EP3692842A1

EP3692842A1 - A substrate

Info

Publication number: EP3692842A1
Application number: EP19155894.9A
Authority: EP
Inventors: designation of the inventor has not yet been filed The
Original assignee: Nerudia Ltd
Current assignee: Nerudia Ltd
Priority date: 2019-02-07
Filing date: 2019-02-07
Publication date: 2020-08-12
Also published as: EP3920741A1; WO2020161295A1

Abstract

A substrate for a reservoir having an aerosol former stored therein, the substrate comprising: a property modifying agent disposed on the substrate, wherein the substrate is configured to be received in the reservoir to contact the aerosol former, so as to facilitate a release of the property modifying agent from the substrate to the aerosol former, and wherein the substrate is insoluble in the aerosol former.

Description

Field of the Invention

The present invention relates to a substrate for an aerosol former and, in particular, a substrate for releasing a property modifying agent to an aerosol former stored in the reservoir.

Background

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.
Combustion of organic material such as tobacco is known to produce tar and other potentially harmful byproducts. There have been proposed various smoking substitute systems in order to avoid the smoking of tobacco.
Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.
Smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a "vapour") that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or a flavourant without, or with fewer of, the odour and health risks associated with traditional smoking.
In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and with combustible tobacco products.
The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories. There are a number of different categories of smoking substitute systems, each utilising a different smoking substitute approach.
One approach is the so-called "vaping" approach, in which a vaporisable liquid, typically referred to (and referred to herein) as "e-liquid", is heated by a heating device (referred to herein as an electronic cigarette or "e-cigarette" device) to produce an aerosol vapour which is inhaled by a user. The e-liquid typically includes a base liquid as well as nicotine and/or a flavourant. The resulting vapour therefore also typically contains nicotine and/or a flavourant. The base liquid may include propylene glycol and/or vegetable glycerine.
A typical e-cigarette device includes a mouthpiece, a power source (typically a battery), a tank for containing e-liquid, as well as a heating device. In use, electrical energy is supplied from the power source to the heating device, which heats the e-liquid to produce an aerosol (or "vapour") which is inhaled by a user through the mouthpiece.
E-cigarettes can be configured in a variety of ways. For example, there are "closed system" vaping smoking substitute systems, which typically have a sealed tank and heating element. The tank is prefilled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute systems include a main body which includes the power source, wherein the main body is configured to be physically and electrically coupled to a consumable including the tank and the heating element. In this way, when the tank of a consumable has been emptied, that consumable is disposed of. The main body can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute systems are completely disposable, and intended for one-use only.
There are also "open system" vaping smoking substitute systems which typically have a tank that is configured to be refilled by a user. In this way the entire device can be used multiple times.
An example vaping smoking substitute system is the myblu™ e-cigarette. The myblu™ e-cigarette is a closed system which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid, as well as a heater, which for this device is a heating filament coiled around a portion of a wick. The wick is partially immersed in the e-liquid, and conveys e-liquid from the tank to the heating filament. The device is activated when a microprocessor on board the main body detects a user inhaling through the mouthpiece. When the device is activated, electrical energy is supplied from the power source to the heating device, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.
For a smoking substitute device it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. As explained above, in the so-called "vaping" approach, e-liquid is heated by a heating device to produce an aerosol vapour which is inhaled by a user. Many e-cigarettes also deliver flavour to the user to enhance the experience. In such e-cigarettes, e-liquid is often sold as a flavoured product, e.g. a specific blend of flavour compounds are already homogeneously mixed with the e-liquid during the manufacturing process. As such, the user would have to purchase flavoured consumables available on the market with limited opportunities to personalise the vaping experience according to their preferences. Further, when blended in the e-liquid, flavour components may interact with other constituent in the e-liquid during storage. In addition, it may put additional strain on the supply chain for distributing a large variety of consumables having different flavours.
There may be a need for improved design of smoking substitute systems, in particular in regards to the delivery of flavour to a user.
The present disclosure has been devised in the light of the above considerations.

Summary of the Invention

At its most general, the present invention relates to a substrate for releasing a property modifying agent to an aerosol former stored in a reservoir. This may allow the user to flavour the aerosol former at the point of use. Therefore the substrate may enable the property modifying agent to be kept separate to the aerosol former, it may minimise the interaction between the two during transport and storage. Further, it may allow the user to specify the type and quantity of property modifying agent to be added to the aerosol former, thus it may enable the user to create an aerosol former with a specific flavour and/or colour tailored to the user's needs.
According to a first aspect there is provided a substrate for a reservoir having an aerosol former stored therein, the substrate comprising:

a property modifying agent disposed on the substrate,
wherein the substrate is configured to be received in the reservoir to contact an aerosol former stored therein, so as to facilitate a release of the property modifying agent from the substrate to the aerosol former, and
wherein the substrate is insoluble in the aerosol former.

The aerosol former may be an e-liquid. The e-liquid may, for example, comprise a base liquid and nicotine. The base liquid may include propylene glycol and/or vegetable glycerine. The e-liquid may be flavourless. That is, the e-liquid may not contain any flavourant and may consist solely of a base liquid of propylene glycol and/or vegetable glycerine and nicotine.
The property modifying agent may comprise a flavourant. The flavourant may be provided in solid, gel or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g. citrus, cherry etc.), vanilla, spice (e.g. ginger, cinnamon) and tobacco flavour. The flavourant may modify a flavour of the aerosol former upon contacting or mixing with the aerosol former.
The property modifying agent may comprise a colorant. The colorant may be provided in solid, gel or liquid form. The colorant may modify a colour of the aerosol former upon contacting or mixing with the aerosol former. Advantageously, when the colorant is provided with the flavourant in the property modifying agent, the colorant may provide visual indication to a user for indicating a progress of agent release. For example, the concentration of the flavourant may correspond to a change in colour of the aerosol former.
The substrate may allow the property modifying agent to be kept separately to the aerosol former stored in the reservoir during transportation and storage. The aerosol former and the property modifying agent may only come into contact once the substrate is received in the reservoir. This may advantageously eliminate or reduce the interaction between the aerosol former and the property modifying agent during transportation and storage. For example, the e-liquid may only be flavoured with flavourant immediately before use.
The substrate may be configured to release the property modifying agent into the aerosol former when it is received in the reservoir. More specifically, the substrate may be configured to contact the aerosol former in the reservoir when it is received in the reservoir. For example, at least a part of the substrate may be immersed in the aerosol former when it is received in, or inserted into, the reservoir. Due to a difference in concentration, the property modifying agent absorbed or adsorbed in the substrate may therefore diffuse or transport out of the substrate into the aerosol former.
The substrate may be formed of an absorbent material configured to absorb or adsorb the property modifying agent. For example, the absorbent material may comprise a cellulose or fibrous material which absorbs or adsorbs the property modifying agent into the body of the material. The absorbent material may comprise a porous material, such as a foam, which absorbs the property modifying agent into the body of the material. Advantageously, the use of an absorbent material may allow a large quantity of property modifying agent to be absorbed or adsorbed therein. The absorbent material may function as a storage for storing the property modifying agent. Advantageously, the property modifying agent as stored within the body of absorbent material may gradually diffuse or transport towards its surface and thereby replenish property modifying agent released to the aerosol former. As a result, the concentration of property modifying agent at the surface of the substrate may be maintained.
Alternatively, the substrate may be formed of a non-absorbent material. For example, the substrate may comprise a non-absorbent surface for the property modifying agent material to attach or adhere onto. Advantageously, the use of a non-absorbent material may prevent the aerosol former from being adsorbed into the substrate when said substrate is put in contact with the aerosol former, and thereby reduces the amount of aerosol former being retained on the substrate.
Optionally, the substrate is configured to be removably received in the reservoir. For example, the substrate may be retained in the reservoir for a predetermined period of time before it is removed, or withdrawn, from the reservoir. Doing so may allow the majority of the property modifying agent to be released into the aerosol former before the substrate is removed. Thereafter the substrate, exhausted of property modifying agent, may be removed and be disposed of. Advantageously, the removal of an exhausted substrate from the reservoir may avoid constricting the flow of aerosol former in the reservoir and as a result, the aerosol former may flow freely in the reservoir. Therefore it may improve the efficiency of aerosol generation.
Optionally, the substrate is configured to be received in a reservoir of a container. That is, the reservoir form a part of a container for storing aerosol former. The container is not configured to generate an aerosol. For example, the container may be a bottle or a canister. The container may be prefilled with unflavoured and/or uncoloured aerosol former. The container may comprise a container outlet for dosing or adding aerosol former to a corresponding reservoir of a smoking substitute apparatus or system.
Optionally, the substrate is configured to be received in a reservoir of a smoking substitute apparatus. That is, the reservoir may form a part of a smoking substitute apparatus. For example, the smoking substitute apparatus may be in the form of a consumable. The consumable may be configured for engagement with a main body (i.e. so as to form a closed smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g. power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g. e-liquid) may be replenished by replacing a used consumable with an unused consumable.
Alternatively, the smoking substitute apparatus may be a non-consumable apparatus (e.g. that is in the form of an open smoking substitute system). In such embodiments an aerosol former (e.g. e-liquid) of the system may be replenished by re-filling e.g. a reservoir of the smoking substitute apparatus with the aerosol former (rather than replacing a consumable component of the apparatus).
In light of this, it should be appreciated that some of the features described herein as being part of the smoking substitute apparatus may alternatively form part of a main body for engagement with the smoking substitute apparatus (i.e. when the smoking substitute apparatus is in the form of a consumable).
The substrate may be fully received into the reservoir through an opening at the reservoir. The substrate may be retained in the reservoir without being removed. Alternatively, the substrate may be retained in the reservoir for a predetermined period of time. The substrate may be removed from the reservoir after a predetermined period of time with the use of a suitable removal mechanism. For example, the substrate may be removed by pulling on a part of the substrate by hand or a tweezer.
The substrate may be partially received into the reservoir through an opening at the reservoir. That is, a first end of the substrate may be received in the reservoir and in contact with the aerosol former, and a second end of the substrate extends, through the opening, outwardly from the reservoir. Advantageously, the second end of the substrate may form a tab for a user to pull onto when removing the substrate from the reservoir.
The first end of the substrate may form of an absorbent material whilst the second end of the substrate may form of an non-absorbent material, such that the aerosol former may not be transported, via capillary force, from the first end of the substrate towards the second end of the substrate when the first end is put in contact with the aerosol former. Advantageously, the second end of the substrate, or the tab, may be free of aerosol former and thereby allowing the user to grip onto the tab more easily.
The opening at the reservoir may be shaped correspond to a cross sectional profile of the substrate. For example, the opening may be a slit for receiving a planar substrate, e.g. a card or a stick, or it may be circular for receiving a cylindrical shaped substrate, e.g. a rod, or it may be rectangular for receiving a cuboid shaped substrate.
The opening may be closed by a closure for preventing the aerosol former stored in the reservoir from leaking out of the reservoir. The closure may be opened to provide passage for the substrate as it inserts and/or extends into the reservoir, and it may be closed and resealed once the substrate is received in, withdrawn from or removed from the reservoir. The closure may, for example, comprise a lid, a cap or a flap that covers the opening, or it may comprise a valve positioned across the opening to close said opening.
The closure may comprise a duck bill valve. For example, the valve may comprise a resilient member for forming a peripheral seal with the substrate as it extends through the opening. Said valve may prevent the aerosol former stored in the reservoir from leaking though the opening when the substrate is partially received in the reservoir. Advantageously, such arrangement may allow the smoking substitute apparatus to be kept in different orientations with the substrate partially inserted therein, yet preventing the aerosol former from leaking out of the reservoir through the opening.
Optionally, the property modifying agent is configured to be deposited on a surface of the substrate. For example, the property modifying agent may be coated onto the surface of the substrate. The property modifying agent may comprise a powder, or microcapsules, adhered to or partially embedded into the surface of the substrate. The property modifying agent may comprise a crystalline structure being formed onto the surface of the substrate by means of crystallisation. The property modifying agent may comprise a liquid property modifying agent absorbed or adsorbed on to the surface of the substrate. Advantageously, the property modifying agent as deposited on the surface of the substrate may be directly and promptly released into the aerosol former once the substrate is received in the reservoir, as such reducing the amount of time require for releasing the property modifying agent.
Optionally, the substrate is coated in a soluble coating containing the property modifying agent. Optionally, the soluble coating is configured to at least partially dissolve in the aerosol former for releasing the property modifying agent. For example, the soluble coating may be a soluble gel or a soluble shell that dissolves in the aerosol former. The soluble coating may provide a means for the property modifying agent to adsorb or attach onto the surface of the substrate. The soluble coating may be formed using vacuum drying technique, for example a soluble shell may be formed by vacuum drying a gel coated on the surface of the substrate. The soluble coating may allow the property modifying agent to be incorporated therein and thus the rate of release of property modifying agent may correspond to the rate of dissolve of the soluble coating when the substrate is put in contact with the aerosol former. The concentration of the property modifying agent may be constant throughout the thickness of the coating, or it may have a varied concentration gradient. Advantageously, such arrangement allows the release of property modifying agent to be controlled more precisely.
The substrate may be formed of a material that does not dissolve in the aerosol former, for example a paper. Advantageously, the use of an insoluble substrate reduces or eliminate contamination of the aerosol former as it is being received in the reservoir. That is, an insoluble substrate only releases the property modifying substrate to the aerosol former and whilst maintaining its structural integrity.
Optionally, the substrate comprises an absorbent paper. For example, the substrate may comprise a card formed from blotting paper, bibulous paper, watercolour paper or any other absorbent paper known to the person skilled in the art. The absorbance of an absorbent paper, e.g. the amount of property modifying agent that can be adsorbed onto absorbent paper, may depend upon its thickness. Advantageously, the dosage and release profile of the property modifying agent may be controlled by varying the type or the thickness of the absorbent paper forming the substrate.
Furthermore, the use of absorbent paper allows the property modifying agent to be disposed on the substrate during its manufacturing process. For example, the property modifying agent may be applied to the pulp for producing the absorbent paper, or it may be applied to the paper prior to or after a drying process.
Optionally, at least a portion of substrate is soluble in the aerosol former. For example, the substrate may comprise rice paper which readily dissolves in the aerosol former. This may allow the property modifying agent to incorporate into the soluble portion of the substrate and thus the rate of release of property modifying agent may correspond to the rate of dissolve of soluble substrate when it is put in contact with the aerosol former. Advantageously, such arrangement allows the release of property modifying agent to be more precisely controlled.
Optionally, the substrate is configured to be removable received in the reservoir. That is, the substrate may be removed from the reservoir once the property modifying agent is released from the substrate to the aerosol former stored in the reservoir.
Optionally, the amount of property modifying agent being released to the aerosol former to a predetermined period of time, or a residence time, the substrate is received in the reservoir. More specifically, in the presence of aerosol former, the property modifying agent may be released from the substrate to the aerosol former at a given rate of release. Thus, the longer the residence time the more property modifying agent may be released to the aerosol former. The release of property modifying agent may continue until it reaches an equilibrium, e.g. the difference in concentration of property modifying agent between the aerosol former and substrate is insignificant.
Therefore, the concentration of property modifying agent, e.g. flavourant and/or colourant, in the aerosol former may be controlled by varying the residence time of the substrate. Advantageously, the flavour and/or colour of the aerosol former may be tailored to a user's preference by removing the substrate from the reservoir after a predetermined period of time. For example, a user may opt to remove the substrate from the reservoir earlier if a less flavoured and/or coloured aerosol former is desired.
Optionally, the predetermined period of time, or the residence time, that the substrate is received in the reservoir, ranges from 1 minute to 2 hours. Optionally, said predetermined period of time is at least 5 minutes, or at least 60 minutes. Optionally, said predetermined period of time is any one of 1 minute, 5 minutes, 10 minutes, 15 minutes, 30 minutes, 60 minutes, 90 minutes and 120 minutes.
According to a second aspect there is provided a reservoir for receiving the substrate, the reservoir is configured to store an aerosol therein, the reservoir comprising an opening for providing access to the substrate as it extends into the reservoir to contact the aerosol former. The reservoir may form a part of a container or smoking substitute apparatus.
Optionally, the reservoir comprises a closure for closing the opening, wherein the closure is configured to open to provide access for the substrate. The opening may be closed by a closure for preventing the aerosol former stored in the reservoir from leaking out of the reservoir. The closure may be opened to provide passage for the substrate as it inserts and/or extends into the reservoir, and it may be closed and resealed once the substrate is received in, withdrawn from or removed from the reservoir.
Optionally, the closure comprises a lid, a cap or a flap for covering the opening, or it may comprise a valve positioned across the opening to said opening.
Optionally, the valve may comprise a resilient member for forming a peripheral seal with the substrate as it extends through the opening. The closure may comprise a duck bill valve. Said valve may prevent the aerosol former stored in the reservoir from leaking though the opening when the substrate is partially received in the reservoir. Advantageously, such arrangement may allow the smoking substitute apparatus to be kept in different orientations with the substrate partially inserted therein, yet preventing the aerosol former from leaking out of the reservoir through the opening.
Optionally, the resilient member may contact a surface of the substrate during its removal from the reservoir so as to remove at least some aerosol former from the surface of the substrate. Advantageously, such arrangement may reduce the amount of aerosol former being removed with the substrate.
Optionally, the reservoir comprises a wall, and wherein at least a portion of the wall is translucent or transparent such that the aerosol former stored in the reservoir is visible through said portion of the wall. Advantageously, this may allow a user to visually inspect the progress of mixing, for example, with the aid of a colourant in the property modifying agent.
Optionally, the closure comprises a valve positioned across the opening to close said opening.
According to a third aspect there is provided a smoking substitute apparatus comprising the reservoir.
According to a fourth aspect there is provided a smoking substitute kit comprising: the substrate and the reservoir or the smoking substitute apparatus.
According to a fifth aspect there is provided a method of producing the substrate, comprising:

preparing a pulp;
applying an property modifying agent to the pulp;
drying the pulp to form the substrate.

Advantageously, applying the property modifying agent to the pulp may allow the property modifying agent to form together with the substrate, as such it may reduce the amount of property modifying agent that is released during transportation and storage.
Optionally, said drying comprises one or more of mechanical drying process, evaporative drying process and vacuum drying process.
Where the smoking substitute apparatus is in the form consumable, the main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is an interference fit between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.
Thus, the smoking substitute apparatus may comprise one or more engagement portions for engaging with a main body. In this way, one end of the smoking substitute apparatus may be coupled with the main body, whilst an opposing end of the smoking substitute apparatus may define a mouthpiece of the smoking substitute system.
The smoking substitute apparatus may comprise a reservoir configured to store an aerosol former, such as an e-liquid. The e-liquid may, for example, comprise a base liquid and e.g. nicotine. The base liquid may include propylene glycol and/or vegetable glycerine. The e-liquid may be flavourless. That is, the e-liquid may not contain any flavourant and may consist solely of a base liquid of propylene glycol and/or vegetable glycerine and nicotine.
The reservoir may be in the form of a tank. At least a portion of the tank may be translucent. For example, the tank may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. A housing of the smoking substitute apparatus may comprise a corresponding aperture (or slot) or window that may be aligned with a translucent portion (e.g. window) of the tank. The reservoir may be referred to as a "clearomizer" if it includes a window, or a "cartomizer" if it does not.
The smoking substitute apparatus may comprise a passage for fluid flow therethrough. The passage may extend through (at least a portion of) the smoking substitute apparatus, between openings that may define an inlet and an outlet of the passage. The outlet may be at a mouthpiece of the aerosol-delivery device. In this respect, a user may draw fluid (e.g. air) into and through the passage by inhaling at the outlet (i.e. using the mouthpiece). The passage may be at least partially defined by the tank. The tank may substantially (or fully) define the passage. In this respect, the tank may surround the passage.
The smoking substitute apparatus may comprise an aerosol-generator. The aerosol generator may comprise a wick. The aerosol generator may further comprise a heater. The wick may comprise a porous material. A portion of the wick may be exposed to fluid flow in the passage. The wick may also comprise one or more portions in contact with liquid stored in the reservoir. For example, opposing ends of the wick may protrude into the reservoir and a central portion (between the ends) may extend across the passage so as to be exposed to fluid flow in the passage. Thus, fluid may be drawn (e.g. by capillary action) along the wick, from the reservoir to the exposed portion of the wick.
The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g. the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e. apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e. drawn from the tank) to be heated so as to form a vapour and become entrained in fluid flowing through the passage. This vapour may subsequently cool to form an aerosol in the passage.
The smoking substitute apparatus (or main body engaged with the smoking substitute apparatus) may comprise a power source. The power source may be electrically connected (or connectable) to a heater of the smoking substitute apparatus (e.g. when engaged with the main body). The power source may be a battery (e.g. a rechargeable battery). A connector in the form of e.g. a USB port may be provided for recharging this battery.
When the smoking substitute apparatus is in the form of a consumable, the smoking substitute apparatus may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to a heater of the consumable.
The electrical interface may also be used to identify the smoking substitute apparatus (in the form of a consumable) from a list of known types. For example, the consumable may have a certain concentration of nicotine and the electrical interface may be used to identify this. The electrical interface may additionally or alternatively be used to identify when a consumable is connected to the main body.
Again, where the smoking substitute apparatus is in the form of a consumable, the main body may comprise an interface, which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of a consumable engaged with the main body. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.
The smoking substitute apparatus or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater of the smoking substitute apparatus (e.g. via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.
The main body or smoking substitute apparatus may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.
A puff sensor may be provided that is configured to detect a puff (i.e. inhalation from a user). The puff sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e. puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. That is, the controller may control power supply to the heater of the consumable in response to a puff detection by the sensor. The control may be in the form of activation of the heater in response to a detected puff. That is, the smoking substitute apparatus may be configured to be activated when a puff is detected by the puff sensor. When the smoking substitute apparatus is in the form of a consumable, the puff sensor may form part of the consumable or the main body.
The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Summary of the Figures

So that the invention may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the invention will now be discussed in further detail with reference to the accompanying figures, in which:

Figure 1A is a front view of a smoking substitute system, according to a first embodiment, in an engaged position;
Figure 1B is a front view of smoking substitute system of the first embodiment in a disengaged position;
Figure 1C is a section view of a smoking substitute apparatus of the first embodiment;
Figure 2A is a section view of a substrate and a smoking substitute apparatus according to a second embodiment;
Figure 2B is a section view of the substrate being received in smoking substitute apparatus of the second embodiment;
Figures 3A and 3B are respectively section views of various substrates and their corresponding openings;
Figure 4A is a section view of a substrate and a smoking substitute apparatus according to a third embodiment;
Figure 4B is a section view of the substrate being received in smoking substitute apparatus of the third embodiment;
Figure 5 is a sectional view of a substrate being received in a container of a fourth embodiment; and
Figures 6A and 6B illustrate the process of producing a substrate according to a fifth embodiment.

Detailed Description of the Invention

Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.
Figures 1A and 1B illustrate a smoking substitute system in the form of an e-cigarette system 101. The system 101 comprises an e-cigarette device defining a main body 102 of the system 101, and an smoking substitute apparatus in the form of an e-cigarette consumable (or "pod") 103. In the illustrated embodiment the consumable 103 (smoking substitute apparatus) is removable from the main body (e-cigarette device), so as to be a replaceable component of the system 101. In other words, the e-cigarette system 101 is a closed system.
As is apparent from Figures 1A and 1B, the consumable 103 is configured to engage the main body 102. Figure 1A shows the main body 102 and the consumable 103 in an engaged state, whilst Figure 1B shows the main body 102 and the consumable 103 in a disengaged state. When engaged, a portion of the consumable 103 is received in a cavity of the main body 102 and is retained in the engaged position by way of a snap-engagement mechanism. In other embodiments, the main body 102 and consumable 103 may be engaged by screwing one into (or onto) the other, through a bayonet fitting, or by way of an interference fit.
The system 101 is configured to vaporise an aerosol-former, which in the illustrated embodiment, is in the form of a nicotine-based e-liquid 104. The e-liquid 104 comprises nicotine and a base liquid including propylene glycol and/or vegetable glycerine. In the present embodiment, the e-liquid 104 is flavourless (and does not include any added flavourant). That is, if the e-liquid 104 were to be inhaled (i.e. in aerosol form) by a user, it would not have a particularly perceptible flavour or taste.
As is more apparent from Figure 1C, this e-liquid 104 is stored within a reservoir in the form of a tank 105 that forms part of the consumable 103. In the illustrated embodiment, the consumable 103 is a "single-use" consumable 103. That is, upon exhausting the e-liquid 104 in the tank 105, the intention is that the user disposes of the entire consumable 103. In other embodiments, the e-liquid (i.e. aerosol former) may be the only part of the system that is truly "single-use". That is, the tank may be refillable with e-liquid or the e-liquid may be stored in a non-consumable component of the system. For example, the e-liquid may be stored in a tank located in the main body or stored in another component that is itself not single-use (e.g. a refillable cartomizer).
The tank 105 surrounds, and thus defines a portion of, a passage 106 that extends between an inlet 107 and an outlet 108 at opposing ends of the consumable 103. In this respect, the passage comprises an upstream end at the end of the consumable 103 that engages with the main body 102, and a downstream end at an opposing end of the consumable 103 that comprises a mouthpiece 109 of the system 101. When the consumable 103 is engaged with the main body 102, a user can inhale (i.e. take a puff) via the mouthpiece 109 so as to draw air through the passage 106, and so as to form an airflow (indicated by arrows) in a direction from the inlet 107 to the outlet 108 of the passage 106. Although not illustrated, the passage 106 may be partially defined by a tube (e.g. a metal tube) extending through the consumable 103. The passage 106 is in fluid communication with a gap defined between the consumable 103 and the main body 102 (when engaged) such that air outside of the system 101 is drawn into the passage 106 (during an inhale).
The smoking substitute system 101 is configured to vaporise the e-liquid 104 for inhalation by a user. To provide this, the consumable 103 comprises a heater having of a porous wick 110 and a resistive heating element in the form of a heating filament 111 that is helically wound around a portion of the porous wick 110. The porous wick 110 extends across the passage 106 (i.e. transverse to a longitudinal axis of the passage106) and opposing ends of the wick 110 extend into the tank 105 (so as to be submerged in the e-liquid 104). In this way, e-liquid 104 contained in the tank 105 is conveyed from the opposing ends of the porous wick 110 to a central portion of the porous wick 110 so as to be exposed to the airflow in the passage 106 (i.e. caused by a user inhaling).
The helical filament 111 is wound about this exposed central portion of the porous wick 110 and is electrically connected to an electrical interface in the form of electrical contacts 112 mounted at the end of the consumable that is proximate the main body 102 (when engaged). When the consumable 103 is engaged with the main body 102, the electrical contacts 112 contact corresponding electrical contacts (not shown) of the main body 102. The main body electrical contacts are electrically connected to a power source (not shown) of the main body 102, such that (in the engaged position) the filament 111 is electrically connected to the power source. In this way, power can be supplied by the main body 102 to the filament 111 in order to heat the filament 111. This heat is transferred from the filament 111 to the porous wick 110 which causes e-liquid 104 conveyed by the porous wick 110 to increase in temperature to a point at which it vaporises. The vaporised e-liquid becomes entrained in the airflow and, between the vaporisation point at the filament 111 and the outlet 108 of the passage 106, condenses to form an aerosol. This aerosol is then inhaled, via the mouthpiece 109, by a user of the system 101.
The power source of the main body 102 may be in the form of a battery (e.g. a rechargeable battery). The main body 102 may comprise a connector in the form of e.g. a USB port for recharging this battery. The main body 102 may also comprise a controller that controls the supply of power from the power source to the main body electrical contacts (and thus to the filament 111). That, is the controller may be configured to control a voltage applied across the main body electrical contacts, and thus the voltage applied across the filament 111. In this way, the filament 111 may only be heated under certain conditions (e.g. during a puff and/or only when the system is in an active state). In this respect, the main body 102 may include a puff sensor (not shown) that is configured to detect a puff (i.e. inhalation). The puff sensor may be operatively connected to the controller so as to be able to provide a signal, to the controller, which is indicative of a puff state (i.e. puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor.
Although not shown, the main body 102 and consumable 103 may comprise a further interface which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of a consumable 103 engaged with the main body 102. In this respect, the consumable 103 may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.
Figures 2A and 2B show a smoking substitute apparatus, or consumable 203, and a substrate 220 for the consumable 203 according to an embodiment of the present invention. Figures 2A shows the substrate 220 being separated from the consumable 203, and Figure 2B shows the substrate is partially received in a reservoir 205 of the consumable 203. For the purpose of illustration, some details of the consumable 203 are omitted from drawing but they are otherwise presented, for example the air flow passage and the heater. The consumable 203 in this embodiment is similar, structurally and functionally, to the consumable 103 as shown in Figures 1A, 1B and 1C. However, the consumable 203 differs to the consumable 103 in that it is configured to receive the substrate 220 into the tank, or reservoir 205 of the consumable 203.
In the illustrated embodiment, the reservoir 205 comprises a supply of aerosol former, or e-liquid 204. The aerosol former is in a liquid form. The aerosol former comprises nicotine and a base liquid, e.g. propylene glycol. The aerosol former does not contain any flavourant and therefore the aerosol former is not flavoured. Additionally, the aerosol former in this embodiment does not contain any colourant. That is, the aerosol former is in the natural colour of the propylene glycol and the nicotine, and therefore it appears as a translucent or transparent liquid.
The consumable 203 comprises an opening 224, which is has a shape corresponding to a cross-sectional profile of the substrate 220. In the illustrated embodiment, the substrate 220 is a card formed from an absorbent paper material, e.g. a bibulous paper. Sectional views of the planar substrate 220 and its corresponding opening 224 are respectively shown in Figures 3A and 3B as planar substrate 350 and planar opening 360. The substrate 220 has a planar form and therefore the opening 224 is a slit that extends longitudinally along a side wall of the reservoir 205. More specifically, the planar substrate 220 is configured to be inserted into the reservoir through the slit 225.
Figures 3A and 3B respectively illustrates various substrates 351, 352, 353, 354, 355 and corresponding openings 361, 362, 363, 364, 365 as featured in other embodiments. For example, the substrate may have a cross sectional profile of a circle 351, polygon such as a triangle 352 and a square 354, a star 353, a crescent 355 or other profiles, and configured to extend through an opening with corresponding shape, e.g. a circle 351, polygon such as a triangle 352 and a square 354, a star 353, a crescent 355 or other profiles. Furthermore, in other embodiments, the cross sectional profile of the substrate may vary along its longitudinal axis. For example, one end of the substrate can be thinner than an opposing end. In addition, the substrate 220 may be curved in the longitudinal direction, e.g. the substrate 220 may have a curved or angled axis.
The substrate 220 comprises a property modifying agent disposed thereon. That is, upon contacting the aerosol former 204 stored in the reservoir 205, the property modifying agent is configured to be released from the substrate 220 and to be diffused into the aerosol former 204. In the illustrated embodiment, the property modifying agent is a power deposited on the substrate 220. The property modifying agent comprises a flavourant and a colourant respectively configured to modify the flavour and colour of the aerosol form 204 as stored in the reservoir 205. In other embodiments, the property modifying agent may be one or more microcapsules, a gel, a liquid or a gas, either coated onto, embedded, absorbed or adsorbed in the substrate 220. The property modifying agent may comprise only a flavourant without the presence of a colorant or it may comprise only a colorant without the presence of a flavourant.
To prevent leakage of the aerosol former through the opening 224, e.g. at least during transportation and storage, the opening is provided a closure 222 for sealing the opening 224. In the illustrated embodiment, a flap 222 is hingedly attached to a sidewall of the reservoir 205 at a position adjacent to the opening 224. As such the flap is pivotable from a closed position where the flap covers the opening 224 to an opened position where the flap moves away from the opening 224. More specifically, in the closed position the flap 222 seals said opening 224 and in the opened position the opening 224 is free of obstruction.
The substrate 220 is configured to be partially inserted into the reservoir 205 through the opening 224 when the flap 222 is put into the opened position. In the illustrated embodiment, at least 90% of the length of substrate 220, towards an immersed end, is immersed in the aerosol former 204 so as to allow a significant amount of the property modifying agent to release from the substrate 220. The un-immersed portion of substrate 220, towards a tab end, forms a tab that allows the user to pull onto in order to withdraw the substrate 220 from the reservoir.
The amount of property modifying agent that is releasable to the aerosol former 204 is directly related to the contacting area between the substrate 220 and the aerosol former 204, a user may control the concentration of, or rate of release of, property modifying agent in the aerosol former by specifying the portion of substrate to submerge into the aerosol former 204. That is, an increased portion of the substrate 220 that remains emerged above the liquid surface of the aerosol former 204 means any property modifying agent in said emerged portion will not, or less likely to, be released into the aerosol former 204. For example, a user may only submerge 50%, or less, of the length of the substrate 220 in the aerosol former 204 so as to limit the amount, or rate, of release of property modifying agent into the aerosol former 204.
In the illustrated embodiment, the substrate 220 may be retained in the reservoir 205 and in contact with the aerosol former 204 for a predetermined period of time. This allow the property modifying agent to be released into the aerosol former 204. Said release approaches an equilibrium as the concentration of property modifying agent in the aerosol former increases throughout the predetermined period of time. Thereafter, the user may opt to withdraw the substrate 220 by pulling on its tab. Since said predetermined period of time is directly related to the amount of property modifying agent that is releasable to the aerosol former, a user may control the concentration of property modifying agent in the aerosol former by specifying the predetermined period of time before the substrate 220 is withdrawn from the reservoir 205. The predetermined period of time is the given example is less than or up to 60 minutes. In other embodiments, in the case of fast releasing property modifying agent, e.g. one with strong hydrophilic properties, the predetermined period of time can be less than a minute. In other embodiments, in the case of slow releasing property modifying agent, the predetermined period of time can be more than 60 minutes.
In the illustrated embodiment, the flap 222 is fully opened when the substrate 220 is partially received in the reservoir 205. As such, the consumable 203 lies on its side when receiving the substrate 220, with the opening 224 facing upwardly, in order to prevent aerosol former from flowing or leaking out of the opening 224 under gravity.
The user may remove the substrate 220 from the reservoir 205 after the lapse of said predetermined period of time, i.e. the aerosol former 204 has already received the required amount of property modifying agent from the substrate 220. The flap 222 may pivot toward the closed position in order to seal the opening 224 before the consumable 203 is assembled on to the main body.
Figure 4 shows a substrate 420 and a consumable 403 according to an embodiment according to the present invention. Figures 4A shows the substrate 420 separated from the consumable 403, and Figure 4B shows the substrate is partially received in a reservoir 405 of the consumable 403. The consumable 403 is structurally and functionally similar to the consumable 403. The consumable 403 differs to consumable 203 in that the consumable 403 comprises a valve 422 positioned across the opening 424 for sealing said opening. The valve 422 is a duck bill valve that comprises a resilient member, e.g. rubber, for forming a seal around the peripheral of the substrate 420 when it is partially received in the reservoir 405. As such, when the substrate 420 is partially received in the reservoir, the opening 424 remains sealed so as to prevent aerosol former 404 from leaking out of the reservoir. Therefore, in the illustrated embodiment, the consumable 403 may be rested in any orientation whilst the aerosol former 404 is prevented from leaking out of the opening 424.
The user may remove the substrate 420 from the reservoir 405 after the lapse of said predetermined period of time, i.e. the aerosol former 404 has already received the required amount of property modifying agent from the substrate 420. As the user withdraws the substrate 420 through the duck bill valve 422, the resilient member of the duck bill valve scrapes along the surface of the substrate and thereby removes excessive aerosol former retained thereon. Once the substrate is fully withdrawn, the resilient member seals the opening 424, thereby allowing the consumable 403 to be assembled on to the main body.
Figure 5 shows a substrate 520 and a container 503 according to an embodiment according to the present invention, showing the substrate is partially received in a reservoir 505 of the container 503. The container 503 comprises an outlet 510 for dosing or adding aerosol former to a corresponding consumable. The container 503 is in the form of a bottle and stored with a supply of aerosol former 504. The container 503 comprises a valve 522 positioned across an opening 524 for sealing said opening. The valve 522 is a duck bill valve that comprises a resilient member, e.g. rubber, for forming a seal around the peripheral of the substrate 520 when it is partially received in the reservoir 505. As such, when the substrate 520 is partially received in the reservoir, the opening 524 remains sealed so as to prevent aerosol former 504 from leaking out of the reservoir. Therefore, in the illustrated embodiment, the consumable 503 may be rested in any orientation whilst the aerosol former 504 is prevented from leaking out of the opening 524.
The user may remove the substrate 520 from the reservoir 505 after the lapse of said predetermined period of time, i.e. the aerosol former 504 has already received the required amount of property modifying agent from the substrate 520. As the user withdraws the substrate 520 through the duck bill valve 522, the resilient member of the duck bill valve scrapes along the surface of the substrate and thereby removes excessive aerosol former retained thereon. Once the substrate 520 is fully withdrawn, the resilient member seals the opening 524. The user may then add the property modified aerosol former 504 to a smoking substitute apparatus via the container outlet 510.
Figures 6A and 6B illustrate a manufacturing process for the substrate. As shown in Figure 6A, a flow of beaten paper pulp 610 is fed onto a moving conveyer belt having fine mesh screening 620. As the paper pulp is being conveyed along the conveyor belt 620 excessive water in the pulp drips through the fine mesh screening and thereby the pulp's water content reduces as it progress along the conveyor belt 620. That is, the fine mesh screening is water permeable mesh. As the paper pulp is being conveyed along the conveyor belt 620, property modifying agent, e.g. flavourant and/or colourant, is applied to the paper pulp. In this illustrated embodiment, the property modifying agent is applied using a sprayer 640 such that a fine mist of property modifying agent may be readily absorbed or adsorbed to the paper pulp. This may allow property modifying agent to be added to a core portion of the substrate.
The paper pulp, added with property modifying agent, may then continue to be conveyed by the conveyor belt 620 to be mechanically pressed using a set of rollers 630. This further reduces water content in the pulp and thereby forms a continuous sheet of substrate.
The continuous sheet of substrate 612 then passes over a series of steam-heated cylinders 650 to remove any remaining moisture in the substrate 612. In the illustrated embodiment, further property modifying agent in the form of an aerosol, is sprayed on using sprayer 660 to the substrate 612 before it is dried by the steam-heated cylinders 650 and wound onto a set of large reels 670. The may allow property modifying agent to be added to the surface of the substrate. The reel of substrate may then be cut to size to create the finished substrate for use with the container and/or the consumable.
The substrate may be added with further property modifying agent with a secondary addition process. This may allow more property modifying agent to be added to the substrate. For example, further property modifying agent may be added by spraying an aerosol of property modifying agent to the surface of substrate, or by dipping the substrate into a storage of property modifying agent.
The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.
While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.
Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.
Throughout this specification, including the claims which follow, unless the context requires otherwise, the words "have", "comprise", and "include", and variations such as "having", "comprises", "comprising", and "including" will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
It must be noted that, as used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent "about," it will be understood that the particular value forms another embodiment. The term "about" in relation to a numerical value is optional and means, for example, +/- 10%.
The words "preferred" and "preferably" are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

Claims

A substrate for a reservoir having an aerosol former stored therein, the substrate comprising:
a property modifying agent disposed on the substrate,

wherein the substrate is configured to be received in the reservoir to contact the aerosol former, so as to facilitate a release of the property modifying agent from the substrate to the aerosol former, and

wherein the substrate is insoluble in the aerosol former.
The substrate of claim 1, wherein the property modifying agent is configured to be deposited on a surface of the substrate.
The substrate of claim 1, wherein the substrate is coated in a soluble coating containing the property modifying agent.
The substrate of any one of the preceding claims, wherein the substrate comprises an absorbent paper.
The substrate of any one of the preceding claims, wherein the substrate is configured to be removably received in the reservoir.
The substrate of any one of the preceding claims, wherein the amount of property modifying agent releasable to the aerosol former corresponds to a predetermined period of time the substrate is received in the reservoir.
The substrate of claim 6, wherein the predetermined period of time ranges from 1 minute to 2 hours.
The substrate of any one of the preceding claims, wherein the substrate is configured to be received in a reservoir of a smoking substitute apparatus.
The substrate of any one of the preceding claims, wherein the property modifying agent comprises flavourant and/or colorant.
A reservoir for receiving the substrate of claims 1 to 9, the reservoir is configured to store an aerosol former therein, the reservoir comprising an opening for providing access to the substrate as it extends into the reservoir to contact the aerosol former.
The reservoir of claim 10, wherein the reservoir comprises a closure for closing the opening, wherein the closure is configured to open to provide access for the substrate.
The reservoir of claim 11, wherein the closure comprises a valve having a resilient member for forming a peripheral seal with the substrate as it extends through the opening.
A smoking substitute apparatus comprising the reservoir of claims 11 to 12.
A smoking substitute kit comprising:
the substrate of any one of the claims 1 to 9; and

the reservoir of any one of claims 10 to 12 or the smoking substitute apparatus of claim 13.
A method of producing a substrate, comprising:
preparing a pulp;

applying an property modifying agent to the pulp;

drying the pulp to form the substrate.