WO2025129652A1

WO2025129652A1 - Aerosol generating apparatus and method of assembly

Info

Publication number: WO2025129652A1
Application number: PCT/CN2023/141080
Authority: WO
Inventors: Baofeng Xie; Yuanqiu XIE; Fuwen LIN
Original assignee: Fontem Beijing Technology Solutions Ltd; IMPERIAL TOBACCO Ltd; Imperial Tobacco Ltd Great Britain
Current assignee: Fontem Beijing Technology Solutions Ltd; IMPERIAL TOBACCO Ltd; Imperial Tobacco Group Ltd
Priority date: 2023-12-22
Filing date: 2023-12-22
Publication date: 2025-06-26
Anticipated expiration: 2026-06-22

Abstract

An aerosol generating apparatus is described. The aerosol generating apparatus comprises a body having an internal wall defining a slot; an aerosol generating unit received within the slot, the aerosol generating unit having an inlet flow path at a first end, an outlet flow path at a second end, and a flow path from the inlet flow path to the outlet flow path; and a sleeve configured to extend about the aerosol generating unit from the second end toward the first end so as to seal a gap between the internal wall of the body and the aerosol generating unit, wherein the sleeve includes an end portion configured to engage the second end of the aerosol generating unit and to contact the internal wall of the body; and wherein the end portion defines an end surface of the sleeve which meets the internal wall at a substantially orthogonal angle. There is also described a method of assembling the aerosol generating apparatus.

Description

AEROSOL GENERATING APPARATUS AND METHOD OF ASSEMBLY

FIELD

The present disclosure relates to an aerosol generating apparatus. More particularly, an aerosol generating apparatus that ensures proper sealing of an interior of the aerosol generating apparatus, and a method of assembly of said 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 apparatuses is a leakage of precursor. For example, a leakage between a body of the apparatus and an aerosol generating unit of the apparatus that is housed within the body.

In spite of the effort already invested in the development of aerosol generating apparatuses/systems further improvements are desirable.

SUMMARY

At its broadest, there is provided an aerosol generating apparatus in which a sleeve is fitted around an aerosol generating unit to seal the sides of said aerosol generating unit. This ensures that precursor held within the aerosol generating apparatus is prevented from leaking.

In an aspect of the present disclosure, there is provided an aerosol generating apparatus comprising a body having an internal wall defining a slot; an aerosol generating unit received within the slot, the aerosol generating unit having an inlet flow path at a first end, an outlet flow path at a second end, and a flow path from the inlet flow path to the outlet flow path; and a sleeve configured to extend about the aerosol generating unit from the second end toward the first end so as to seal a gap between the internal wall of the body and the aerosol generating unit.

For the avoidance of doubt, by ‘extend about the aerosol generating unit’ , it is meant that the sleeve is fitted or arranged around the aerosol generating unit, such that at least a portion of the aerosol generating unit is enclosed or encompassed within the sleeve.

Suitably, the slot is a tunnel structure into the body that is surrounded, enclosed, encompassed and/or defined on all sides by an internal wall of the body. The slot may extend all the way through the body, or alternatively may stop part way into the body to form a closed end within the body.

The sleeve may be a tubular structure having open ends. The sleeve may extend only along a portion of the aerosol generating unit. Alternatively, the sleeve may extend all the way between the first and second end of the aerosol generating unit, such that the entire length of the aerosol generating unit is enclosed, encompassed, or fitted within the sleeve.

Advantageously, providing a sleeve between the aerosol generating unit and internal wall of the body allows the gap between the aerosol generating unit and internal wall of the body to be securely sealed, ensuring that no (liquid) precursor is able to leak from within the aerosol generating apparatus. The sleeve may also prevent airflow from passing from a first to second side of the aerosol generating unit via a gap between the aerosol generating unit and the internal wall of the body, as well as from leaking out of the flow path within the aerosol generating unit between the inlet flow path and the outlet flow path.

In some embodiments, the sleeve includes an end portion configured to engage the second end of the aerosol generating unit and to contact the internal wall of the body; and wherein the end portion defines an end surface of the sleeve which meets the internal wall at a substantially orthogonal (perpendicular) angle. In other words, the end surface is substantially orthogonal to the internal wall at least at the points where the end surface meets the internal wall, such that a corner formed between the end surface of the sleeve and internal wall proximal to the end portion of the sleeve forms a right angle.

In some embodiments, the end surface of the sleeve lies in a plane that is substantially orthogonal to the internal wall. In other words, the entire or whole end surface of the sleeve forms a flat surface that is orthogonal or substantially orthogonal to the internal wall of the body.

Alternatively, only the outermost radial portion of the end surface (i.e., the portions of the end surface that are directly adjacent the wall) may be orthogonal to the internal wall. Other portions of the end surface may be at nonorthogonal angles relative to the internal wall.

In some embodiments, the second end of the aerosol generating unit comprises an end surface which lies in a plane that is substantially orthogonal to the internal wall. In other words, the entire or whole end surface of the aerosol generating unit sleeve forms a flat surface that is orthogonal or substantially orthogonal to the internal wall of the body.

In some embodiments, the end surface of the aerosol generating unit and the end surface of the sleeve are flush. In other words, the end surface of the aerosol generating unit and the end surface of the sleeve form a single continuous surface. This improves sealing of the gap between the aerosol generating unit and internal wall of the body.

In some examples, the side (s) of the sleeve is (are) complete. In other words, there are no holes, apertures or gaps through any side surfaces of the sleeve. For avoidance of doubt, the side surface (s) of the sleeve being referred to here are the surface (s) which extend along the length of the aerosol generating unit. In other words, the side surface (s) of the sleeve are those portions of the sleeve that fill the gap between the aerosol generating unit and the internal wall of the body.

In some embodiments, the sleeve further comprises a flange configured to engage a corresponding recess in the aerosol generating unit.

For the avoidance of doubt, said flange extends inwardly into the space enclosed by the sleeve, so as to project toward the aerosol generating unit. Advantageously, the inclusion of the flange and recess prevents relative movement between the sleeve and aerosol generating unit within the slot of the body. For example, when the aerosol generating unit moves in a longitudinal direction along the slot, a force will be transferred to the sleeve via the engagement of the flange in the recess, such that the sleeve will also move along the longitudinal direction with the aerosol generating unit.

Optionally, the recess is at the second end of the aerosol generating unit.

Correspondingly, the flange may also be located at an end of the sleeve, such that the end of the sleeve comprising the flange may be proximal to the second end of the aerosol generating unit. Suitably, the end portion of the sleeve comprises the flange, and the flange defines the end surface (or defines at least a portion of the end surface) of the sleeve.

By positioning the recess for engagement with the sleeve flange at a second end of the aerosol generating unit, an increased level of sealing may be achieved at this position, such that precursor located in a volume of the slot adjacent to the second side of the aerosol generating unit is more effectively prevented from leaking out between the aerosol generating unit and internal wall of the body.

In some embodiments, the sleeve comprises a ribbed structure configured to extend around an outer surface of the sleeve and engage the internal wall. The engagement of the ribbed structure with the internal wall of the body may advantageously increase the sealing between the aerosol generating unit and internal wall. The ribbed structure may also improve the contact between the sleeve and the internal surface of the body, such that the sleeve is better held in position relative to the body.

The ribbed structure may be formed out of one or more ribs that encircle an outer surface of the sleeve. The outer surface of the sleeve being a surface facing outward and away from the aerosol generating unit that the sleeve is extended around.

Suitably, the ribbed structure includes a rib at a first end of the sleeve and a rib at the second end of the sleeve. In this way, sealing between the aerosol generating unit and internal wall of the body at both a first end of the sleeve and a second end of the sleeve is further improved.

The ribbed structure may also comprise additional ribs at the first and second ends of the sleeve. For example, two, three, four or more ribs may be located at each of the first end and the second end of the sleeve. There may also be a different number of ribs located at each of the first end and the second end of the sleeve respectively. For example, there may be one rib at the first end and two ribs at the second end.

The ribbed structure may further comprise ribs along a middle portion of the sleeve.

Preferably, the ribbed structure may comprise one or more ribs having a triangular cross-section. This triangular cross section allows for increased deformity of the ribs (i.e., as a result of the decreasing width of the ribs at more radially distant points from the sleeve) , making it easier for the sleeve to be fitted into the body slot, as well as allowing increased sealing against the internal wall of the slot.

Suitably the triangular cross section is such that a first side of the triangle engages the outer surface of the sleeve, whilst the other two sides of the triangle protrude away from the sleeve to form the rib. In other words, two of the corners of the triangle contact the outer surface of the sleeve, whilst the third corner protrudes away from (and is pointed away from) the sleeve.

In some embodiments, the ribbed structure is configured to engage with one or more recesses (grooves) formed by the internal wall of the slot. This allows the sleeve to be ‘locked’ into position within the slot. Additionally, the combination of rib and groove increases the sealing between the aerosol generating unit and the internal wall of the body.

Suitably, there may be a corresponding number of grooves in the in the internal wall of the slot to the number of ribs on the sleeve.

In some embodiments, the sleeve is formed of an elastic material. This allows the sleeve to both be fitted onto the aerosol generating unit and into the slot of the body more easily.

Suitably, the sleeve may be formed of silicone.

In some embodiments, the sleeve has a polygonal cross section. For avoidance of doubt, the word ‘polygonal’ is being used to mean a cross section having at least three (preferably straight) sides and three corners.

Suitably, the sleeve has a cross section with five or more corners. Accordingly, the cross section of the sleeve may be pentagonal, hexagonal, heptagonal, or a shape with a higher number of sides.

In some embodiments, the cross section of the sleeve has rounded corners. This increases the sealing between the aerosol generating unit and the internal wall of the body.

In some examples, the cross section of the sleeve is circular. In other words, the sleeve has a cylindrical shape.

In some embodiments, the sleeve has (i.e., is moulded/formed/made to have) a different cross-sectional shape to the aerosol generating unit around which it extends. In other words, if the sleeve did not extend around the aerosol generating unit (i.e., if the sleeve were removed from around the aerosol generating unit) , then the cross sectional shape of the sleeve would be different to the cross sectional shape of the aerosol generating unit. But the sleeve is configured to (elastically) deform to match the cross sectional shape of the aerosol generating unit when fitted around (i.e., extending about) the aerosol generating unit. This advantageously provides a tighter fit between the sleeve and the aerosol generating unit, and therefore a more secure sealing of the gap between the aerosol generating unit and the internal wall of the body.

In some embodiments, the sleeve has a circular cross sectional shape (i.e., cross section) and the aerosol generating unit has a non-circular cross sectional shape (i.e., the sleeve is cylindrical, and the aerosol generating unit is non-cylindrical) , and the sleeve conforms to the non-circular cross sectional shape of the aerosol generating unit when fitted onto, or extending about, the aerosol generating unit.

In other examples, the sleeve may have any other type of cross sectional shape, such as a square, pentagonal or hexagonal shape, whilst the aerosol generating unit may have any other non-matching cross sectional shape.

In some embodiments, the aerosol generating unit comprises one or more baffles, wherein the sleeve is configured to seal against the one or more baffles; and one or more of the baffles include one or more notches and/or apertures for fluid communication between a first side and a second side of the baffle. The inclusion of the (notched) baffles can be used to increase the complexity of the flow path between the inlet flow path and the outlet flow path, meaning that it is more difficult for any precursor located at the second end of the aerosol generating unit to leak back along the flow path to the inlet flow path (i.e., travelling along the flow path in the opposite direction to what is intended) . Such a structure therefore reduces leakage through the aerosol generating unit via the flow path.

In some embodiments, a storage portion of the aerosol generating apparatus is defined between an upper end of the slot and the second end of the aerosol generating unit received within the slot.

According to a second aspect of the present invention, there is provided a method of assembling an aerosol generating apparatus, comprising steps of: providing an aerosol generating unit having an inlet flow path at a first end, an outlet flow path at a second end and an airflow passage between the inlet flow path and the outlet flow path; providing a sleeve and fitting the sleeve around the aerosol generating unit; providing a body having an internal wall that defines a slot; inserting the aerosol generating unit with the sleeve fitted around the aerosol generating unit into the slot, wherein the sleeve seals a gap between the internal wall and aerosol generating unit.

Advantageously, an aerosol generating apparatus assembled in this way can provide a more secure sealing between the aerosol generating unit and the internal wall of the body.

In some examples, the sleeve may have a cross sectional chape that does not match the cross sectional shape of the aerosol generating unit, and the step of fitting the sleeve around the aerosol generating unit requires the manipulation of the sleeve to match the cross sectional shape of the aerosol generating unit. This advantageously provides a better fit between the aerosol generating unit and the sleeve, and thus better sealing.

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 above and/or proceeding examples may be combined in any suitable combination 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 FIGURES

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 liquid precursor.

Figs. 3A and 3B are schematic diagrams showing an example implementation of the apparatus of Fig. 2.

Fig. 4 is a cross-sectional view of an aerosol generating apparatus according to an embodiment of the present invention.

Fig. 5 is a cross-sectional perspective view of a sleeve fitted around an aerosol generating unit according to an embodiment of the present invention.

Fig. 6 is a zoomed-in perspective view of the aerosol generating unit of Fig. 5.

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 generating system" may be a system that includes an aerosol generating apparatus and optionally other circuitry/components associated with the function of the apparatus, e.g. one or more external devices and/or one or more external components (here “external” is intended to mean external to the aerosol generating apparatus) . As used herein, an “external device” and “external component” may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol generating apparatus, e.g. via a wireless or wired connection) ; a networked-based computer (e.g. a remote server) ; a cloud-based computer; any other server system.

An example aerosol generating system may be a system for managing an aerosol generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol generating apparatus.

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, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path 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.

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. The consumable may include an information carrying medium. 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.

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.

Electrical circuitry (not shown in figure 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 from a liquid precursor.

In this example, the apparatus 1 includes a device body 10 and a consumable 30.

In this example, the body 10 includes the power supply 4. 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 and consumable 30, 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 one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 3) .

The consumable 30 includes a storage portion implemented here as a tank 32 which stores the liquid precursor 6 (e.g. e-liquid) . The consumable 30 also includes a heating system 34, one or more air inlets 36, and a mouthpiece 38. The consumable 30 may include one or more other components 40.

The body 10 and consumable 30 may each include a respective electrical interface (not shown) to provide an electrical connection between one or more components of the body 10 with one or more components of the consumable 30. In this way, electrical power can be supplied to components (e.g. the heating system 34) of the consumable 30, without the consumable 30 needing to have its own power supply.

In use, a user may activate the aerosol generating apparatus 1 when inhaling through the mouthpiece 38, i.e. when performing a puff. The puff, performed by the user, may initiate a flow through a flow path in the consumable 30 which extends from the air inlet (s) 34 to the mouthpiece 38 via a region in proximity to the heating system 34.

Activation of the aerosol generating apparatus 1 may be initiated, for example, by an airflow sensor in the body 10 which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the mouthpiece) , or by actuation of an actuator included in the body 10. Upon activation, the electrical circuitry 12 (e.g. under control of the processing resource) may supply electrical energy from the power supply 2 to the heating system 34 which may cause the heating system 32 to heat liquid precursor 6 drawn from the tank to produce an aerosol which is carried by the flow out of the mouthpiece 38.

In some examples, the heating system 34 may include a heating filament and a wick, wherein a first portion of the wick extends into the tank 32 in order to draw liquid precursor 6 out from the tank 32, wherein the heating filament coils around a second portion of the wick located outside the tank 32. The heating filament may be configured to heat up liquid precursor 6 drawn out of the tank 32 by the wick to produce the aerosol.

In this example, the aerosol generating unit 4 is provided by the above-described heating system 34 and the delivery system 8 is provided by the above-described flow path and mouthpiece 38.

In variant embodiments (not shown) , any one or more of the precursor 6, heating system 34, air inlet (s) 36 and mouthpiece 38, may be included in the body 10. For example, the mouthpiece 36 may be included in the body 10 with the precursor 6 and heating system 32 arranged as a separable cartomizer.

Figs. 3A and 3B show an example implementation of the aerosol generating device 1 of Fig. 2. In this example, the consumable 30 is implemented as a capsule/pod, which is shown in Fig. 3A as being physically coupled to the body 10, and is shown in Fig. 3B as being decoupled from the body 10.

In this example, the body 10 and the consumable 30 are configured to be physically coupled together by pushing the consumable 30 into an aperture in a top end 11 of the body 10, with the consumable 30 being retained in the aperture via an interference fit.

In other examples (not shown) , the body 10 and the consumable 30 could be physically coupled together in other ways, e.g. by screwing one onto the other, through a bayonet fitting, or through a snap engagement mechanism, for example.

The body 10 also includes a charging port (not shown) at a bottom end 13 of the body 10.

The body 10 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a light 15, which may e.g. be configured to illuminate when the apparatus 1 is activated. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

In this example, the consumable 30 has an opaque cap 31, a translucent tank 32 and a translucent window 33. When the consumable 30 is physically coupled to the body 10 as shown in Fig. 3A, only the cap 31 and window 33 can be seen, with the tank 32 being obscured from view by the body 10. The body 10 includes a slot 15 to accommodate the window 33. The window 33 is configured to allow the amount of liquid precursor 6 in the tank 32 to be visually assessed, even when the consumable 30 is physically coupled to the body 10.

Referring to Fig. 4, there is shown an aerosol generating apparatus 100, which may be implemented in any of the preceding examples. The aerosol generating apparatus 100 includes a body 102 having a generally rectangular shape with a mouthpiece 104 extending from one end (i.e., a ‘top end’ of the body 102) . The mouthpiece 104 being usable to draw aerosol from the aerosol generating apparatus 100. At an opposite end of the body 102 (i.e., a ‘bottom end’ of the body 102 that is opposite the end including the mouthpiece 104) there are included apertures 106 107 through which air may be drawn into the body 102. Said apertures 106 107 are fluidly connected to the mouthpiece 104, such that air may be drawn into the body 102 via the apertures 106 107, travel through the body 102, and exit via the mouthpiece 104. In other words, there exists a passageway or flow path though the body 102 fluidly connecting the apertures 106 107 to the mouthpiece 104 (described in more detail below) .

A locking device 108 is slidably attached to the bottom end of the body 102 so as to be slidable between a first, unlocked, position in which the apertures 106 107 are revealed (shown in Fig. 4) and a second, locked, position in which the locking device 108 blocks the apertures 106 107. In the locked position, air is unable to enter the body 102 via the apertures 106 107, which prevents a user from being able to draw air, and aerosol, from the aerosol generating apparatus 100. The locking device 108 may be intended to prevent unauthorised parties from intentionally or unintentionally using the aerosol generating apparatus 100. For example, the locking device 108 may allow a parent to lock the apparatus 100 whilst it is not in active use, so that children picking up the apparatus 100 cannot accidently draw on the mouthpiece 104 and receive a dose of aerosol. In other words, the locking device 108 may be a ‘child lock’ . However, the present disclosure is not limited to apparatuses that include a locking device 102.

The aerosol generating apparatus 100 further comprises a battery 108, a sensor system 110, a storage portion 112 for storing precursor, an aerosol generating unit 120, and a sleeve 170, all of which are housed within the body 102.

The body 102 includes a slot 114, enclosed within (and/or bounded by) internal walls 116, that extends into the body 102 from the mouthpiece 104. The aerosol generating unit 120 is received in the slot 114, and fluidly connected to the mouthpiece 104 via a tunnel 118 that extends into the slot 108. The aerosol generating unit 120 is (at least partially) fitted within the sleeve 170, which fits within, and seals, a gap between the aerosol generating unit 120 and the internal wall 116 that bounds the slot 114. The aerosol generating unit 120 and sleeve 170 are described in more detail in relation to Figs. 5 and 6 below.

The sensor system 114 is positioned proximal to a first end of the aerosol generating unit 120 (see Fig. 5: 121) , and is further connected to the apertures 106 107. In conjunction, the sensor system 114, aerosol generating unit 120 and tunnel 118 define the passageway (flow path) between the apertures 106 107 and the mouthpiece 104 along which air or other fluids may flow. More specifically, air enters through the apertures 106 107, then follows one or more paths through the sensor system 110, the aerosol generating unit 120 and the tunnel 118 to arrive at the mouthpiece 104.

The sensor system 110 includes an airflow structure 111-1 and a sensor 111-2. The airflow structure is connected to the apertures 106 107 in such a way that air entering the aperture 106 bypasses the sensor 111-2, and air entering the aperture 107 is forced past the sensor 111-2. The sensor 111-2 may be for detecting a rate of airflow through the aerosol generating apparatus 100, which may be used to determine when the aerosol generating unit 120 is supplied with energy from the battery 108. However, the sensor system 111-2 is not limited in this way.

The storage portion 112 is located proximal to a second end of the aerosol generating unit 120 (see Fig. 5: 121) . More particularly, the storage portion 112 is a region within the slot 114 which is bounded between the internal walls 116 and the combination of the second end of the aerosol generating unit 120 and the sleeve 170. In this way, a precursor may be kept within the slot 114 without leaking out into other spaces enclosed within the body 102 or out of the body 102 altogether.

In the present example, the storage portion is located in a section of the slot 114 that is proximal to the mouthpiece 104, with the tunnel 118 extending through the storage portion 112 between the mouthpiece 104 and the aerosol generating unit 120. The storage portion 112 is not limited in this way however. For example, the storage portion 112 may be located in a different portion of the slot 114, or may even be a tank-like structure.

The battery 108 is housed in a separate section of the body 102. However, the present disclosure is not limited in this way, and the battery 108 may instead, in some examples, be housed within the slot 114.

The battery 108 is intended to supply energy to a heating element 154 of the aerosol generating unit 120. In the present example, the heating element 154 is a resistive heater. More particularly, the heating element 154 is a mesh heater attached around a wall defining a section of the flow path (airflow passage) through the aerosol generating unit 120. It is envisaged that other heating elements may be used instead.

It is noted that the above is for explanatory purposes only, and that the present disclosure is not limited in this way. In particular, the components housed within the body 102 (i.e., the battery 108, the sensor system 110, the aerosol generating unit 120 and the sleeve 170) may be arranged in an alternative way.

Referring to Fig. 5, this shows a cross sectional perspective view of the aerosol generating unit 120 and sleeve 170 of Fig. 4.

The aerosol generating unit 120 extends longitudinally between a first end 121 and a second end 122, and comprises a frame 130, a tube 150, a wick 152, and a heating element (not shown in Fig. 5, see Fig. 4: 154) . The wick 152 is preferably made of cotton.

The frame 130 defines a flow path (indicated by the thick dashed line 131) for air to move between an inlet flow path 132 and an outlet flow path 134. The flow path generally moves in the longitudinal direction indicated by the arrow 123.

A lower portion of the frame 130, located proximal to the first end of the aerosol generating unit 121, includes the inlet flow path 132 through which air may enter the aerosol generating unit 120 (for example, air received from the sensor structure 110 shown in Fig. 4) .

In the present example, the lower end of the frame 130 is further configured to receive one or more additional components (not shown) of the aerosol generating apparatus 100, such as wiring associated with the heating element 154, and the sensor system 110 shown in Fig. 4. Additionally, the lower end of the frame 132 may also be configured to engage the internal walls 116 of the slot 114 into which the aerosol generating unit 120 is fit, so as to hold the aerosol generating unit 120 in a generally fixed position relative to the body 102. For example, the lower end of the frame 130 may include one or more protrusions (not shown) that project radially outward from the frame 130, which are configured to engage with corresponding holes/recesses/gaps in the internal wall 116. However, the present disclosure is not limited to such examples.

An upper portion of the frame 130, located proximal to the second end of the aerosol generating unit 122, includes the outlet flow path 134, via which an air/aerosol may exit the aerosol generating unit 120. In the present example the outlet flow path is connected to the tunnel 118 via the tube 150, so that aerosol leaving the aerosol generating unit 120 immediately enters the tunnel 118.

The upper portion of the frame 130 comprises a cavity 136 into which the tube 150, wick 152, and heating element 154 are fitted. The wick 152 is configured to absorb (liquid) precursor held within the storage portion 112, the storage portion 112 being positioned adjacent to, and bounded by, the second end of the aerosol generating unit 122 (see Fig. 4) . The wick 152 is configured to communicate the absorbed precursor along the path indicated by the thin dashed line 156 into the aerosol generating unit 120. The aerosol is then aerosolised by the heating element 154 and introduced into the air flow path 131. The tube 150 is configured to engage the tunnel 118, so as to prevent precursor from entering the aerosol generating unit 120 by means other than through the wick 152.

The frame 130 includes a plurality of baffles 138-142 extending radially outward. That is, extending outward from the frame 130 in a plane that is perpendicular to the longitudinal direction 123. In this example, each of the plurality of baffles 138-142 seal against the sleeve 170. The plurality of baffles 138-142 are spaced along the longitudinal direction 123, and include a first baffle 138, a second baffle 139, a third baffle 140, a fourth baffle 141 and a fifth baffle 142.

The inclusion of baffles helps to prevent precursor from the storage portion 112 leaking through the aerosol generating unit 120 in a direction opposite to the direction indicated by arrow 123. In other words, the baffles help to prevent precursor from leaking out of the inlet flow path 132. This is because the baffles allow for a more complex air flow path 131 to be devised, making it more difficult for precursor to travel through the flow path 131 to the inlet flow path 132.

Compartments 144-147 are formed between adjacent baffles. That is, between the first and second baffles 138 139 there is defined a first compartment 144, between the second and third baffles 139 140 there is defined a second compartment 145, between the third and fourth baffles 140 141 there is defined a third compartment 146, and between fourth and fifth baffles 141 142 there is defined a fourth compartment 147.

In this example, the first and second compartments 144 145 form part of the air flow path 131. More particularly, air from the inlet flow path 132 first enters the second compartment 145. The air is then fluidly communicated through to the first compartment 144, before entering into the cavity 136 where it is combined with precursor to form aerosol.

The third and fourth compartments 146 147 form a reservoir structure, into or out of which excess precursor and/or pressure may be communicated through the pressure relief passage 148 located in the fourth baffle 142. The present embodiment includes two pressure relief passages 148 located on opposite sides of the fourth baffle 142, but alternatives are envisaged. For example, in some examples there may only be a single pressure relief passage 148.

The baffles 138-141 include notches 149 to fluidly connect adjacent compartments, as shown in Fig. 6. More particularly, in the present example the fourth baffle 141 includes a notch 149-1, allowing fluid communication (i.e., the transfer of precursor) between the third compartment 146 and the fourth compartment 147. Similarly, the third baffle 140 includes notch 149-2, allowing fluid communication between the second compartment 145 and the third compartment 146.

Although not shown, the second baffle 139 includes a means for communicating fluid between the first compartment 144 and the second compartment 145, such that air is able to follow the flow path 131.

The inclusion of notches in each of the second baffle 139, third baffle 140 and fourth baffle 141, and the pressure relief passage 148 in the fifth baffle 142, provides fluid communication between the external environment and the storage portion 112, so as to allow pressure equalisation whilst the aerosol generating apparatus 100 is in use.

The present disclosure is not limited to notches, however. Other means of providing fluid communication between opposite sides of the baffles, such as grooves, apertures, holes or cut-outs are also envisaged.

Returning to Fig. 5, the sleeve 170 is fitted around the aerosol generating apparatus 120 so as to extend from the second end of the aerosol generating unit 122 down toward the first end 121. In the present example, the sleeve 170 is shown as extending down to a point between the first baffle 138 and the first end 121.

In the present example, an end of the sleeve 170 proximal with the second end of the aerosol generating unit 122 is flush with an end of the frame 130 proximal the second end of the aerosol generating unit 122.

The sleeve 170, in combination with the aerosol generating unit 120, bounds the storage portion 112.

The sleeve 170 is configured to seal a gap between the aerosol generating unit 120 and the internal wall 116. More particularly, an inner surface of the sleeve 172 that faces toward the aerosol generating unit 120 is configured to seal against the baffles 138-142, so as to bound a radial outer edge of the compartments 144-147. An outer surface of the sleeve 174 that faces away from the aerosol generating unit 120 is configured to seal against the internal wall 116. In this way, the sleeve 170 prevents precursor held in the storage portion 112 from leaking out between the aerosol generating unit 120 and the internal wall 116. Additionally, the sleeve prevents air from leaking around the baffles 138-141, and thereby disrupting proper air flow along the flow path 131.

The sleeve 170 is preferably formed of elastic material. More preferably, the sleeve 170 is formed of silicone. However, the present disclosure is not limited in this way. In particular, the skilled person equipped with the present disclosure would recognise alternative materials from which the sleeve 170 could be made.

In the present example, the sleeve 170 has a circular cross section, which matches the circular cross section of the aerosol generating unit 120 (said cross section being in a plane that is perpendicular to the longitudinal direction 123) . However, the present disclosure is not limited in this way, and it is also envisaged that the sleeve 170 may instead have a polygonal cross section. That is, a cross section with three or more sides. For example, the sleeve 170 may have a pentagonal, hexagonal or heptagonal shaped cross section, or a cross sectional shape with an even greater number of sides.

Preferably, a sleeve 170 having a non-circular cross section will have rounded corners, which may increase the sealing between the aerosol generating unit 120 and the internal wall 116.

The inner surface of the sleeve 172 includes a flange 176 protruding inwardly, which engages or fits into a corresponding recess 124 in the frame 130 of the aerosol generating unit 120. This helps to improve the sealing between the aerosol generating unit 120 and the internal wall 116. The flange 176 may also help to prevent relative movement between the aerosol generating unit 120 and the sleeve 170. For example, moving the aerosol generating unit in the longitudinal direction indicated by arrow 123 will cause a corresponding movement in the sleeve 170.

In the present example, the flange 176 and recess 124 are located at the second end of the aerosol generating unit 122. More particularly, a surface of the flange 176 is flush with the end of the frame 130 proximal the second end of the aerosol generating unit 122.

In alternative embodiments, the sleeve 170 may comprise one or more additional flanges spaced along the longitudinal length of the sleeve 170. For example, there may be a flange at an end of the sleeve 170 opposite the end of the sleeve 170 proximal to the second end of the aerosol generating unit 122.

The outer surface of the sleeve 174 includes a ribbed structure, comprising a plurality of ribs 178 and 179.

The plurality of ribs 178 179 extend around the circumference of the sleeve 170, and are configured to press against or engage the internal wall 116.

The plurality of ribs 178 179 have a triangular cross section, which may increase the sealing between aerosol generating unit 120 and the internal wall 116.

In the present example, the plurality of ribs 178 179 are split between a first end of the sleeve 170 and a second end of the sleeve 170 that is opposite the first end of the sleeve 170. The first end of the sleeve 170 comprises three ribs 178-1 178-2 178-3. The second end of the sleeve 170, which is proximal to the second end of the aerosol generating unit 120 in the present example, comprises four ribs 179-1 179-2 179-3 179-4. However, the present example is not intended to be limiting, and there may be any number of ribs at each of the first and second ends of the sleeve 170. There may also be ribs in a middle portion of the sleeve 170.

The internal wall 116 may comprise one or more recesses into which the plurality of ribs 178 179 can be fit, which may improve sealing. Preferably, there may be a corresponding number of recesses and ribs 178 179.

Claims

An aerosol generating apparatus comprising:

a body having an internal wall defining a slot;

an aerosol generating unit received within the slot, the aerosol generating unit having an inlet flow path at a first end, an outlet flow path at a second end, and a flow path from the inlet flow path to the outlet flow path; and

a sleeve configured to extend about the aerosol generating unit from the second end toward the first end so as to seal a gap between the internal wall of the body and the aerosol generating unit,

wherein the sleeve includes an end portion configured to engage the second end of the aerosol generating unit and to contact the internal wall of the body; and wherein the end portion defines an end surface of the sleeve which meets the internal wall at a substantially orthogonal angle.
The aerosol generating apparatus of claim 1, wherein the end surface of the sleeve lies in a plane that is substantially orthogonal to the internal wall.
The aerosol generating apparatus of claim 1 or claim 2, wherein the second end of the aerosol generating unit comprises an end surface which lies in a plane that is substantially orthogonal to the internal wall.
The aerosol generating apparatus of any preceding claim, wherein the end surface of the aerosol generating unit and the end surface of the sleeve are flush.
The aerosol generating apparatus of any preceding claim, wherein the end portion of the sleeve further comprises a flange configured to engage a corresponding recess in the aerosol generating unit, and wherein the flange defines the end surface of the sleeve.
The aerosol generating apparatus according to any preceding claim, wherein the sleeve comprises a ribbed structure configured to extend around an outer surface of the sleeve and engage the internal wall.
The aerosol generating apparatus according to claim 6, wherein the ribbed structure includes a rib at a first end of the sleeve and a rib at the second end of the sleeve.
The aerosol generating apparatus according to claim 6 or claim 7, wherein the ribbed structure comprises one or more ribs having a triangular cross-section.
The aerosol generating apparatus of any one of claims 6-8, wherein the ribbed structure is configured to engage with one or more recesses formed by the internal wall of the slot.
The aerosol generating apparatus of any preceding claim, wherein the sleeve has a cross section with five or more corners.
The aerosol generating apparatus of claim 10, wherein the cross section of the sleeve has rounded corners.
The aerosol generating apparatus according to any previous claim, wherein the sleeve has a circular cross sectional shape and the aerosol generating unit has a non-circular cross sectional shape, and the sleeve conforms to the non-circular cross sectional shape of the aerosol generating unit when extending around the aerosol generating unit.
The aerosol generating apparatus of any preceding claim, wherein the aerosol generating unit comprises one or more baffles and the sleeve is configured to seal against the one or more baffles; and

wherein one or more of the baffles include one or more notches and/or apertures for fluid communication between a first side and a second side of the baffle.
The aerosol generating apparatus of any preceding claim, wherein a storage portion of the aerosol generating apparatus is defined between an upper end of the slot and the second end of the aerosol generating unit received within the slot
A method of assembling an aerosol generating apparatus, comprising steps of:

providing an aerosol generating unit having an inlet flow path at a first end, an outlet flow path at a second end and a flow path between the inlet flow path and the outlet flow path;

providing a sleeve and fitting the sleeve around the aerosol generating unit;

providing a body having an internal wall that defines a slot;

inserting the aerosol generating unit with the sleeve fitted around the aerosol generating unit into the slot, wherein the sleeve seals a gap between the internal wall and aerosol generating unit.