Delivery Device

The present application is a National Phase entry of PCT Application No.: PCT/GB2023/051164 filed May 3, 2023, which claims priority to GB Application No.: 2208019.6 filed May 31, 2022, each of which is hereby incorporated by reference in their entirety.

The present specification relates to a delivery device, such as a non-combustible aerosol provision device, or an aerosol-free delivery device. The invention also relates to a delivery device according to the invention in combination with an accessory for charging the delivery device. An end cap attachable to an end of a housing of a delivery device according to the invention is also disclosed.

Smoking articles, such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternative delivery devices to these articles by creating products that release compounds without combustion. Examples of such delivery devices are electronic cigarettes, also known as a vaping devices, and so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, a substrate. For example, tobacco heating devices heat an aerosol generating substrate, which may be tobacco or other non-tobacco products which may or may not contain nicotine, to form an aerosol by heating the substrate without burning it.

According to an aspect of the invention, there is provided a delivery device comprising: an elongate housing; a battery received in the housing; an end cap attached to and closing an end of the housing; and a vent opening in the end cap in fluid communication with the battery.

A conduit in the housing may extend between the battery and the vent opening in the end cap.

The delivery device may comprise a mouthpiece at an opposite end of the housing and a pressure sensor in the housing, the pressure sensor being configured to detect when a user draws on the device through the mouthpiece and to activate the device based on detection of a user drawing on the mouthpiece.

The pressure sensor may be in fluid communication with the vent opening in the end cap.

A conduit in the housing may extend between the pressure sensor and the vent opening in the end cap. The conduit in the housing extending between the pressure sensor and the vent opening may at least partially be the same conduit that extends between the battery and the vent opening in the end cap. Alternatively, there may be different conduits extending between the battery and the vent opening, and between the pressure sensor and the vent opening.

The delivery device may comprise a buzzer or speaker in the housing configured to provide an audible indication to a user relating to a function of the device. The buzzer or speaker may be mounted in the end cap or elsewhere in the housing. The buzzer or speaker may be positioned relative to the vent opening such that the vent opening acts as an acoustic channel to enhance sound delivery and magnitude.

The buzzer or speaker may be disposed within the housing so as to generate a sound wave in the conduit.

Irrespective of where the buzzer or speaker is mounted, it can be in fluid communication with the vent opening in the end cap.

The delivery device may comprise a conduit in the housing that extends between the buzzer or speaker and the vent opening in the end cap.

The conduit extending between the buzzer or speaker and the vent opening in the end cap may at least partially the same conduit that extends between the battery and the vent opening in the end cap, and between the pressure sensor and the vent opening in the end cap. Alternatively, the conduit extending between the buzzer or speaker and the vent in the end cap may be separate to any other conduit.

In some embodiments, the delivery device may comprise a secondary vent opening in the housing, in addition to the vent opening in the end cap. The vent opening in the housing may be in fluid communication with any or all of the battery, the pressure sensor and/or a buzzer or speaker. One or more of these items may be in fluid communication with both the vent opening in the end cap and the secondary vent opening in the housing. Alternatively, some of them may be in fluid communication with the vent opening in the end cap and others may be in fluid communication with the secondary vent opening in the housing.

A membrane formed from a gas permeable material may extend over the secondary vent opening in the housing.

The end cap can comprise a push-fit portion received within the end of the housing and a head portion that protrudes from the end of the housing. The head portion and the push-fit portion may meet at a shoulder that engages an end face of the housing.

A sealing member may be located between the push-fit portion of the end cap and an inner surface of the housing.

A membrane formed from a gas permeable material may extend over the vent opening in the end cap. The membrane may be attached to a surface of the end cap. It can be glued to the end cap.

The end cap may comprise an internal surface facing the inside of the housing and an external surface facing outside of the housing. The membrane may be attached to the internal surface of the end cap.

The internal surface of the end cap may comprise a recess, and the membrane may be received in said recess.

The vent opening may comprise a passage extending through the end cap between the internal and external surfaces, such that the membrane is spaced from the external surface by the length of the passage.

According to an embodiment, there is provided a delivery system comprising the delivery device according to the invention, that may comprise a substrate aerosolizing module including a heater and a consumable comprising ana aerosolizable substrate, the substrate aerosolizing module being configured to aerosolize the substrate in response to activation of the delivery device.

According to another embodiment, there is provided a delivery device according to the invention, and an accessory for charging the delivery device and to which the delivery device may be coupled in a charging configuration. The charging accessory may comprise a guide member that locates in the passage in the end cap when the delivery device and charging accessory are in the charging configuration.

The length of the guide pin of the charging accessory may be less than the length of the passage in the end cap.

The guide pin and/or the passage may be shaped such that gas can still pass through the passage when the delivery device is attached to the accessory with the guide member received in the passage.

The delivery device may comprise a plurality of vent openings in the end cap, each vent opening comprising a passage. The number of passages in the end cap may exceed the number of guide members on the charging accessory such that at least one passage remains free of a guide member when the delivery device is attached to the charging accessory.

According to another embodiment of the invention, there is provided an end cap attachable to an end of a housing of a delivery device to close said end, wherein the end cap comprises a vent opening extending through the end cap, and a membrane comprising a gas permeable material attached to, and extending over, the vent opening in the end cap.

The end cap may comprise a push-fit portion defining an inner end surface for insertion into a housing of a delivery device, and a larger head portion defining an exterior surface. The membrane may be attached to, and extend over, the inner end surface of the end cap.

According to another aspect of the invention, there is provided a delivery device and an accessory for charging the delivery device, the delivery device and the accessory being attachable to each other in a charging configuration, wherein the delivery device comprises:

The vent opening may comprise a passage in the housing extending between inner and outer surfaces. A gas permeable membrane may be located in the housing and extend across the vent opening at an inner end of the passage, i.e. the membrane may be attached to, or pressed against, the inner surface of the housing. The membrane is therefore recessed within the housing at the end of the passage to protect it from damage.

The guide member can be shorter than the length of the passage such that the guide member does not come into contact with the membrane when the delivery device and the charging accessory are in said charging configuration.

According to another aspect of the invention, there is provided a delivery device comprising:

The delivery device may comprise a conduit in the housing extending between the battery and the vent opening to fluidly communicate the battery and the vent opening.

The delivery device may also comprise a conduit in the housing extending between the pressure sensor and the vent opening to fluidly communicate the pressure sensor and the vent opening.

The conduit in the housing extending between the pressure sensor and the vent opening may at least be partially the same conduit as the conduit extending between the battery and the vent opening.

As used herein, the term “delivery device” is intended to encompass devices that deliver at least one substance to a user, and includes: non-combustible aerosol provision devices that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

Embodiments according to the invention provide a delivery device that includes a housing and a battery contained within the housing. One end of the housing is closed by an end cap. The end cap has a vent opening to allow gases to escape from the housing through the vent opening, thereby preventing a build-up of pressure within the housing, for example in the event of a problem with the device or the battery during use of the device, or whilst the battery is being charged. In the absence of the vent opening the housing may be a sealed unit.

is a schematic drawing of a non-combustible aerosol provision device, in accordance with an example embodiment. The devicecomprises two main components,, each of which have proximal and distal ends.

The first componentof the deviceincludes a control module, which includes a batteryand a circuit board. The control moduleis received within a housingwhich encloses the control moduleand forms the external appearance of the device. The housingmay be a tubular sleeve, in which case the control moduleis inserted into the housingfrom its distal end during assembly of the device. The distal end of the housingis then closed by an end cap. However, the housingmay, alternatively, be formed from multiple parts or shells that are attached together to form an enclosure around the control module. If the housingis formed from two half-shells for instance, the control modulemay be placed in one half-shell part before the other half-shell part is placed on, and is attached to, the other half-shell part prior to attachment of the end capto the distal end of the housingthereby encapsulate the control modulewithin the housing. The housingis preferably formed from a metal, such as aluminium, although other materials for the housingare also possible. It is also envisaged that the end capcould be partially integrated with the housing, i.e. the end capcould be integral with one half-shell.

The second componentof the deviceincludes a heaterand a liquid reservoirthat may collectively form an aerosol-generating module. A mouthpiece (not shown) is integrally or removably attached to the proximal end of the second componentthrough which a user may draw when the deviceis in use. The first and second components,may be modular, i.e. the second componentmay have its own housingand its distal end can be separable from a proximal end of the first component(at a join marked X in) for repair or replacement. A releasable electrical connection joins the first and second components,to enable power and/or control signals to be transmitted between them. However, the first and second components,may not be separable, other than by disassembly or destruction of the device. More specifically, the first and second components,may be permanently connected together during assembly. Alternatively, housingmay be a single unitary component integrating both the first and second components,, i.e. the housingmay define a single compartment or chamber in which all the parts of the deviceare received together.

When the device ofis used, and a user draws on the mouthpiece, air is drawn into an air inlet of the heater, as indicated by the arrow. The heateris controlled by the control moduleand heats the incoming air. The heated air is directed to the liquid reservoir, where an aerosol is generated. The aerosol exits the deviceat an air outlet, as indicated by the arrow A, into the mouth of a user of the device. The devicemay be puff-actuated, i.e. the devicemay include a puff-sensor(see), such as a pressure sensor, capable of detecting a change in pressure within the housingthat occurs when a user puffs or draws on the mouthpiece. The puff-sensormay be configured to activate the heaterand other components of the delivery deviceto generate the aerosol in response to detecting such a change in pressure. Puff activation typically requires a comparison of two pressures, i.e. a pressure in the airflow path at the mouthpiece (which reduces when the user draws on the mouthpiece), and a pressure within the device housing that is taken as a reference value (i.e. representative of ambient pressure).

The heater is activated when the pressure on the mouthpiece side falls below the reference pressure (i.e. ambient) by at least a threshold amount. Mis-activation occurs when the reference pressure increases as opposed to the external pressure decreasing, which may result in a sufficient pressure differential to activate the heater even though the user may not be drawing on the mouthpiece.

Depending on the device, two separate pressure sensors could be used (i.e. one to measure the pressure in the airflow channel at the mouthpiece, and one to provide a reference pressure measurement), or a single differential pressure sensor could be used (i.e. a single component that measures the pressure different between opposite sides of the sensor). If two separate sensors are used, the pressure sensor that measures a reference pressure should be in fluid communication with the vent opening, whereas the sensor which detects the draw on the mouthpiece does not have to be in fluid communication with the vent opening.

The pressure sensors or differential pressure sensor may be configured to convert the measurements of pressure to corresponding electrical signals. A microprocessor is coupled to the heating element and the sensor and is configured to receive the corresponding electrical signals and operate in an active mode only in an instance in which a predetermined threshold pressure, or predetermined differential threshold pressure has been reached, so as to activate the heating element to vaporize components of the aerosol-generating material.

is a more detailed exploded view of the first componentshown in, the second componentbeing omitted. It can be seen fromthat the housingis in the form of a sleeve and the remaining components of the control moduleare inserted into the housingfrom one end. The end is then closed by the end cap.

As shown in, the control moduleincludes a frame or carrierin which the batteryis received and retained. The circuit boardis mounted to the top, outside surface of the carrierand is supported by both the carrierand by the outside of one major faceof the battery. An insulated spacer or support padmay be located between the major faceof the batteryand the circuit boardwhere they overlie each other. The support padmay be adhesive, so that the circuit boardis held in place on the major faceof the batteryby the adhesive pad. Various electrical circuit and control elements, including the pressure sensor, may be mounted to the circuit board, which also has connectorsfor electrical connection of the circuit boardto the aerosol generating module of the second component. These connectorsare positioned on a section of the circuit boardthat overhangs one end of the carrier.

A metal or conductive plateis mounted to the underside of the carrierand to the other major faceof the batteryon the opposite side of the batteryto the circuit board. An insulated pador spacer may be located between the other major faceof the batteryand the metal plateand may be adhesive so that the metal plateis held in place on the other major faceof the battery. The metal plateforms an electrical connection between the batteryand the circuit and control elements on the circuit board. It will be understood that the carrieris open, in the sense that it does not completely cover or surround the battery. Even with the circuit boardand metal platemounted to the carrierand extending over the major facesof the battery, the batteryis still partially exposed. This enables any heat or gases generated by the battery, which may occur either as a result of normal use, or due to a malfunction, to escape or dissipate internally into regions of the housingthat surround the battery, rather than being trapped within the carrier.

The control modulemay include a press button on/off switch, which is mounted to the metal plateand is accessible through an aperture in the housing. Pressing the on/off switchconnects, or disconnects, the batteryfrom the circuitryon the circuit board, thereby switching the device on or off, or performing other control functions as required. However, a switchis not essential as the devicecan be activated solely by the puff sensor, referred to above.

As the housingis a sealed unit once assembled, gas may collect within the housingresulting in a build-up of pressure. Therefore, a vent opening(see) is provided in the end capto enable any gases to escape and to maintain a nominal or atmospheric pressure within the housing. The vent openingalso allows air to circulate into and out of the housingto minimise temperature differences internally and externally of the delivery device.

A partial cross-sectional side elevation of a delivery deviceaccording to an embodiment of the invention is illustrated in, and from which it can be seen that the end caphas a first portionslidably received within the end of the housingand a second, larger, head portionwhich is outside the housingand defines a shoulderthat sits against the end face of the housing. The first portioncan be a push-fit, preferably a friction or snug fit, in the housingand can include a sealing elementto form a seal between the first portionand the inner wall of the housing. The end capcan be removable or permanently attached to the housing. For example, the end capcould be glued to the housingin addition, or alternatively to, it being a push-fit. The end capand the housingmay also have complimentary screw threads to enable the end capto be screwed to the housing.