GB2622245A

GB2622245A - Device

Info

Publication number: GB2622245A
Application number: GB2213120.5A
Authority: GB
Inventors: William Owen Smith Charles
Original assignee: Inlab Ventures Ltd
Current assignee: Inlab Ventures Ltd
Priority date: 2022-09-08
Filing date: 2022-09-08
Publication date: 2024-03-13
Also published as: GB202213120D0; WO2024052657A1

Abstract

An inhalation device cartridge 20 comprises: a chamber 28, 30 formed of a film or sheet material; and a wick 26, wherein the chamber 28, 30 defines a reservoir for storing a liquid aerosol precursor and holds the wick 26. The chamber 28, 30 may be substantially planar and formed of at least two bonded layers of the film or sheet material. The chamber 28, 30 may comprise first 28 and second 30 sub-chambers separated by a seal 24 that is breakable to fluidly connect the sub-chambers 28, 30, wherein the first sub-chamber 28 defines the reservoir for storing the precursor and the second sub-chamber 30 holds the wick. The seal 24 may be frangible or single-use, or may be resealable, and may be formed of the film or sheet material. The wick 26 may be encapsulated in a removable cover, and/or one or more support ribs may be formed in the film or sheet material. A pack of cartridges 20 may be provided, wherein each cartridge may be detachably attached to at least one other, and separated by a tear, cut or perforation line.

Description

DEVICE

The invention relates to an inhalation device cartridge, a pack of inhalation device cartridges, an inhalation device, a method of manufacturing an inhalation device cartridge and a method of manufacturing a pack of inhalation device cartridges, preferably for electronic cigarettes and vaping devices.

It is known to use replaceable cartridges in electronic cigarettes and vaping devices.

According to a first aspect of the invention, there is provided an inhalation device cartridge comprising a chamber and a wick, the chamber formed of film or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, and the chamber holds the wick.

Forming the chamber of a film or sheet material not only results in a compact and lightweight configuration of the inhalation device cartridge (which may take the form of a pouch) but also reduces the overall number of parts in comparison to conventional inhalation device cartridges, which enables faster and cheaper production and also reduces cost and waste. Furthermore, forming the chamber of a film or sheet material results in a ready-to-use inhalation device cartridge due to the inclusion of the wick.

Moreover, forming the chamber of a film or sheet material results in an inhalation device cartridge having the structural integrity to handle changes in temperature and air pressure without risk of leakage.

Preferably the chamber is formed of only the film or sheet material. However, it is envisaged that the chamber may instead be formed of the film or sheet material and at least one other material.

Preferably the entire inhalation device cartridge, except the wick, is formed of only the film or sheet material but in other embodiments may instead be formed of the film or sheet material and at least one other material.

It will be appreciated that the film or sheet material may comprise a single material piece or multiple material pieces.

In embodiments of the invention, the inhalation device cartridge may include a liquid aerosol precursor stored in the reservoir. The liquid aerosol precursor may include, but is not limited to: a vaping substance (also known as vape juice, e-juice and e-liquid); nicotine, a cannabinoid, cannabidiol, tetrahydrocannabinol, a psychoactive substance, a non-psychoactive substance and/or a nicotine-free substance and/or a derivative thereof.

The properties and configuration of the film or sheet material may vary.

Preferably the film or sheet material is impermeable. The film or sheet material may include, but is not limited to, a polymeric material, such as a thermoplastic material, and/or a metallic material, such as aluminium.

In further embodiments of the invention, the first and second chambers may be formed of flexible film or sheet material.

In still further embodiments of the invention, the chamber may be formed of at least two bonded layers of the film or sheet material. It will be appreciated that the at least two bonded layers of the film or sheet material forming the chamber may belong to the same material piece or different material pieces. The bonding of the layers may be carried out using heat sealing, pressure sealing, ultrasonic welding, high frequency welding, fusing or adhesive.

The chamber may be formed as a planar, or substantially planar, chambers. Forming the chamber as such not only provides a more compact configuration of the inhalation device cartridge but also makes it easier to form the chamber of the film or sheet material.

The chamber may be shaped and/or sized so that the inhalation device cartridge has an asymmetric shape. This makes it easier for a user to insert the asymmetric inhalation device cartridge in the correct position and orientation in an inhalation device. In other embodiments, the chamber may be shaped and/or sized so that the inhalation device cartridge has a symmetric shape.

In embodiments of the invention, the wick may be pre-wetted with the liquid aerosol precursor.

In other embodiments of the invention, the chamber may include first and second sub-chambers, and wherein the inhalation device cartridge includes a seal, the first and second sub-chambers separated by the seal that is breakable to fluidly connect the first and second sub-chambers, wherein the first sub-chamber defines the reservoir for storing a liquid aerosol precursor, and the second sub-chamber holds the wick.

The purpose of the seal is to prevent accidental leakage or displacement of the liquid aerosol precursor from the first sub-chamber prior to the point of intended use and also to prevent ingress of outside air, moisture or water into the first sub-chamber prior to the point of intended use. This is particularly beneficial during manufacture of the inhalation device cartridge or transport of the inhalation device cartridge, e.g. being carried by a person. Hence, the wick may be kept dry prior to breakage of the seal.

This not only maintains the freshness of the inhalation device cartridge to the point of intended use and extends the shelf life of the inhalation device cartridge but also may permit the use of cheaper or single polymer film or sheet material.

Furthermore, the unbroken seal can act as a seal of quality or authenticity to, for example, indicate that the liquid aerosol precursor in the first sub-chamber is supplied by the original manufacturer. This addresses quality and/or safety issues arising from counterfeit inhalation device cartridges or from genuine inhalation device cartridges that are refilled with a liquid aerosol precursor not supplied by the original manufacturer.

Optionally the seal may be formed of at least two bonded layers of the film or sheet material. It will be appreciated that the at least two bonded layers of the film or sheet material forming the seal may belong to the same material piece or different material pieces. The bonding of the layers may be carried out using heat sealing, pressure sealing, ultrasonic welding, high frequency welding, fusing or adhesive.

Preferably the seal is a frangible seal or a single-use seal. That is to say, the frangible or single-use seal is not resealable after being opened. Configuring the seal as a frangible seal or a single-use seal enables the state of the seal to indicate whether or not the inhalation device cartridge has been used, which may be desirable for safety reasons. However, it is envisaged that the seal may be resealable (e.g. reclosable after being opened) to separate the first and second sub-chambers in other embodiments. For example, the seal may be biased (e.g. by being made of resilient material) to reclose when not in use with an inhalation device).

The seal may be formed of the film or sheet material. Preferably the seal is formed of only the film or sheet material. However, it is envisaged that the seal may instead be formed of the film or sheet material and at least one other material.

The wick may vary in configuration so long as the wick is capable of withdrawing the liquid aerosol precursor from the reservoir and transferring the liquid aerosol precursor to a location for heating and/or evaporation.

The wick is preferably configured so that the liquid aerosol precursor is drawn through the wick by capillary action.

The wick may be made of a fibrous material. The wick may be made of a porous material. The wick may be made of an absorbent material. The wick may be made from one or more materials such as, but not limited to, cotton, paper and/or silica.

In embodiments of the invention, the wick may be formed as a planar, or substantially planar, wick. Forming the wick as such not only provides a more compact configuration of the inhalation device cartridge but also makes it easier for the wick to be held by the chamber.

In further embodiments of the invention, the wick may be encapsulated in a removable cover. This protects the wick from damage or contamination prior to use. The removable cover may be formed of the film or sheet material. In particular, the removable cover may be initially integrated with the chamber but is configured to be detachable (e.g. tearable) from the chamber. Alternatively the removable cover may be formed of a different material from the film or sheet material, e.g. another film or sheet material.

In still further embodiments of the invention, one or more support ribs may be formed in the film or sheet material. For example, the one or more support ribs may be embossed in the film or sheet material. The provision of the one or more support ribs in the film or sheet material provides rigidity and/or a grip surface to the film or sheet material, which in turn makes it easier for a user to handle the inhalation device cartridge.

According to a second aspect of the invention, there is provided a kit of parts for an inhalation device cartridge, the kit of parts comprising a chamber and a wick, the chamber formed of film or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, the chamber and the wick combinable to form the inhalation device cartridge according to any one of the first aspect of the invention and its embodiments.

The features and advantages of the preceding aspect of the invention and its embodiments apply mutatis mutandis to the features and advantages of the second aspect of the invention and its embodiments.

According to a third aspect of the invention, there is provided a pack of inhalation device cartridges including a plurality of inhalation device cartridges, each inhalation device cartridge detachably attached to at least one other inhalation device cartridge, each inhalation device cartridge in accordance with any one of the first aspect of the invention and its embodiments.

The features and advantages of the preceding aspects of the invention and its embodiments apply mutatis mutandis to the features and advantages of the third aspect of the invention and its embodiments.

The provision of a pack of detachably attached inhalation device cartridges allows a user to easily store and carry around the inhalation device cartridges. Furthermore the construction of the inhalation device cartridge from the film or sheet material results in a lightweight and compact pack that is easy to carry. The detachable attachment between the inhalation device cartridges enables a user to easily detach an inhalation device cartridge from the pack without damaging the inhalation device cartridge or the rest of the pack.

There are different ways of detachably attaching the inhalation device cartridges to each other. For example, each inhalation device cartridge may be separated from the at least one other inhalation device cartridge by a tear line, a cut line or a perforation line.

According to a fourth aspect of the invention, there is provided an inhalation device for dispensing an inhalable aerosol, the inhalation device comprising a mouthpiece, a housing and a replaceable inhalation device cartridge, the inhalation device cartridge in accordance with any one of the first aspect of the invention and its embodiments, the inhalation device cartridge removably received in the housing, the inhalation device including a flow channel configured to, in use, guide aerosol from the wick to the mouthpiece.

S

The features and advantages of the preceding aspects of the invention and their embodiments apply mutatis mutandis to the features and advantages of the fourth aspect of the invention and its embodiments.

The flow channel may form part of the inhalation device cartridge or the housing, or may be separate from the inhalation device cartridge and the housing. The mouthpiece may form part of the inhalation device cartridge or the housing, or may be separate from the inhalation device cartridge and the housing.

As mentioned above, forming the chamber of a film or sheet material results in a compact and lightweight configuration of the inhalation device cartridge with fewer parts in comparison to conventional inhalation device cartridges. This in turn results in a compact and lightweight inhalation device with reduced cost and waste.

Also, as mentioned above, forming the chamber of a film or sheet material results in a ready-to-use inhalation device cartridge, which makes it straightforward for a user to use the inhalation device cartridge with the inhalation device.

In a preferred embodiment of the invention, the inhalation device is an electronic cigarette or a vaping device.

In embodiments of the invention, the inhalation device may include a heating element for heating the wick. The heating element and the wick may be arranged in a variety of ways, including being in physical contact or being spaced apart from each other, so long as the heating element is capable of heating the wick. The wick and the heating element together function as an atomiser to produce the inhalation aerosol from the liquid aerosol precursor.

The inhalation device may include a pressure sensor configured to detect a pressure inside a cavity formed by the inhalation device cartridge being received in the housing.

The cavity may be in fluid communication with the flow channel. The pressure sensor may be configured to trigger activation of the heating element upon detection of a change in pressure inside the cavity exceeding a predefined threshold. This configuration ensures that the heating element can only be activated when the inhalation device cartridge is received in the housing.

In embodiments of the invention employing the use of a seal, the housing may include a seal breaker configured to, in use, apply pressure to the inhalation device cartridge to break the seal. This provides a reliable means for establishing the fluid connection between the first and second sub-chambers in order to allow the liquid aerosol precursor in the first sub-chamber to enter the second sub-chamber and thereby contact (e.g. wet) the wick.

There are different ways of breaking the seal using the seal breaker, non-limiting examples of which are described as follows.

The seal breaker may be pushable to apply pressure to the inhalation device cartridge to break the seal. The seal breaker may form part of, or may be coupled to, a door, a button, a protrusion or a depression formed in or on the housing.

The seal breaker may be configured to, in use, apply pressure to the first sub-chamber to break the seal. The resulting increase in internal pressure inside the second sub-chamber then forces the seal to break and thereby establish the fluid connection between the first and second sub-chambers. Additionally or alternatively the seal breaker may be configured to, in use, apply pressure to the seal to break the seal.

The housing may include one or more protrusions that are arranged to engage the inhalation device cartridge so that, when the seal breaker applies pressure to the inhalation device cartridge to break the seal, the inhalation device cartridge bends between the one or more protrusions and the seal breaker. Preferably the or each protrusion and the seal breaker are configured to engage opposite sides of the inhalation device cartridge. The or each protrusion may be arranged to be offset from the seal breaker when the or each protrusion and the seal breaker engage opposite sides of the inhalation device cartridge. This helps to increase the size of the opening formed by the unsealed seal.

It is envisaged that, in other embodiments of the invention, the seal may be broken by direct user interaction with the frangible seal, such as bending, pressing or twisting.

According to a fifth aspect of the invention, there is provided a method of manufacturing an inhalation device cartridge according to any one of the first aspect of the invention and its embodiments, the method including the steps of: using a film or sheet material to form a chamber of the inhalation device cartridge; providing a liquid aerosol precursor in the chamber; arranging a wick to be held by the chamber.

The features and advantages of the preceding aspects of the invention and their embodiments apply mutatis mutandis to the features and advantages of the fifth aspect of the invention and its embodiments.

The formation of the chamber of the film or sheet material enables the production of the inhalation device cartridge using a single production line to perform the above manufacturing steps.

According to a sixth aspect of the invention, there is provided a method of manufacturing a pack of inhalation device cartridges according to any one of the second aspect of the invention and its embodiments, the method including the steps of: using the film or sheet material to form a chamber of each inhalation device cartridge; providing a respective liquid aerosol precursor in the chamber of each inhalation device cartridge; arranging a respective wick to be held by the chamber of each inhalation device cartridge; configuring the film or sheet material so that each inhalation device cartridge is detachably attached to at least one other inhalation device cartridge.

The features and advantages of the preceding aspects of the invention and their embodiments apply mutatis mutandis to the features and advantages of the sixth aspect of the invention and its embodiments.

Similarly, the formation of the chamber of the film or sheet material enables the production of the pack of inhalation device cartridges using a single production line to perform the above manufacturing steps.

It will be appreciated that the use of the terms "first" and "second", and the like, in this patent specification is merely intended to help distinguish between similar features, and is not intended to indicate the relative importance of one feature over another feature, unless otherwise specified.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, and the claims and/or the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and all features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Preferred embodiments of the invention will now be described, by way of non-limiting examples, with reference to the accompanying drawings in which: Figure 1 shows an inhalation device cartridge according to an embodiment of the invention; Figure 2 shows an inhalation device cartridge together with components of an inhalation device according to an embodiment of the invention; Figure 3 shows the inhalation device cartridge inserted into an open inhalation device according to an embodiment of the invention; Figures 4 and 5 show the inhalation device cartridge inserted into a closed inhalation device according to an embodiment of the invention; Figure 6 shows the breakage of a seal of the inhalation device cartridge inserted into a closed inhalation device according to an embodiment of the invention; Figure 7 shows a closed inhalation device without the inhalation device cartridge; and Figure 8 shows a method of manufacturing an inhalation device cartridge according to an embodiment of the invention.

The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic form in the interests of clarity and conciseness.

The following embodiments of the invention are described with reference to closed system electronic cigarettes, but it will be appreciated that the following embodiments of the invention are applicable mutatis mutandis to other types of inhalation devices for dispensing an inhalable aerosol.

An inhalation device cartridge according to an embodiment of the invention is shown in Figure 1 and is designated generally by the reference numeral 20. The inhalation device cartridge 20 can be used as a disposable consumable for inhalation devices. In the embodiment shown, the inhalation device cartridge 20 is used as a replaceable cartridge for an electronic cigarette 22.

The inhalation device cartridge 20 is in the form of a pouch that comprises a chamber, a frangible seal 24 and a wick 26.

The chamber comprises first and second sub-chambers 28,30. The first and second sub-chambers 28,30 are formed by, e.g., bonding two layers of flexible polypropylene film to create two discrete sub-chambers 28,30. Other film or sheet materials may be used in place of the polypropylene film, non-limiting examples of which are described throughout the specification. For example, the film or sheet material may be biaxially oriented polypropylene (BoPP) film or polyolefin film. The first and second sub-chambers 28,30 have different sizes to give the inhalation device cartridge 20 an asymmetric shape. In the embodiment shown, the first sub-chamber 28 is larger than the second sub-chamber 30 but may be smaller than the second sub-chamber 30 in other embodiments. As a result of using the polypropylene film, the first and second sub-chambers 28,30 are formed as planar, or substantially planar, sub-chambers 28,30.

The two layers of flexible polypropylene film are also bonded at a section between the first and second sub-chambers 28,30 to form the frangible seal 24 separating the first and second sub-chambers 28,30. Preferably the bond between the layers of polypropylene film forming the frangible seal 24 is weaker than the bond between the layers of polypropylene film forming the first and second sub-chambers 28,30, so that the frangible seal 24 can be broken while leaving the first and second sub-chambers 28,30 intact.

The bonding is achieved using heat sealing in this embodiment but may be achieved by other bonding means such as pressure sealing, ultrasonic welding, high frequency welding, fusing or adhesive. In other embodiments of the invention, the first and second sub-chambers 28,30 and the frangible seal 24 may be formed of other film or sheet material, and non-limiting examples of other film or sheet materials are

described throughout the specification.

Support ribs 32 may be embossed in the polypropylene film to provide rigidity or a grip surface for easier handling of the inhalation device cartridge 20.

The first sub-chamber 28 is configured as a reservoir that stores a liquid aerosol precursor, which may be selected from a group consisting of: * a vaping substance; * nicotine, a cannabinoid, cannabidiol, tetrahydrocannabinol, a psychoactive substance, a non-psychoactive substance, a nicotine-free substance and/or a derivative thereof.

The second sub-chamber 30 is configured to hold the wick 26 so that one end of the wick 26 extends into the second sub-chamber 30 and the other opposite end of the wick 26 extends outside the second sub-chamber. The wick 26 is made of a fibrous material, such as cotton. The wick 26 is formed as a planar, or substantially planar, wick 26. The end of the wick 26 outside the second sub-chamber 30 is preferably encapsulated in a removable film for protection from damage or contamination up to the point of use.

The purpose of the frangible seal 24 is to prevent accidental leakage or displacement of the liquid aerosol precursor from the first sub-chamber 28 prior to the point of intended use and also to prevent ingress of outside air, moisture or water into the first sub-chamber 28 prior to the point of intended use. The latter is particularly important when the liquid aerosol precursor is hygroscopic. The frangible seal 24 is designed to be breakable so that a fluid connection is established between the first and second sub-chambers, which allows fluid to be exchanged between the first and second sub-chambers 28,30 via a fluid path provided by the broken frangible seal 24. Exemplary ways of breaking the frangible seal 24 are described throughout the specification. The frangible seal 24 is formed as a single-use seal which after breakage cannot be resealed.

Separating the liquid aerosol precursor and the wick 26 in the first and second sub- chambers 28,30 respectively allows the wick 26 to be kept dry before the frangible seal 24 is broken. This beneficially not only provides control of the egress of the inhalation aerosol from the inhalation device cartridge 20 but also allows the dry wick 26 to absorb any unexpected leakage of liquid aerosol precursor from the first sub-chamber 28 in the event of damage or untimely breakage of the frangible seal 24.

The inhalation device cartridge 20 may form part of a pack of inhalation device cartridges 20 in which each inhalation device cartridge 20 is separated from the at least one other inhalation device cartridge 20 by a tear line, a cut line or a perforation line. This allows multiple inhalation device cartridges 20 to be manufactured, transported, stored or sold as a pack, where an individual inhalation device cartridge 20 is detached from the pack without damaging the individual inhalation device cartridge 20 or the rest of the pack.

The inhalation device cartridge 20 or the pack of inhalation device cartridges 20 may be stored inside a package, such as a box or a cardboard container, in order to protect the inhalation device cartridge 20 or the pack of inhalation device cartridges 20 during transport or storage.

An electronic cigarette 22 according to an embodiment of the invention is shown in Figures 2 to 6.

The electronic cigarette 22 comprises a mouthpiece 34, a housing 36, a battery 37 and a replaceable inhalation device cartridge 20. The inhalation device cartridge 20 is as described hereinabove, particularly with respect to Figure 1.

The housing 36 includes a receptacle 38, a door 40, a heating element 42 and a flow channel 44. The receptacle 38 is for removably receiving the inhalation device cartridge 20, and is formed in a body of the housing 36. The door 40 is hingably attached to the body so that it can be opened and closed in order to selectively permit and block access to the receptacle 38. The flow channel 44 is provided in the body of the housing 36. The mouthpiece 34 is positioned at the end of the flow channel 44, and may be integral or attached to the body of the housing 36. In alternative embodiments, the flow channel 44 may form part of the inhalation device cartridge 20 instead of the housing 36, or may be separate from the inhalation device cartridge 20 and the housing 36.

When the inhalation device cartridge 20 is removably received in the housing 36 as shown in Figures 2 and 3, the end of the wick 26 outside the second sub-chamber 30 is positioned next to the heating element 42 and is aligned with the flow channel 44. The housing 36 may include one or more location features, such as a rod, a wall or a clip, that acts to locate the inhalation device cartridge 20 in the correct position and orientation inside the receptacle 38. Furthermore, the asymmetric shape of the inhalation device cartridge 20 helps to ensure that it is correctly positioned and oriented inside the receptacle 38. The inhalation device cartridge 20 and the receptable may be correspondingly shaped to provide a mating fit (e.g. a push fit) between the inhalation device cartridge 20 and the receptable so that the inhalation device cartridge 20 is correctly positioned inside the receptacle 38.

When the door 40 is closed (Figure 4), the exposed end of the wick 26, an outer part 46 of the second sub-chamber 30 and the heating element 42 are sandwiched between first and second containment parts 48,50 to form a cavity 52 between the first and second containment parts 48,50. The cavity 52 is in fluid communication with the flow channel 44 so that fluid can flow from the cavity 52 to the flow channel 44. The outer part 46 of the second sub-chamber 30 sandwiched between the first and second containment parts 48,50 helps to seal off the cavity 52 from the rest of the receptacle 38.

The first containment part 48 is attached to the body of the housing 36, while the second containment part 50 is attached to the door 40 of the housing 36. In alternative embodiments, the first containment part 48 may be integral to the body of the housing 36, and/or the second containment part 50 may be integral to the door 40 of the housing 36. The containment parts 48,50 are preferably made of silicone or another resilient material that provide excellent sealing properties due to its ability to take up tolerance or manufacturing variance.

The heating element 42 is provided in the first containment part 48 in the embodiment shown but in other embodiments may be provided in the second containment part 50.

In other embodiments, the entire receptacle 38 may be sealed off from the outside of the housing 36.

The door 40 functions as a seal breaker to break the frangible seal 24. In particular, the door 40 and the receptacle 38 may be shaped and dimensioned so that the door 40 itself when closed is capable of squeezing the first sub-chamber 28 to apply pressure to the first sub-chamber 28, thus building up internal pressure inside the first sub-chamber 28. Once sufficient internal pressure is built up inside the first sub-chamber 28, the internal pressure pushes outward against the layers of polypropylene film to the extent that the bond at the frangible seal 24 starts to weaken. This eventually leads to separation of the layers of polypropylene film at the frangible seal 24 and thereby breakage of the frangible seal 24. In this way the seal breaker provides a controlled way of breaking the frangible seal 24.

Alternative designs of the seal breaker are envisaged, non-limiting examples of which are described throughout the specification.

In one embodiment, the door 40 may be deformable so that the door 40 when closed may be pushed to apply pressure to the first sub-chamber 28 in order to break the frangible seal 24.

In another embodiment, the seal breaker may take the form of a protrusion 54 formed on an inner surface of the door 40, as shown in Figure 3. When a pushing force is applied to the closed door 40 and therefore the protrusion 54, the protrusion 54 in turn applies pressure to the first sub-chamber 28 in order to break the frangible seal 24.

Optionally the protrusion 54 may be sized so that closing the door 40 is sufficient to apply pressure to the first sub-chamber 28 in order to break the frangible seal, without the need for an additional pushing force.

As shown in Figure 6(a), protrusions 56 in the form of bumps or ribs may be formed in the receptacle 38. The bumps or ribs 56 are positioned in the receptacle 38 so that an outer rim 58 of the inhalation device cartridge 20 rests on the bumps or ribs 56 when the protrusion on the door 40 pushes against the first sub-chamber 28, as shown in Figure 6(b). As a result, the inhalation device cartridge 20 bends between the bumps or ribs 56 and the protrusion 54 on the door 40, which helps to separate the layers of polypropylene film at the frangible seal 24 in order to increase the size of the opening formed by the unsealed frangible seal 24.

The battery 37 is stored in a compartment inside the housing 36 and is used to power the heating element 42 and a pressure sensor 60 provided in the first containment part 48. Optionally the battery 37 may be used to power a controller, e.g. a microcontroller, that is used to control the heating element 42.

A non-limiting example of a method of using the inhalation device cartridge 20 is described as follows.

Initially the film is removed from the end of the wick 26 outside the second sub-chamber 30 to create an exposed wick end. The inhalation device cartridge 20 is then placed in its intended position and orientation in the receptacle 38 before closing the door 40. It may be necessary to remove a used inhalation device cartridge 20 from the receptacle 38 before inserting the inhalation device cartridge 20 into the receptacle 38.

The door 40 is then closed, which results in the build-up of internal pressure in the first sub-chamber 28 and thereby results in breakage of the frangible seal 24. This establishes a fluid connection between the first and second sub-chambers 28,30 in order to allow the liquid aerosol precursor in the first sub-chamber 28 to enter the second chamber and thereby wet the wick 26. Thereafter, the liquid aerosol precursor diffuses throughout the wick 26 by way of capillary action.

The heating element 42 is controlled to heat up the liquid aerosol precursor in the wick 26 to create an inhalation aerosol that emanates from the wick 26. In this way the wick 26 and the heating element 42 together function as an atomiser to produce the inhalation aerosol from the liquid aerosol precursor.

The flow channel 44 then guides the inhalation aerosol from the wick 26 to the mouthpiece 34, so that a user may inhale the inhalation aerosol through the mouthpiece 34. In particular, the housing 36 includes an air conduit 62 that is configured to connect the outside of the housing 36 to the cavity 52 between the first and second containment parts 48,50. This forms an air path 64 comprising the air conduit 62, the cavity 52, the flow channel 44 and the mouthpiece 34 through which air can flow from the outside of the housing 36, into the air conduit 62, through the cavity 52, through the flow channel 44 and through the mouthpiece 34 in that order when a user sucks on the mouthpiece 34. This assists the flow of the inhalation aerosol from the wick 26 to the mouthpiece 34.

When the inhalation device cartridge 20 is in the electronic cigarette 22 (Figure 5), a change in pressure occurs inside the sealed cavity 52 between the first and second containment parts 48,50 when a user sucks on the mouthpiece 34. The pressure sensor 60 is configured to detect the change in pressure inside the cavity 52 and thereby triggers activation of the heating element 42 upon detection of the change in pressure. In this way, the heating element 42 is controlled to heat up the liquid aerosol precursor in the wick 26 to create the inhalation aerosol.

When the inhalation device cartridge 20 is not in the electronic cigarette 22 (Figure 7), the cavity 52 is not sealed off from the rest of the receptacle 38, which means that air can flow freely 66 between the cavity 52 and the rest of the receptacle 38. As a result, the activation of the heating element 42 is not triggered by the pressure sensor due to an insufficient change in pressure inside the cavity 52 between the first and second containment parts 48,50 when a user sucks on the mouthpiece 34. This ensures that the heating element 42 cannot be activated when the inhalation device cartridge 20 is not in the electronic cigarette 22.

Once the liquid aerosol precursor is used up, the inhalation device cartridge 20 can be removed from the receptacle 38 and replaced by a new inhalation device cartridge 20.

The configuration of the invention, particularly the formation of the first and second sub-chambers 28,30 and the frangible seal 24 in the film material, results in a closed system electronic cigarette 22 that is more compact and lightweight, has fewer parts, is cheaper and is less wasteful than conventional electronic cigarettes. In addition the inhalation device cartridge 20 is in a ready-to-use state due to the inclusion of the wick 26 and the ability to form the fluid connection between the first and second sub-chambers 28,30 upon breakage of the frangible seal 24. Moreover the configuration of the first and second sub-chambers 28,30 and the frangible seal 24 of the invention permits the design of the inhalation device cartridge 20 to control the usage, and thereby reduce the wastage, of the stored liquid aerosol precursor.

In contrast, conventional cartridges for closed system electronic cigarettes contain multiple parts, including the heating element, metal connectors, wick and nicotine liquid, which are contained in a rigid shelled plastic assembly. This is expensive and produces considerable landfill waste due to the number of parts involved and types of material used.

A non-limiting example of a method of manufacturing the inhalation device cartridge 20 is described as follows, with reference to Figure 8.

In step 100, a plurality of wells is formed in a first layer of the polypropylene film, where each pair of wells correspond to the first and second sub-chambers 28,30 of an individual inhalation device cartridge 20. The wells may be formed using thermo forming, such as vacuum forming or pressure forming.

In step 102, liquid aerosol precursor is dispensed into each well corresponding to the first sub-chamber 28 of an individual inhalation device cartridge 20. A respective wick 26 is placed in each well corresponding to the second sub-chamber 30 of an individual inhalation device cartridge 20.

in step 104, a second layer of the polypropylene film is then placed over the first layer of the polypropylene firm. The two layers of the polypropylene film are then bonded together by heat sealing, thus forming the first and second sub-chambers 28,30 and the frangible seal 24 in the process.

Next, in step 106, a die is then used to create perforation lines in the bonded layers of the polypropylene film to produce a pack of inhalation device cartridges 20 in which the inhalation device cartridges 20 are detachably attached from each other by the perforation lines. Alternatively, the die may be used to cut through the bonded layers of the polypropylene film to produce individual inhalation device cartridges 20 that are detached from each other. Alternatively a laser may be used in place of the die. The laser may be used to score the surface to create tear lines instead of penetrating the surface to create the perforation lines. Other ways of creating tear lines, cut lines or perforation lines in the bonded layers of the polypropylene film may be used.

Die-cutting, laser-cutting or other cutting or marking techniques may be used to add perforations, notches, cut-outs or marks that provide information about the inhalation device cartridge 20. The information may be directed to a consumer or a manufacturer, and may indicate the type, flavour and/or strength of liquid aerosol precursor used.

The foregoing manufacturing steps permit the use of a single production line for end-to-end manufacture of the inhalation device cartridge 20, particularly due to the formation of the first and second sub-chambers 28,30 and the frangible seal 24 in the film or sheet material and due to the reduced number of parts of the inhalation device cartridge 20. The single production line comprises a thermoforming machine, a liquid aerosol precursor dispensing station, a wick placement machine, a heat sealing apparatus and a die cutter. As a result, high speed and cost-effective production in a single location is possible.

In contrast, conventional inhalation device cartridges require multiple manufacturing lines that include metal die casting, lathes, plastic injection moulding and so on. These require large and specialist manufacturing facilities that are usually distributed around the world, thus requiring expensive and time-consuming transport of parts between manufacturing locations.

The listing or discussion of an apparently prior-published document or apparently prior-published information in this specification should not necessarily be taken as an acknowledgement that the document or information is part of the state of the art or is common general knowledge.

Preferences and options for a given aspect, feature or parameter of the invention should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention.

Claims

CLAIMS1. An inhalation device cartridge comprising a chamber and a wick, the chamber formed of film or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, and the chamber holds the wick.
2. An inhalation device cartridge according to Claim 1 wherein the inhalation device cartridge includes a liquid aerosol precursor stored in the reservoir.
3. An inhalation device cartridge according to Claim 2 wherein the liquid aerosol precursor includes a vaping substance.
4. An inhalation device cartridge according to Claim 2 or Claim 3 wherein the liquid aerosol precursor includes nicotine, a cannabinoid, cannabidiol, tetrahydrocannabinol, a psychoactive substance, a non-psychoactive substance, a nicotine-free substance and/or a derivative thereof.
5. An inhalation device cartridge according to any one of the preceding claims wherein the chamber is formed of at least two bonded layers of the film or sheet material.
6. An inhalation device cartridge according to any one of the preceding claims wherein the chamber is formed as a planar, or substantially planar, chamber.
7. An inhalation device cartridge according to any one of the preceding claims wherein the chamber is shaped and/or sized so that the inhalation device cartridge has an asymmetric shape.
8. An inhalation device cartridge according to any one of the preceding claims wherein the chamber includes first and second sub-chambers, and wherein the inhalation device cartridge includes a seal, the first and second sub-chambers separated by the seal that is breakable to fluidly connect the first and second sub-chambers, wherein the first sub-chamber defines the reservoir for storing a liquid aerosol precursor, and the second sub-chamber holds the wick.
9. An inhalation device cartridge according to Claim 8 wherein the seal is formed of the film or sheet material.
10. An inhalation device cartridge according to Claim 9 wherein the seal is formed of at least two bonded layers of the film or sheet material.
11. An inhalation device cartridge according to any one of Claims 8 to 10 wherein the seal is a frangible seal or a single-use seal.
12. An inhalation device cartridge according to any one of Claims 8 to 10 wherein the seal is resealable to separate the first and second sub-chambers.
13. An inhalation device cartridge according to any one of the preceding claims wherein the wick is encapsulated in a removable cover.
14. An inhalation device cartridge according to any one of the preceding claims wherein one or more support ribs are formed in the film or sheet material. 15
15. A kit of parts for an inhalation device cartridge, the kit of parts comprising a chamber and a wick, the chamber formed of film or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, the chamber and the wick combinable to form the inhalation device cartridge according to any one of the preceding claims.
16. A pack of inhalation device cartridges including a plurality of inhalation device cartridges, each inhalation device cartridge detachably attached to at least one other inhalation device cartridge, each inhalation device cartridge in accordance with any one of Claims 1 to 14.
17. A pack of inhalation device cartridges according to Claim 16 wherein each inhalation device cartridge is separated from the at least one other inhalation device cartridge by a tear line, a cut line or a perforation line.
18. An inhalation device for dispensing an inhalable aerosol, the inhalation device comprising a mouthpiece, a housing and a replaceable inhalation device cartridge, the inhalation device cartridge in accordance with any one of Claims 1 to 14, the inhalation device cartridge removably received in the housing, the inhalation device including a flow channel configured to, in use, guide aerosol from the wick to the mouthpiece.
19. An inhalation device according to Claim 18 wherein the inhalation device is an electronic cigarette or a vaping device.
20. An inhalation device according to Claim 18 or Claim 19 including a heating element for heating the wick.
21. An inhalation device according to Claim 20 including a pressure sensor configured to detect a pressure inside a cavity formed by the inhalation device cartridge being received in the housing, the cavity in fluid communication with the flow channel, wherein the pressure sensor is configured to trigger activation of the heating element upon detection of a change in pressure inside the cavity exceeding a predefined threshold.
22. An inhalation device according to any one of Claims 18 to 21 when dependent from any one of Claims 8 to 12 wherein the housing includes a seal breaker configured to, in use, apply pressure to the inhalation device cartridge to break the seal.
23. An inhalation device according to Claim 22 wherein the seal breaker is pushable to apply pressure to the inhalation device cartridge to break the seal.
24. An inhalation device according to Claim 22 or Claim 23 wherein the seal breaker is configured to, in use, apply pressure to the first sub-chamber and/or the seal to break the seal.
25. An inhalation device according to any one of Claims 22 to 24 wherein the housing includes one or more protrusions that are arranged to engage the inhalation device cartridge so that, when the seal breaker applies pressure to the inhalation device cartridge to break the seal, the inhalation device cartridge bends between the one or more protrusions and the seal breaker.
26. A method of manufacturing an inhalation device cartridge according to any one of Claims 1 to 14, the method including the steps of: using a film or sheet material to form a chamber of the inhalation device cartridge; providing a liquid aerosol precursor in the chamber; arranging a wick to be held by the chamber.
27. A method of manufacturing a pack of inhalation device cartridges according to Claim 16 or Claim 17, the method including the steps of: using the film or sheet material to form a chamber of each inhalation device cartridge; providing a respective liquid aerosol precursor in the chamber of each inhalation device cartridge; arranging a respective wick to be held by the chamber of each inhalation device cartridge; configuring the film or sheet material so that each inhalation device cartridge is detachably attached to at least one other inhalation device cartridge.