EP4684655A1

EP4684655A1 - Aerosol-generating apparatus accessory

Info

Publication number: EP4684655A1
Application number: EP24190335.0A
Authority: EP
Inventors: Sean Dignum; Andrew Robert WALLACE; Adam BARAGWANATH
Original assignee: Imperial Tobacco Ltd United Kingdom
Current assignee: Imperial Tobacco Ltd United Kingdom
Priority date: 2024-07-23
Filing date: 2024-07-23
Publication date: 2026-01-28
Also published as: WO2026021833A1

Abstract

Herein is provided a cap (50) for mounting over a mouthpiece (136) of an aerosol-generating apparatus (100). The cap (50) comprises: a cavity (53) for receiving the mouthpiece (136), an airflow path extending from at least one cap inlet to a cap outlet (54), the cavity (53) containing a portion of, or in fluid communication with, the airflow path; the cap (50) houses a carrier material (52) for containing flavourant, the carrier material (52) comprising an upstream end and a downstream end. The cap inlet is configured to receive an aerosol from the mouthpiece (136) when received in the cap (50). The carrier material (52) is positioned on, or defines at least a portion of, the airflow path. The airflow path extends between the upstream end and downstream end of the carrier material (52). Also provided is a kit of parts comprising a mouthpiece (136) for an aerosol-generating apparatus (100) and a cap (50) for mounting over the mouthpiece (136), a method of fitting a cap (50) to a mouthpiece (136) of an aerosol-generating apparatus (100), and an assembly of a component (104) for an aerosol-generating apparatus (100) and a cap (50).

Description

FIELD

The present disclosure relates to a cap for mounting over the mouthpiece of an aerosol-generating apparatus, a kit of parts comprising a mouthpiece for an aerosol-generating apparatus and a cap for mounting over the mouthpiece, a method of fitting a cap to the mouthpiece of an aerosol-generating apparatus, and an assembly of a cap and a component of an aerosol-generating apparatus.

BACKGROUND

A typical aerosol-generating apparatus may comprise a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol-generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user.
A drawback with known aerosol-generating apparatus is that flavourants for the aerosol provided to a user of the apparatus need to be contained in the aerosol precursor. However, regulation around the inclusion of flavourants in the aerosol precursor means that it is desired to provide flavour to the user in a different manner (i.e. without the aerosol precursor containing that flavourant).
A further drawback with known aerosol-generating apparatus is that flavourants contained in the aerosol precursor undergo heating and vaporisation in order to be carried in the aerosol. This can degrade the flavourant (i.e. due to chemical reaction (oxidation) of the flavourants at elevated temperatures necessary for vaporisation), and limits the flavours that can be provided, because the flavourants contained in the aerosol precursor are required to vaporise at similar temperatures to other compounds contained in the aerosol precursor.
Further improvements in aerosol-generating apparatus are desirable.

SUMMARY

In a first aspect, the present disclosure provides a cap for mounting over a mouthpiece of an aerosol-generating apparatus, wherein the cap houses a carrier material for containing flavourant, the carrier material comprising an upstream end and a downstream end.
In some examples, the cap comprises a cavity for receiving the mouthpiece, the cap defining an airflow path extending from a cap inlet to a cap outlet, the cavity containing a portion of, or being in fluid communication with, the airflow path, and the cap inlet being configured to receive an aerosol from the mouthpiece when received in the cap; the carrier material is positioned within, or defines at least a portion of, the airflow path; the airflow path extends between the upstream end and the downstream end of the carrier material.
In this way, the cap is configured to allow flavourant contained within the carrier material to be aerosolised (e.g. without the direct application of heat from a heating element) by the air flowing along the airflow path to the cap outlet. As a result, the aerosol precursor in an aerosol-generating device or component does not need to contain flavourant in order to provide the user with a flavoured vapour. Alternatively, where the aerosol precursor in the aerosol generating device or component does contain flavourant, that flavourant can be combined with the flavourant provided by the cap. The cap inlet may be positioned in the cavity of the cap such that the cap inlet is configured to receive an aerosol from the mouthpiece when received in the cap and the aerosol-generating apparatus is operated. The cap inlet may be considered an aerosol inlet of the cap. By being positioned in the cavity, the cap inlet may not be positioned on an external surface of the cap (i.e. the cap inlet is not configured to receive ambient air during operation of the aerosol-generating apparatus). By the airflow path extending between the upstream and downstream ends of the carrier material, the airflow path may flow through, or adjacent to, the carrier material along substantially the whole length of the carrier material in the direction of the airflow path such as to aerosolise flavourant therefrom. The cap inlet may be the only inlet for an airflow into the cap (i.e. the cap may not comprise a second airflow inlet). The cap is an accessory for the mouthpiece of the aerosol-generating apparatus.
The mouthpiece may comprise an aerosol outlet, through which aerosol generated by the aerosol-generating apparatus can flow out of the mouthpiece. The cap inlet is configured to receive an aerosol from the mouthpiece when received in the cap (e.g. by the cap inlet being positioned in the cavity). Accordingly, when the mouthpiece is received in the cavity of the cap, the cap inlet may be defined as being (immediately) adjacent the aerosol outlet of the mouthpiece. In this way the aerosol from the mouthpiece can flow through the cap inlet and along the airflow path.
An airflow direction along the airflow path may be defined as the direction along the airflow path from the cap inlet to the cap outlet.
The cap outlet may be provided on an external surface of the cap (e.g. may be an aperture on an external surface of the cap), such that the user inhaling on the cap (e.g. inhaling on the cap at the cap outlet) draws an airflow (e.g. an airflow containing an aerosol) out of the cap via the cap outlet for inhalation by the user. Accordingly, a user inhaling on the cap at the cap outlet generates an airflow through the cap along the airflow path between the cap inlet and cap outlet. By positioning the carrier material within the airflow path, or by the carrier material defining at least a portion of the airflow path, flavourant can be aerosolised from the carrier material by the airflow along the airflow path. By way of example, the user inhaling on the cap (e.g. inhaling at the cap outlet) may generate a negative gauge pressure in, or in the vicinity of, the carrier material , thereby promoting aerosolization.
The cap may be elongate and have a longitudinal axis extending along the elongate dimension of the cap. The cap may be rotationally symmetrical about the longitudinal axis (i.e. the longitudinal axis may be a central axis of the cap).
In some examples, the cap inlet and/or the cap outlet may be positioned along the longitudinal axis of the cap. Where both the cap inlet and cap outlet are positioned on the longitudinal axis, the airflow path may also extend along the longitudinal axis; for example, the airflow path may be a substantially linear path between the cap inlet and cap outlet along the longitudinal axis. In other examples, the cap inlet and cap outlet may be co-axial, but offset from the longitudinal axis of the cap. In such examples, the airflow path may be a linear path along the common axis of the air inlet and air outlet.
The cavity may be configured to receive the mouthpiece such that the aerosol outlet of the mouthpiece is coaxial with the cap inlet and the cap outlet (e.g. positioned on the longitudinal axis of the cap).
In some examples, the mouthpiece may comprise a longitudinal axis, and the cavity may be configured to receive the mouthpiece such that the longitudinal axis of the mouthpiece is coaxial with the longitudinal axis of the cap.
In examples where the cap inlet is (immediately) adjacent the aerosol outlet of the mouthpiece such that aerosol from the mouthpiece flows through the cap inlet into the airflow path, aerosol flowing along the airflow path is provided in fluid communication with the carrier material. In this way, flavourant contained within the carrier material can be aerosolised by the aerosol from the mouthpiece.
In examples where the carrier material is positioned within the airflow path (i.e. where the airflow path passes through the carrier material), the carrier material may be completely contained in the airflow path (i.e. no portion of the carrier material may extend out of the airflow path). Alternatively, where the carrier material is positioned within the airflow path, the airflow path may pass through a portion of the carrier material, and a portion of the carrier material may not have the airflow path passing through it (e.g. a portion of the carrier material may be positioned off/outside the airflow path). In some examples, the carrier material occupies the entire cross-section of the airflow path in a plane perpendicular to the air flow direction along the airflow path. In this way, all of the air flowing along the airflow path flows through the carrier material. By way of example, where the airflow path extends along, or parallel to, the longitudinal axis, the carrier material may occupy the entire cross-section of the airflow path in a plane perpendicular to the longitudinal axis.
In further examples where the carrier material is positioned within the airflow path, the carrier material may extend along at least a portion of the airflow path in the airflow direction. For example, the carrier material may extend along the entire airflow path (i.e. from the cap inlet to the cap outlet).
An internal surface of the cap defines the cavity. The cap may comprise a bore therethrough between the internal surface and the external surface. In further examples, the cap outlet may be provided by the bore extending to the external surface.
In some examples, the carrier material is disposed in the cavity. For example, the carrier material may be positioned in the cavity on the airflow path between the cap inlet (e.g. adjacent the aerosol outlet of the mouthpiece) and the cap outlet on the external surface of the cap (i.e. the carrier material is interposed between the mouthpiece (e.g. the aerosol outlet of the mouthpiece) and the cap outlet.
The carrier material may be disposed in the bore between the internal and external surface of the cap. For example, the cap inlet may be provided by the bore on the internal surface and the cap outlet may be provided by the bore on the external surface, with the carrier material therebetween. Where the carrier material is positioned in the bore, extends along the entire airflow path and occupies the entire cross-section of the airflow path in a plane perpendicular to the airflow direction of the airflow path, the carrier material fills the bore. In this way, it can be ensured that the airflow passing out of the cap via the cap outlet has interacted with the carrier material (i.e. for aerosolising flavourant contained in the carrier material).
In examples where the carrier material defines at least a portion of the airflow path, it may be a surface of the carrier material that defines said at least a portion of the airflow path. By way of further example, the airflow path may be at least partially defined by a conduit, and the carrier material may (partially) define at least one surface of the conduit. In a further example, the carrier material may comprise a through hole extending therethrough, the through hole defining (at least a portion of) the airflow path i.e. the carrier material may provide the conduit. In examples where the airflow path is along the longitudinal axis of the cap, the carrier material may be an annulus (e.g. a circular annulus) having its longitudinal axis substantially coincident with the longitudinal axis of the cap. In this way, the air flowing along the airflow path flows past a surface of the carrier material, rather than through the carrier material. In this way the airflow can still aerosolise flavourant contained in the carrier material and the pressure drop along the airflow path can be reduced compared to examples where the airflow path passes through the carrier material.
In some examples, the carrier material may comprise a first portion comprising a first flavourant and a second portion comprising a second flavourant. The first flavourant and second flavourant may be different. Where the carrier material is positioned within the airflow path, the first and second portions of the carrier material may be positioned within different parts of the airflow path. Similarly, where the carrier material defines at least a portion of the airflow path, the first and second portions of the carrier material may define different portions of the airflow path. For example, where the airflow path extends along the longitudinal axis of the cap, the first and second portions of the carrier material may be provided on opposite (e.g. diametrically opposed) sides of the longitudinal axis. Alternatively, or additionally, the first and second portions of the carrier material may be positioned at different positions along the length of the airflow path between the cap inlet and the cap outlet.
In some examples, the carrier material is porous. In this way, flavourant can be transported through the carrier material e.g. by wicking (i.e. capillary action). The carrier material may be of any porous construction, e.g. fibrous or foamed. For example, the carrier material may be formed of cellulose acetate, or polyethylene foam or ceramic. By being porous, the carrier material allows an airflow to be drawn therethrough by inhalation of the user on the cap at the cap outlet. The carrier material can be formed in a variety of shapes and may be shaped to increase flavour transfer or reduce total particulate matter (TPM) loss (e.g. by having a high macro-surface area to volume ratio). The carrier material may have a central hollow through hole or the carrier material may have multiple through holes. Such through holes may be aligned with the airflow path. One or multiple through holes would reduce TPM loss but not reduce flavour delivery to the user.
In some examples, the carrier material may contain flavourant, for example, the carrier material may be pre-imbued with flavourant prior to insertion into the cavity of the body.
The carrier material may be configured to be activated (e.g. to allow air to flow therethrough and/or to allow flavourant to be aerosolised therefrom) by the application of heat thereto (i.e. the carrier material may be heat-activated). The heat required to activate the carrier material may be such that the temperature of the carrier material upon activation is less than: the temperature of a heating element, the temperature of the aerosol generated adjacent the heating element, and/or the vaporisation temperature of aerosol precursor contained in the aerosol generating apparatus. For example, the carrier material may be configured to be activated in response to being heated by aerosol exiting the aerosol outlet of the mouthpiece contacting the carrier material. By the time the aerosol is exiting the aerosol outlet of the mouthpiece, the temperature of the aerosol will be substantially lower than the temperature of a heating element, the temperature of the aerosol generated adjacent the heating element, and/or the vaporisation temperature of aerosol precursor contained in the aerosol generating apparatus. As an example, the carrier material may include flavourant that is contained within microcapsules (e.g. made of gelatin, or the like), the microcapsules being arranged to rupture on application of heat (e.g. heat from an aerosol drawn out of the mouthpiece). In another example, the carrier material may comprise a barrier layer that encapsulates the flavourant. The barrier layer may be configured to rupture or disintegrate upon heating by the aerosol exiting the aerosol outlet, so that the flavourant can then be aerosolised and released from the carrier material. In this way, release of flavourant prior to use of the cap can be prevented, thereby extending the shelf-life of the cap.
The flavourant may be provided in solid, gel or liquid form. The flavourant may be a water-based (e.g. aqueous or water soluble) flavourant. The flavourant 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 an aerosol or airflow upon contacting or being aerosolised by said aerosol/airflow.
In some examples, the cap further houses a reservoir containing flavourant. In further examples, the cap may be provided such that the carrier material does not contain flavourant and instead the reservoir contains flavourant. In this way, it is possible to provide a greater volume of flavourant than would be possible absent the reservoir, since the volume of flavourant that can be stored in the carrier material is then not the limiting factor on the amount of flavourant the cap can contain.
In some examples, the reservoir is porous. In this way, flavourant can be transported through the reservoir towards the carrier material e.g. by wicking (i.e. capillary action). The reservoir may be of any porous construction e.g. fibrous or foamed. For example, it may be formed of cellulose acetate, or polyethylene foam or ceramic. In other examples, the reservoir may be a casing (e.g. may comprise a single chamber containing flavourant).
In some examples, a fluid path is provided between the reservoir and the carrier material. In this way, flavourant (e.g. liquid flavourant) contained in the reservoir can be provided to the carrier material (e.g. under capillary action and/or gravity) from the reservoir.
In further examples, the cap may comprise a valve, the valve configured to be actuatable from a closed state in which the fluid path is closed to an open state in which the fluid path is open.
The valve may be actuatable from the closed state to the open state by movement of the cap, or a portion thereof, relative to the reservoir and/or the carrier material, for example, by movement of the cap between a disactivated position in which the valve is in the closed state, and an activated position in which the valve is in the open state. In this way, an easy manner in which to actuate the valve is provided. In further examples, movement of the cap between the disactivated position and the activated position may be effected by movement of the cap relative to the mouthpiece. By way of example, the cap may be moved from the disactivated position to the activated position by moving the cap towards the mouthpiece, such that a greater portion of the cavity is occupied by the mouthpiece. In other examples, movement of the cap between the disactivated position and the activated position may be effected by twisting of the cap relative to the mouthpiece (e.g. about the longitudinal axis of the cap).
In some examples, the valve is actuatable from the open state to the closed state in addition to being actuatable from the closed state to the open state. In this way, the valve can open and subsequently close the fluid path. The valve may be configured such that it is repeatably actuatable between the closed state and the open state.
In some examples the valve may comprise a barrier element interposed between the reservoir and the carrier material. By way of further example, the cap may be configured such that with the valve in the closed state, a barrier element is interposed between the reservoir and the carrier material (e.g. in a gap between the reservoir and carrier material), and with the valve in the open state, the barrier element is not interposed between the reservoir and the carrier material (e.g. is spaced from a gap between the reservoir and carrier material).
Where the carrier material and/or reservoir is interposed between the cap and the mouthpiece when the mouthpiece is received in the cavity, the mouthpiece and/or cap may be movable relative to the carrier material and/or reservoir such that the carrier material and/or reservoir can be compressed between the cap and the mouthpiece to promote release of flavourant therefrom (e.g. along the fluid path between the reservoir and carrier material or from the carrier material into the airflow path, respectively). In further examples, the reservoir may initially be sealed (e.g. such that flavourant cannot be transported along the fluid path to the carrier material). Where the reservoir is initially sealed, at least a portion of the reservoir may be frangible, pierceable, or otherwise capable of being broken, for example, the reservoir may fracture on being compressed (e.g. the reservoir may be a crushable member). By the reservoir initially being sealed, release of flavourant (e.g. transport of flavourant along the fluid path to the carrier material) prior to the user desiring the release of flavourant can be avoided, which may extend the shelf-life of the cap and/or prevent leakage of flavourant from the cap.
Where a portion of the reservoir is frangible, pierceable, or otherwise capable of being broken, the reservoir may be interposed between the cap and the mouthpiece, and the cap may be configured such that the reservoir may be compressed and subsequently fractured / pierced between the cap and mouthpiece by movement of the cap from a disactivated position to an activated position.
The cavity may be configured to receive the mouthpiece by at least a portion of an internal surface of the cap that defines the cavity corresponding to at least a portion of the outer surface of the mouthpiece and/or a component of an aerosol-generating apparatus the mouthpiece forms part of. By way of example, at least a portion of the internal surface of the cap may be shaped such that, on insertion of the mouthpiece into the cavity, at least a portion of the internal surface of the cap extends substantially parallel to at least a portion of the outer surface of the mouthpiece.
In some examples, at least a portion of the internal surface of the cap may be configured to abut at least a portion of the outer surface of the mouthpiece (i.e. forming a frictional/interference fit with the outer surface of the mouthpiece). In other examples, the cap may be configured to engage with the mouthpiece by snap-fit engagement (e.g. the cap and/or mouthpiece may comprise one or more snap-fit members). In this way, the likelihood of inadvertent detachment of the cap from the mouthpiece can be reduced in comparison to attachment solely by an interference fit between the cap and the mouthpiece.
In further examples, the cap may be configured to be reversibly attachable to the mouthpiece (i.e. the mouthpiece can be removed from the cavity of the cap after being received in said cavity). In this way, the cap is provided as a detachable accessory that the user can replace, for example, when the flavourant in the cap (e.g. in the carrier material) has been exhausted, or when the user desires a different flavour, or desires to use the aerosol-generating apparatus without the cap. The interference fit and/or snap-fit engagement may provide this reversible attachment. In this way, detachment of the cap from the mouthpiece is made easy.
In some examples, the cap may comprise a soft/elastomeric outer coating. This may provide a comfortable surface for the user contact with their mouth when inhaling on the cap.
In some examples, the cap may further comprise a sealing member configured to form a seal between the cap and the mouthpiece when the mouthpiece is received in the cavity. In this way, the release of flavourant and/or other liquid condensing from the aerosol in the cavity can be prevented other than through the cap outlet. The sealing member may be positioned within the cavity. In further examples, the sealing member may be configured to form a seal with the mouthpiece that circumscribes the aerosol outlet. In other examples, the mouthpiece may further comprise a sealing member such as that described above for the cap.
In some examples, the cap may house an inner shell sleeve. The inner shell may be movable relative to the cap (e.g. the inner shell may be removable from, or slidable relative to, the cap). Where the cap houses an inner shell, the cap cavity may be separated into an outer cavity portion bounded by the inner shell and cap (e.g. between an external surface of the inner shell and the internal surface of the cap), and an inner cavity portion bounded by the inner shell (e.g. by an internal surface of the inner shell). In some examples, the inner cavity portion may be configured to receive the mouthpiece.
Where the inner shell and cap provide inner and outer cavity portions, the carrier material and/or reservoir may be received in the outer cavity portion (i.e. interposed between the inner shell and cap). In some examples, the carrier material and/or reservoir may be stationary with respect to the inner shell (e.g. the carrier material and/or reservoir may be mounted to the inner shell in the outer cavity portion) and the cap may be movable relative to the inner shell and carrier material and/or reservoir. In further examples, the cap may be movable relative to the carrier material and/or reservoir such that the carrier material and/or reservoir can be compressed between the inner shell and cap to promote release of flavourant therefrom (e.g. transport of flavourant along the fluid path between the reservoir and carrier material or from the carrier material into the airflow path, respectively). It can be appreciated that in an alternative example to that described above, the reservoir and carrier material may be stationary relative to the cap (e.g. mounted on the internal surface of the cap in the outer cavity portion), the inner shell may then be movable relative to the carrier material and/or reservoir such that the carrier material and/or reservoir can be compressed between the inner shell and cap to promote release of flavourant therefrom.
Where the cap comprises a barrier element, the barrier element may be extend from the cap (e.g. the barrier element being a wall to be interposed between the carrier material and reservoir). The inner shell and cap may be slidably mounted relative to each other, such that the cap can be slid between the disactivated position, in which the barrier element (e.g. the wall) is interposed between the carrier material and the reservoir (e.g. in a gap between the carrier material and reservoir), and the activated position, in which the barrier element is removed from (e.g. spaced from) said gap. In some examples, in the disactivated position the inner shell and cap are slid together, and in the activated position the inner shell and cap are slid apart. It can be appreciated that in an alternative example to that described above, the reservoir and carrier material may be stationary relative to the cap (e.g. mounted on the cap, for example, in the outer cavity portion), and the barrier element may be provided on the inner shell.
In some examples, where the cap houses an inner shell, the carrier material may be interposed between the inner shell and the cap i.e. in the outer cavity portion (for example, mounted on an external surface of the inner shell, or an internal surface of the cap).
In some examples, the carrier material may be removably received in the cavity. Where the carrier material is removably received in the cavity, the carrier material may be provided in a casing. The casing may be impermeable (e.g. to flavourant and/or airflow) and thus may be provided with a through hole extending therethrough. In this way, air can flow through the casing to aerosolise flavourant contained in the carrier material. The carrier material may fill the casing (i.e. occupy the entire volume of the casing); however, where the cap houses a reservoir, the reservoir may also be provided in the casing.
By providing the carrier material (and optionally the reservoir) in a casing, production of the cap is made easier, because a universal cap can be provided that is independent of the flavourant to be contained within the cap, and subsequently a casing containing a suitable flavourant (either in the carrier material or reservoir) can be paired with the universal cap, depending on which flavour needs to be provided.
In further examples, the casing is disposed in the cavity such that it is configured to be interposed between the cap and the mouthpiece when the mouthpiece is received in the cavity. In this manner, the carrier material can be provided in a suitable position for the airflow along the airflow path to aerosolise flavourant contained in the carrier material within the casing.
In some examples, the casing comprises a base and a lid, the base and the lid configured to fit together (e.g. via an interference fit or by snap-fit means provided on the base and lid) to provide the casing. In examples where the casing comprises the through hole, the through hole may extend through both the base and the lid (i.e. the base may comprise an aperture and the lid may comprise an aperture).
In examples where the casing comprises the through hole, the through hole may further be aligned with (e.g. coaxial with) the cap inlet and/or cap outlet when the casing is received in the cavity. The cap may be configured such that the mouthpiece abuts the base of the casing when received in the cavity, such that the aerosol outlet is aligned with (e.g. coaxial with) the casing's through hole (e.g. by the shape of the cavity).
In some examples, the cap may further house a filter (e.g. a cotton or gauze filter) such that air flowing along the airflow path passes through the filter. The filter may be interposed between the cap and the carrier material, for example, such that air flowing along the airflow path passes through the filter after flowing through the carrier material (e.g. by the filter underlying the cap outlet). In this way, the filter can prevent the passage of large solid and/or liquid phase particles out of the cap. In further examples where a casing for the carrier material (and optionally the reservoir) is present, the filter may be interposed between the casing and the cap.
In a second aspect there is provided a kit of parts comprising a mouthpiece for an aerosol-generating apparatus, the mouthpiece having an aerosol outlet and a cap according to the first aspect.
The mouthpiece is configured to allow a user to inhale thereon absent the cap. For example, where the mouthpiece forms part of a component of an aerosol-generating apparatus, the aerosol-generating apparatus may be configured to generate and supply aerosol to the user via the aerosol outlet when the user inhales on the mouthpiece absent the cap.
In some examples, the kit of parts may further comprise a component (e.g. a consumable) of an aerosol-generating apparatus, the mouthpiece providing an outer surface of the component. The mouthpiece is configured for a user to contact with their mouth and inhale on during use of the component.
In a third aspect there is provided an assembly of a component for an aerosol-generating apparatus, the component having a mouthpiece having an aerosol outlet and a cap according to the first aspect wherein the mouthpiece is received in the cavity such that the cap is mounted on the component.
In some examples, the mouthpiece is received in the cavity such that the aerosol outlet is in fluid communication with the airflow path i.e. the airflow path extends from the cap inlet that is adjacent the aerosol outlet to the cap outlet.
In some examples, the cap outlet is located on the cap such that the cap outlet overlies the aerosol outlet of the mouthpiece that the cap is configured to receive. In further examples, the cap outlet and aerosol outlet are coaxial. By way of example, the cap outlet may be positioned on the longitudinal axis of the cap, the aerosol outlet may be positioned on a longitudinal axis of the mouthpiece, and the mouthpiece may be received in the cavity of the cap such that the longitudinal axes of the cap and the mouthpiece are co-incident (e.g. by way of the shape of the cavity with respect to the mouthpiece). In this way, the pressure drop between the aerosol outlet and cap outlet can be reduced in comparison to arrangements where the cap outlet does not overlie the aerosol outlet, resulting in a more contorted airflow path through the cap.
In some examples, the component may comprise an airflow passage that extends from an air inlet to the aerosol outlet of the mouthpiece. In this way, a user may draw fluid (e.g. air) into and along the component's airflow passage by inhaling at the aerosol outlet (i.e. inhaling on the mouthpiece), or by inhaling at the cap outlet (i.e. inhaling on the cap where the mouthpiece is received in the cavity of the cap). In some examples, the component may be configured to allow a user to inhale on the mouthpiece to generate and inhale an aerosol/vapour absent the cap.
In some examples, the component's airflow passage may pass a vaporiser between the air inlet and the outlet. In some examples, the vaporiser may be housed in a vaporising chamber.
In some examples, the component's airflow passage may comprise a first portion extending from the air inlet towards the vaporiser. In further examples, a second portion of the component's airflow passage may pass through the vaporising chamber and/or over/around the vaporiser to a conduit that extends to the aerosol outlet. In further examples, the conduit may extend along the axial centre of the component.
Thus, the second portion of the component's airflow passage is downstream of the first portion of the component's airflow passage.
In some examples, the component may comprise a tank for housing the aerosol precursor (e.g. a liquid aerosol precursor). In some examples, the aerosol precursor may comprise an e-liquid, for example, comprising a base liquid and e.g. nicotine. In further examples, the base liquid may include propylene glycol and/or vegetable glycerine. In some examples, the aerosol precursor may further include a flavouring. In alternative examples, the aerosol precursor may not include a flavouring.
In some examples, the conduit may extend through the tank with the conduit walls defining an inner region of the tank. In this way, the tank may surround the conduit e.g. the tank may be annular. In some examples, the tank may be defined by one or more side walls (e.g. laterally opposed first and second side walls) extending longitudinally from the mouthpiece portion. In further examples, the tank may further comprise one or more walls, e.g. opposing front and rear walls spaced by the laterally opposed first and second side walls.
In some examples, the distance between the first and second side walls may define a width of the tank. In some examples, the distance between the front and rear walls may define a depth of the tank. In some examples, the width of the tank may be greater than the depth of the tank. In some examples, the length of the tank/component housing may be greater than the width of the tank/component housing. In some examples, the depth of the tank/component housing may be smaller than each of the width and the length.
In some examples, the tank wall(s) may be integrally formed with the mouthpiece portion. In some examples, the tank walls may be integrally formed and may additionally be integrally formed with the mouthpiece portion. In this way, the component may be easily manufactured using injection moulding.
The tank may be transparent or translucent. In this way, a liquid level in the tank may be viewed through the tank. In other examples, the tank may comprise a translucent window, the window configured to allow the liquid level in the tank to be viewed through the window. Where the tank is translucent or comprises a window, the cap may be shaped (e.g. comprise a slot or window aperture) to allow the amount of liquid in the tank to be visually assessed even when the mouthpiece is received in the cavity of the cap.
In some examples, the component housing may comprise a lower shell that at least partly forms the base portion of the component. In further examples, the lower shell may overlap the tank walls.
As discussed above, the component's airflow passage may pass over/around the vaporiser between the air inlet and the outlet. In some examples, the vaporiser may be disposed in the vaporising chamber. In further examples, the vaporising chamber may form part of the airflow passage.
In some examples, the vaporiser may comprise a heating element. In other examples, the vaporiser may comprise an ultrasonic or flow expansion unit, or an induction heating system.
In some examples, the vaporiser may comprise a wick. In further examples, the wick may form the base of the tank so that the aerosol precursor may be in contact with the wick. In further examples, the wick may comprise one or more channels on its upper surface (facing the tank), the channels being in fluid communication with the tank.
In some examples, the wick may have a length and width defining its upper surface with a depth aligned with the longitudinal axis of the component. In this way, the upper surface and opposing lower surface of the wick may lie in respective planes that are perpendicular to the longitudinal axis of component and longitudinal to the first and second portions of the component's airflow passage.
In some examples, the wick may comprise a porous material e.g. a ceramic material. In some examples, a portion of the wick e.g. at least a portion of the lower surface and/or at least a portion of at least one side wall extending between the upper and lower surface (in a depth direction of the wick) may be exposed to airflow in the second portion of the component's airflow passage.
In some examples, the heating element may be in the form of a heater track on the wick e.g. on the lower surface of the wick. In other examples, the wick may be a cylindrical, porous wick e.g. formed of cotton or ceramic. In some examples, it may be oriented so as to extend in the direction of the width dimension of the component (perpendicular to the longitudinal axis of the component). In this way, the wick may extend in a direction perpendicular to the direction of airflow in the component's airflow passage. In some examples, opposing ends of the wick may protrude into the tank and a central portion (between the ends) may extend across the component's airflow passage so as to be exposed to airflow. In this way, fluid may be drawn (e.g. by capillary action) along the wick, from the tank to the exposed portion of the wick. In some examples, 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.
In some examples, the heating element may be electrically connectable (or connected) to a power source. In this way, 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 along the airflow passage. In some examples, this vapour may subsequently cool to form an aerosol in the airflow passage (e.g. the second portion of the airflow passage).
In some examples, the component may be an aerosol-generating (e.g. a smoking substitute) consumable i.e. in some examples the component may be a consumable component for engagement with the aerosol-generating (e.g. a smoking substitute) device to form the aerosol-generating apparatus (e.g. a smoking substitute apparatus).
In a fourth aspect there is provided an aerosol-generating apparatus comprising an aerosol-generating device, a component comprising a mouthpiece having an aerosol outlet, and a cap according to the first aspect mounted on the component, wherein the mouthpiece is received in the cavity such that the cap is mounted on the component.
In some examples, the component may be a consumable component. In further examples, the device may be configured to receive the consumable component. For example, the device and the consumable component may be configured to be physically coupled together. For example, the consumable component may be at least partially received in a recess of the device, such that there is snap engagement between the device and the consumable component. In other examples, the device and the consumable component may be physically coupled together by screwing one onto the other, or through a bayonet fitting. Thus, the consumable component may comprise one or more engagement portions for engaging with the device.
In some examples, the device and consumable component may be coupled together by magnetic attraction. For example, the device may comprise at least one magnet whilst the component may comprise a magnet or ferrous metal plate/portion.
In other examples, the component may be integrally formed with the aerosol-generating device (e.g. a smoking substitute device) to form the aerosol-generating apparatus (e.g. a smoking substitute apparatus).
In such examples, the aerosol former (e.g. e-liquid) may be replenished by re-filling a tank that is integral with the device (rather than replacing the consumable). Access to the tank (for re-filling of the e-liquid) may be provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap).
In a fifth aspect there is provided a method of fitting a cap according to the first aspect to a mouthpiece of an aerosol-generating apparatus, wherein:

the mouthpiece has an aerosol outlet; and
the method comprises the step of inserting the mouthpiece into the cavity of the cap such that the aerosol outlet is in fluid communication with the airflow path.

The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the preceding examples may be combined in any suitable combination, including combinations of examples relating to different aspects, to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGS.

Aspects, features, and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

Fig. 1 is a block system diagram showing an example aerosol-generating apparatus.
Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol-generating apparatus is configured to generate aerosol from a solid precursor.
Fig. 3A is a front schematic view of an aerosol-generating apparatus.
Fig. 3B is a front schematic view of a device of the apparatus in Fig. 3A.
Fig. 3C is a front schematic view of a component and a mouthpiece of the apparatus.
Fig. 4A is a schematic of the elements of the device.
Fig. 4B is a schematic of the elements of the component.
Fig. 5 is a further schematic view of the component.
Fig. 6 is a schematic cross-sectional view through the component, said component comprising a mouthpiece, and a first cap mounted on said mouthpiece.
Fig. 7 is a schematic cross-sectional view through a second cap.
Fig. 8 is a schematic cross-sectional view through a third cap.
Fig. 9A is a schematic cross-sectional view through the component, said component comprising a mouthpiece, and a fourth cap mounted on said mouthpiece and in a disactivated position.
Fig. 9B is a schematic cross-sectional view through the component, said component comprising a mouthpiece, and the fourth cap mounted on said mouthpiece and in an activated position.
Fig. 10A is a schematic cross-sectional view through a fifth cap in a first state.
Fig. 10B is a schematic cross-sectional view through the fifth cap in a second state.
Fig. 11 is a schematic cross-sectional view through a portion of a cap accessory.

DETAILED DESCRIPTION OF EMBODIMENTS

Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and/or methods described herein could be embodied differently and/or be practiced or carried out in various alternative ways.
Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.
Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.
All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.
The use of the term "a" or "an" in the claims and/or the specification may mean "one," as well as "one or more," "at least one," and "one or more than one." As such, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.
The use of the term "or" in the present disclosure (including the claims) is used to mean an inclusive "and/or" unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition "A or B" is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
As used in this specification and claim(s), the words "comprising, "having," "including," or "containing" (and any forms thereof, such as "comprise" and "comprises," "have" and "has," "includes" and "include," or "contains" and "contain," respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase "in one embodiment," "according to an embodiment," and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an,' 'one,' or 'some' embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.
The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably:
As used herein, an "aerosol-generating apparatus" (or "electronic(e)-cigarette") may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally/alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and/or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol-generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and/or an airflow sensor.
Each occurrence of the aerosol-generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an "activation" of the aerosol-generating apparatus. The aerosol-generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol-generating unit of the apparatus for a variable amount of time, e.g. based on the strength/duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).
The aerosol-generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.
As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to/include a vapour. An aerosol may include one or more components of the precursor.
As used herein, a "precursor" may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol-generating unit of an aerosol-generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and/or glycerine. The term "flavouring" may refer to a component that provides a taste and/or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.
As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.
As used herein, an "airflow passage" may refer to a path or enclosed passageway through an aerosol-generating apparatus, e.g. for delivery of an aerosol to a user. The airflow passage may extend through the component of an aerosol-generating apparatus. The airflow passage may be arranged to receive aerosol from an aerosol-generating unit. When referring to the airflow passage, upstream and downstream may be defined in respect of a direction of flow in the airflow passage, e.g. with an outlet being downstream of an inlet. An airflow may include a flow of aerosol or vapour.
As used herein, an "airflow path" may refer to a path through a cap extending from a cap inlet to a cap outlet, e.g. a path that an aerosol from the mouthpiece subsequently flows along through the cap to a user. The airflow path may be arranged to receive aerosol from the mouthpiece. When referring to the airflow path, upstream and downstream may be defined in respect of a direction of flow in the airflow passage e.g. with the aerosol aperture being downstream of an inlet to the airflow path. An airflow may include a flow of aerosol or vapour.
As used herein, "positioned within" with reference to the carrier material being "positioned within" airflow path may be understood to mean that at least a portion of the air flowing along the airflow path flows through the carrier material in order to continue flowing along the airflow path (e.g. the carrier material is porous) and/or that the carrier material is substantially surrounded by air flowing along the airflow path (e.g. all surfaces of the carrier material are exposed to the air flowing along the airflow path).
As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a flow passage, a mouthpiece and a cap.
As used herein, a "flow" may refer to a flow in a flow path/passage. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path/passage via a puff by a user.
As used herein, a "puff" (or "inhale" or "draw") by a user may refer to expansion of lungs and/or oral cavity of a user to create a pressure reduction that induces flow through the flow path/passage.
As used herein, an "aerosol-generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol-generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol-generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol-generating apparatus.
As used herein, a "heating system" may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.
As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol-generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. With liquid or gel implementations of the precursor, e.g. an e-liquid, the consumable may be referred to as a "capsule" or a "pod" or an "e-liquid consumable". The capsule/pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.
As used herein "heat-not-burn" (or "HNB" or "heated precursor") may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).
As used herein "downstream" in relation to the airflow path and/or airflow passage is intended to refer to the direction towards the cap/aerosol aperture. Conversely, as used herein "upstream" is intended to refer to the direction towards the air inlet.
References to "upper", "lower", "above" or "below" are intended to refer to the component when in an upright/vertical orientation i.e. with elongate (longitudinal/length) axis of the component vertically aligned and with the mouthpiece vertically uppermost.
Referring to Fig. 1, an example aerosol-generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol-generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and/or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol-generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user. The delivery system 8 includes a cap.
Electrical circuitry (not shown in Fig. 1) may be implemented to control the interoperability of the power supply 4 and aerosol-generating unit 6.
In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol-generating unit implemented as an atomiser with flow expansion may not require a power supply.
Fig. 2 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol-generating apparatus 1 is configured to generate aerosol by a heat not-burn process.
In this example, the apparatus 1 includes a device body 10 and a consumable 30, the consumable comprising a mouthpiece 31.
In this example, the body 10 includes the power supply 2 and a heating system 34. The heating system 34 includes at least one heating element 35. The body may additionally include any one or more of electrical circuitry 12, a memory 14, a wireless interface 16, one or more other components 18.
The electrical circuitry 12 may include a processing resource for controlling one or more operations of the body 10, e.g. based on instructions stored in the memory 14.
The wireless interface 16 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.
The other component(s) 18 may include an actuator, one or more user interface devices configured to convey information to a user and/or a charging port, for example.
The body 10 is configured to engage with the consumable 30 such that the at least one heating element 35 of the heating system 34 penetrates into the solid precursor 6 of the consumable 30. In use, a user may activate the aerosol-generating apparatus 1 to cause the heating system 34 of the body 10 to cause the at least one heating element 35 to heat the solid precursor 6 of the consumable 30 (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user by inhaling on the mouthpiece 31.
Fig. 3A shows an embodiment of an aerosol-generating apparatus 100. In this example, the aerosol-generating apparatus 100 includes a device 102, a component 104, and a cap 50. The component 104 may alternatively be referred to as a "pod", "cartridge" or "cartomizer". The aerosol-generating apparatus 100 is configured to generate aerosol from a liquid precursor.
Fig. 3A shows the smoking substitute system 100 with the device 102 physically coupled to the component 104 and the mouthpiece received in the cavity of the cap 50. Fig. 3B shows the device 102 of the smoking substitute system 100 without the component 104, and Fig. 3C shows the component 104 of the smoking substitute system 100 without the device 102 and with the cap 50 dismounted from the mouthpiece 136 of the component 104.
It should be appreciated that in other examples (i.e. open systems), the device 102 may be integral with the component 104. In such systems, a tank of the aerosol delivery system may be accessible for refilling the device 102. The component 104 includes a mouthpiece at an upper end 109 of the component 104, the mouthpiece configured for the user to inhale on when using the system to generate and inhale an aerosol.
The cap 50 is configured to be physically attached to the mouthpiece 136 by comprising a cavity that receives the mouthpiece 136 (i.e. the cap 50 provides a cover over at least a portion of the mouthpiece 136). In Fig. 3A, the mouthpiece 136 is received in the cavity of the cap 50 such that the cap 50 is mounted on the mouthpiece 136. In Fig. 3C, the cap 50 is shown as being detached from the mouthpiece 136. The cap comprises an airflow path, the cavity containing a portion of, or being in fluid communication with, the airflow path. The airflow path extends from a cap inlet configured to receive an aerosol from the mouthpiece when received in the cap (e.g. by the cap inlet being positioned in the cavity) to a cap outlet 54. The cap 50 further houses carrier material for containing flavourant, the carrier material comprising an upstream end and a downstream end. The carrier material is positioned within, or defines at least a portion of, the airflow path and the airflow path extends between the upstream end and the downstream end of the carrier material. By the airflow path extending between the upstream and downstream ends of the carrier material, the airflow path may flows through, or adjacent to, substantially the whole length of the carrier material in the direction of the airflow path such as to aerosolise flavourant therefrom.
The consumable 104 includes a storage portion implemented here as a tank 106 which stores the liquid precursor (e.g. e-liquid). In this example, the smoking substitute system 100 is a closed system vaping system, wherein the component 104 includes a sealed tank 106 and is intended for single-use only. The component 104 is removably engageable with the device 102 (i.e. for removal and replacement) and the cap 50 is mountable on the mouthpiece 136 of the component 104 by receipt of the mouthpiece 136 in the cavity of the cap 50.
The device 102 and the component 104 are configured to be physically coupled together by pushing the component 104 into a cavity at an upper end 108 of the device 102, such that there is an interference fit and/or a magnetic connection between the device 102 and the component 104. In other examples, the device 102 and the component may be coupled by screwing one onto the other, or through a bayonet fitting. In yet further examples, the cavity in the device houses a magnet and the component 104 comprises a metal portion (e.g. a metal base) and the component 104 is coupled to the device by magnetic attraction between the magnet and the metal portion of the component 104.
The component 104 and the cap 50 are configured to be physically coupled together by pushing the component 104 into the cavity of the cap 50, such that there is an interference fit between the mouthpiece 136 of the component 104 and the cap 50. In other examples, the cap 50 may be secured to the mouthpiece 136 by snap-fit means provided on the mouthpiece 136 and/or the cap 50.
The component 104 includes one or more air inlets (not shown) in fluid communication with the mouthpiece 136 such that air can be drawn into and through the component 104 when a user inhales through the mouthpiece 136. The tank 106 containing e-liquid is located at the lower end 111 of the component 104.
The tank 106 includes a window 112, which allows the amount of e-liquid in the tank 106 to be visually assessed. The window 112 of the component 104 can be seen whilst the rest of the tank 106 is obscured from view when the component 104 is inserted into the cavity at the upper end 108 of the device 102. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.
The lower end 110 of the device 102 also includes a light 116 (e.g. an LED) located behind a small translucent cover. The light 116 may be configured to illuminate when the smoking substitute system 100 is activated. Whilst not shown, the component 104 may identify itself to the device 102, via an electrical interface, RFID chip, or barcode.
The lower end 110 of the device 102 also includes a charging connection 115, which is usable to charge a battery within the device 102. The charging connection 115 can also be used to transfer data to and from the device, for example to update firmware thereon.
Figs. 4A and 4B are schematic drawings of the device 102 and component 104, respectively. As is apparent from Fig. 4A, 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, external, 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 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 component 104, the electrical interface 126 is configured to transfer electrical power from the power source 118 to the component 104 (i.e. upon activation of the smoking substitute system 100).
The electrical interface 126 may also be used to identify the component 104 from a list of known components. For example, the component 104 may be a particular flavour and/or have a certain 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 component 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 component 104 such that, when connected, the component 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 also comprises the charging connection 115 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.
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 a 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 component 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 component 104. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece 136 or how many times a user draws on the mouthpiece 136 in a particular time period. Additionally, or alternatively, an actuator may be included in the body for activation of the aerosol-generating apparatus. Upon activation, the controller 120 may supply electrical energy from the power source 118 to the vaporiser 132, which may cause the vaporiser 132 to heat liquid precursor drawn from the tank 106 to produce an aerosol which is carried by the flow out of the mouthpiece 136, and, where the mouthpiece 136 is received in the cavity of the cap 50, subsequently along the airflow path of the cap 50.
The additional component(s) 128 may include one or more user interface devices configured to convey information to a user. 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. 4B, the component 104 includes the tank 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 component 104 may include one or more electrical contacts. The electrical interface 126 of the device 102 and an electrical interface 130 of the component 104 are configured to contact each other and thereby electrically couple the device 102 to the component 104 when the lower end 111 of the component 104 is inserted into the upper end 108 of the device 102 (as shown in Fig. 5A). 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 component 104.
The vaporiser 132 is configured to heat and vaporise e-liquid contained in the tank 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 component 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 component 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 or by inhaling on the cap 50 in which the mouthpiece 136 is received (e.g. at the cap outlet 54), i.e. when performing a puff on the apparatus 100. The puff, performed by the user, may initiate a flow through a flow passage in the component 104 which extends from the air inlet(s) to the mouthpiece 136 via a region in proximity to the vaporiser, and subsequently along the airflow path through the cap 50 (when the mouthpiece is received in the cavity). 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 tank 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 component 104 is an interface for obtaining an identifier of the component 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 component. The component 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 device 102.
It should be appreciated that the smoking substitute system 100 shown in Figs. 3A to 4B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).
Fig. 5 is a schematic view of an example of the component 104 described above in relation to Figs. 3A to 4B. The component 104 comprises a tank 106 for storing e-liquid, a mouthpiece 136 and a conduit 140 extending along a longitudinal axis of the component 104. In the illustrated embodiment the conduit 140 is in the form of a tube having a substantially circular transverse cross-section (i.e. transverse to the longitudinal axis). The tank 106 surrounds the conduit 140, such that the conduit 140 extends centrally through the tank 106.
A component housing 142 defines an outer casing of the component 104. The component housing 142 extends from a lower shell 158 at the lower end 111 of the component 104 to the mouthpiece 136 at the upper end 109 of the component 104. The component housing may define a lip or shoulder which acts as a stop feature when the component 104 is inserted into the device 102 (i.e. by contact with an upper edge of the device 102).
The tank 106, the conduit 140 and the mouthpiece 136 are integrally formed with each other so as to form a single unitary component and may e.g. be formed by way of an injection moulding process. Such a component may be formed of a thermoplastic material.
The mouthpiece 136 comprises a mouthpiece aperture defining an aerosol outlet 148 of the conduit 140. The vaporiser 132 is downstream of the inlet 134 of the component 104 and is fluidly connected to the mouthpiece aperture (i.e. the aerosol outlet 148) by the conduit 140.
In some embodiments, the vaporiser 132 comprises a porous ceramic wick and a heater track (not shown) printed onto the bottom surface (facing the inlet 34) of the ceramic wick.
The vaporiser 132 forms the base of the tank 106 so that the aerosol precursor is in contact with the wick and liquid aerosol precursor can move axially into the wick.
In other embodiments, the vaporiser 132 comprises a porous cylindrical wick with a coiled heating filament, the wick extending into an annular portion of the tank surrounding the vaporiser so that liquid aerosol precursor can move radially into the wick.
The aerosol precursor is heated by the heater track or heating filament (when activated e.g. by detection of inhalation), which causes the aerosol precursor to be vaporised and to be entrained in air flowing past the wick. This vaporised liquid may cool to form an aerosol in the conduit 140, which may then be inhaled by a user.
The lower shell 158 of the component housing 142 has an opening that accommodates the electrical interface 119 of the consumable component 102 comprising two electrical contacts 137a, 137b that are electrically connected to the heater track. In this way, when the consumable component 104 is engaged with the device 102, power can be supplied from the power source 118 of the device to the heater track/heating filament.
Fig. 6 is a schematic cross-sectional view through the component 104 in Fig. 4 and a first cap 50 mounted on the mouthpiece 136 of said component 104.
An internal surface of the cap 50 defines the cavity 53. In the case of the first cap 50 in Fig. 6, the cavity 53 is shaped such that at least a portion of the internal surface of the cap 50 corresponds to at least a portion of the outer surface of the mouthpiece 136 and/or component 104. Thus, the mouthpiece 136 can be received in the cavity 53. By way of example, in Fig. 6 the cap 50 is such that a portion of the outer surface of the mouthpiece 136 abuts a portion of the internal surface of the cap 50 to form an interference fit between the mouthpiece 136 and cap 50 when the upper end 109 of the component 104 is inserted into the cavity 53.
The carrier material 52 is housed in the cavity 53. In the first cap 50 in Fig. 6, the carrier material 52 contains flavourant, typically this is achieved by the carrier material being porous such that solid, gel, or liquid flavourant can be stored in, and (in the case of liquid flavourant) transported along, the pores of the carrier material 52.
The carrier material 52 is received in the cavity 53 in a position whereby it is interposed between the portion of the cavity 53 that receives the mouthpiece 136 and the cap outlet 54 provided on the cap 50. In this manner, the carrier material 52 is interposed between the cap 50 and the mouthpiece 136, and more particularly, between the aerosol outlet 148 of the mouthpiece 136 and the cap outlet 54 of the cap 50.
The cap outlet 54 is in fluid communication with the aerosol outlet 148 of the mouthpiece when the mouthpiece 136 is received in the cavity 53 by way of the airflow path through the first cap 50. The airflow path extends from a cap inlet, located at the portion of the cavity 53 that receives the aerosol outlet 148, to the cap outlet 54 (i.e. the cavity 53 contains a portion of the airflow path). From Fig. 6 it can be appreciated that the cap outlet 54 is located on the cap 50 such that it overlies the aerosol outlet 148, and that the cap outlet 54 and aerosol outlet 148 are coaxial and positioned along the longitudinal axes of cap 50 and mouthpiece 136 / consumable 104, respectively. Accordingly, the airflow path through the first cap 50 is a straight path extending along the longitudinal axis of the cap 50 between the cap inlet immediately adjacent the aerosol outlet 148 and the cap outlet 54. Thus, the airflow path passes through the central portion of the carrier material 52 that is interposed between the cap inlet and the cap outlet 54 (i.e. (a portion of) the carrier material 52 is positioned within the airflow path). During use of the cap 50, the user inhales on the cap 50 such as to generate an airflow along the airflow passage of the consumable 104 and also along the airflow path of the cap 50. In this way, aerosol exiting the mouthpiece 136 via the aerosol aperture 148 can aerosolise flavourant in the portion of the carrier material 52 positioned within the airflow path whilst flowing along the airflow path.
As discussed above, the central portion of the carrier material 52 is positioned within the airflow path and more specifically, the carrier material occupies the entire cross-section of the airflow path in a plane perpendicular to the direction of air flowing along the airflow path (i.e. a plane perpendicular to the longitudinal axis of the cap 50). Consequently, (substantially) all of the air flowing out of the aerosol outlet 148 and along the airflow path flows through the carrier material 52. A lateral portion of the carrier material 52 that is spaced further from the longitudinal axis of the cap 50 than the central portion of the carrier material 52 is positioned off, but adjacent, the airflow path.
It can be appreciated that flavourant stored in the central portion of the carrier material 52 provided on the airflow path will be aerosolised first, and subsequently flavourant stored in the lateral portion of the carrier material 52 can be wicked towards the central portion (i.e. under capillary action) and then aerosolised by the airflow.
Because the cap 50 is only attached to the mouthpiece 136 by an interference fit, the cap 50 is reversibly attached to the mouthpiece 136 and thus can be detached from the mouthpiece 136 such that the user can replace it with another cap 50 (e.g. when the flavourant in the carrier material 52 has been exhausted, or when the user desires a different flavour) or use the aerosol-generating apparatus without a cap 50 (i.e. by inhaling directly on the mouthpiece 136).
Although in Fig. 6 the consumable 104 and cap 50 are shown assembled, the consumable 104 and cap 50 may be provided to the user separate from each other i.e. as a kit of parts for the user to assemble into an assembly. The consumable 104 and cap 50 may be assembled using a method of fitting the cap 50 to the mouthpiece 136, the method comprising the step of inserting the mouthpiece 136 into the cavity 53 of the cap 50 such that the aerosol outlet 148 is in fluid communication with the airflow path of the cap 50.
Although the assembled consumable 104 and cap 50 in Fig. 6 are shown in isolation, the consumable 104 may be coupled to, or integral with, an aerosol-generating device such that an aerosol-generating apparatus is provided.
Fig. 7 is a schematic cross-sectional view through a second cap 50. Where features and components of the first and second caps 50 are alike, they are indicated by the same reference number. A description of the common features of the first and second caps is not repeated below, and reference may be made back to the description of the first cap. Instead, in the following description of Fig. 7 the differences between the first and second caps are discussed.
A consumable of the aerosol-generating apparatus is not shown in Fig. 7 for simplicity. However, it can be appreciated that the second cap 50 can be mounted on the mouthpiece of a consumable in a similar manner to that shown for the first cap in Fig. 6. That is, the second cap 50 also comprises a cavity 53, the cavity 53 being configured for receiving the mouthpiece of a consumable by virtue of its shape.
As with the first cap of Fig. 6, the second cap 50 also houses a porous carrier material 52 containing flavourant. However, the positioning of the carrier material 52 within the second cap 50 differs from that of the first cap. The second cap 50 comprises a bore therethrough to provide the cap outlet 54 and the carrier material 52 is disposed in the bore through the cap 50. In particular, the bore is positioned on downstream-most portion of the cap 50 and extends along the cap's longitudinal axis. The carrier material 52 occupies the entire cross-section of the bore in a plane perpendicular to the longitudinal axis of the cap 50. Moreover, the carrier material 52 extends along the longitudinal extent of the bore (i.e. from the internal surface of the cap 50 to an external surface of the cap 50. The airflow path of the cap 50 extends from the cap inlet positioned at the entrance to the bore at the internal surface of the cap 50 to the cap outlet 54 positioned at the exit of the bore at the external surface of the cap 50. The whole of the carrier material 52 is thus positioned within the airflow path and has an airflow through it during use of the cap 50.
As a result of this arrangement, all of the aerosol flowing out of the mouthpiece via the aerosol outlet, through the cap 50 along the airflow path and out of the cap 50 via the cap outlet 54, interacts with the carrier material 52 and thereby is able to aerosolise flavourant contained in the carrier material 52.
By positioning the carrier material 52 in the bore through the cap 50, the carrier material 52 does not occupy space within the cavity 53. Consequently, in comparison to the first cap in Fig. 6, the cavity 53 of the second cap can be shaped such that a greater proportion of the internal surface of the cap 50 that defines the cavity 53 comes into contact with the outer surface of the mouthpiece when the mouthpiece is received in the cavity 53. Thus, the interference fit between the mouthpiece and cap 50 may be provided over a larger surface area, thereby increasing the force required to detach the cap 50 from the mouthpiece.
Fig. 8 is a schematic cross-sectional view through a third cap 50. Where features and components of the first and third caps 50 are alike, they are indicated by the same reference number. A description of the common features of the first and third caps is not repeated below, and reference may be made back to the description of the first cap. Instead, in the following description of Fig. 8 the differences between the first and third caps are discussed.
A consumable of the aerosol-generating apparatus is not shown in Fig. 8 for simplicity. However, it can be appreciated that the third cap 50 can be mounted on the mouthpiece of a consumable in the same manner to that shown for the first cap 50 in Fig. 6. That is, the third cap 50 also comprises a cavity 53, the cavity 53 being configured for receiving the mouthpiece of a consumable by virtue of its shape.
The third cap 50 differs from the first cap in that the carrier material 52 of the third cap is not positioned within the airflow path through the cap 50. Rather, the carrier material 52 comprises a through hole that defines a surface of a conduit 70 that extends between a location in the cavity 53 where the aerosol outlet of the mouthpiece is positioned when the mouthpiece is received in the cavity 53 and the cap outlet 54 . That is, the entrance to the conduit 70 adjacent the aerosol outlet is the cap inlet and the cap outlet 54 is adjacent the exit of the conduit 70. In other words, the surface of the through hole in the carrier material 52 defines the portion of the airflow path contained within the cavity 53. In this way, when the cap 50 is mounted on a mouthpiece, the airflow along the airflow path between the cap inlet and the cap outlet 54 when a user inhales on the cap 50 flows past a surface of the carrier material 52 rather than through the carrier material 52.
The arrangement of the third cap 50 is beneficial in that the aerosol flowing along the airflow path is still able to aerosolise flavourant contained in the carrier material 52 by its interaction with the surface of the carrier material 52, whilst simultaneously the resistance to airflow along the airflow path is reduced in comparison to the first cap because the pressure drop associated with air flowing through the carrier material 52 when inhaling on the first cap does not occur when inhaling on the third cap 50.
Figs. 9A and 9B are schematic cross-sectional views through the component 104 in Fig. 6 and a fourth cap 50 mounted on the mouthpiece 136 of said component 104. Fig. 9A shows the cap 50 in a disactivated position and Fig. 9B shows the cap 50 in an activated position. Where features and components of the first and fourth caps 50 are alike, they are indicated by the same reference number. A description of the common features of the first and fourth caps is not repeated below, and reference may be made back to the description of the first cap. Instead, in the following description of Figs. 9A and 9B the differences between the first and fourth caps are discussed.
Firstly, the fourth cap 50 differs from the first cap in that the fourth cap 50 further houses a reservoir 55 containing flavourant that is positioned in the cavity 53 adjacent the carrier material 52. As shown in Fig. 9A, the reservoir 55 extends around an outer circumferential surface of the carrier material 52.
Whereas in the first cap there is a central portion of the carrier material that is positioned within the airflow path and a lateral portion of the carrier material that is positioned off the airflow path, in the fourth cap 50 (substantially) all of the carrier material 52 is positioned within the airflow path between the cap inlet adjacent the aerosol outlet 148 and the cap outlet 54 and thus all of the carrier material 52 has air flowing through it when the user inhales on the cap 50. As is described in further detail below, the reservoir 55 is configured to provide flavourant to the carrier material 52 such that the flavourant is aerosolised by air flowing through the carrier material 52 to the cap outlet 54 and to the user. Accordingly, the cap 50 may be provided to the user in a state wherein the carrier material 52 does not contain flavourant, and instead flavourant is subsequently provided to the carrier material 52 from the reservoir 55 along a fluid path extending between the two.
The reservoir 55 housed in the fourth cap 50 contains flavourant. With the cap 50 in the disactivated position as shown in Fig. 9A, the reservoir 55 is initially sealed such that flavourant cannot be provided to and transported along the fluid path to the carrier material 52.
However, the reservoir 55 is frangible. Thus, on moving the cap 50 from the disactivated position to the activated position relative to the reservoir 55 as shown in Fig. 9B (e.g. by sliding the cap 50 downwards further onto the mouthpiece 136 such that the mouthpiece is moved further into the cavity 53), the reservoir 55 is compressed between the cap 50 and the mouthpiece 136 and fractures. Once the reservoir 55 has been fractured, flavourant is able to exit the reservoir 55 and pass along the fluid path to the adjacent carrier material 52. Once flavourant has reached the carrier material 52, it can be aerosolised by air flowing through the carrier material 52 in order to impart flavour to that airflow.
In this way, release of the flavourant from the reservoir 55 into the carrier material 52 can be initiated by the user by movement of the cap 50 from the disactivated position to the activated position. Providing the user with a means through which to control the release of flavourant from the reservoir 55 can extend the shelf-life of the cap 50 (by preventing oxidation of the flavourant prior to use of the cap 50 by the user) and prevent leakage of flavourant from the cap 50 prior to use of the cap 50.
Figs. 10A and 10B are schematic cross-sectional views through a fifth cap 50. Fig. 10A shows the cap 50 in a disactivated position and Fig. 10B shows the cap 50 in an activated position. Where features and components of the first and fifth caps 50 are alike, they are indicated by the same reference number. A description of the common features of the first and fifth caps is not repeated below, and reference may be made back to the description of the first cap. Instead, in the following description of Figs. 10A and 10B the differences between the first and fifth caps are discussed.
A consumable of the aerosol-generating apparatus is not shown in Figs. 10A and 10B for simplicity. However, it can be appreciated that the fifth cap 50 can be mounted on the mouthpiece of a consumable in a similar manner to that shown for the first cap in Fig. 6. That is, the fifth cap 50 also comprises a cavity 53, the cavity 53 being configured for receiving the mouthpiece of a consumable by virtue of its shape.
The fifth cap 50 firstly differs from the first cap in that the fifth cap 50 houses an inner shell 51 that is slidably mounted to the cap 50. An internal surface of the cap 50 defines the cavity 53. An outer cavity portion 53b is defined between the internal surface of the cap 50 and an external surface of the inner shell 51 and an inner cavity portion 53a is defined by an internal surface of the inner shell 51. The inner cavity portion 53a is configured to receive the mouthpiece.
As in the fourth cap, the fifth cap 50 also houses a carrier material 52 and a reservoir 55 containing flavourant that is positioned in the cavity 53 adjacent the carrier material 52. As shown in Fig. 10A, the reservoir 55 extends around an outer circumferential surface of the carrier material 52. In the fifth cap 50 a small (annular) gap is provided between the adjacent surfaces of the carrier material 52 and reservoir 55. All of the carrier material 52 is positioned in the cavity such that it is on the airflow path between the aerosol outlet of the mouthpiece and the aerosol aperture 54 when in use, and thus all of the carrier material 52 has air flowing through it when the user inhales on the cap 50.
The carrier material 52 and reservoir 55 are interposed between the inner shell 51 and the cap 50 (i.e. in the outer cavity portion 53b). As illustrated by Fig. 10B, the carrier material 52 and reservoir 55 are mounted to the external surface of the inner shell 51 such that if the cap 50 is slid relative to the inner shell 51, the carrier material 52 and reservoir 55 remain stationary relative to the inner shell 51.
As is described in further detail below, the reservoir 55 is configured to provide flavourant to the carrier material 52 such that the flavourant is aerosolised by air flowing through the carrier material 52 to the cap outlet 54 and subsequently to the user. Accordingly, the cap 50 may be provided to the user in a state wherein the carrier material 52 does not contain flavourant, and instead flavourant is subsequently provided to the carrier material 52 from the reservoir 55 along a fluid path between the two.
The cap 50 further comprises a barrier element 56 extending from the cap 50 adjacent the cap outlet 54, the barrier element 56 extending inwards into the outer cavity portion 53b. The barrier element 56 and the movable nature of the cap 50 with respect to the reservoir 55 and carrier material 52 provides the cap 50 with a valve. The barrier element 56 takes the form of a wall that can be interposed between the carrier material 52 and reservoir 55.
In Fig. 10A, the cap 50 is in the disactivated position in which the inner shell 51 and cap 50 are slid together, meaning that the barrier element 56 is inserted into the gap between the carrier material 52 and the reservoir 55 (i.e. interposed between the carrier material 52 and reservoir 55). With the cap 50 in the disactivated position, the passage of flavourant between the adjacent surfaces of the reservoir 55 and the carrier material 52 (i.e. along the fluid path) is prevented by the barrier member 56, which is substantially impermeable to flavourant, and thus the valve is in a closed state.
In Fig. 10B, the cap 50 is in the activated position in which the inner shell 51 and cap 50 are slid apart, meaning that the barrier element 56 is (at least partially) withdrawn from the gap between the carrier material 52 and the reservoir 55. With the cap 50 in the activated position, the passage of flavourant between the adjacent surfaces of the reservoir 55 and the carrier material 52 (i.e. along the fluid path) is possible, thereby allowing the carrier material 52 to be provided with flavourant and for flavourant reaching the carrier material 52 to be aerosolised by air flowing through the carrier material 52 during user inhalations on the cap 50, and thus the valve is in an open state.
Comparing the barrier element in the fifth cap 50 in Figs. 10A and 10B with the frangible reservoir in the fourth cap in Figs. 9A and 9B, it can be appreciated that the barrier element in the fifth cap 50 is actuatable from the open state to the closed state in addition to being actuatable from the closed state to the open state. That is, having slid the inner shell 51 and cap 50 apart to open the fluid path between the reservoir 55 and carrier material 52 as shown in Fig. 10B, it is possible to slide the inner shell 51 and cap 50 together again (i.e. back to the state in Fig. 10A) such that the fluid path is closed. In contrast, in the fourth cap illustrated in Figs. 9A and 9B, once the reservoir housing has been fractured to release flavourant therefrom, it cannot be returned to a state in which the reservoir is sealed.
Fig. 11 is a schematic cross-sectional view through an upper portion of a sixth cap 50. Fig. 11 shows the upper portion of the cap comprising the cap outlet 54 and housing the carrier material 52. Where features and components of the first and sixth caps 50 are alike, they are indicated by the same reference number. A description of the common features of the first and sixth caps is not repeated below, and reference may be made back to the description of the first cap. Instead, in the following description of Fig. 11 the differences between the first and sixth caps 50 are discussed.
A consumable of the aerosol-generating apparatus is not shown in Fig. 11 for simplicity. However, it can be appreciated that the sixth cap 50 can be mounted on the mouthpiece of a consumable in a similar manner to that shown for the first cap 50 in Fig. 6. That is, the sixth cap 50 also comprises a cavity 53, the cavity 53 being configured for receiving the mouthpiece of a consumable by virtue of its shape.
Further to the first cap in Fig. 6, the sixth cap 50 in Fig. 11 the carrier material 52 is provided inside a casing. The casing is disposed in the cavity 53 of the cap 50. As with the positioning of the carrier material in the first cap in Fig. 6, the casing and thus also the carrier material 52 in the sixth cap 50 in Fig. 11 are disposed in the cavity 53 such that they are interposed between the cap 50 and the mouthpiece when the mouthpiece is received in the cavity 53.
The casing comprises a base 62 and a lid 60 that fit together to provide the casing that is filled with the carrier material 52. The material(s) of the base 62 and lid 60 of the casing is typically impermeable to aerosol exiting the mouthpiece. Accordingly, in order to facilitate flow along the airflow path through the cap 50 and aerosolization of flavourant contained in the carrier material 52, a through hole is provided through the casing in the form of base aperture 63 and a lid aperture 61. Accordingly, aerosol exiting the aerosol outlet of a mouthpiece received in the cavity 53 can enter the airflow path via the cap inlet that is inside the cavity 53 and adjacent the base aperture 63, pass into the casing via the base aperture 63, flow through the carrier material 52 from its upstream end to its downstream end to aerosolise flavourant contained therein, and pass out of the casing via the lid aperture 61 to reach the cap outlet 54.
It can be appreciated from Fig. 11 that the through hole is aligned and coaxial with the cap outlet 54. Similarly, the cap 50 (e.g. the shape of the cavity 53) is typically configured such that the mouthpiece abuts the base 62 of the flavour pod when received in the cavity 53 and the aerosol outlet of the mouthpiece is aligned and coaxial with the through hole of the casing. Accordingly, aerosol from the mouthpiece can flow along a straight airflow path along the longitudinal axis of the cap 50 from the cap inlet in the cavity 53, into the casing, through the carrier material 52, out of the casing, and out of the cap outlet 54 to reach the user.
By providing the carrier material 52 in the casing, production of the cap 50 is made easier, because a universal cap 50 can be provided that is independent of the flavourant to be contained within the cap 50, and subsequently a casing containing a suitable flavourant in the carrier material 52 can be paired with the universal cap 50, depending on which flavour needs to be provided.
The sixth cap 50 in Fig. 11 further differs from the first cap in that it further houses a filter 59 (e.g. a cotton or gauze filter) interposed between the carrier material 52 and the cap 50. The filter 59 underlies the cap outlet 54 of the cap 50 such that air flowing along the airflow path between the cap inlet and the cap outlet 54 passes through the filter. In this way, the filter 59 prevents the passage of large solid and/or liquid phase particles out of the cap 50. Specifically, in the sixth cap 50 in Fig. 11, the filter is interposed between the casing and the cap 50 (i.e. between the lid 60 of the casing and the internal surface of the cap 50 that are adjacent each other). As well as underlying the cap inlet 54, the filter 59 also overlies the lid aperture 61 such that between the lid aperture 61 and the aerosol aperture 54, the airflow path passes through the filter 59. Accordingly, the airflow along the airflow path is filtered after flowing through the carrier material 52. It can be appreciated that the filter 59 may also act to prevent/reduce leakage of flavourant from the cap 50 by absorbing any flavourant that released from the carrier material 52 (and/or reservoir, where present) without being aerosolised.
Although the first to sixth caps described above in relation to Figs. 6 to 11 are illustrated as being used with the mouthpiece of an aerosol-generating apparatus configured to generate aerosol from a liquid precursor, it can be appreciated that the above-described caps can equally be applied in aerosol-generating apparatus configured to generate aerosol by a heat-not-burn process by receipt of the mouthpiece of a heat-not-burn consumable in the cavity of a cap.

Claims

A cap (50) for mounting over an aerosol-generating apparatus (100) having a mouthpiece (136), the cap (50) comprising:
a cavity (53) for receiving the mouthpiece (136); and

an airflow path extending from at least one cap inlet to a cap outlet (54), the cavity (53) containing a portion of, or being in fluid communication with, the airflow path;
wherein:
the cap inlet is configured to receive an aerosol from the mouthpiece (136) when received in the cap (50);

the cap (50) houses a carrier material (52) for containing flavourant, the carrier material (52) comprising an upstream end and a downstream end;

the carrier material (52) is positioned within, or defines at least a portion of, the airflow path; and

the airflow path extends between the upstream end and the downstream end of the carrier material (52).
The cap (50) according to claim 1, wherein the carrier material (52) is pre-imbued with flavourant.
The cap (50) according to claim 1 or 2, wherein the carrier material (52) is configured to be activated by the application of heat thereto.
The cap (50) according to any preceding claim, wherein the carrier material (52) is disposed in the cavity (53).
The cap (50) according to claim 4, wherein the carrier material (52) is positioned within the airflow path.
The cap (50) according to claim 4, wherein:
the airflow path is at least partially defined by a conduit (70); and

the carrier material (52) at least partially defines at least a surface of the conduit (70).
The cap (50) according to any preceding claim, wherein the cap (50) further houses a reservoir (55) containing flavourant and wherein a fluid path is provided between the reservoir (55) and carrier material (52).
The cap (50) according to claim 8, further comprising a valve, the valve configured to be actuatable from a closed state in which the fluid path is closed to an open state in which the fluid path is open, wherein the valve is further configured to be actuatable from the open state to the closed state.
The cap (50) according to claim 8, wherein the valve comprises a barrier element interposed between the reservoir and the carrier material.
The cap (50) according to claim 8 or 9, wherein
the valve is actuatable from the closed state to the open state by movement of the cap (50), or a portion thereof, relative to the reservoir (55) and/or carrier material (52).
The cap (50) according to any of claims 7 to 10, wherein at least a portion of the reservoir (55) is frangible, pierceable, or otherwise capable of being broken to release the flavourant from the reservoir (55).
A kit of parts comprising a mouthpiece (136) for an aerosol-generating apparatus (100) and a cap (50) for mounting over the mouthpiece (136), wherein:
the mouthpiece (136) has an aerosol outlet (148); and

the cap (50) comprises:
a cavity (53) for receiving the mouthpiece (136), and

an airflow path extending from at least one cap inlet to a cap outlet (54), the cavity (53) containing a portion of, or in fluid communication with, the airflow path;

the cap inlet is configured to receive an aerosol from the mouthpiece (136) when received in

the cap (50);

the cap (50) houses a carrier material (52) for containing flavourant, the carrier material (52) comprising an upstream end and a downstream end;

the carrier material (52) is positioned within, or defines at least a portion of, the airflow path; and

the airflow path extends between the upstream end and the downstream end of the carrier material (52).
The kit of parts according to claim 12, further comprising a component (104) of an aerosol-generating apparatus (100), the mouthpiece (136) providing an outer surface of the component (104).
A method of fitting a cap (50) to a mouthpiece (136) of an aerosol-generating apparatus (100), wherein:
the mouthpiece (136) has an aerosol outlet (148);

the cap (50) comprises:
a cavity (53) for receiving the mouthpiece (136); and

an airflow path extending from at least one cap inlet to a cap outlet (54), the cavity (53) containing a portion of, or in fluid communication with, the airflow path;

the cap inlet is configured to receive an aerosol from the mouthpiece (136) when received in the cap (50);

the cap (50) houses a carrier material (52) for containing flavourant, the carrier material (52) comprising an upstream end and a downstream end;

the carrier material (52) is positioned within, or defines at least a portion of, the airflow path;

the airflow path extends between the upstream end and the downstream end of the carrier material (52); and

the method comprises the step of inserting the mouthpiece (136) into the cavity (53) of the cap (50) such that the aerosol outlet (148) is in fluid communication with the airflow path via the cap inlet.
An assembly of a component (104) for an aerosol-generating apparatus (100) and a cap (50), wherein:
the component (104) comprises a mouthpiece (136) having an aerosol outlet (148);

the cap (50) comprises:
a cavity (53) for receiving the mouthpiece (136); and

an airflow path extending from at least one cap inlet to a cap outlet (54), the cavity (53) containing a portion of, or in fluid communication with, the airflow path;

the cap inlet is configured to receive an aerosol from the mouthpiece (136) when received in the cap (50);

the cap (50) houses a carrier material (52) for containing flavourant, the carrier material (52) comprising an upstream end and a downstream end;

the carrier material (52) is positioned within, or defines at least a portion of, the airflow path;

the airflow path extends between the upstream end and the downstream end of the carrier material (52); and

the mouthpiece (136) is received in the cavity (53) such that the cap (50) is mounted on the component (104) and the aerosol outlet (148) is in fluid communication with the airflow path via the cap inlet.