Aerosol Delivery Device

This application is a non-provisional application claiming benefit to the international application no. PCT/EP2020/067259, filed on Jun. 19, 2020, which claims priority to EP 19181679.2, filed on Jun. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/067256, filed on Jun. 19, 2020, which claims priority to EP 19181683.4, filed on Jun. 21, 2019; EP 19181686.7, filed on Jun. 21, 2019; and EP 19181694.1, filed on Jun. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/067257, filed on Jun. 19, 2020, which claims priority to EP 19181690.9, filed on Jun. 21, 2019. The entire contents of each of the above-referenced applications are hereby incorporated herein by reference in their entirety.

In one aspect, the present disclosure relates to an aerosol delivery device and system and particularly, although not exclusively, to an aerosol delivery device and system which aims to reduce leakage.

In another aspect, the present disclosure also relates to an aerosol delivery device and system and particularly, although not exclusively, to an aerosol delivery device and system which can be assembled more reliably.

In another aspect, the present disclosure also relates to an aerosol delivery device and system and particularly, although not exclusively, to an aerosol delivery device and system configured to reduce leakage.

One form of an aerosol delivery system (or device) is a smoking-substitute system that permits the user to simulate the act of smoking by producing an aerosol or vapor that is drawn into the lungs through the mouth and then exhaled. The inhaled aerosol or vapor typically bears nicotine and/or other flavorings without the odor and health risks associated with traditional smoking and tobacco products. In use, the user experiences a similar satisfaction and physical sensation to those experienced from a traditional smoking or tobacco product, and exhales an aerosol or vapor of similar appearance to the smoke exhaled when using such traditional smoking or tobacco products.

One approach for a smoking substitute system is the so-called “vaping” approach, in which a vaporizable liquid, typically referred to (and referred to herein) as “e-liquid”, is heated by a heating element to produce an aerosol/vapor which is inhaled by a user. The e-liquid typically includes a base liquid as well as nicotine and/or flavorings. The resulting vapor therefore also typically contains nicotine and/or flavorings. The base liquid may include propylene glycol and/or vegetable glycerin.

A typical vaping smoking substitute system includes a mouthpiece, a power source (typically a battery), a tank for containing e-liquid, as well as a heating element. In use, electrical energy is supplied from the power source to the heating element, which heats the e-liquid to produce an aerosol (or “vapor”) which is inhaled by a user through the mouthpiece.

Vaping smoking substitute systems can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute systems, which typically have a sealed tank and heating element. The tank is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute systems include a base unit which includes the power source, wherein the base unit is configured to be physically and electrically coupled to a consumable including the tank and the heating element. The consumable may also be referred to as a cartomizer. In this way, when the tank of a consumable has been emptied, the consumable is disposed of. The base unit can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute systems are completely disposable, and intended for one-use only.

An example vaping smoking substitute system is the Myblu® e-cigarette. The Myblu® e-cigarette is a closed system which includes a base unit and a consumable. The base unit and consumable are physically and electrically coupled together by pushing the consumable into the base unit. The base unit includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid, as well as a heating element, which for this system is a heating filament coiled around a portion of a wick. The wick is partially immersed in the e-liquid, and conveys e-liquid from the tank to the heating filament. The system is activated when a microprocessor on board the base unit detects a user inhaling through the mouthpiece. When the system is activated, electrical energy is supplied from the power source to the heating element, which heats e-liquid from the tank to produce a vapor which is inhaled by a user through the mouthpiece.

For a smoking-substitute system (or device), it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. As explained above, in the vaping approach, e-liquid is heated by a heating device to produce an aerosol/vapor which is inhaled by a user. Many e-cigarettes also deliver flavor to the user, to enhance the experience. Flavor compounds are contained in the e-liquid that is heated. Heating of the flavor compounds may be undesirable as the flavor compounds are inhaled into the user's lungs. Toxicology restrictions are placed on the amount of flavor that can be contained in the e-liquid. This can result in some e-liquid flavors delivering a weak and underwhelming taste sensation to consumers in the pursuit of safety.

In some aerosol delivery systems (or devices), it is desirable to avoid leakage of aerosol precursor. The first mode of the present disclosure has been devised in light of the above considerations.

In some aerosol delivery systems (or devices), it is desirable to be able to assemble component parts of the system in an easy and reliable manner. In some smoking-substitute systems, liquid used to form an aerosol can leak from the system and/or can collect in or on parts of the device. When such liquid collects in parts of the system that are within an airflow path of the system, such liquid can be entrained in an airflow in the airflow path. It may also be desirable to increase the degree of sanitation relating to the system. The second mode of the present disclosure has been devised in light of the above considerations.

In some aerosol delivery systems (or devices), it is desirable to avoid leakage of e-liquid as such leakage can result in inconvenience for the user. Leakage of e-liquid has been observed during use of the known systems and it is believed that the leakage occurs as a result of condensation of the e-liquid vapor on internal surfaces of the system. The condensed e-liquid then leaks from the system either through the mouthpiece or through air inlets provided in the device. The third mode of the present disclosure has been devised in light of the above considerations.

First Mode: An Aerosol Delivery Device in which Aerosol Precursor from a Liquid Transfer Element Forms an Obstruction in an Air Bleed Channel to Reduce Flow Through the Air Bleed Channel.

Generally, a first mode of the present disclosure relates to an aerosol delivery device in which aerosol precursor from a liquid transfer element forms an obstruction in an air bleed channel to reduce flow through the air bleed channel.

According to the first mode, there is provided aerosol delivery device comprising: a storage for storing aerosol precursor liquid, the storage comprising an air bleed channel for permitting air to enter the storage as the storage empties of aerosol precursor in use; and a liquid transfer element for transferring aerosol precursor liquid from the storage to an aerosol generator, wherein the air bleed channel and the liquid transfer element are configured such that aerosol precursor liquid from the liquid transfer element forms an obstruction in the air bleed channel in use to reduce flow through the air bleed channel, the aerosol delivery device further configured such that the obstruction is removed to open the air bleed channel in response to a user drawing on the aerosol delivery device.

The air bleed channel and the liquid transfer element may be positioned such that a meniscus forms between them in use, the meniscus providing the obstruction. When the user draws on the aerosol delivery device, the aerosol generator forms an aerosol from aerosol precursor liquid, which causes the amount of aerosol precursor liquid in the liquid transfer element to reduce. The liquid transfer element then absorbs further aerosol precursor liquid from the storage, which causes the obstruction to be pulled from the air bleed channel and into the storage. This temporarily opens the air bleed channel and permits air to enter the storage to reduce the pressure difference between the storage and the external environment. Once the liquid transfer element reaches a certain level of saturation with liquid, the obstruction forms again, closing the air bleed channel.

The air bleed channel being closed prevents further liquid being transferred through the liquid transfer element until the user draws on the device again, reducing leakage. Additionally, the obstruction may prevent leakage of liquid through the air bleed channel.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the first mode.

The aerosol delivery device may further comprise an aerosol generator, the aerosol generator comprising an aerosol generator portion configured to receive the aerosol precursor from the storage, the aerosol delivery device further comprising an air flow passage configured to direct air past the aerosol generator portion to pick up the aerosol precursor from the aerosol generator portion to form an aerosol.

The aerosol delivery device may further comprise a member, the member comprising the liquid transfer element and the aerosol generator portion. An external opening of the air bleed channel may have a diameter of less than 1 mm. The external opening may have a diameter of substantially 0.5 mm.

The external opening of the air bleed channel may be located adjacent to the liquid transfer element. The liquid transfer element may define a side of the air bleed channel.

The air bleed channel may follow a tortuous path. The tortuous path may be implemented by the air bleed channel following a non-linear path, for example by turning away from the liquid transfer element.

The aerosol delivery device may further comprise a sealing element for inhibiting flow through the air bleed channel when in a deactivated state, wherein the sealing element is openable into an activated state to permit air flow through the air bleed channel when the obstruction is removed from the air bleed channel. The sealing element may comprise a bung received in the air bleed channel in the deactivated state, the bung movable into the activated state.

The bung may comprise an enlarged portion and a neck portion, wherein the enlarged portion extends fully across the air bleed channel to block the air bleed channel in the deactivated state, and the enlarged portion moves out of the air bleed channel and the neck portion moves into the air bleed channel when the bung is moved from the deactivated to the activated state, the neck portion extending partially across the air bleed channel.

The aerosol delivery device may further comprise a barrier arrangement for inhibiting flow of aerosol precursor from the storage to the liquid transfer element, wherein the barrier arrangement is openable so that the liquid transfer element can receive aerosol precursor from the storage.

The liquid transfer element may be movable to contact the barrier arrangement to open the barrier arrangement.

The aerosol delivery device may be a consumable for a vaping device.

The aerosol delivery device may further comprise an additional aerosol generator, the additional aerosol generator configured to produce an additional aerosol from an additional aerosol precursor.

The additional aerosol generator may be configured to heat the additional aerosol precursor to form the additional aerosol.

The liquid transfer element may be configured to transfer aerosol precursor to a heated vaporizer.

The aerosol delivery device may comprise a vapor flow passage for fluid flow therethrough. The vapor flow passage may extend in a longitudinal direction between (and may fluidly connect) an inlet of the aerosol delivery device to an outlet aperture of the aerosol delivery device. The inlet may define an upstream end of the vapor flow passage, whilst the outlet aperture may define a downstream end of the vapor flow passage. The outlet aperture may be at a mouthpiece of the device and may therefore hereinafter be described as a mouthpiece aperture. In this respect, a user may draw fluid (e.g., air) into and through the vapor flow passage of the aerosol delivery device by inhaling at the mouthpiece aperture.

The terms “upstream” and “downstream” are used with reference to the direction of airflow (from inlet to outlet) through the device during normal use of the device (i.e., by way of inhalation at the mouthpiece aperture). The vapor flow passage may comprise a plurality of passage branches that each define a separate airflow path through the aerosol delivery device. For example, in one embodiment of the first mode, the aerosol delivery device may comprise first and second passage branches that are spaced laterally so as to extend along opposite lateral sides of the aerosol delivery device. The first and second passage branches may branch (e.g., in a transverse/radial direction) proximate to the vapor passage inlet, and may merge (i.e., re-join) proximate to the mouthpiece aperture.

In other embodiments of the first mode, at least a portion of the vapor flow passage may comprise an annular transverse-cross sectional shape.

The aerosol delivery device may comprise a tank defining a storage chamber for containing a first aerosol precursor (e.g., a flavor liquid). The first aerosol precursor may, for example, comprise a flavorant having a menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and/or tobacco flavor.

The first aerosol precursor may be stored in the form of a free liquid. Alternatively, a porous body may be disposed within the storage chamber, which may contain the first aerosol precursor.

The tank may at least partially define the vapor flow passage. For example, where the vapor flow passage comprises first and second passage branches, the first and second passage branches may be defined between an outer surface of the tank and an inner surface of a housing of the aerosol delivery device (i.e., a space may be formed between the tank and the housing for flow of vapor therethrough). Similarly, where at least a portion of the vapor flow passage is annular, the annular portion of the vapor flow passage may be defined between the tank and the housing.

The aerosol delivery device may comprise an air bleed channel configured to allow the bleeding of air into the storage chamber to replace (first) aerosol precursor that is removed from the storage chamber. The air bleed channel may be in fluid communication with the vapor flow passage, such that (e.g., under certain conditions) air from the vapor flow passage can enter the storage chamber through the air bleed channel.

The aerosol delivery device may comprise an aerosol generator in the form of a porous liquid transfer element (i.e., formed of a porous material). As will be described further below, the liquid transfer element may be configured to generate an aerosol in the vapor flow passage. The liquid transfer element, however, may do this in such a way that does not use heat to form the aerosol, and therefore in some embodiments may be referred to as a “passive” aerosol generator.

The liquid transfer element may comprise a conveying portion and an aerosol generating portion. The conveying portion may be elongate and generally cylindrical, and may be at least partially enclosed within one or more internal walls of the aerosol delivery device. The one or more internal walls enclosing the conveying portion may form part of the tank defining the storage chamber. In this respect, the tank may at least partly surround (e.g., may fully surround) the conveying portion of the liquid transfer element. That is, the tank may define a conduit through which the conveying portion passes. Thus, the conveying portion may extend generally longitudinally (e.g., centrally) through a portion of the tank (i.e., through the conduit defined by the tank). The liquid transfer element may be supported in the aerosol delivery device by the mouthpiece. That is, the mouthpiece may comprise a holder for holding (and gripping) the liquid transfer element in position within the aerosol delivery device.

The aerosol generating portion of the liquid transfer element may be disposed at a downstream end of the conveying portion and may thus define a downstream longitudinal end of the liquid transfer element. The aerosol generating portion may be at least partly located in the vapor flow passage so as to be exposed to airflow within the vapor flow passage. In particular, the aerosol generating portion of the liquid transfer element may extend into an aerosolization chamber forming part of the vapor flow passage. The aerosolization chamber may be located proximate to (and in fluid communication with) the mouthpiece aperture of the device and may define a portion of the vapor flow passage at the first and second passage branches of the vapor flow passage merge. Airflow through the flow passage may pass across or through the aerosol generating portion of the liquid transfer element prior to being discharged through the mouthpiece aperture.

The aerosol generating portion may define an enlarged (e.g., radially enlarged) portion of the liquid transfer element. For example, the aerosol generating portion may be bulb-shaped or bullet-shaped, and may comprise a portion which is wider than the conveying portion. The aerosol generating portion may taper (inwardly) to a tip at a downstream end of the aerosol generating portion (i.e., proximate the outlet/mouthpiece aperture). The aerosol-generating portion may have a flattened downstream end surface.

The liquid transfer element may extend into the storage chamber so as to be in contact with (e.g., at least partially submerged in) the first aerosol precursor. In this way, the liquid transfer element may be configured to convey (e.g., via a wicking/capillary action) the first aerosol precursor from the storage chamber to the aerosolization chamber. As will be described further below, this may allow the first aerosol precursor to form an aerosol and be entrained in an airflow passing through aerosolization chamber (i.e., for subsequent receipt in a user's mouth).

The vapor flow passage may be constricted (i.e., narrowed) at the aerosolization chamber. For example, the presence of the aerosol generating portion in the vapor flow passage may create a constricted or narrowed portion of the vapor flow passage (because the aerosol generating portion extends partway across the vapor flow passage). In this respect, the narrowest portion of the vapor flow passage may be at aerosolization chamber (adjacent to the aerosol generating portion of the liquid transfer element). This constriction of the vapor flow passage increases the velocity of air/vapor passing through the aerosolization chamber. In this respect, the constriction may be referred to as a Venturi aperture. The constriction may have a toroidal shape (i.e., extending about the aerosol generating portion of the liquid transfer element). The toroidal shape may, however, be interrupted by supports (e.g., projections, ribs, etc.) protruding inwardly from wall(s) of the vapor flow passage to support the aerosol generating portion in the aerosolization chamber.

In addition to increasing the airflow velocity, the constriction reduces the air pressure of the airflow flowing through the constriction (i.e., in the vicinity of the aerosol generating portion). This low pressure and high velocity facilitate the generation of an aerosol from the first aerosol precursor held in the aerosol generating portion (i.e., transferred from the storage chamber by the liquid transfer element). This aerosol, which is hereinafter referred to as the first aerosol, is entrained in the airflow passing through the constriction and is discharged from the mouthpiece aperture of the aerosol delivery device. In other examples the liquid transfer element does not comprise an aerosol generator, and is instead configured to transfer liquid, for example to a separate aerosol generator or vaporizer.

The first aerosol may be sized to inhibit pulmonary penetration. The first aerosol may be formed of particles with a mass median aerodynamic diameter that is greater than or equal to 15 microns, e.g., greater than 30 microns, or greater than 50 microns, or may be greater than 60 microns, or may be greater than 70 microns.

The first aerosol may be sized for transmission within at least one of a mammalian oral cavity and a mammalian nasal cavity. The first aerosol may be formed by particles having a maximum mass median aerodynamic diameter that is less than 300 microns, o, e.g., less than 200 microns, or less than 100 microns. Such a range of mass median aerodynamic diameter can produce aerosols which are sufficiently small to be entrained in an airflow caused by a user drawing air through the aerosol delivery device and to enter and extend through the oral and or nasal cavity to activate the taste and/or olfactory receptors.

The size of aerosol formed without heating may be typically smaller than that formed by condensation of a vapor.

It is noted that the mass median aerodynamic diameter is a statistical measurement of the size of the particles/droplets in an aerosol. That is, the mass median aerodynamic diameter quantifies the size of the droplets that together form the aerosol. The mass median aerodynamic diameter may be defined as the diameter at which 50% of the particles/droplets by mass in the aerosol are larger than the mass median aerodynamic diameter and 50% of the particles/droplets by mass in the aerosol are smaller than the mass median aerodynamic diameter. The “size of the aerosol”, as may be used herein, refers to the size of the particles/droplets that are comprised in the particular aerosol. The above configuration of the aerosol delivery device may be representative of an activated state of the aerosol delivery device. The aerosol delivery device may additionally be configurable in a deactivated state. In the deactivated state, the liquid transfer element may be isolated from the first aerosol precursor. This isolation may, for example, be provided by a plug (e.g., formed of silicon). The plug may be located at an end (i.e., upstream end) of the conduit (defined by the tank) so as to provide a barrier between the first aerosol precursor in the storage chamber and the conveying portion of the liquid transfer element.

Alternatively, the aerosol delivery device may comprise a duck bill valve, a split valve or diaphragm; or a sheet of foil isolating the liquid transfer element from the first aerosol precursor.