similar. Also, the inlet wall 33 may define more than just one side or surface of the outer housing 31, and as a single part may extend further around the outer housing, such as by also forming all or part of one or more adjacent surfaces.
Regardless of the shape or location of the inlet wall 33, according to the present concept, the inlet orifice 32 and its associated valve 34 are integrally formed with the inlet wall 33. By integrally formed, it is meant that the various parts of formed as a single continuous element or component, rather than being formed from separate elements made individually and then joined together. This approach allows for speed of fabrication, since the assembly of parts into a larger component is eliminated. Also, the risk of leakage from the inlet orifice when the article is being used or stored is reduced, because there are no seams or joints between the valve and its surroundings, which might be vulnerable to leaks if improperly formed, or weakened by repeated use such as repeated engagement of the inlet orifice with the fluid conduit. Once formed, the inlet wall is installed with the other wall or walls to create the complete outer housing. The installation may be via a push-fit friction connection, where the inlet wall is formed as a plug that closes an otherwise open cavity defined by the other wall or walls, or may be affixed by adhesive, welding, a snap-fit connection, or any other method that will be apparent to the skilled person.
Any suitable fabrication technique can be used to make the integral valve and wall component. Plastics materials and natural or synthetic rubbers are suitable, and can be used conveniently in techniques including moulding and three-dimensional printing.
A particular example material is silicone. These type of flexible, resilient but deformable materials are suitable for forming into valves that can be opened by deformation under the pressure of the engaging end of the fluid conduit or nozzle when it is inserted into the inlet orifice, and which will return to its original closed configuration once the conduit end is withdrawn. Silicone can be used as it is suitable for self-sealing valves, in which one or more slits or cuts in the silicone can open to let the conduit end through, and close again once the conduit end is removed.
Examples of suitable types of valve that can be formed in this way, integrally with the inlet orifice and the inlet wall, are slit valves (comprising a single slit in a planar or curved membrane), cross-slit valves (comprising two intersecting slits in a planar or curved membrane or other shaped portion), dome valves (a domed portion having one or more slits or similar formed in it), duckbill valves, and flap valves. Other valve types are not excluded, however.
Furthermore, while an integrally formed valve offers the features noted above, other, lo separately formed valves might be used in a refillable pod that otherwise has one or more features described herein. The valve types mentioned already could be used, fabricated separately and later coupled into the inlet orifice. Also, valves comprising individual elements that preclude integral formation as one piece could be used, such as a ball valves, spring valves and poppet valves.
Figure 25A shows a simplified schematic cross-sectional view of an example article 30, shown as a simple rectangular box for simplicity (with all elements of the article not relevant to the refilling arrangement mitted for clarity). Prior to full engagement within the refilling device or dock, the article 30, having as before a valve 34 integral with an inlet wall 33, is aligned with a fluid delivery end or distal end of a fluid conduit 58, such as the nozzle 60 of the reservoir in Figure 3. The valve 34 is closed at this time. Relative movement, shown by the double arrow, then occurs between the article 30 and the fluid conduit 58 in order to engage the end of the fluid conduit with the inlet orifice 32. The conduit end enters the inlet orifice 32 and pushes the valve 34 into its open position. The relative movement could be, for example upward movement of the article 30 towards fluid conduit 58, automated by the refilling device, for example a motorised movement, or a consequence of cooperating mechanical movable parts operated as the user closes a hatch, door, tray or similar of the refilling device that gives access to the article port, or movement of an arm or lever by the user. Alternatively, the fluid conduit 58 could move towards the article 30.
Figure 25B shows the article 30 engaged with the fluid conduit 58 such that the end of the conduit has entered the inlet orifice 32 and opened the valve 34. The fluid conduit 58 now reaches directly into the storage area 3 of the article 30, so that fluid F flowing along the conduit 58 is emitted from the conduit end and flows into the storage area, thereby refilling the article 30 with aerosol-generating material.
In the examples of Figures 24 and 25A/5B, the inlet orifice is an aperture in the inlet wall, so that the valve closing the inlet orifice lies substantially in the same plane as the inlet wall. Also, the inlet orifice and the valve are arranged so that the valve opens or leads directly into the storage area. This is not essential however. As noted above, the storage area can have any shape and configuration according to the design and operation of the aerosol provision system, and it may be that the arrangement shown thus far, in which the inlet wall effectively forms a boundary wall of the storage area (or directly overlies the storage area) is not suitable. In this case, the storage area can be located away from the inlet wall.
Figure 26 shows a simplified schematic cross-sectional view of a further example article 30, shown as before for simplicity as a rectangular box containing a storage area 3.
Also as before, the inlet wall 33 is an end wall of the article 30, shown with its mouthpiece end 36 downwards. As a difference from previous examples, in this case the inlet orifice 32 is centrally positioned within the inlet wall 33, in contrast to the offset positions illustrated earlier. The storage area 3 is arranged at one side of the interior of the article 30, spaced apart from the inlet wall 33. In order for fluid injected or delivered through the valve 34 to reach the storage area, a fluid flow path 38 is provided through the interior of the article 30 that connects the inlet orifice 32 to an inlet 141 of the storage area 3. The fluid flow path may comprise tubing or pipes, or a bore formed through or between solid elements inside the article, and may follow any direction needed to get between the inlet orifice 32 and the storage area inlet 41, having regard to intervening elements and components in the article 30.
Figure 27 shows a simplified schematic cross-sectional view of another example article 30. In this example, we return to an offset inlet orifice 32 and a storage area 3 bounded by the inlet wall 33. However, the particular features specific to this example can also be combined with a central inlet orifice and/or a differently located storage area.
In this example, the inlet orifice is not merely a simple aperture in the inlet wall 33.
Instead the inlet orifice 32 comprises a tubular inlet 39 extending from an aperture in the inlet wall inwardly into the interior of the article, in this case the interior of the storage area 3. The valve 34 is located at an end of the tubular inlet 39, being a distal end of the tubular inlet 39, remote from a proximal end of the tubular inlet 39 at the inlet wall 33.
Proximal and distal are defined with respect to the direction of fluid flow during refilling. Hence, the valve 34 is inset or inwardly displaced with respect to the plane of the inlet wall 33 around the aperture of the inlet orifice 32 in the inlet wall 33. In use, the delivery end of the fluid conduit is inserted into the tubular inlet 39 and reaches down to the valve 34, where relative movement pushes the fluid conduit end through the valve 34 as before.
This inset location for the valve offers some protection against damage for the valve, and protection against the ingress of contaminants and foreign bodies that could otherwise enter the storage area. Also, the tubular inlet offers spatial guidance for the end of the fluid conduit as it approaches the valve. If the end of the fluid conduit is close in width to the interior width of the tubular inlet, lateral movement of the conduit end is reduced or prevented so that the end of the fluid conduit, which might be shaped for improved engagement with the valve, is properly aligned with the valve as it makes contact. Also, the tubular element can act as a fluid flow path as described with regard to Figure 25, if the storage area is separated from the inlet wall. The valve could be located at the inlet to the storage area, for example. For ease of insertion of the fluid conduit into the tubular inlet, the fluid conduit may have a circular exterior cross section, and the tubular inlet may have a circular interior cross section.
Given the relatively small scale of a typical article for an aerosol provision system, the length of the tubular inlet will not be great. For example, the length from the proximal end lo to the distal end (the inlet wall to the valve) may be in the range of 5 mm to 20 mm, or the range of 7 mm to 15 mm. Other lengths are not excluded, however. Further regarding dimensions, the tubular inlet (if included), the inlet orifice and the valve can be shaped to engage with an fluid conduit such as a nozzle which has a width in the range of 1.5 mm to 2.5 mm, or 1.5 mm to 3 mm, or 1.5 mm to 2 mm. For example, the width might be about 2 mm, or about 1.6 mm, or about 1.8 mm. Other widths are not excluded, however.
Figure 28 shows a photographic image of an example inlet wall according to the present disclosure. The inlet wall 33 is formed from silicone by moulding, and is in an inverted position compared to the examples of earlier Figures. The inlet wall 33 is intended as an end wall of an article with a transverse cross-sectional shape which is rectangular with rounded corners. This is consistent with an overall shape for an aerosol provision system which is a flattened elongate shape, rather than cylindrical. The inlet wall 33 comprises an end face 33a that forms the external surface of the article, and a flange 33b perpendicular to the end face 33a which allows the inlet wall 33 to be slotted into and engage with the open end of the remainder of the outer housing of the article. The flange can provide a secure watertight seal between the inlet wall and the surrounding outer housing, thereby closing the storage area if required, or otherwise providing a leak-proof joint. In this example the inlet orifice is offset at one end of the rectangular shape of the inlet wall 33. An offset arrangement, in which the inlet orifice is spaced apart from the centre of the inlet wall, can be appropriate for keeping the refilling facility separate from, or fitted around, other components, such as electrical contacts (see Figure 24). The inlet orifice has a format as in the Figure 7 example, comprising a tubular inlet 39, at the distal end of which the integrally formed valve 34 is situated. The valve 34 is a cross-slit valve; the four arms of the cross can be seen.
As described above, the article can be received in an article port or article interface in a refilling dock. In order for the article to be held firmly in place during insertion of the fluid conduit for refilling, the article port can comprise a recess shaped to correspond with the external profile of the article, and of sufficient depth to enclose the article over a large portion of its length, leaving the inlet wall exposed for refilling access. For example the recess may be between one half and the whole of the length of the article, along a dimension perpendicular to the inlet wall, might be received in a closely-fitting recess or cavity of the article port. Relative movement between the article and the fluid conduit along the same dimension brings the two into engagement for refilling.
As noted above, the inlet orifice may or may not be centrally located within the inlet wall. Where the article has some degree of rotational symmetry about an axis or dimension perpendicular to the inlet wall, for example its cross-section is circular or oval or square or rectangular, there will be more than one orientation in which the article can be inserted into the article port recess. If the inlet orifice is centrally disposed with respect to the inlet wall, this will not matter, and the fluid conduit will be in alignment with the inlet orifice for all possible orientations. However, if the inlet orifice is offset from the centre of the inlet wall, for example located near to or next to the edge of the inlet wall, as in the Figure 28 example, the fluid conduit and the inlet orifice will only be aligned for one orientation of the article in the article port recess. In order to prevent erroneous insertion of the article by the user, which will not allow refilling and could damage either or both of the article and the refilling device, it is proposed to provide the outer housing of the article with one or more locating features that force the correct insertion orientation of the article into the refilling device.
Figure 29 shows a perspective view of an example outer housing for an article.
The outer housing is partial, forming the side surfaces 45 and mouthpiece end surface 36 of the article, and being configured to receive the inlet wall of Figure 28 into its open end (shown uppermost) in order to close the interior of the article and form the completed outer housing.
A location feature 146 is provided on the outer surface of the side wall of outer housing 31.
In this example, the location feature 146 is configured as a small protrusion extending from the surface of the outer housing, but it may alternatively comprise a recess such as a groove or slot. In other words, the location feature is a surface feature that may be convex or concave. More than one location feature may be provided, although only one is necessary to achieve the desired effect. Protrusions and recesses may be combined on the same article.
The location feature acts to break any rotational symmetry of the article that may otherwise exist for rotation of the article about an axis perpendicular to the inlet wall. In a transverse cross-section of the article substantially parallel to the inlet wall and in a plane that includes the location feature or features, the perimeter of the article, as defined by the external surface of the outer housing, has no rotational symmetry.
Accordingly, if the cavity or recess of the article port or article interface is correspondingly shaped, with a recess or protrusion matching the protrusion or recess of the location feature, the article can only be inserted in a single orientation, which is selected to be the correct orientation to align the inlet orifice with the fluid conduit.

Figure 30 shows a schematic transverse cross-sectional view through an example outer housing of an article. The transverse cross-section is parallel to the plane of the inlet wall, perpendicular to an axis which is orthogonal to the inlet wall, and in the case of the Figure 29 example, perpendicular to the axis between the inlet wall and the mouthpiece end.
The outer housing 31 has a protruding location feature 146a, similar to the location feature 146 of the Figure 9 example, and a recessed location feature 146b, which is on an opposite side of the perimeter defined by the outer wall 31 in this example, but could be elsewhere or omitted altogether.
It is desirable that any location features do not intrude overly much on the overall external appearance or tactile feel of the article. Accordingly, they may be kept to a low profile. For example, a protruding surface feature may extend by, or have a height above the external surface of the article (defined by the outer housing) of not more than 1 mm. A
recessed surface feature may have a depth below the external surface of not more than 1 mm. Larger sized location features may be acceptable in some designs, such as having a height or depth of less than 2 mm.
Location features as described may be provided in an article separately from a refilling wall with an integrally formed valve. For example, an article with a different configuration of refill valve may include location features, or location features may be useful in articles that lack refilling capability if alignment with a device or system of some kind is required.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims (89)

Claims

1. A reservoir for use in a refilling device, the reservoir comprising:
a fluid storage volume bounded by one or more side walls and an end wall;
an outlet orifice in or near the end wall, configured to form, or engage with, a fluid conduit engagable with an inlet orifice of an article of an aerosol provision system to provide a fluid flow path from the fluid storage volume to a storage area in the article when the reservoir and the article are installed in the refilling device; and a moveable wall disposed opposite to the end wall to close the fluid storage volume, the movable wall configured to slide towards the end wall, and engagable with a pushing element of the refilling device operable to push the moveable wall towards the end wall in order to reduce a capacity of the fluid storage volume such that fluid in the fluid storage volume is moved through the outlet orifice to the fluid flow path in order to fill the storage area of the article.

2. A reservoir according to claim 1, wherein the one or more side walls and the end wall define a cylindrical fluid storage volume, and the moveable wall is circular.

3. A reservoir according to claim 1 or claim 2, wherein the outlet orifice is in the end wall.

4. A reservoir according to any preceding claim, wherein the outlet orifice comprises a nozzle extending from the end wall.

5. A reservoir according to claim 4, wherein the nozzle forms the fluid conduit and has a distal end remote from the end wall which is configured to engage with the inlet orifice of the article.

6. A reservoir according to claim 4 or claim 5, wherein the nozzle comprises a venting channel configured to carry air from the storage area which is displaced by fluid filling the storage area.

7. A reservoir according to claim 6, comprising a venting chamber within the end wall which is in fluid communication with an outlet of the venting channel.

8. A reservoir according to claim 7, wherein the venting chamber is shaped such that any fluid drawn along the venting channel and entering the venting chamber flows away from the outlet of the venting channel under gravity.

9. A reservoir according to claim 8, wherein the reservoir is configured to be installed in the refilling device with the end wall lowermost, and the venting chamber has a floor which slopes downwardly away from the outlet of the venting channel when the reservoir is in this orientation.

10. A reservoir according to any one of claims 3 to 9, further comprising at least one socket wall portion extending from the end wall around the outlet orifice and defining a socket into which the article is wholly or partly received for engagement with the fluid conduit.

11. A reservoir according to claim 10, comprising one or more guiding elements on the inner surface of the at least one socket wall portion configured to cooperate with shaping on an outer surface of the article to guide the article into engagement with the fluid conduit.

12. A reservoir according to claim 10 or claim 11, wherein the at least one socket wall portion extends beyond a distal end of the outlet orifice.

13. A reservoir according to any one of claims 1 to 12, wherein the one or more side walls are formed from a transparent material such that the interior of the fluid storage volume can be observed from outside the reservoir.

14. A reservoir according to any one of claims 1 to 12, comprising a window of transparent material in the one or more side walls to allow observation of the interior of the fluid storage volume.

15. A reservoir according to any preceding claim, wherein the movable wall comprises a sealing element at its perimeter which contacts an inner surface of the one or more side walls.

16. A reservoir according to claim 15, in which the sealing element comprises one or more flanges integrally formed with the moveable wall.

17. A reservoir according to claim 15, in which the sealing element is a separate component fitted onto or around the moveable wall.

18. A reservoir according to any preceding claim, further comprising aerosol generating material in the fluid storage volume.

19. A refilling device configured for refilling of an article of an aerosol provision system received in the refilling device with aerosol generating material from a reservoir, the refilling device comprising a reservoir according to any one of claims 1 to 18.

20. A method of refilling a storage area with fluid, the method comprising:
dispensing fluid from a reservoir according to any one of claims 1 to 18 into the storage area.

21. A method according to claim 20, wherein the storage area is within an article of an aerosol provision system, and the fluid comprises aerosol generating material.

22. A refilling device for refilling an article from a reservoir, comprising:
a reservoir interface for receiving a reservoir containing fluid, the reservoir having a moveable wall configured to be inwardly pushable to reduce a capacity of the reservoir and move fluid in the reservoir out of an outlet orifice of the reservoir;
an article interface for receiving an article of an aerosol provision system having a storage area for fluid, such that a fluid flow path is formed between the outlet orifice of the reservoir and the storage area of the article;
a motor;
a plunger configured to be driven by the motor to provide linear movement comprising advancement of the plunger from a retracted position to engage with and inwardly push the moveable wall of a received reservoir, and retraction of the plunger away from the moveable wall; and a controller configured to control the motor to drive the plunger.

23. A refilling device according to claim 22, wherein the motor comprises a stepper motor with a lead screw and a lead screw nut, the plunger being coupled to the lead screw nut such that rotation of the lead screw produces the linear movement of the plunger.

24. A refilling device according to claim 22, wherein the linear movement of the plunger is along a direction which is coaxial with a longitudinal axis of the lead screw.

25. A refilling device according to claim 22, wherein the linear movement of the plunger is along a direction which is parallel with a longitudinal axis of the lead screw.

26. A refilling device according to any one of claims 22 to 25, wherein the controller is configured to recognise when a reservoir is received in the reservoir interface, and control the motor to advance the plunger to engage with the moveable wall.

27. A refilling device according to any one of claims 22 to 26, wherein the controller is lo configured to recognise when an article is received in the article interface, and control the motor to advance the plunger to inwardly push the moveable wall to move fluid out of the reservoir, along the fluid flow path, and into the article.

28. A refilling device according to claim 27, wherein the refilling device comprises a sensor configured to sense an amount of fluid in the article and provide an indication of the sensed amount of fluid to the controller, and wherein the controller is further configured to control the motor to cease or prevent advancement of the plunger in response to an indication that the sensed amount of fluid is at or above a predetermined threshold, leaving the plunger in engagement with the moveable wall.

29. A refilling device according to claim 28, wherein the controller is further configured to, after controlling the motor to cease advancement of the plunger, control the motor to retract the plunger from engagement with the moveable wall so as to reduce pressure on fluid in the reservoir such that fluid ceases to move out of the outlet orifice.

30. A refilling device according to any one of claims 22 to 29, wherein the refilling device is configured to move one or both of an article received in the article interface and a reservoir received in the reservoir interface towards one another to form the fluid flow path.

31. A refilling device according to claim 30, wherein the controller is configured to recognise when a reservoir is received in the reservoir interface and an article is received in the article interface, and in response, control the refilling device to move the article and/or the reservoir in order to form the fluid flow path.

32. A refilling device according to any one of claims 22 to 31, wherein the controller is configured to recognise when the reservoir has been emptied of fluid, and to control the motor to retract the plunger to the retracted position.

33. A refilling device according to any one of claims 22 to 32 wherein refilling device comprises an access cover openable to allow a reservoir to be inserted into the reservoir interface or removed from the reservoir interface, and the controller is configured to recognise that the access cover is open, and in response, to control the motor to retract the plunger to the retracted position, to allow insertion or removal of a reservoir.

34. A refilling device according to any one of claims 22 to 33, wherein the article interface comprises a cavity for holding an article, the cavity having a boundary wall with oppositely lo disposed cut-out portions through which the article may be gripped during insertion into and removal from the article interface.

35. A refilling device according to claim 34, wherein the cavity is shaped to hold an article during refilling with a mouthpiece end of the article facing downwards and an opposite end of the article having an inlet orifice for refilling facing upwards.

36. A refiling device according to any one of claims 22 to 35, wherein the refilling device comprises an outer housing, the outer housing including an aperture through which an amount of fluid in a reservoir received in the reservoir interface, or the presence of a reservoir received in the reservoir aperture, can be observed by a user.

37. A method of refilling an article from a reservoir, comprising:
forming a fluid flow path between an outlet orifice of the reservoir and an inlet orifice of the article, wherein the reservoir has a moveable wall configured to be inwardly pushable to reduce a capacity of the reservoir and move fluid out of the outlet orifice, and the article is an article of a vapour provision system having a storage area in fluid communication with the inlet orifice; and controlling a motor-driven plunger to inwardly push the moveable wall of the reservoir to move fluid out of the outlet orifice, along the fluid flow path and into the inlet orifice in order to fill the storage area of the article with fluid from the reservoir.

38. A method according to claim 37, wherein forming the fluid flow path comprises placing the reservoir and the article into a reservoir interface and an article interface in a refilling device, the refilling device comprising the motor-driven plunger and a controller configured to control a motor in the refilling device to drive the plunger.

39. A method according to claim 38, further comprising controlling the motor to advance the plunger to engage with the moveable wall in response to a recognition by the controller that the reservoir has been placed in the reservoir interface.

40. A method according to claim 38 or claim 39, further comprising controlling the motor to advance the plunger to inwardly push the moveable wall in response to a recognition by the controller that the article has been placed in the article interface.

41. A method according to claim 40, further comprising controlling the motor to cease or prevent advancement of the plunger in response to an indication received by the controller that an amount of fluid in the article is at or above a predetermined threshold.

42. A method according to claim 41, further comprising, after ceasing advancement of the plunger, controlling the motor to retract the plunger from engagement with the moveable wall so as to reduce pressure on fluid in the reservoir such that fluid ceases to move out of the outlet orifice.

43. A method according to any one of claims 38 to 42, further comprising moving the article and/or the reservoir in order to form the fluid flow path in response to a recognition that the reservoir has been placed in the reservoir interface and the article has been placed in the article interface.

44. A method according to any one of claims 38 to 43, further comprising controlling the motor to retract the plunger to a retracted position away from the moveable wall in response to a recognition that the reservoir has been emptied of fluid.

45. A kit comprising:
a refilling device according to any one of claims 22 to 36; and an aerosol provision system comprising an article having a storage area for aerosol generating material and a device to which the article can be coupled to form the aerosol provision system, wherein the article is configured to be received in the article interface of the refilling device.

46. A kit according to claim 45, further comprising one or more reservoirs containing fluid, wherein the fluid is aerosol generating material for use in the aerosol provision system, wherein the one or more reservoirs are configured to be received in the reservoir interface of the refilling device.

47. A nozzle for dispensing fluid, comprising:
a tubular outer wall extending between a proximal end and a distal end and surrounding a nozzle volume;
an inner wall dividing the nozzle volume into a fluid channel for the flow of fluid from the proximal end to the distal end, and a venting channel for the flow of air from the distal end towards the proximal end;
the inner wall and the outer wall configured such that, at the distal end, the fluid channel extends beyond the venting channel.

48. A nozzle according to claim 47, wherein the outer wall has a width of 2 mm or less, and the fluid channel extends beyond the venting channel for at least 3 mm.

49. A nozzle according to claim 47 or claim 48, wherein fluid channel extends beyond the venting channel for at least 4.5 mm.

50. A nozzle according to any one of claims 47 to 49, wherein the inner wall is tubular, the fluid channel is defined by an inner surface of the inner wall, and the venting channel is defined by an outer surface of the inner wall and an inner surface of the outer wall.

51. A nozzle according to claim 50, wherein the inner wall is substantially coaxial with the outer wall.

52. A nozzle according to claim 50, wherein the inner wall is offset from a longitudinal axis of the outer wall.

53. A nozzle according to claim 52, wherein the inner wall is in contact with the inner surface of the outer wall.

54. A nozzle according to any one of claims 50 to 53, wherein one or both of the inner wall and the outer wall have a substantially circular transverse cross-sectional shape.

55. A nozzle according to any one of claims 47 to 49, wherein the inner wall extends across the nozzle volume.

56. A nozzle according to claim 55, wherein the inner wall is straight.

57. A nozzle according to claim 55, wherein the inner wall is curved.

58. A nozzle according to any one of claims 47 to 57, wherein, in a transverse cross-section of the nozzle, the area of the venting channel is greater than the area of the fluid channel.

59. A nozzle according to claim 58, wherein the area of the venting channel is in the range of 1.5 to 2.5 times the area of the fluid channel.

60. A nozzle according to claim 58, wherein the area of the venting channel is substantially twice the area of the fluid channel.

61. A nozzle according to one of claims 58 to 60, wherein a ratio of the area of the venting channel to the area of the fluid channel is substantially constant along a length of the nozzle.

62. A nozzle according to any one of claims 47 to 61, comprising at least one aperture in the outer wall which provides an outlet for air flowing in the venting channel.

63. A nozzle according to any one of claims 47 to 62, wherein the nozzle has been fabricated using three-dimensional printing.

64. A reservoir for storing fluid, the reservoir comprising a nozzle according to any one of claims 47 to 63 for dispensing fluid from the reservoir.

65. A reservoir according to claim 64, further comprising aerosol-generating material stored in the reservoir.

66. A refilling device configured for refilling an article of an aerosol provision system received in the refilling device with aerosol-generating material from a reservoir, the refilling device comprising a reservoir according to claim 64 or claim 65.

67. A nozzle for dispensing fluid, comprising:
a tubular inner wall defining a fluid channel for the flow of fluid from a first end to a second end of the nozzle; and a tubular outer wall surrounding the inner wall and defining a venting channel for the flow of air from the second end towards the first end of the nozzle, the venting channel defined by an inner surface of the outer wall and an outer surface of the inner wall;
wherein the inner wall is eccentrically located within the outer wall.

68. A method of refilling a storage area with fluid, the method comprising:
using a nozzle according to any one of claims 47 to 63 or claim 67 to transfer fluid from a reservoir into the storage area.

69. A method according to claim 68, wherein the storage area is within an article of an aerosol provision system, and the fluid comprises aerosol-generating material.

70. An article for an aerosol provision system, comprising:
an outer housing comprising one or more walls including an inlet wall;
a storage area for aerosol-generating material defined within the outer housing;
an inlet orifice in fluid communication with an interior of the storage area by which aerosol-generating material can be added into the storage area; and a valve closing the inlet orifice; wherein the inlet orifice is located in the inlet wall of the outer housing and the valve is integrally formed with inlet orifice and the inlet wall.

71. An article according to claim 70 wherein the inlet wall is an end wall of the article opposite to a mouthpiece end of the article.

72. An article according to claim 70 or claim 71, wherein the inlet wall forms one or more sides of the outer housing.

73. An article according to any one of claims 70 to 72, wherein the inlet orifice comprises an aperture in the inlet wall.

74. An article according to any one of claims 70 to 72, wherein the inlet orifice comprises a tubular inlet extending inwardly from the inlet wall towards an interior of the article, the valve located at a distal end of the tubular inlet remote from the inlet wall.

75. An article according to claim 74, wherein the tubular inlet has a length between the inlet wall and the valve in the range of 5 to 20 mm.

76. An article according to any one of claims 70 to 75, wherein the valve leads directly into the interior of the storage area.

77. An article according to any one of claims 70 to 75, further comprising a fluid flow path between the valve and the interior of the storage area.

78. An article according to any one of claims 70 to 77, wherein the inlet wall, the inlet orifice and the valve are integrally formed as a moulded component.

79. An article according to any one of claims 70 to 77, wherein the inlet wall, the inlet orifice and the valve are integrally formed as a three-dimensional printed component.

80. An article according to any one of claims 70 to 79, wherein the inlet wall, the inlet orifice and the valve are integrally formed from silicone.

81. An article according to any one of claims 70 to 80, wherein the valve comprises a self-sealing valve.

82. An article according to any one of claims 70 to 81, wherein the valve comprises a slit valve, a cross-slit valve, a dome valve or a flap valve.

83. An article according to any one of claims 70 to 82, wherein the inlet orifice is located substantially centrally within the inlet wall.

84. An article according to any one of claims 70 to 83, wherein the inlet orifice is offset from a centre of the inlet wall.

85. An article according to any one of claims 70 to 84, further comprising at least one surface feature on the outer housing that gives an external surface of the article a lack of rotational symmetry about an axis perpendicular to the inlet wall.

86. An article according to claim 85, wherein the at least one surface feature is at least one protrusion or at least one recess.

87. An article according to claim 85 or claim 86, wherein the at least one surface feature has a height or depth above or below the external surface of 1 mm or less.

88. An aerosol provision system comprising an article according to any one of claims 70 to 87.

89. A wall for an article for an aerosol provision system, the wall configured to define at least part of an outer housing of the article, and comprising:
an inlet orifice by which aerosol-generating material can be added into a storage area of the article; and a valve closing the inlet orifice; wherein the wall, the inlet orifice and the valve are integrally formed.