EP4147586A1

EP4147586A1 - Method and kit for forming an aerosol delivery component

Info

Publication number: EP4147586A1
Application number: EP21195894.7A
Authority: EP
Inventors: Matthew PILKINGTON
Original assignee: Nerudia Ltd
Current assignee: Nerudia Ltd
Priority date: 2021-09-10
Filing date: 2021-09-10
Publication date: 2023-03-15

Abstract

Disclosed is a kit of parts for forming an aerosol delivery component for a substitute smoking system. The kit of parts comprises first and second moulded component parts configured such that, when joined together, the first and second moulded component parts define an airflow passage and aerosol precursor reservoir therebetween. Also disclosed is a method of forming an aerosol delivery component for a substitute smoking system. The method comprises moulding a first component part, moulding a second component part, and joining the first and second component parts to one another such that, when joined together, the first and second component parts define an airflow passage and an aerosol precursor reservoir therebetween.

Description

TECHNICAL FIELD

The present disclosure relates to a kit of parts and a method for forming an aerosol delivery component, and a component part forming part of the kit of parts.

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 by-products. There have been proposed various smoking substitute devices in order to avoid the smoking of tobacco.
Such smoking substitute devices can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.
Smoking substitute devices, which may also be known as electronic nicotine delivery systems, may comprise electronic systems that permit a user to simulate the act of smoking by producing an aerosol, also referred to as a "vapour", which is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour and health risks associated with traditional smoking.
In general, smoking substitute devices 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 tobacco products.
The popularity and use of smoking substitute devices 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 devices as desirable lifestyle accessories. Some smoking substitute devices are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute devices do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form).
There are a number of different categories of smoking substitute devices, each utilising a different smoking substitute approach. A smoking substitute approach corresponds to the manner in which the substitute system operates for a user.
One approach for a smoking substitute device 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 heater to produce an aerosol vapour which is inhaled by a user. An e-liquid typically includes a base liquid as well as nicotine and/or flavourings. The resulting vapour therefore typically contains nicotine and/or flavourings. The base liquid may include propylene glycol and/or vegetable glycerine.
A typical vaping smoking substitute device includes a mouthpiece, a power source (typically a battery), a tank or liquid reservoir for containing e-liquid, as well as a heater. In use, electrical energy is supplied from the power source to the heater, which heats the e-liquid to produce an aerosol (or "vapour") which is inhaled by a user through the mouthpiece.
Vaping smoking substitute devices can be configured in a variety of ways. For example, there are "closed system" vaping smoking substitute devices which typically have a heater and a sealed tank (or reservoir) which is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute devices 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 heater. In this way, when the tank of a consumable has been emptied, the main body can be reused by connecting it to a new consumable. Another subset of closed system vaping smoking substitute devices are completely disposable, and intended for one-use only.
There are also "open system" vaping smoking substitute devices which typically have a tank (or reservoir) that is configured to be refilled by a user, so the device can be used multiple times.
An example vaping smoking substitute device is the myblu^™ e-cigarette. The myblu^™ e cigarette is a closed system device 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 vaporiser, which for this device is a heating filament coiled around a portion of a wick which is partially immersed in the e-liquid. 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 vaporiser, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.
Known consumables for smoking substitute systems can include many parts that must be assembled to form the consumable. This presents issues in regards to the cost and time for producing these consumables and, due to the complexity of such consumables, they can be susceptible to leakage (e.g. through joins). Given consumables form a disposable part of such systems it is especially desirable to minimise the cost of producing them.

SUMMARY

According to a first aspect there is provided a kit of parts for forming an aerosol delivery component for a substitute smoking system, the kit of parts comprising first and second moulded component parts configured such that, when joined together, the first and second component parts define an airflow passage and aerosol precursor reservoir therebetween.
Such an arrangement may result in an overall reduction in the number of components required to assemble the aerosol delivery component and, as such, may reduce the complexity of such assembly. As a result, assembly time may be reduced and fewer production tools may be required. Additionally, the limited number of joins required to form the aerosol delivery component may assist in minimising (or eliminating) leakage of aerosol precursor from the component (e.g. stored in the reservoir).
The first component may be substantially the same as the second component (i.e. the first and second components may be substantially identical). In this respect, the first and second components may be considered as two "halves" of the component being joined.
The first and second component parts may be configured to be joined along a joining plane parallel to a longitudinal axis of the airflow passage when formed.
Each component part may comprise a passage recess formed therein. The passage recesses may be arranged such that, when the component parts are joined, the passage recesses combine (i.e. align) to define the airflow passage. The passage recesses may be configured such that, when the component parts are joined, the airflow passage extends through the (formed) component from an inlet to an outlet. In this respect, each of the first and second component parts may define an inlet portion and/or an outlet portion that, when combined, define the inlet and/or the outlet.
Each component part may comprise a reservoir recess. The reservoir recesses may be arranged such that, when the component parts are joined, the reservoir recesses combine to define the aerosol precursor reservoir. The reservoir may be substantially sealed between the first and second component parts, when joined. The reservoir may, for example, be configured to store a liquid aerosol precursor, which may comprise a base liquid and e.g. nicotine. The base liquid may include propylene glycol and/or vegetable glycerine.
Each component part may comprise a separator wall that separates the passage recess from the reservoir recess.
Thus, the component parts may be configured such that, when joined, the passage recesses combine to define an airflow passage, the reservoir recesses combine to define an aerosol precursor reservoir, and the separator walls connect (e.g. abut or join) to define a partition wall that separates the passage from the reservoir. In other words, the component parts are configured such that, when joined, they define a component comprising an airflow passage extending therethrough and separated from an aerosol precursor reservoir by a partition wall.
Each component part may comprise an outer wall (or housing). The outer wall may comprise an external side that may define an outer (i.e. external) surface of the component when the component parts are joined. The outer wall may comprise an internal side that may partly define the recesses.
At least one of the component parts may comprise a supply inlet for receipt of aerosol precursor to fill the reservoir when the component parts are joined. The supply inlet may be formed in a portion of the outer wall defining the reservoir recess. Thus, the supply inlet may provide fluid access to the reservoir. The supply inlet may comprise a one-way valve to permit fluid flow in a direction into the reservoir (but prevent fluid flow out of the reservoir).
Alternatively or additionally, each component part may comprise a diaphragm or septum sealing the reservoir recess (e.g. sealing over an open top of the reservoir recess). The diaphragm may be configured to be removable or pierceable upon joining of the component parts together.
The passage recess of each component part may be elongate (e.g. so as to be in the form of a groove or channel). The passage recess may extend in a direction of a longitudinal axis of the component part.
The component parts may be configured to join in a plane that extends in the longitudinal direction. Thus, for example, the first component part may form a front portion of the component when formed and the second component part may form an opposing rear portion of the component when formed (or vice-versa).
The separator wall of each component may project from the internal side of the outer wall. The separator wall may extend substantially in the longitudinal direction. In this respect, the passage recess and the reservoir recess may extend longitudinally alongside one another (i.e. separated by the separator wall). The separator may extend for substantially the length of the component part.
A distal edge (e.g. distal from the inner side of the outer wall) of the separator wall of the first component part may abut (or join with) the distal edge of the of the separator wall of the second component part when the component parts are joined.
A periphery of the outer wall of first component part may abut (or join) a periphery of the outer wall of the second component part when the component parts are joined.
The component parts may be configured such that, when joined, two aerosol precursor reservoirs are defined between the component parts. The reservoir recess of each component part may be a first reservoir recess, and each component part may further comprise a second reservoir recess. The first and second reservoir recesses of each component part may be arranged such that, when the component parts are joined, the first recesses combine to form a first aerosol precursor reservoir and the second recesses combine to form a second aerosol precursor reservoir (i.e. defined between the component parts).
The separator wall of each component part may be a first separator wall (separating the passage recess from the first reservoir recess). Each component part may further comprise a second separator wall that separates the passage recess from the second reservoir recess. The second separator wall may be as otherwise described above with respect to the first separator wall.
The first and second reservoir recesses of each component part may be disposed (e.g. laterally) either side of the passage recess of the component part. In this respect, the passage recess may extend substantially centrally in the longitudinal direction.
The component parts may be configured to retain a filter therebetween when joined. The component parts may be configured to retain the filter in the passage. In this respect, each passage recess comprises a filter retaining portion for retaining a filter when the component parts are joined. The filter retaining portion may be in the form of an enlarged portion of the passage recess (i.e. that may be filled by the filter), or may be e.g. in the form of a rib. The filter retaining portion may be proximate the outlet. The kit of parts may comprise a filter (i.e. a porous filter).
The component parts may be configured to retain a vaporiser (e.g. comprising a wick) therebetween when joined. The component parts may be configured so as to retain (when joined) the vaporiser such that a portion of the vaporiser is disposed within the airflow passage. The component parts may be configured such that a wick of a vaporiser retained therebetween extends across the passage. At least one of the component parts may comprise a vaporiser locating portion for locating (or retaining) a vaporiser in the passage when the component parts are joined. The vaporiser locating portion may comprise a locating slot formed in a distal edge of a separator wall (e.g. for receipt of a portion of a vaporiser therein). The or each separator wall of each component part may comprise a vaporiser locating portion (e.g. slot) formed in the distal edge thereof.
Where each component part comprises first and second separator walls, each of the first and second separator walls (of at least one component) may comprise a vaporiser locating portion (e.g. locating slot). The vaporiser locating portions may be arranged to each receive a portion of a vaporiser, such as a portion of a wick of a vaporiser. The vaporiser locating portions may be disposed on opposite sides of the passage recess (e.g. directly opposite). Thus, for example, the vaporiser locating portions may be configured such that ends of the wick may be supported by the vaporiser locating portions in such a way that the wick extends transversely across the passage (i.e. when the component parts are joined). In this way, a portion of the wick may be exposed to fluid flow in the passage and end portions of the wick may protrude into respective reservoirs. Accordingly, fluid may be drawn (e.g. by capillary action) along the wick, from the reservoir to the exposed portion of the wick.
In some embodiments the separator walls of both the first and second component parts may comprise retaining slots that combine to form apertures (i.e. from the passage to the reservoirs) when the first and second components parts are joined.
The component parts may be configured to retain an electrical connector therebetween (when joined). The connector may be retained such that a portion of the connector is exposed (i.e. externally of the component). The connector may be for connection with a smoking substitute device (when the component is engaged with the device). Thus, at least one component part may comprise a connector locating portion for locating an electrical connector (i.e. for connection with a smoking substitute device when the component is engaged therewith). The connector locating portion may be in the form of a locating slot. The locating slot may be formed in an edge of an end wall (which may form part of the outer wall) of the component part.
The connector locating portion may be configured to restrict movement of the electrical connector when the components are joined (and the connector is received therebetween). For example, the connector locating portion may be configured to restrict rotation of the electrical connector. In this regard, the connector locating portion may comprise a retaining feature (e.g. a protrusion) for engagement with the connector so as to prevent such movement. Alternatively or additionally, the connector locating portion may comprise a non-circular profile for receipt of a non-circular portion of the connector (i.e. so as to restrict rotation).
Where both component parts comprise a connector locating portion (e.g. locating slot) the connector locating portions may combine to form an aperture, which may be configured to retain the connector therein.
The or each component part may comprise two spaced connector locating portions (each being as described above) for locating two corresponding electrical connectors.
The kit of parts may comprise an electrical connector (or two connectors) for locating by the connector locating portion(s). The connector may be electrically connectable or connected to the vaporiser. The connector may be configured for electrical connection with a smoking substitute device. Thus, when the component (when formed) is engaged with a smoking substitute device, the connector may transfer power from a power source of the device to the vaporiser.
At least one of the component parts may be configured for welding (e.g. ultrasonic welding) to the other component part. The at least one component part may comprise an energy director for facilitating ultrasonic welding of the component part to the other part. The energy director may be a pointed rib (i.e. having a pointed apex). The rib may extend about a periphery of a reservoir recess of the component part (e.g. the first reservoir recess).
At least a portion of the outer wall of each component part may be translucent. For example, the outer wall may comprise a window to allow a user to visually assess the quantity of aerosol precursor in a reservoir of the component (when formed). The component may be referred to as a "clearomizer" if it includes a window, or a "cartomizer" if it does not.
The kit of parts may comprise a vaporiser comprising a wick (i.e. such as the vaporiser described above). The vaporiser may comprise a heater that may include a heating element (e.g. a heating coil surrounding the wick). The wick may comprise a porous material.
The heating element 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 connectable to a power source (i.e. when forming part of a formed component). 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 reservoir) 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 component parts may be configured such that, when joined to form a component, they may be physically coupled with a smoking substitute device. For example, the joined component parts may be configured for snap engagement, screwing engagement, or a bayonet engagement with a smoking substitute device. Thus, at least one of the component parts may comprise an engagement portion for engagement (e.g. snap engagement) with a smoking substitute device.
Each component party may be injection moulded. Each component part may be configured so as to be formable by a straight-pull mould (i.e. without side-actions).
According to a second aspect there is provided a component part configured for joining with a like-component part such that, when joined therewith, the component parts define an airflow passage and an aerosol precursor reservoir therebetween.
The component part may be configured to join with a like-component that has been rotated about a longitudinal axis thereof by 180 degrees (i.e. relative to the component part) so as to define the airflow passage and aerosol precursor reservoir therebetween.
The component part of the second aspect may be as defined with respect to the first or second component part of the first aspect.
According to a third aspect there is provided an aerosol delivery component formed from the kit of parts as described with respect to the first aspect. The component may be a consumable for a smoking substitute system (e.g. an e-cigarette consumable).
According to a fourth aspect there is provided an aerosol delivery component comprising a housing having spaced front and rear outer walls, outer surfaces of the front and rear outer walls defining external surfaces of the component and opposing inner surfaces defining an internal cavity therebetween, and an internal separator wall extending across the cavity from the front wall to the rear wall so as to divide the cavity into a first portion comprising a reservoir for storing a liquid aerosol precursor and a second portion comprising an airflow passage for airflow through the component.
Thus, each of the passage and reservoir may extend across the space defined between the front and rear walls (i.e. they take up the entire distance between the walls).
The internal separator wall may be a first internal separator wall and the component may comprise a second internal separator wall extending across the cavity from the front wall to the rear wall, the first and second separator walls further dividing the cavity into a third portion comprising a further reservoir for storing a liquid aerosol precursor.
The aerosol delivery component of the fourth aspect may be as otherwise defined in the third aspect.
According to an fifth aspect there is provided an aerosol delivery component comprising an aerosol precursor reservoir and an elongate airflow passage extending along a longitudinal axis, the component comprising two component parts that are joined along a joining plane that extends parallel to the longitudinal axis.
The aerosol delivery component of the fifth aspect may be as otherwise defined in the third aspect.
According to a sixth aspect there is provided a method of forming an aerosol delivery component for a substitute smoking system, the method comprising:

moulding a first component part;
moulding a second component part;
joining the first and second component parts to one another such that, when joined together, the first and second component parts define an airflow passage and an aerosol precursor reservoir therebetween.

The steps of moulding the first and second component parts may comprise injection moulding the first and second components parts.
The steps of moulding the first and second component parts may be performed using a straight-pull mould.
The step of joining the first and second component parts may comprise positioning the second component part so as to be rotated 180 degrees about a longitudinal axis relative to the first component part.
The step of joining the first and second component parts may comprise welding the first and second component parts together. The welding may be performed using an ultrasonic welding process.
The method may comprise, subsequent to joining the first and second component parts, filling (i.e. with aerosol precursor) one or more aerosol precursor reservoirs defined between the first and second component parts. The method may comprise, subsequent to filling the one or more aerosol precursor reservoirs, sealing (e.g. welding) the one or more aerosol precursor reservoirs. The sealing of the one or more reservoirs may be performed using an ultrasonic welding process.
The first and second component parts may be as described above with respect to the first aspect. Thus, for example, each of the first and second component parts may comprise a passage recess and a reservoir recess, and each of the first and second component parts may be substantially the same.
The step of joining the component parts may be performed such that the passage recesses combine to form the airflow passage and the reservoir recesses combine to form the reservoir.
In a seventh aspect there is provided an aerosol delivery component formed using the method of the sixth aspect.
In an eighth aspect there is provided a smoking substitute system comprising an aerosol delivery component according to the third, fourth, fifth or seventh aspects, and a smoking substitute device, the component being engageable with the device such that a vaporiser of the component is connected to a power source of the device.
The device may, for example, be an e-cigarette device for supplying power to the aerosol delivery component.
The smoking substitute device may include a power source. The device may comprise a controller. The device may be configured for engagement with the aerosol delivery component. The aerosol delivery component may comprise parts of the system that are disposable, and the device may comprise non-disposable or non-consumable parts (e.g. power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the component. Thus, aerosol precursor (e.g. e-liquid) may be replenished by replacing a used aerosol delivery component with an unused aerosol delivery component.
The power source may include a battery (e.g. a rechargeable battery). The electrical connection between the heater of the aerosol delivery component and the power source may be controlled or controllable by an electronic switch.
The device may comprise a memory, which 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 aerosol delivery component and/or device 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.
An airflow (i.e. puff) sensor may be provided that is configured to detect a puff (i.e. inhalation from a user). The airflow 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 airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the device or the aerosol delivery component.
The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

BRIEF DESCRIPTION OF THE DRAWINGS

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

Figure 1A is a front schematic view of a smoking substitute system;
Figure 1B is a front schematic view of a device of the system;
Figure 1C is a front schematic view of an aerosol delivery component of the system;
Figure 2A is a schematic of the components of the device;
Figure 2B is a schematic of the components of the aerosol delivery component;
Figures 3A and 3B are perspective and bottom views of the aerosol delivery component;
Figure 4 is a front view of a component part forming part of the aerosol delivery component; and
Figure 5 is a front view of a variation of the component part of Figure 4.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Aspects and embodiments will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.
Fig. 1A shows an exemplary smoking substitute system 100 according to a first embodiment. In this example, the smoking substitute system 100 includes a smoking substitute device 102 and an aerosol delivery component, which forms a disposable portion of the system and will henceforth be referred to as a consumable 104. The consumable 104 may alternatively be referred to as a "pod", "cartridge" or "cartomizer".
The smoking substitute system 100 is a closed system vaping system, wherein the consumable 104 includes one or more sealed aerosol precursor reservoirs (not shown) and is intended for single-use. The consumable 104 is removably engageable with the device 102 (i.e. for removal and replacement). Fig. 1A shows the smoking substitute system 100 with the device 102 physically coupled to the consumable 104, Fig. 1B shows the device 102 of the smoking substitute system 100 without the consumable 104, and Fig. 1C shows the consumable 104 of the smoking substitute system 100 without the device 102.
The device 102 and the consumable 104 are configured to be physically coupled together by pushing the consumable 104 into a cavity at an upper end 108 of the device 102, such that there is an interference fit between the device 102 and the consumable 104. In other examples, the device and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.
The consumable 104 includes an outlet (not shown) forming part of a mouthpiece at an upper end 109 of the consumable 104, and one or more air inlets (not shown) in fluid communication with the outlet such that air can be drawn into and through the consumable 104 when a user inhales through the outlet.
The consumable 104 includes a window 112, which allows the amount of aerosol precursor (e.g. e-liquid) in the reservoir(s) to be visually assessed. The device 102 includes a slot 114 so that the window 112 of the consumable 104 can be seen whilst the rest of the consumable 104 is obscured from view when the consumable 104 is inserted into the cavity at the upper end 108 of the device 102.
The lower end 110 of the device 102 also includes a light 116 (e.g. an LED) located behind a translucent cover. The light 116 may be configured to illuminate when the smoking substitute system 100 is activated. Whilst not shown, the consumable 104 may identify itself to the device 102, via an electrical interface, RFID chip, or barcode.
Figs. 2A and 2B are schematic drawings of the device 102 and consumable 104. As is apparent from Fig. 2A, the device 102 includes a power source 118, a controller 120, a memory 122, a wireless interface 124, an electrical interface 126, and, optionally, one or more additional components 128.
The power source 118 is preferably a battery, more preferably a rechargeable battery. The controller 120 may include a microprocessor, for example. The memory 122 preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 to perform certain tasks or steps of a method.
The wireless interface 124 is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth^®. To this end, the wireless interface 124 could include a Bluetooth^® antenna. Other wireless communication interfaces, e.g. WiFi^®, are also possible. The wireless interface 124 may also be configured to communicate wirelessly with a remote server.
The electrical interface 126 of the device 102 may include one or more connectors comprising electrical contacts. The electrical interface 126 may be located in a base of the aperture in the upper end 108 of the device 102. When the device 102 is physically coupled to the consumable 104, the electrical interface 126 is configured to transfer electrical power from the power source 118 to the consumable 104 (i.e. upon activation of the smoking substitute system 100).
The electrical interface 126 may be configured to receive power from a charging station when the device 102 is not physically coupled to the consumable 104 and is instead coupled to the charging station. The electrical interface 126 may also be used to identify the consumable 104 from a list of known consumables. For example, the consumable 104 may include aerosol precursor of a particular flavour and/or have a particular concentration of nicotine (which may be identified by the electrical interface 126). This can be indicated to the controller 120 of the device 102 when the consumable 104 is connected to the device 102. Additionally, or alternatively, there may be a separate communication interface provided in the device 102 and a corresponding communication interface in the consumable 104 such that, when connected, the consumable 104 can identify itself to the device 102.
The additional components 128 of the device 102 may comprise the light 116 discussed above.
The additional components 128 of the device 102 may also comprise a charging port (e.g. USB or micro-USB port) configured to receive power from the charging station (i.e. when the power source 118 is a rechargeable battery). This may be located at the lower end 110 of the device 102. Alternatively, the electrical interface 126 discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.
The additional components 128 of the device 102 may, if the power source 118 is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).
The additional components 128 of the device 102 may include a sensor, such as an airflow (i.e. puff) sensor for detecting airflow in the smoking substitute system 100, e.g. caused by a user inhaling through a mouthpiece 136 of the consumable 104. The smoking substitute system 100 may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.
The additional components 128 of the device 102 may include a user input, e.g. a button. The smoking substitute system 100 may be configured to be activated when a user interacts with the user input (e.g. presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100.
As shown in Fig. 2B, the consumable 104 includes one or more reservoirs 106, an electrical interface 130, a vaporiser 132, one or more air inlets 134, a mouthpiece 136, and one or more additional components 138.
The electrical interface 130 of the consumable 104 may include one or more electrical contacts. The electrical interface 126 of the device 102 and an electrical interface 130 of the consumable 104 are configured to contact each other and thereby electrically couple the device 102 to the consumable 104 when the lower end 111 of the consumable 104 is inserted into the upper end 108 of the device 102 (as shown in Fig. 1A). In this way, electrical energy (e.g. in the form of an electrical current) is able to be supplied from the power source 118 in the device 102 to the vaporiser 132 in the consumable 104.
The vaporiser 132 is configured to heat and vaporise e-liquid contained in the reservoir(s) 106 using electrical energy supplied from the power source 118. As will be described further below, the vaporiser 132 includes a heating filament and a wick. The wick draws e-liquid from the tank 106 and the heating filament heats the e-liquid to vaporise the e-liquid.
The one or more air inlets 134 are preferably configured to allow air to be drawn into the smoking substitute system 100, when a user inhales through the mouthpiece 136. When the consumable 104 is physically coupled to the device 102, the air inlets 134 receive air, which flows to the air inlets 134 along a gap between the device 102 and the lower end 111 of the consumable 104.
In operation, a user activates the smoking substitute system 100, e.g. through interaction with a user input forming part of the device 102 or by inhaling through the mouthpiece 136 as described above. Upon activation, the controller 120 may supply electrical energy from the power source 118 to the vaporiser 132 (via electrical interfaces 126, 130), which may cause the vaporiser 132 to heat e-liquid drawn from the reservoir(s) 106 to produce a vapour which is inhaled by a user through the mouthpiece 136.
An example of one of the one or more additional components 138 of the consumable 104 is an interface for obtaining an identifier of the consumable 104. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104 may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102.
Figures 3A and 3B illustrate the consumable 104 of figure 1A to 1B in more detail. Although not immediately apparent from the figure, the consumable 104 (i.e. aerosol delivery component) is formed of two (e.g. first and second) identical component parts 140 that are joined together to form the consumable 104. Referring, in particular, to Figure 3B, the components parts 140 are joined along a plane that is horizontal and extends into the page. The component parts 140 will be described in more detail below with respect to Figure 4.
Figure 3A is a perspective view that is oriented so as to show the upper end 109 of the consumable 104. As is apparent from this view, the upper end 109 comprises an outlet 142, which forms part of the mouthpiece 136, and from which a user may inhale an aerosol produced by the consumable 104. The mouthpiece 136 forms part of a housing of the component 104, which is formed of outer walls 146 of the component parts 140.
Figure 3B shows the lower end 111 of the consumable 104. This shows, in particular, the electrical interface 126, which comprises a pair of electrical connectors 144. As is discussed above, these allow electrical connection of the consumable 104 to a smoking substitute device (e.g. for the purpose of providing power to the consumable 104). This figure also illustrates two inlets 134 formed in the lower end 111 of the consumable 104. These inlets 134 are spaced either side of the electrical connectors 144, such that each inlet 134 is formed in a respective one of the component parts 140.
The inlets 134 are generally rectangular in shape and, although not apparent from figures 3A and 3B, they open to a singular passage extending through the consumable 104 to the outlet 142. Thus, the inlets 134 are in fluid communication with the outlet 142 and inhalation at the outlet 142 results in airflow into the inlets 134.
Figure 4 shows a component part 140 used to form the consumable 104 shown in figures 3A and 3B. The illustrated face of the component part 140 (i.e. parallel to the page) in Figure 4 is the face along which the component part 140 is joined with a like-component part to form the consumable 104.
The outer wall 146 of the component forms a shell that defines a cavity including a passage recess 148, and first 150a and second 15b reservoir recesses.
The passage recess 142 is arranged such that, when the component part 140 is joined with a like-component part the passage recesses 142 combines with that of the component part 140 to define the airflow passage extending through the component 104. Thus, the passage recess 142 is elongate and extends centrally along a longitudinal axis of the component part 140.
In particular the passage extends from the inlets 134 (shown in Figure 3B) to the outlet 142 (shown in Figure 3A). The component part 140 comprises an outlet portion 147 that combines with the outlet portion of a like-component, when joined, to form the outlet 142. The outlet portion 147 is in the form of a semi-circular slot formed in an edge of outer wall 146 at the upper end 109 of the component part 140.
A filter retaining portion 168 of the passage recess 148 is disposed adjacent the outlet portion 147. This is an enlarged portion of the passage recess 148 that is configured to retain a filter (i.e. a correspondingly shaped filter) therein when the component part 140 is joined with a like-component part.
The reservoir recesses 150a, 150b are elongate, and extend longitudinally either side of the passage recess 148. Thus, the reservoir recesses 150a, 150b are separated from one another by the passage recess 148. As should be apparent from Figure 4, when the component part 140 is joined with a like-component part, each of the reservoir recesses 150a, 150b combines with a corresponding reservoir recess of the like-component to define a reservoir in the component 104. These reservoirs of the component 104 are then fillable with an aerosol precursor (e.g. an e-liquid).
The component part 140 also comprises first 152a and second 152b separator walls. The first separator wall 152a separates the first reservoir recess 150a from the passage recess 148 and the second separator wall 152b separates the second reservoir recess 150b from the passage recess 148.
Each of the separator walls 152a, 152b projects (inwardly) from an internal side of the outer wall 146 of the component part 140. Thus, in essence, the separator walls 152a, 152b divide the cavity defined by the outer wall into the passage 148 and reservoir recesses 150a, 150b. In this way, the passage recess 148 is defined by surfaces of the outer wall 146 and the separator walls 150a, 150b. As a result, the passage recess 148 has a substantially rectangular cross-sectional shape.
The separator walls 152a, 152b each extend in the longitudinal direction substantially for the length of the component part 140. The height of each separator wall 152a, 152b from the internal side of the outer wall 146 is such that, when the component part 140 is joined with a like-component part 140, the distal edges (distal from the internal side) of the separator walls 152a, 152b join so as to device a cavity defined by the component parts 140 into the passage and the two reservoirs.
When joined in this manner, the reservoirs that are forms are separate from one another and are sealed for storage of aerosol precursor. The component part 140 comprises a supply inlet 166 formed therein for filling the reservoirs. The supply inlet 166 is in the form of an aperture formed in a portion of the outer wall 146 that defines the first reservoir recess 150a. As should be appreciated, such an arrangement provides two apertures when the component 104 is formed, each for filling one of the two reservoirs of the component 104. The supply inlet 166 may be sealed (e.g. by ultrasonic welding) once the reservoirs are filled. Alternatively the supply inlet 166 may comprise a valve to prevent leakage of aerosol precursor therefrom.
An alternative solution is to provide a sealing diaphragm for sealing over each of the reservoir recesses 150a, 150b and to retain aerosol precursor in the recesses 150a, 150b. This can subsequently be broken, removed or may disintegrate upon joining of the component part 140 to a like-component part.
Each separator wall 152a, 152b comprises a vaporiser locating portion 154 in the form of a semi-circular slot formed in distal edge thereof. These vaporiser locating portion 154 are disposed proximate the lower end 111 of the component part 140 (i.e. so as to proximate to the inlet 134), and are positioned so as to directly oppose one another across the passage recess 148.
The vaporiser locating portions 153 are each configured for receipt of a respective end portion of a porous wick 156 of the vaporiser 132. In this way, the wick 156, when received in the vaporiser locating portions 154, extends transversely across the passage recess 148. A heater filament 158 of the vaporiser 132 is coiled about the portion of the wick 156 that spans the passage recess 148. When the component part 140 is joined with a like-component part, the wick 156 is captured in the vaporiser locating portions 154 (i.e. slots) of the component part and the like-component part so as to be retained in the position shown in Figure 4.
The component part 140 also comprises connector locating portions 160 for receipt of connectors of the consumable 104. Each connector locating portion 160 is in the form of a semi-circular slot and seats a narrowed portion of an electrical connector 162 (i.e. an electrical contact forming part of the electrical interface). When the component part 140 is joined to a like-component part, the connectors 162 are thus held between the component parts 140 in the connector locating portions 160.
In other embodiments, each connector locating portion 160 and each corresponding narrowed portion of a connector 162 may have a non-circular cross-sectional shape, which may restrict rotation of the connector 162. Alternatively, each connector locating portion 160 may comprise a retaining feature (such as a protrusion) that engages the connector 162 to prevent rotation of the connector 162. This may be desirable where the component part 140 is joined to a like-component part using ultrasonic welding. The vibrations imparted on the component parts 140 during such welding could otherwise result in rotation (or dislodgement) of the connectors 162.
Each of the connectors 162 is electrically connected to the heater filament 158, such that upon receipt of a power supply from e.g. a power source of a smoking substitute device, the power is supplied from the connectors 162 to the heater filament 158.
As is set forth above, the component part 140 is joined with a like-component part to form the component 104 as shown in Figures 3A and 3B. In particular, the joining occurs along the distal edges of the separator walls 152a, 152b and along a periphery of the outer wall 146. These all lie in substantially the same plane (i.e. parallel to the page), such that the joining generally occurs along a single joining plane.
To facilitate the joining of the component part 140 with a like-component part, the component part 140 comprises an energy director in the form of a pointed rib 164 (i.e. having a pointed apex). The rib 164 extends about a periphery of the first reservoir recess 150a (i.e. along the distal edge of the first separator wall 152a and a portion of the periphery of the outer wall 146). The extension of the energy director 164 about the periphery of the first reservoir recess 150a ensures that the corresponding reservoir is adequately sealed upon joining of the component part 140 to a like-component part. As should be appreciated, the energy director of the like-component part abuts, and seals, the periphery of the second reservoir recess 150b upon joining of the components 140. The component part 140 is symmetrical about a central longitudinal axis, except for the presence of the energy director 164.
Thus, in general the component 104, as shown in Figure 3A and 3B may be formed by providing two identical component parts 140 as shown in Figure 4. Each component part 140 may be formed by a moulding process (e.g. an injection moulding process). Due to shape of each component part 140, the forming process may be performed with a straight pull mould (e.g. without side-actions).
A vaporiser 132 and connectors 160 are positioned between the component parts 140, which are then joined to one another by using e.g. an ultrasonic welding process. The supply inlets 166 of the component parts 140, may then subsequently be used to fill each reservoir of the component 104 with aerosol precursor. After filling, the supply inlets 166 may be sealed through a further ultrasonic welding process.
This process involves very small number of different parts, which minimises the tooling required to produce an aerosol delivery component. This results in a more cost effective and less complex aerosol delivery component, and one having less joins susceptible to aerosol precursor leakage.
Figure 5 illustrates a component part 140' that is a variation of the component part 140 shown in Figure 4. This component part 140' includes many of the features of those of the component part 140 of Figure 4 and, for that reason, corresponding reference numerals have been sued.
The illustrated component part 140' differs in that it comprises only one reservoir recess 150 and the passage recess 148 does not extend centrally through the component part 140' (it instead extends along one side of the component part 140'). Thus, the component part 140' also includes a single separator wall 152 that separate the passage recess 148 from the reservoir recess 150.
Unlike the previously described embodiment, this component part 140' cannot be joined with a like-component, because it is not symmetrical. Rather, the component part 140' is joined with a second component part 140' in which the features are flipped about the longitudinal axis.
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 set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope defined in the claims.
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 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 kit of parts for forming an aerosol delivery component for a substitute smoking system, the kit of parts comprising first and second moulded component parts configured such that, when joined together, the first and second moulded component parts define an airflow passage and aerosol precursor reservoir therebetween.
A kit of parts according to claim 1 wherein the first component part is substantially the same as the second component part.
A kit of parts according to claim 1 or 2 wherein the first and second component parts are configured to be joined along a joining plane parallel to a longitudinal axis of the airflow passage when formed.
A kit of parts according to any one of the preceding claims wherein each component part comprises a passage recess formed therein, the passage recesses arranged such that, when the components parts are joined, the passage recesses combine to define an airflow passage.
A kit of parts according to claim 4 wherein each component parts comprises a reservoir recess formed therein, the reservoir recesses arranged such that, when the components parts are joined, the reservoir recesses combine to define a reservoir for storing aerosol precursor.
A kit of parts according to claim 5 wherein each component part comprises a separator wall that separates the passage recess from the reservoir recess.
A kit of parts according to claim 6 wherein each component part comprises an outer wall, the outer wall comprising an external side defining an outer surface of the component when the component parts are joined, and an internal side from which the separator wall projects.
A kit of parts according to claim 7 wherein each component part comprises a supply inlet formed in a portion of the outer wall defining the reservoir recess.
A kit of parts according to claim 5 wherein the reservoir recess of each component part is a first reservoir recess and each component part further comprises a second reservoir recess, the first and second reservoir recesses of each component part disposed either side of the passage recess of the component part.
A kit of parts according to any one of the preceding claims wherein the component parts are configured to retain a vaporiser therebetween when joined.
A method of forming an aerosol delivery component for a substitute smoking system, the method comprising:
moulding a first component part;

moulding a second component part;

joining the first and second component parts to one another such that, when joined together, the first and second component parts define an airflow passage and an aerosol precursor reservoir therebetween.
A method according to claim 11 wherein the steps of moulding the first and second component parts comprises injection moulding the first and second components parts.
A method according to claim 11 or 12 wherein the step of joining the first and second component parts comprises welding the first and second component parts together using an ultrasonic welding process.
A method according to any one of claims 11 to 13 comprising, subsequent to joining the first and second component parts, filling one or more aerosol precursor reservoirs defined between the first and second component parts, and, optionally,, subsequent to filling the one or more aerosol precursor reservoirs, sealing (e.g. welding) the one or more aerosol precursor reservoirs.
A component produced by the method according to any one of claims 11 to 14.