AEROSOL PROVISION DEVICE

TECHNICAL FIELD

The present invention relates to an aerosol provision device comprising a check valve. The present invention also relates to an outer cover for an aerosol provision device comprising a check valve.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating products that release compounds without burning. Examples of such products are heating devices which release compounds by heating, but not burning, the material. The material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine.

SUMMARY

In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a body, a heating assembly defining a heating chamber arranged to receive at least a portion of an article comprising aerosol generating material, an air passage extending between the heating chamber and the air inlet, and a check valve arranged to selectably close the air passage from the air inlet to the heating chamber.

The check valve may be openable in dependence on air flow along the air passage.

The check valve may be puff actuated.

The check valve may be a manual check valve.

The check valve may be a proximal to the air inlet.

The body may comprise an opening and the check valve may be proximal to the opening.

The check valve may be at the opening.

The check valve may be fluid impermeable in a closed condition.

The aerosol provision device may comprise an outer cover. The outer cover may cover the opening.

The check valve may be on the outer cover.

The outer cover may be fluid permeable. The outer cover may comprise at least one vent.

The outer cover may be separable from the body.

The check valve may be arranged to act as a flow restrictor in the air passage in an open condition.

The heating assembly may comprise a heating element arranged to heat the heating chamber.

The body may comprise a tubular member defining at least part of the air passage. The body may comprise a housing.

The heating element may be a primary heating element. The tubular member may be a secondary heating element. The secondary heating element may heat air in the air passage.

The secondary heating element may be arranged to be heated by the primary heating element.

The tubular member may extend between the heating chamber and the opening.

The tubular member may extend to the heating chamber.

The tubular member may extend to the opening.

The valve may be a duckbill valve.

The aerosol provision device may comprise an actuator arranged to actuate the valve.

The aerosol provision device may comprise a puff detector.

The aerosol provision device may comprise a pressure sensor arranged to detect a change in pressure in the air passage.

The valve may comprise a flexible material.

The valve may comprise a silica material.

In accordance with some embodiments described herein, there is provided an aerosol provision system comprising: an aerosol provision device as described in any of the above; and an article comprising aerosol generating material, wherein the article is dimensioned to be at least partially received within the heating chamber.

In accordance with some embodiments described herein, there is provided an outer cover for an aerosol provision device comprising: a check valve arranged to selectably close an air passage from the air inlet to the heating chamber.

In accordance with some embodiments described herein, there is provided an aerosol provision system comprising: an aerosol provision device comprising the outer cover as described above.

The system may comprise an article comprising aerosol generating material, wherein the article is dimensioned to be at least partially received within the aerosol provision device.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which:

FIG. 1 shows a front view of an aerosol provision device;

FIG. 2 shows a perspective side view of the aerosol provision device of FIG. 1;

FIG. 3 shows a schematic side view of an aerosol generator of the aerosol provision device of FIG. 1;

FIG. 4 shows a schematic side view of the distal end of the aerosol provision device of FIG. 1; and

FIG. 5 shows a schematic side view of the distal end of the aerosol provision device of FIG. 1 with the check valve on the outer cover and the outer cover in a disengaged condition.

DETAILED DESCRIPTION

As used herein, the term “aerosol-generating material” is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavorants. Aerosol-generating material may include any plant based material, such as tobacco-containing material and may, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Aerosol-generating material also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. Aerosol-generating material may for example be in the form of a solid, a liquid, a gel, a wax or the like. Aerosol-generating material may for example also be a combination or a blend of materials. Aerosol-generating material may also be known as “smokable material”.

The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise or be an “amorphous solid”. The amorphous solid may be a “monolithic solid”. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may, for example, comprise from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid.

The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially tobacco free.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

An aerosol generating device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilize the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article.

FIG. 1 shows an aerosol provision device 100 for generating aerosol from an aerosol generating material. In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol generating material, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100.

The device 100 comprises a body 102. A housing arrangement 120 surrounds and houses various components of the body 102. An article aperture 104 is formed at one end of the body 102, through which the article 110 may be inserted for heating by an aerosol generator 200 (refer to FIG. 3). In use, the article 110 may be fully or partially inserted into the aerosol generator 200 where it may be heated by one or more components of the aerosol generator 200. The article 110 and the device 100 together form an aerosol provision system 101.

The device 100 may also include a user-operable control element 150, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 150.

The aerosol generator 200 defines a longitudinal axis (A).

FIG. 2 shows a perspective view of the device 100. FIG. 3 shows a schematic view of the device 100. The device 100 comprises a first body assembly 130 and a second body assembly 140. The first body assembly 130 comprises the aerosol generator 200.

The first body assembly 130 comprises a first housing 131. The second body assembly 140 comprises a second housing 141. The first and second body assemblies 130, 140 are fixedly mounted. The first and second body assemblies 130, 140 form the body 102.

The body 102 has end surfaces of the device 100. The end of the device 100 closest to the article aperture 104 may be known as the proximal end (or mouth end) 106 of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the aperture 104, operates the aerosol generator 200 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path towards the proximal end of the device 100.

The other end of the device furthest away from the aperture 104 may be known as the distal end 108 of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the longitudinal axis.

As used herein, one-piece component refers to a component of the device which is not separable into two or more components following assembly of the device. Integrally formed relates to two or more features that are formed into a one piece component during a manufacturing stage of the component.

An air flow passage 180 extends through the body 102 as shown in FIG. 3. The airflow passage is also known as an air passage. The air flow passage 180 extends to an opening 190. The opening 190 acts as an air inlet. An outer cover 300 covers the opening 190. The outer cover 300 in embodiments is vented to allow the flow of air into the air flow passage 180. The outer cover is an end door of the device. The outer cover may be a clean out door to aid with cleaning. The clean out door in embodiments is removable from the device.

FIG. 3 shows a cross-sectional view of the aerosol generator 200. In one example, the aerosol generator 200 comprises an induction-type heating system, including a magnetic field generator 210. The magnetic field generator 210 comprises an inductor coil assembly 211. The aerosol generator 200 comprises a heating element 220. The heating element is also known as a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

The aerosol generator 200 is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article 110 via an inductive heating process. Induction heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction.

The inductor coil assembly 211 includes a first inductor coil 212 and a second inductor coil 213. In embodiments, the number of inductor coils 212, 213 differs. In embodiments, a single inductor coil is used. The inductor coil assembly 211 also comprises a coil support 214. The coil support 214 is tubular. The coil support 214 comprises a guide 215 for the coils 212, 213. The guide 215 comprises a channel on an outer side of the coil support 214.

The heating element 220 is part of a heating assembly 221. The heating element 220 of this example is hollow and therefore defines at least part of a receptacle 222 within which aerosol generating material is received. For example, the article 110 can be inserted into the heating element 220. The heating element 220 is tubular, with a circular cross section. The heating element 220 has a generally constant diameter along its axial length.

The heating element 220 is formed from an electrically conducting material suitable for heating by electromagnetic induction. The susceptor in the present example is formed from a carbon steel. It will be understood that other suitable materials may be used, for example a ferromagnetic material such as iron, nickel or cobalt.

In other embodiments, the feature acting as the heating element 220 may not be limited to being inductively heated. The feature, acting as a heating element, may therefore be heatable by electrical resistance. The aerosol generator 200 may therefore comprise electrical contacts for electrical connection with the apparatus for electrically activating the heating element by passing a flow of electrical energy through the heating element.

The receptacle 222 and article 110 are dimensioned so that the article 110 is received by the heating element 220. This helps ensure that the heating is most efficient. The article 110 of this example comprises aerosol generating material. The aerosol generating material is positioned within the receptacle 222. The article 110 may also comprise other components such as a filter, wrapping materials and/or a cooling structure.

A first end support 230 supports the heating element 220. The first end support 230 supports the heating element 220 at a first, distal, end. A second end support 231 supports the heating element 220. The second end support 231 supports the heating element 220 at a second, proximal, end. The first and second end supports 230, 231 act as receptacle supports.

The air flow passage 180 extends from the heating element 220. The air flow passage 180 is at the first, distal, end. The air flow passage 180 protrudes from the heating element 220. The air flow passage 180 extending from the heating element 220 is defined by a flow path member 182. The heating element 220 and the flow path member 182 forms part of an airflow path arrangement 181.

The flow path member 182 extends between the heating element 220 and the opening 190. The flow path member 182 is tubular. The flow path member 182 defines a bore. The flow path member extends in an axial direction along its length.

The flow path member 182 and the heating element 220 intersect at a juncture 183. The flow path member 182 overlaps the heating element 220. The flow path member 182 comprises a first section 184 having a first diameter and a second section 185 having a second diameter. The diameter of the first section 184 is greater than the diameter of the second section 185. An intermediate section 186 extends between the first and second sections 184, 185. The intermediate section 186 forms a shoulder. The shoulder acts as a stop to limit insertion of the article 110.

The flow path member 182 overlaps the heating element 220 between about 1 mm and about 3 mm. In this particular example, the overlap is 2 mm. In examples, there is no overlap. The juncture 183 assists with forming a thermally conductive path.

The fluid seal at the juncture 183 is formed in embodiments by a mechanical fabricated joint, for example a weld. The fluid seal at the juncture 183 is formed by a laser weld process, however it will be understood that other methods may be used such as brazing and adhering. The flow path member 182 is formed from a thermally conductive material. In embodiments, the flow path member 182 is formed from a carbon steel. The flow path member 182 in embodiments is formed from the same material as the heating element 220. By such processes the heating element 220 and flow path member 182 are fabricated as a one-piece component.

The flow path member 182 comprises a housing 187. In embodiments, the heating element 220 may be a primary heating element. The flow path member 182 member may be a secondary heating element. The secondary heating element may heat air in the air flow passage 180. The flow path member 182 in embodiments is heated by the primary heating element. The abutment of the heating element 220 and the flow path member 182 provides for heat transfer by conduction. As such, it is possible to aid passive heating of the flow path member 182. Such an arrangement may aid reduction in condensate formation. The flow path member 182 may extend between the heating chamber and the opening. The flow path member may extend to the heating chamber. The flow path member may extend to the opening 190. The second end support 231 defines an insertion chamber 234. The insertion chamber 234 is configured to receive the article 110 therethrough.

The heating element 220 extends between the first and second end supports 230, 231. A barrier member 233 extends between the first end support 231 and the second end support 232.

FIG. 4 shows a schematic side view of the distal end 108 of the aerosol provision device 100. The first housing 131 of the first body assembly 130 surrounds the flow path member 182. The flow path member 182 is a tubular member. A distal end member 240 is disposed near the distal end 108 of the flow path member 182. In the shown embodiment, the distal end member 240 is integral with the flow path member 182. The distal end member 240 defines the opening 190 at the distal end 108 of the first body assembly 130. The opening 190 is an inlet of the device 100. The distal end member 240 forms a fluid seal 242 with an inner surface 132 of the first housing 131. The distal end member 240 is disposed a depth D within the first body assembly 130 such as to define a cavity 250 at the distal end 108 of the first body assembly 130. In embodiments, the distal end member 240 is not integral with the flow path member 182. In embodiments, the opening 190 of the distal end member 240 may fluidly communicate the flow path arrangement 181 with the environment external of the first body assembly 130.

A check valve 260 is disposed within the flow path arrangement 181. The check valve 260 acts as a restriction in the air flow passage 180. The check valve 260 is operable by a user drawing on the device 100. When the user draws on the device 100, it may be known as the user taking a puff. When the user takes a puff on the device 100, the pressure in the flow path member 182 drops relative to the air pressure of the environment as a result of air being drawn out of the proximal end 106 of the device 100. The relative pressure change means that the check valve 260 is subject to a force. The check valve 260 moves from a closed condition to an open condition. Air is then able to be drawn into the device 100 from the distal end 108. Once the user finishes drawing on the device 100, the check valve 260 returns to the closed condition. The check valve is openable in dependence on air flow along the air flow passage 180. The check valve 260 operates automatically upon a puff on the device 100 by the user.

The check valve 260 is puff actuated. The check valve 260 opens responsive to a puff on the device 100 by the user. The check valve 260 is also known as a one-way valve. The check valve 260 allows fluid flow when fluid flows in a direction towards the proximal end 106 of the device 100, but restricts fluid flowing in a direction towards the distal end 108 of the device 100. Fluids include gases, such as air, and liquids, such as condensate. The check valve 260 allows fluid to flow into the device 100, but inhibits fluid from exiting the device 100. The check valve 260 allows air to flow into the device 100, but inhibits air and condensate from exiting the device 100. The check valve 260 provides a one-way air inlet.

In the shown embodiment, the check valve is disposed at the distal end of the flow path member. The check valve 260 comprises a base portion 262 and a lip portion 264. The base portion 262 is connected to an inner surface 188 of the flow path member 182. The base portion 262 is rigid. The base portion 262 is annular and extends around the inner surface 188 of the flow path member 182. The base portion 262 is a ring. The lip portion 264 defines a seal 266. The seal 266 is selectively openable. The lip portion 264 is operable between an open condition (not shown) and a closed condition (FIG. 4). The check valve 260 is biased into the closed condition. The lip portion 264 of the check valve flexes in response to the force exerted when the user takes a puff on the device 100. The seal 266 is released when the lip portion 264 is in an open condition and is fluid impermeable when the lip portion 264 is in a closed condition. The lip portion 264 is a flexible portion. The lip portion 264 flexes to transfer between the open and closed condition. The lip portion 264 extends from the base portion 262 in a substantially axial direction at an angle to the axis (A).

The seal 266 is located at the vertex of the conical shape when in the closed configuration. The seal 266 is substantially aligned with the axis (A) when in the closed condition. The check valve 260 is a duckbill valve. The valve comprises a flexible material. The valve comprises a silica material. It can be appreciated that in embodiments any selectively openable valve may be used. Any suitable material for the valve may be used, for example an elastomeric material.

The check valve 260 is configured to move from a closed condition to an open condition. In embodiments the check valve is configured to act as a flow restrictor in an open condition. In this embodiment, the extent to which the flexible portion bends may vary. The volume of air allowed to enter the device may vary. The speed at which the air entering the device is travelling may vary. The extent to which the valve opens may vary with the force exerted by the user when taking a puff on the device. The extent to which the check valve opens may be manually adjustable.

In embodiments, the check valve may be a manual valve. The user may open the valve via a user operable element, such as a button or a switch. In embodiments, the check valve may be an automatically actuated valve. In this embodiment, a sensor assembly may detect the user taking a puff on the device. The sensor assembly may include a puff detector. The sensor assembly may comprise a pressure sensor arranged to detect a change in pressure in the air flow passage 180. The aerosol provision device may comprise an actuator arranged to actuate the valve.

The airflow into the first body assembly may be adjusted by the user. The user could set the restriction of the airflow using the check valve to a preferred amount before drawing on the device. In embodiments, the user is able to adjust the restriction of the airflow dynamically by changing the manner that they draw on the device. The user is able to tailor the experience by adjusting the air mixed with the aerosol generated by the device.

In embodiments, the check valve 260 may be separable from the flow path member 182. The check valve 260 may be removable from the first body assembly 130. The check valve 260 may be a first check valve of a plurality of interchangeable check valves that includes at least the first check valve and a second check valve. The first check valve may be configured to provide a restriction to the airflow into the first body assembly 130. The second check valve may be substantially similar to the first check valve previously described, however the second check valve may be additionally configured to provide a different restriction to the airflow entering the device 100. The second check valve may place a different restriction on the air flow into the first body assembly 130. The user may be able to interchange the plurality of check valves to select the restriction to the airflow entering the device 100. The user could adjust the volume of air flowing through the air flow passage 180. The user would be able to tailor the experience delivered by the device 100 by increasing or decreasing the volume of air mixed with the aerosol generated by the device 100. The different restriction of the first and second check valves may be achieved by any appropriate means. For example, the maximum flex of the lip portion 264 may vary. In another example, the force required to flex the lip portion 264 may vary.

In FIG. 5, a schematic side view of the distal end 108 of the device 100 is shown. The outer cover 300 is shown. The outer cover 300 can be inserted into the cavity 250 at the distal end 108 of the first body assembly 130. The outer cover 300 is separable from the first body assembly 130. The outer cover 300 is fluid permeable. The outer cover 300 has an airflow path 302. The airflow path 302 of the outer cover extends from a first side 304 of the outer cover 300 to a second side (305). A slot 306 in the first side 304 defines an end of the airflow path 302. In the shown embodiment, the outer cover 300 has a second airflow path 307, wherein the airflow path 302 is a first airflow path. The outer cover 300 has a second slot 308 in the first side 304 that defines an end of the second airflow path 307. It can be appreciated that the number of airflow paths through the outer cover 300 may differ in embodiments, for example there may only be one airflow path. In embodiments, the check valve 260 may be disposed on the outer cover 300. The check valve 260 may be separable from the first body assembly 130 with the outer cover 300.

In embodiments, the flow path member 182 is the secondary heating element that heats air in the air flow passage 180. The check valve 260, being located proximal the distal end 108 of the flow path member 182, prevents warm air from exiting the distal end 108 of the air flow passage 180. The check valve 260 retains warm air in the air flow passage 180. This helps minimize the formation of condensation in the air flow passage 180. This improves the performance of the device 100 and the user experience by minimizing the need for cleaning and maintenance of the device. In embodiments, the flow path member 182 may be actively heated. Actively warming the flow path member 182 may aid to further minimize condensation together with the check valve 260.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

AEROSOL PROVISION DEVICE

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