WO2025129635A1

WO2025129635A1 - Aerosol generating apparatus

Info

Publication number: WO2025129635A1
Application number: PCT/CN2023/141009
Authority: WO
Inventors: Liangjie SU; Haowen ZHU; 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

There is provided an aerosol generating unit (1) comprising: a liquid precursor (6); a heating system for generating an aerosol from the liquid precursor; and a liquid communication structure for conveying the liquid precursor to a heating chamber of the heating system. The liquid communication structure comprises a liquid inlet for receiving the liquid precursor and a liquid pathway fluidically connecting the liquid inlet and the heating chamber of the heating system. In a first aspect, the liquid pathway comprises a first funnel (332) and a second funnel provided (334) around the heating chamber. In a second aspect, the aerosol generating unit further comprises a chamber wall (222) with a chamber aperture (224) for fluidically connecting the heating chamber to the liquid pathway and a wick (240) provided along the liquid pathway, wherein the liquid communication structure further comprises a shelf provided between the fluid inlet and the chamber aperture for receiving the wick; wherein the first funnel (332) and the second funnel (334) extend around an axis; wherein the first funnel has a first height, as measured along the axis, and wherein the second funnel has a second height, as measured along the axis, and which is at least 75% of the first height and is up to 125% of the first height.

Description

AEROSOL GENERATING APPARATUS

FIELD

The present disclosure relates to an aerosol generating apparatus.

BACKGROUND

A typical aerosol generating apparatus may comprise a power supply, an aerosol generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user.

A drawback with known aerosol generating apparatuses is the leakage of aerosol precursor liquids. This is often addressed by filling the liquid storage portions with a porous material to absorb and store the aerosol precursor liquids; however, this reduces the available space within the liquid storage portion, meaning that a lower volume of aerosol precursor liquid can be stored.

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

SUMMARY

In a first aspect the present disclosure provides an aerosol generating unit that comprises a liquid precursor and a heating system for generating an aerosol from the liquid precursor. The aerosol generating unit further comprises a liquid communication structure for conveying the liquid precursor to a heating chamber of the heating system.

The liquid communication structure comprises a liquid inlet for receiving the liquid precursor. The liquid inlet and the heating chamber are fluidically connected by a liquid pathway.

In some examples, the liquid pathway comprises a first funnel provided between the liquid inlet and the heating chamber. The liquid pathway narrows in the first funnel from the liquid inlet towards the heating chamber.

In some examples, the liquid pathway further comprises a second funnel provided around the heating chamber, which fluidically connects the first funnel and the heating chamber. The liquid pathway narrows in the second funnel from the first funnel towards the heating chamber.

In other words, the liquid communication structure comprises a series of funnels arranged one after another between the liquid inlet and the heating system for transferring the liquid precursor to the heating system.

By providing a staggered funnel arrangement, with the first funnel feeding into the second funnel, leakage from the liquid communication structure, and in particular from the join between the liquid communication structure and the heating system, is reduced. This is at least in part due to the narrowing of the liquid pathway in the funnels as they approach the heating system, as less liquid will be held at the interface between the liquid pathway and the heating system, thereby reducing the likelihood of leaks occurring.

The liquid precursor may be any suitable liquid for generating an aerosol.

In some examples, the first funnel and the second funnel extend around an axis. The first funnel may have a first height, as measured along the axis. The second funnel may have a second height, as measured along the axis. The second height of the second funnel may be at least 75%of the first height and may be up to 125%of the first height. Optionally the second height may be at least 85%of the first height and may be up to 115%of the first height. Optionally the first height and the second height may be substantially equal.

The described arrangement of the heights of the first funnel and the second funnel may contribute to leakage control and, in particular, optimise liquid flow and reduce leakage from the aerosol generating unit.

In some examples, a maximum width of the second funnel is less than a minimum width of the first funnel. In this way, the device may further reduce the unintentional leakage of liquid precursor from the liquid pathway by further reducing the amount of liquid held at the interface between the liquid pathway and the heating system.

In some examples, the aerosol generating unit further comprises a wick provided in the liquid pathway of the liquid communication structure between the first funnel and the second funnel. The first funnel is configured to communicate the liquid precursor towards the wick and the second funnel is configured to communicate the liquid precursor from the wick towards the heating chamber. In this way, the device may include a wick, which may be a porous material such as a fibre or a porous ceramic, adapted to absorb the liquid precursor as it travels along the liquid towards the heating system. The wick provides an additional measure of controlling the flow of liquid through the aerosol generating unit and prevents the interface between the liquid pathway and the heating system from being overloaded with fluid. In this way, the wick further reduces the likelihood of leaks occurring. Thus, the liquid communication structure may include an absorptive, or porous, material instead of a liquid storage portion requiring such a material, meaning that the aerosol generating unit may hold proportionally more liquid precursor in the volume that would have otherwise been occupied by a porous, absorptive material.

In addition, by providing a wick, the liquid communication structure does not need to be entirely gravity fed in order to draw liquid precursor towards the heating system due to the capillary action of the wick. Further, as the aerosol generating unit empties of liquid precursor, the wick will retain the remaining liquid precursor closer to the heating system thereby reducing the lead time for providing the liquid precursor to the heating system and increasing the efficiency of the system as a whole.

In some examples, the aerosol generating unit further comprises a chamber wall at least partially surrounding the heating chamber, wherein the heating chamber comprises a chamber aperture for fluidically connecting the heating chamber to the liquid pathway. The second funnel surrounds the heating chamber and the chamber aperture. The liquid communication structure further comprises a shelf for receiving the wick, the shelf being arranged between the first funnel and the second funnel. Accordingly, the wick is arranged such that the chamber aperture is at least partially directly exposed to the liquid pathway. In this way, the heating system may receive liquid precursor directly from the liquid pathway rather than from the wick. This may improve the flow of liquid to the heating system by providing a transfer window at the second funnel, where liquid may flow from the wick, through the second funnel, through the chamber aperture and into the heating system and air may flow from the heating system, through the chamber aperture, through the second funnel and through the wick to replace the expended liquid precursor.

In some examples, the heating system comprises a heating element and a heating wick at least partially surrounding the heating element, and wherein the chamber wall further comprises a wick aperture adapted to receive a portion of the heater wick. The portion of the heating wick that is received in the wick aperture extends through the chamber wall. The chamber aperture exposes the heating wick to the liquid pathway. In this way, the amount of liquid precursor delivered to the heating element may be controlled by the heater wick. The portion of the heater wick received in the wick aperture may perform two functions. The first function of the portion of the heater wick received in the wick aperture may be to improve the stability of the heating system within the liquid communication structure. The second function of the portion of the heater wick received in the wick aperture may be to form a reservoir of liquid precursor when the heater wick is soaked as the portion of the heater wick received in the wick aperture may not be in direct contact with the heating element.

In a second aspect, the present disclosure provides an aerosol generating unit that comprises a liquid precursor, a heating system for generating an aerosol from the liquid precursor and a liquid communication structure for conveying the liquid precursor to a heating chamber of the heating system. The liquid communication structure comprises a liquid inlet for receiving the liquid precursor and a liquid pathway fluidically connecting the liquid inlet and the heating chamber.

In some examples, the aerosol generating unit comprises a chamber wall at least partially surrounding the heating chamber. The chamber wall comprises a chamber aperture for fluidically connecting the heating chamber to the liquid pathway.

In some examples, the liquid communication structure comprises a wick provided along the liquid pathway. The liquid communication structure further comprises a shelf for receiving the wick, wherein the shelf is provided between the fluid inlet and the chamber aperture.

In other words, the aerosol generating unit may comprise a wick interposed between a liquid inlet and a heating system along a liquid pathway.

In this way, the device may include a wick, which may be a porous material such as a fibre or a porous ceramic, adapted to absorb the liquid precursor as it travels along the liquid pathway towards the heating system. The wick provides an additional measure of controlling the flow of liquid through the aerosol generating unit and prevents the interface between the liquid pathway and the heating system from being overloaded with fluid. In this way, the wick further reduces the likelihood of leaks occurring. Thus, the liquid communication structure may include an absorptive, or porous, material instead of a dedicated liquid storage portion requiring such a material, meaning that the dedicated liquid storage portion may hold proportionally more liquid precursor in the volume that would have otherwise been occupied by a porous, absorptive material.

Further, due to the positioning of the wick relative to the chamber aperture, the heating system may receive liquid precursor directly from the liquid pathway rather than from the wick. This may improve the flow of liquid to the heating system by providing a transfer window at the end of the liquid pathway, where liquid may flow from the wick, through the chamber aperture and into the heating system and air may flow from the heating system, through the chamber aperture and through the wick to replace the expended liquid precursor.

In some examples, the liquid pathway comprises a first liquid flow section fluidically connected to the liquid inlet and a second liquid flow section surrounding the heating chamber and fluidically connected to the chamber aperture. The first liquid flow section and the second liquid flow section are fluidically connected to each other by way of a wicking section, which is adapted to receive the wick. The wicking section includes the shelf for receiving the wick. In this way, the device may provide a liquid pathway having multiple stages of liquid flow control for controlling the movement of the liquid precursor towards the heating system in order to reduce leakage.

In some examples, the wicking section comprises a straight passage from the shelf towards the liquid inlet. The straight passage may extend around an axis. The straight passage may have a height, as measured along the axis, and the wick may have a wick height, as measured along the axis, which may be at least 50%of the height of the straight passage. Optionally the wick height is at least 60%or 70%of the height of the straight passage.

The described arrangement of the wicking section may contribute to leakage control and, in particular, optimise liquid flow and reduce leakage from the aerosol generating unit.

In some examples, the wick height is at least 1.5 millimetres, optionally at least 2 millimetres.

In some examples, the first liquid flow section comprises a first funnel, wherein the liquid pathway narrows from the liquid inlet towards the heating chamber. The first funnel is configured to communicate the liquid precursor towards the wick. In some examples, the second liquid flow section comprises a second funnel, wherein the liquid pathway narrows from the first funnel towards the heating chamber. The second funnel is configured to communicate the liquid precursor from the wick towards the heating chamber.

In other words, the liquid communication structure comprises a series of funnels arranged one after another between the liquid inlet and the heating system for transferring liquid precursor to the heating system.

By providing a staggered funnel arranged, with the first funnel feeding into the second funnel, leakage from the liquid communication structure, and in particular from the join between the liquid communication structure and the heating system, is reduced. This is at least in part due to the reduction in width of the funnels as they approach the heating system, as less liquid will be held at the interface between the liquid pathway and the heating system, thereby reducing the likelihood of leaks occurring. Further, by providing a liquid communication structure as described above, the need to fill a dedicated liquid storage portion with porous material may be eliminated due to the reduced leakage risk. Accordingly, the liquid storage portion may hold proportionally more liquid precursor in the volume that would have otherwise been occupied by a porous, absorptive material.

In some examples, the height of the straight passage is greater than a height of the first funnel and/or greater than a height of the second funnel. The heights of the straight passage, the first funnel and the second funnel may be measured along the axis. Optionally, the height of the straight passage may be at least 30%greater than the height of the first funnel and/or the second funnel. Optionally, the height of the straight passage may be at least 50%greater than the height of the first funnel and/or the second funnel.

The described arrangement of the heights of the straight passage and the first funnel and/or the straight passage and the second funnel may contribute to leakage control and, in particular, optimise liquid flow and reduce leakage from the aerosol generating unit.

In some examples, the heating system comprises a heating element and a heating wick at least partially surrounding the heating element. The chamber wall further comprises a wick aperture adapted to receive a portion of the heater wick such that the portion of the heating wick extends through the chamber wall and out of the heating chamber. The chamber aperture exposes the heating wick to the liquid pathway. In this way, the amount of liquid precursor delivered to the heating element may be controlled by the heater wick. The portion of the heater wick received in the wick aperture may perform two functions. The first function of the portion of the heater wick received in the wick aperture may be to improve the stability of the heating system within the liquid communication structure. The second function of the portion of the heater wick received in the wick aperture may be to form a reservoir of liquid precursor when the heater wick is soaked as the portion of the heater wick received in the wick aperture may not be in direct contact with the heating element.

The present disclosure further provides an aerosol generating system comprising a liquid communication structure as described above, and a tank shell adapted to receive the aerosol generating unit. The tank shell and the aerosol generating unit at least partially defining a liquid storage portion for storing the liquid precursor.

In this way, there may be provided an aerosol generating system capable of holding an increased volume of liquid precursor with a reduce risk of leakage.

In some examples, the aerosol generating system is absent of any absorptive material between the tank shell and the liquid inlet of the liquid communication structure. Put another way, the first absorptive, or porous, material that the liquid precursor may come into contact with is the wick of the liquid pathway of the liquid communication structure or the heating wick of the heating system. In other words, the portion of the system adapted to store the liquid precursor, i.e., that portion of the system first filled with the liquid precursor on manufacture, may be absent of porous material.

By providing a liquid communication structure as described above, the need to fill the liquid storage portion with porous material may be eliminated due to the reduced leakage risk. Accordingly, the liquid storage portion may hold proportionally more liquid precursor in the volume that would have otherwise been occupied by a porous, absorptive material.

In some examples, the tank shell is formed from a translucent, or a transparent, material such that the liquid precursor is visible through the tank shell. In this way, the amount of liquid precursor stored in the tank shell may be monitored with ease by the user.

In some examples, the tank shell comprises an air flow channel connecting the heating system to an air outlet in the tank shell, and wherein the tank shell forms a mouthpiece of the aerosol generating system.

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. 4A shows a schematic cross section of a liquid communication structure.

Fig. 4B shows a schematic cross section of a liquid communication structure.

Fig. 5 shows a cross section of a liquid communication structure.

Fig. 6 shows a perspective cross section of a liquid communication structure.

Fig. 7 shows a perspective cross section of a liquid communication structure.

Fig. 8 shows a perspective view of a wick.

Fig. 9 shows a perspective cross section of a heating system.

Fig. 10 shows a perspective cross section of a heating system.

Fig. 11 shows a cross section of an aerosol generation unit.

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 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. 4A an aerosol generating unit 100, which may be implemented in any of the preceding examples, comprises a liquid communication structure 105 having a liquid inlet 110 for receiving the liquid precursor 115 and a liquid pathway 130 fluidically connecting the liquid inlet 110 and the heating chamber 120.

The liquid pathway 130 comprises a first funnel 132 provided between the liquid inlet 110 and the heating chamber 120 and a second funnel 134 provided around the heating chamber 120. The second funnel 134 fluidically connects the first funnel 132 and the heating chamber 120. The liquid pathway 130 narrows in the first funnel 132 from the liquid inlet 110 towards the heating chamber 120 and further narrows in the second funnel 134 from the first funnel 132 towards the heating chamber 120.

The liquid precursor 115 flows from the liquid inlet 110 towards the heating chamber 120 through the liquid pathway 130 defined by the first and second funnels 132, 134. As the liquid precursor 115 flows through the fluid pathway 130, the flow is restricted by the narrowing of the firsts and second funnels 132, 134, thereby controlling the amount of liquid precursor 115 delivered to the heating chamber 120. The first funnel 132 and the second funnel 134 define an axis 135. More particularly, the first funnel 132 and the second funnel 134 extend around the axis 135. In this example, the first funnel 132 and the second funnel 134 are coaxially arranged and thus define the axis 135.

The first funnel 132 has a height, as measure along the axis 135, which is substantially equal to a height of the second funnel 134, also measured along the axis 135.

Referring to Fig. 4B an aerosol generating unit 200, which may be implemented in any of the preceding examples, comprises a liquid communicating structure 205 having a liquid inlet 210 for receiving the liquid precursor 215 and a liquid pathway 230 fluidically connecting the liquid inlet 210 and the heating chamber 220.

The aerosol generating unit 200 further comprises a chamber wall 222 at least partially surrounding the heating chamber 220. The chamber wall comprises a chamber aperture 224 for fluidically connecting the heating chamber 220 to the liquid pathway 230. A wick 240 is provided along the liquid pathway on a shelf 250. The shelf 250 is provided between the fluid inlet 210 and the chamber aperture 224. The shelf 250 is positioned in order to hold the wick 240 substantially clear of the chamber aperture, such that liquid precursor 215 that has flowed past the wick 240 may flow directly into the heating chamber 220.

The liquid precursor 215 flows from the liquid inlet 210 towards the heating chamber 220 through the liquid pathway 230 containing a wick 240. As the liquid precursor 215 flows through the fluid pathway 230, the flow is restricted by the wick 240, thereby controlling the amount of liquid precursor 215 delivered to the heating chamber 220.

Figure 5 shows a cross section of a liquid communication structure 300 which may be implemented in any of the preceding examples. Figures 6 and 7 show perspective cross sections of the liquid communication structure 300 shown in Figure 5, taken across two different planes.

Figure 8 shows a perspective view of a wick 400 that may be received on a shelf of the liquid communication structure shown in Figures 5 to 7. Figures 9 and 10 show perspective cross sections of a heating system 500, taken across two different planes, that may be received in the liquid communication structure shown in Figures 5 to 7.

Figures 5 to 7 show a liquid communication structure 300 having a liquid inlet 310 for receiving the liquid precursor and a liquid pathway 330 fluidically connecting the liquid inlet 110 and the heating chamber 520 (as shown in Figures 9 and 10) .

The liquid pathway 330 comprises a first liquid flow section 331 fluidically connected to the liquid inlet 310. The first liquid flow section 310 includes a first funnel 332. The liquid pathway 330 narrows in the first funnel 332 from the liquid inlet 310 towards the heating chamber 520.

The liquid pathway 330 further comprises a second liquid flow section 333 surrounding the heating chamber 520 and fluidically connected to the chamber aperture 524 in the chamber wall 522. The second liquid flow section 333 comprises a second funnel 334 and the liquid pathway 330 which in the second funnel 334 from the first funnel 332 towards the heating chamber 520.

The second liquid flow section 333, and the second funnel 334, surround the heating chamber 520 when the heating system 500 shown in Figures 9 and 10 is received in the liquid communicating structure 300. When the heating system 500 shown in Figures 9 and 10 is received in the liquid communicating structure 300, the heating system may be supported by a heating system support 360 in the liquid communicating structure, and in particular, the chamber wall 522 defining the heating chamber 520 may be received in the heating system support 360.

The liquid pathway 330 further comprises a wicking section 335 provided between the first liquid flow section 331 and the second liquid flow section 333, wherein the wicking section 335 comprises the shelf 350 for receiving the wick 400 (as shown in Figure 8) . The wick may surround the heating chamber 520 when both the wick 400 and the heating system 500 are received in the liquid communicating structure 300. 355

The wicking section 335 further comprises a straight passage 355 from the shelf towards the liquid inlet. The straight passage extends around an axis 357. In the present example, the straight passage 355 neither converges nor diverges, i.e. is straight.

The straight passage has a height, as measured along the axis 357. The wick 400 has a wick height, as measured along the axis 357, which is 70%of the height of the straight passage 357.

The height of the straight passage 355 is greater than the height of the first funnel 332 and is greater than the height of the second funnel 334. In this example, the height of the straight passage 355 is approximately 50%greater than the height of each of the first funnel 332 and the second funnel 334.

The first funnel 332 directs the liquid precursor towards the wick 400 held on the shelf 350 from the liquid inlet 310. The second funnel 334 directs the liquid precursor from the wick 400 towards the heating chamber 520 and in particular to the chamber apertures 524 in the chamber wall 522.

The shelf 350 is positioned in order to hold the wick 400 substantially clear of the chamber apertures 524, such that liquid precursor that has flowed past the wick 400 may flow directly into the heating chamber 520.

As shown in Figures 5 to 7, a maximum width of the second funnel 334 is less than a minimum width of the first funnel 332. Accordingly, the liquid pathway 330 narrows from the liquid inlet 310 to the heating chamber 520.

Figures 9 and 10 show a heating system 500 that may be received in the liquid communication structure 300 shown in Figures 5 to 7. The heating system includes a heating chamber 520, at least partially surrounded by, and defined by, a chamber wall 522. Chamber apertures 524 fluidically link the heating chamber within the chamber wall 522 to the liquid pathway 330, and in particular the second funnel 336, which surrounds the heating chamber 520.

The heating system 500 comprises a heating element 580 and a heating wick 570 at least partially surrounding the heating element 580. The chamber wall 522, which surrounds both the heating element 580 and the heating wick 570, further comprises a wick aperture 590 adapted to receive a portion of the heating wick 575 such that the portion of the heating wick 575 extends through the chamber wall 522 and out of the heating chamber 520. Thus, the heating wick 575 may be formed from one or more flat sheets of wicking material, folded around a heating element 580 and secured within the heating chamber 520 by slotting the heating wick 570 and the heating element 570 into the chamber wall 523, with a portion of the heating wick 575 extending through a wick aperture 590 of the chamber wall 522. Fig. 11 shows an aerosol generating system 600 comprising the aerosol generating unit 605 described above, comprising the liquid communication structure 300 shown in Figures 5 and 7, the heating system 500 (not shown in Fig. 11) and the wick 400 (not shown in Fig. 11) .

The aerosol generating system 600 further comprises a tank shell 620 adapted to receive the aerosol generating unit 605, the tank shell 620 and the aerosol generating unit 605, and in particular the liquid communicating structure 300, defining a liquid storage portion 625 for storing the liquid precursor 615. The liquid storage portion 625 between the tank shell 620 and the liquid inlet 310 of the liquid communication structure 300 is absent of any absorptive material. The tank shell 620 may be formed from a translucent, or a transparent, material such that the liquid precursor is visible through the tank shell 620.

The tank shell 620 comprises an air flow channel 630 connecting the heating system 500 to an air outlet 635 in the tank shell 620, and wherein the tank shell forms a mouthpiece of the aerosol generating system 600.

Claims

An aerosol generating unit comprising:

a liquid precursor;

a heating system for generating an aerosol from the liquid precursor; and

a liquid communication structure for conveying the liquid precursor to a heating chamber of the heating system, the liquid communication structure comprising:

a liquid inlet for receiving the liquid precursor; and

a liquid pathway fluidically connecting the liquid inlet and the heating chamber of the heating system, wherein the liquid pathway comprises:

a first funnel provided between the liquid inlet and the heating chamber, wherein the liquid pathway narrows in the first funnel from the liquid inlet towards the heating chamber; and

a second funnel provided around the heating chamber, wherein the second funnel fluidically connects the first funnel and the heating chamber, and wherein the liquid pathway narrows in the second funnel from the first funnel towards the heating chamber;

wherein the first funnel and the second funnel extend around an axis;

wherein the first funnel has a first height, as measured along the axis, and

wherein the second funnel has a second height, as measured along the axis, and which is at least 75%of the first height and is up to 125%of the first height.
The aerosol generating unit claimed in claim 1, wherein a maximum width of the second funnel is less than a minimum width of the first funnel.
The aerosol generating unit claimed in any of claims 1 to 2, wherein the aerosol generating unit further comprises a wick provided in the liquid pathway of the liquid communication structure between the first funnel and the second funnel, wherein the first funnel is configured to communicate the liquid precursor towards the wick and the second funnel is configured to communicate the liquid precursor from the wick towards the heating chamber.
The aerosol generating unit claimed in claim 3, wherein the aerosol generating unit further comprises a chamber wall at least partially surrounding the heating chamber, wherein the chamber wall comprises a chamber aperture for fluidically connecting the heating chamber to the liquid pathway, wherein the second funnel surrounds the heating chamber and the chamber aperture, and wherein the liquid communication structure further comprises a shelf for receiving the wick, wherein the shelf is provided between the first funnel and the second funnel;

wherein the heating system comprises a heating element and a heating wick at least partially surrounding the heating element, and wherein the chamber wall further comprises a wick aperture adapted to receive a portion of the heating wick such that the portion of the heating wick extends through the chamber wall and out of the heating chamber, and wherein the chamber aperture exposes the heating wick to the liquid pathway.
The aerosol generating unit of any preceding claim, wherein the first height and the second height are substantially equal.
An aerosol generating unit comprising:

a liquid precursor;

a heating system for generating an aerosol from the liquid precursor; and

a liquid communication structure for conveying the liquid precursor to a heating chamber of the heating system, the liquid communication structure comprising:

a liquid inlet for receiving the liquid precursor;

a liquid pathway fluidically connecting the liquid inlet and the heating chamber of the heating system, and

wherein the aerosol generating unit further comprises:

a chamber wall at least partially surrounding the heating chamber, wherein the chamber wall comprises a chamber aperture for fluidically connecting the heating chamber to the liquid pathway; and

a wick provided along the liquid pathway,

wherein the liquid communication structure further comprises a shelf for receiving the wick, wherein the shelf is provided between the fluid inlet and the chamber aperture;

a first liquid flow section fluidically connected to the liquid inlet;

a second liquid flow section surrounding the heating chamber and fluidically connected to the chamber aperture; and

a wicking section provided between the first liquid flow section and the second liquid flow section, wherein the wicking section comprises the shelf for receiving the wick and comprises a straight passage from the shelf towards the liquid inlet;

wherein the straight passage extends around an axis;

wherein the straight passage has a height, as measured along the axis;

wherein the wick has a wick height, as measured along the axis, which is at least 50%of the height of the straight passage.
The aerosol generating unit claimed in claim 6, wherein the wick has a height of at least 1.5 millimetres, optionally at least 2 millimetres.
The aerosol generating unit claimed in claim 6 or 7, wherein the first liquid flow section comprises a first funnel, wherein the liquid pathway narrows from the liquid inlet towards the heating chamber, wherein the first funnel is configured to communicate the liquid precursor towards the wick.
The aerosol generating unit claimed in any of claims 7 to 8, wherein the second liquid flow section comprises a second funnel, wherein the liquid pathway narrows from the first funnel towards the heating chamber, wherein the second funnel is configured to communicate the liquid precursor from the wick towards the heating chamber.
The aerosol generating unit as claimed in claim 9 when dependent on claim 8, wherein the straight passage has a height which is greater than a height of the first funnel and/or which is greater than a height of the second funnel, wherein the heights of the straight passage, the first funnel and the second funnel are measured along the axis;

optionally wherein the height of the straight passage is at least 30%greater than the height of the first funnel and/or the second funnel;

optionally wherein the height of the straight passage is at least 50%greater than the height of the first funnel and/or the second funnel.
The aerosol generating unit as claimed in any of claims 6 to 10, wherein the heating system comprises a heating element and a heating wick at least partially surrounding the heating element, and wherein the chamber wall further comprises a wick aperture adapted to receive a portion of the heating wick such that the portion of the heating wick extends through the chamber wall and out of the heating chamber, and wherein the chamber aperture exposes the heating wick to the liquid pathway.
An aerosol generating system comprising:

the aerosol generating unit as claimed in any of claims 1 to 11; and

a tank shell adapted to receive the aerosol generating unit, the tank shell and the aerosol generating unit at least partially defining a liquid storage portion for storing the liquid precursor.
The aerosol generating system claimed in claim 12, wherein the aerosol generating system is absent of any absorptive material between the tank shell and the liquid inlet of the liquid communication structure.
The aerosol generating system claimed in any of claims 12 to 13, tank shell is formed from a translucent, or a transparent, material such that the liquid precursor is visible through the tank shell.
The aerosol generating system claimed in any of claims 12 to 14, wherein the tank shell comprises an air flow channel connecting the heating system to an air outlet in the tank shell, and wherein the tank shell forms a mouthpiece of the aerosol generating system.