Suction device cartridge comprising core-containing chamber formed from film or sheet material

Abstract

The invention provides an inhalation device cartridge (20) comprising a chamber (28, 30) and a core (26), the chamber (28, 30) being formed from a film or sheet material, where the chamber (28) defines a reservoir for storing a liquid aerosol precursor and the chamber (30) accommodates the core (26).

Description

Technical Field

[0001] The present invention relates to an atomizer cartridge for an inhalation device, preferably for an electronic cigarette and a vaping device, a package for an atomizer cartridge for an inhalation device, an inhalation device, a method for manufacturing an atomizer cartridge for an inhalation device, and a method for manufacturing a package for an atomizer cartridge for an inhalation device. Background Art

[0002] It is known to use replaceable cartridges in electronic cigarettes and vaping devices. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided an atomizer cartridge for an inhalation device, which comprises a chamber and a core. The chamber is formed of a film or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, and the chamber houses the core.

[0004] Forming the chamber of a film or sheet material not only makes the configuration of the atomizer cartridge for an inhalation device (which can be in the form of a bag) compact and lightweight, but also reduces the total number of components compared to conventional atomizer cartridges for inhalation devices, which enables faster and cheaper production, and also reduces costs and waste. In addition, since the core is included, forming the chamber of a film or sheet material produces a ready-to-use atomizer cartridge for an inhalation device. Furthermore, forming the chamber of a film or sheet material gives the atomizer cartridge for an inhalation device structural integrity to withstand changes in temperature and air pressure without the risk of leakage.

[0005] Preferably, the chamber is formed only of a film or sheet material. However, it is conceivable that the chamber may alternatively be formed of a film or sheet material and at least one other material.

[0006] Preferably, except for the core, the entire atomizer cartridge for an inhalation device is formed only of a film or sheet material, but in other embodiments, it may alternatively be formed of a film or sheet material and at least one other material.

[0007] It should be understood that the film or sheet material may include a single sheet of material or multiple sheets of material.

[0008] In an embodiment of the present invention, the atomizer cartridge for an inhalation device may contain a liquid aerosol precursor stored in the reservoir. The liquid aerosol precursor may include but is not limited to: vaping substances (also known as vape juice, e-liquid, and e-cigarette liquid); nicotine, psychoactive substances, non-psychoactive substances, and / or nicotine-free substances and / or their derivatives.

[0009] The properties and configuration of the film or sheet material may vary.

[0010] Preferably, the film or sheet material is impermeable. The film or sheet material may include but is not limited to polymer materials such as thermoplastic materials and / or metal materials such as aluminum.

[0011] In a further embodiment of the present invention, the first and second chambers may be formed of a flexible membrane or sheet material.

[0012] In yet a further embodiment of the present invention, the chamber may be formed of at least two bonded layers of a membrane or sheet material. It should be understood that the at least two bonded layers of the membrane or sheet material forming the chamber may belong to the same sheet of material or different sheets of material. Heat sealing, pressure sealing, ultrasonic welding, high-frequency welding, fusing or adhesion may be used to bond the layers.

[0013] The chamber may be formed as a planar or substantially planar chamber. Forming the chamber in this way not only provides a more compact configuration for the cartridge of the inhalation device, but also makes it easier to form the chamber from a membrane or sheet material.

[0014] The chamber may be shaped and / or sized such that the cartridge of the inhalation device has an asymmetric shape. This makes it easier for the user to insert the asymmetric cartridge of the inhalation device into the inhalation device in the correct position and orientation. In other embodiments, the chamber may be shaped and / or sized such that the cartridge of the inhalation device has a symmetric shape.

[0015] In an embodiment of the present invention, the core may be pre-wetted with a liquid aerosol precursor.

[0016] In other embodiments of the present invention, the chamber may comprise a first sub-chamber and a second sub-chamber, and wherein the cartridge of the inhalation device comprises a seal, the first sub-chamber and the second sub-chamber being separated by a seal that is rupturable to fluidly connect the first sub-chamber and the second sub-chamber, wherein the first sub-chamber defines a reservoir for storing a liquid aerosol precursor, and the second sub-chamber houses the core.

[0017] The purpose of the seal is to prevent the liquid aerosol precursor from accidentally leaking or shifting from the first sub-chamber before the intended point of use, and also to prevent external air, moisture or water from entering the first sub-chamber before the intended point of use. This is particularly beneficial during the manufacture or transportation of the cartridge of the inhalation device (e.g., carried by a person). Thus, the core may remain dry until the seal is ruptured. This not only maintains the freshness of the cartridge of the inhalation device and extends the shelf life of the cartridge of the inhalation device before the intended use, but also permits the use of cheaper or single polymer membranes or sheet materials.

[0018] Furthermore, the unruptured seal may act as a seal of quality or authenticity, for example, to indicate that the liquid aerosol precursor in the first sub-chamber is supplied by the original manufacturer. This addresses the quality and / or safety issues caused by counterfeit cartridges of the inhalation device or genuine cartridges of the inhalation device refilled with liquid aerosol precursors supplied by non-original manufacturers.

[0019] Optionally, the seal may be formed by at least two bonded layers of film or sheet material. It should be understood that the at least two bonded layers of film or sheet material forming the seal may belong to the same sheet of material or different sheets of material. Heat sealing, pressure sealing, ultrasonic welding, high-frequency welding, fusion or adhesion may be used to bond the layers.

[0020] Preferably, the seal is a frangible seal or a single-use seal. That is, after opening, the frangible or single-use seal cannot be resealed. Configuring the seal as a frangible seal or a single-use seal enables the state of the seal to indicate whether the inhaler cartridge has been used, which may be desirable for safety reasons. However, in other embodiments, it is contemplated that the seal may be resealable (e.g., reclosable after opening) to separate the first subchamber and the second subchamber. For example, the seal may be biased (e.g., made of an elastic material) to reclose when not in use with the inhaler.

[0021] The seal may be formed of film or sheet material. Preferably, the seal is formed solely of film or sheet material. However, it is contemplated that the seal may alternatively be formed of film or sheet material and at least one additional material.

[0022] The configuration of the core may vary as long as the core is capable of withdrawing the liquid aerosol precursor from the reservoir and delivering the liquid aerosol precursor to a location for heating and / or evaporation.

[0023] Preferably, the core is configured such that the liquid aerosol precursor is drawn through the core by capillary action.

[0024] The core may be made of fibrous material. The core may be made of porous material. The core may be made of absorbent material. The core may be made of one or more materials such as, but not limited to, cotton, paper, and / or silica.

[0025] In an embodiment of the present invention, the core may be formed as a planar or substantially planar core. Forming the core in this way not only provides a more compact configuration of the inhaler cartridge, but also makes it easier for the core to be accommodated by the chamber.

[0026] In a further embodiment of the present invention, the core may be encapsulated in a removable cap. This protects the core from damage or contamination before use. The removable cap may be formed of film or sheet material. Specifically, the removable cap may initially be integrated with the chamber, but is configured to be detachable (e.g., tearable) from the chamber. Alternatively, the removable cap may be formed of a material different from the film or sheet material, such as another film or sheet material.

[0027] In yet another embodiment of the present invention, one or more support ribs may be formed in the membrane or sheet material. For example, one or more support ribs may be embossed in the membrane or sheet material. Providing one or more support ribs in the membrane or sheet material provides rigidity and / or a gripping surface to the membrane or sheet material, which in turn makes it easier for a user to hold the cartridge of the inhalation device.

[0028] According to a second aspect of the present invention, there is provided a kit for a cartridge of an inhalation device, the kit comprising a chamber and a core, the chamber being formed of a membrane or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, and the chamber and the core are combinable to form a cartridge of an inhalation device according to any one of the first aspect of the present invention and its embodiments.

[0029] The features and advantages of the foregoing aspects and embodiments of the present invention apply, with necessary modifications, to the features and advantages of the second aspect and its embodiments of the present invention.

[0030] According to a third aspect of the present invention, there is provided a package for cartridges of inhalation devices, the package containing a plurality of cartridges of inhalation devices, each cartridge of inhalation device being detachably attached to at least one other cartridge of inhalation device, and each cartridge of inhalation device conforming to any one of the first aspect of the present invention and its embodiments.

[0031] The features and advantages of the foregoing aspects and embodiments of the present invention apply, with necessary modifications, to the features and advantages of the third aspect and its embodiments of the present invention.

[0032] Providing a package of cartridges of inhalation devices detachably attached allows a user to easily store and carry the cartridges of inhalation devices. In addition, constructing the cartridges of inhalation devices from a membrane or sheet material results in a lightweight and compact package that is easy to carry. The detachable attachment between the cartridges of inhalation devices enables a user to easily detach a cartridge of inhalation device from the package without damaging the cartridge of inhalation device or the rest of the package.

[0033] There are different ways to detachably attach cartridges of inhalation devices to each other. For example, each cartridge of inhalation device may be separated from at least one other cartridge of inhalation device by a tear line, a cut line, or a perforation line.

[0034] According to a fourth aspect of the present invention, there is provided an inhalation device for dispensing an inhalable aerosol, the inhalation device comprising a mouthpiece, a housing, and a replaceable cartridge of an inhalation device, the cartridge of the inhalation device conforming to any one of the first aspect of the present invention and its embodiments, the cartridge of the inhalation device being detachably received in the housing, and the inhalation device including a flow path configured to direct the aerosol from the core to the mouthpiece during use.

[0035] The features and advantages of the foregoing aspects and embodiments of the present invention are applicable to the fourth aspect and its embodiments of the present invention with necessary modifications.

[0036] The flow channel may form part of the cartridge or the housing of the inhalation device, or may be separated from the cartridge and the housing of the inhalation device. The mouthpiece may form part of the cartridge or the housing of the inhalation device, or may be separated from the cartridge and the housing of the inhalation device.

[0037] As mentioned above, forming the chamber from a membrane or sheet material results in a compact and lightweight configuration of the inhalation device cartridge, with fewer components compared to conventional inhalation device cartridges. This in turn results in a compact and lightweight inhalation device with reduced cost and waste.

[0038] Furthermore, as mentioned above, forming the chamber from a membrane or sheet material results in a ready-to-use inhalation device cartridge, which allows the user to directly use the inhalation device cartridge with the inhalation device.

[0039] In a preferred embodiment of the present invention, the inhalation device is an electronic cigarette or a vaping device.

[0040] In an embodiment of the present invention, the inhalation device may include a heating element for heating the core. The heating element and the core can be arranged in various ways, including physical contact or spaced apart from each other, as long as the heating element can heat the core. The core and the heating element together act as an atomizer to generate an inhalation aerosol from a liquid aerosol precursor.

[0041] The inhalation device may include a pressure sensor configured to detect the pressure inside the cavity formed by receiving the inhalation device cartridge in the housing. The cavity may be in fluid communication with the flow channel. The pressure sensor may be configured to trigger the activation of the heating element when a pressure change inside the cavity exceeds a predefined threshold. This configuration ensures that the heating element can be activated only when the inhalation device cartridge is received in the housing.

[0042] In an embodiment of the present invention using a seal, the housing may include a seal breaker configured to apply pressure to the inhalation device cartridge during use to break the seal. This provides a reliable method for establishing a fluid connection between the first sub-chamber and the second sub-chamber to allow the liquid aerosol precursor in the first sub-chamber to enter the second sub-chamber and thereby contact (e.g., wet) the core.

[0043] There are different ways to use a seal breaker to break the seal, and non-limiting examples thereof are described below.

[0044] The seal breaker can be pushed to apply pressure to the cartridge of the inhalation device to break the seal. The seal breaker can form part of a door, button, protrusion, or recess formed in or on the housing, or can be coupled to the door, button, protrusion, or recess.

[0045] The seal breaker can be configured to apply pressure to the first sub-chamber during use to break the seal. This causes an increase in the internal pressure inside the second sub-chamber, which then forces the seal to break, and thereby establishes a fluid connection between the first sub-chamber and the second sub-chamber. Additionally or alternatively, the seal breaker can be configured to apply pressure to the seal during use to break the seal.

[0046] The housing can include one or more protrusions arranged to engage with the cartridge of the inhalation device such that when the seal breaker applies pressure to the cartridge of the inhalation device to break the seal, the cartridge of the inhalation device bends between the one or more protrusions and the seal breaker. Preferably, the protrusion or each protrusion and the seal breaker are configured to engage opposite sides of the cartridge of the inhalation device. The protrusion or each protrusion can be arranged to be offset from the seal breaker when the protrusion or each protrusion and the seal breaker engage opposite sides of the cartridge of the inhalation device. This helps to increase the size of the opening formed by the unsealed seal.

[0047] It is contemplated that in other embodiments of the present invention, the seal can be broken by the user directly interacting with the frangible seal (e.g., bending, pressing, or twisting).

[0048] According to a fifth aspect of the present invention, there is provided a method of manufacturing a cartridge of an inhalation device according to any one of the first aspect of the present invention and its embodiments, the method comprising the steps of:

[0049] Using a film or sheet material to form a chamber of the cartridge of the inhalation device;

[0050] Providing a liquid aerosol precursor in the chamber;

[0051] Arranging a core to be received by the chamber.

[0052] The features and advantages of the foregoing aspects and embodiments of the present invention apply, with necessary modifications, to the features and advantages of the fifth aspect and its embodiments of the present invention.

[0053] Forming the chamber from a film or sheet material enables the above manufacturing steps to be performed using a single production line to produce cartridges of inhalation devices.

[0054] According to a sixth aspect of the present invention, there is provided a method of manufacturing a package for a cartridge of an inhalation device according to any one of the second aspect of the present invention and its embodiments, the method comprising the steps of:

[0055] Use a membrane or sheet material to form the chamber of each inhaler cartridge;

[0056] Provide a corresponding liquid aerosol precursor in the chamber of each inhaler cartridge;

[0057] Arrange a corresponding core to be received by the chamber of each inhaler cartridge;

[0058] Configure the membrane or sheet material such that each inhaler cartridge is detachably attached to at least one other inhaler cartridge.

[0059] The features and advantages of the foregoing aspects and embodiments of the present invention are subject to necessary modifications to the features and advantages of the sixth aspect and its embodiments of the present invention.

[0060] Similarly, forming the chamber from a membrane or sheet material enables the above manufacturing steps to be performed using a single production line to produce packages of inhaler cartridges.

[0061] It should be understood that, unless otherwise specified, the terms "first", "second", etc. used in this patent specification are only intended to help distinguish similar features and are not intended to indicate the relative importance of one feature over another.

[0062] Within the scope of the present application, it is expressly desired that the various aspects, embodiments, examples and alternatives set forth in the foregoing paragraphs, as well as the claims and / or the following description and drawings, and in particular their individual features, can be adopted independently or in any combination. That is, all embodiments and all features of any embodiment can be combined in any way and / or combination, unless these features are incompatible. The applicant reserves the right to change any originally proposed claim or to correspondingly propose any new claim, including the right to amend any originally proposed claim to depend on and / or incorporate any feature of any other claim, even though the claims were not originally presented in that manner. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Preferred embodiments of the present invention will now be described by way of non - limiting examples with reference to the accompanying drawings, in which:

[0064] Figure 1 An inhaler cartridge according to an embodiment of the present invention is shown;

[0065] Figure 2 An inhaler cartridge according to an embodiment of the present invention and components of an inhaler are shown;

[0066] Figure 3 An inhaler cartridge according to an embodiment of the present invention inserted into an activated inhaler is shown;

[0067] Figure 4 and 5 show an inhaler cartridge inserted into a closed inhalation device according to an embodiment of the present invention;

[0068] Figure 6 show the rupture of a seal of an inhaler cartridge inserted into a closed inhalation device according to an embodiment of the present invention;

[0069] Figure 7 show a closed inhalation device without an inhaler cartridge; and

[0070] Figure 8 show a method of manufacturing an inhaler cartridge according to an embodiment of the present invention.

[0071] The figures are not necessarily drawn to scale, and for clarity and simplicity, certain features and certain views of the figures may be enlarged in scale or shown in schematic form. Detailed Description

[0072] The following embodiments of the present invention are described with reference to a closed-system electronic cigarette, but it should be understood that the following embodiments of the present invention can be adapted, with necessary modifications, to other types of inhalation devices for dispensing inhalable aerosols.

[0073] An inhaler cartridge according to an embodiment of the present invention is shown in Figure 1 and is generally designated by reference numeral 20. The inhaler cartridge 20 can be used as a disposable consumer product of an inhalation device. In the illustrated embodiment, the inhaler cartridge 20 is used as a replaceable cartridge of an electronic cigarette 22.

[0074] The inhaler cartridge 20 is in the form of a pouch including a chamber, a frangible seal 24, and a core 26.

[0075] The chamber includes a first sub-chamber 28 and a second sub-chamber 30. The first sub-chamber 28 and the second sub-chamber 30 are formed by, for example, bonding two layers of a flexible polypropylene film to produce two discrete sub-chambers 28, 30. Other film or sheet materials can be used instead of the polypropylene film, and non-limiting examples thereof are described throughout the specification. For example, the film or sheet material can be a biaxially oriented polypropylene (BoPP) film or a polyolefin film. The first sub-chamber 28 and the second sub-chamber 30 have different sizes to make the inhaler cartridge 20 have an asymmetric shape. In the illustrated embodiment, the first sub-chamber 28 is larger than the second sub-chamber 30, but in other embodiments, it can be smaller than the second sub-chamber 30. Due to the use of the polypropylene film, the first sub-chamber 28 and the second sub-chamber 30 are formed as planar or substantially planar sub-chambers 28, 30.

[0076] The two layers of the flexible polypropylene film are also joined at the section between the first sub-chamber 28 and the second sub-chamber 30 to form a frangible seal 24 that separates the first sub-chamber 28 and the second sub-chamber 30. Preferably, the bond between the layers of the polypropylene film forming the frangible seal 24 is weaker than the bond between the layers of the polypropylene film forming the first sub-chamber 28 and the second sub-chamber 30, such that the frangible seal 24 can rupture while the first sub-chamber 28 and the second sub-chamber 30 remain intact.

[0077] In this embodiment, heat sealing is used to effect the joining, but the joining can be achieved by other joining means such as pressure sealing, ultrasonic welding, high-frequency welding, fusing, or adhesion. In other embodiments of the present invention, the first sub-chamber 28 and the second sub-chamber 30, as well as the frangible seal 24, can be formed of other film or sheet materials, and non-limiting examples of other film or sheet materials are described throughout the specification.

[0078] Support ribs 32 can be embossed in the polypropylene film to provide a rigid or grippable surface for easier gripping of the aerosol inhalation device cartridge 20.

[0079] The first sub-chamber 28 is configured as a reservoir for storing a liquid aerosol precursor, the liquid aerosol precursor being optionally selected from the group consisting of:

[0080] ● Vaping substances;

[0081] ● Nicotine psychoactive substances, non-psychoactive substances, nicotine-free substances, and / or their derivatives.

[0082] The second sub-chamber 30 is configured to receive the core 26 such that one end of the core 26 extends into the second sub-chamber 30 and the other opposite end of the core 26 extends outside the second sub-chamber. The core 26 is made of a fibrous material such as cotton. The core 26 is formed as a planar or substantially planar core 26. The end of the core 26 outside the second sub-chamber 30 is preferably encapsulated in a removable film to prevent damage or contamination prior to use.

[0083] The purpose of the frangible seal 24 is to prevent the accidental leakage or displacement of the liquid aerosol precursor from the first sub-chamber 28 prior to the intended point of use, and also to prevent external air, moisture, or water from entering the first sub-chamber 28 prior to the intended point of use. The latter is particularly important when the liquid aerosol precursor is hygroscopic. The frangible seal 24 is designed to be rupturable such that a fluid connection is established between the first sub-chamber and the second sub-chamber, which allows for the exchange of fluid between the first sub-chamber 28 and the second sub-chamber 30 via the fluid path provided by the ruptured frangible seal 24. Exemplary ways of rupturing the frangible seal 24 are described throughout the specification. The frangible seal 24 is formed as a single-use seal that cannot be resealed after rupture.

[0084] Separating the liquid aerosol precursor and the core body 26 in the first sub-chamber 28 and the second sub-chamber 30 respectively allows the core body 26 to remain dry before the frangible seal 24 breaks. This not only helps to provide control over the outflow of the inhaled aerosol from the cartridge 20 of the inhalation device, but also allows the dry core body 26 to absorb any liquid aerosol precursor that accidentally leaks from the first sub-chamber 28 in the event that the frangible seal 24 is damaged or ruptures prematurely.

[0085] The cartridge 20 of the inhalation device can form part of the packaging of the cartridge 20 of the inhalation device, wherein each cartridge 20 of the inhalation device is separated from at least one other cartridge 20 of the inhalation device by a tear line, a cut line or a perforation line. This allows for the manufacture, transportation, storage or sale of multiple cartridges 20 of the inhalation device in a packaged form, wherein an individual cartridge 20 of the inhalation device can be detached from the packaging without damaging the individual cartridge 20 of the inhalation device or the remainder of the packaging.

[0086] The cartridge 20 of the inhalation device or the packaging of the cartridge 20 of the inhalation device can be stored inside a package (such as a box or a cardboard container) in order to protect the cartridge 20 of the inhalation device or the packaging of the cartridge 20 of the inhalation device during transportation or storage.

[0087] In Figures 2 to 6 an electronic cigarette 22 according to an embodiment of the present invention is shown.

[0088] The electronic cigarette 22 includes a mouthpiece 34, a housing 36, a battery 37 and a replaceable cartridge 20 of the inhalation device. The cartridge 20 of the inhalation device is as described above especially with respect to Figure 1 that.

[0089] The housing 36 includes a receptacle 38, a door 40, a heating element 42 and a flow channel 44. The receptacle 38 is used to removably receive the cartridge 20 of the inhalation device and is formed in the body of the housing 36. The door 40 is hingeably attached to the body such that it can be opened and closed to selectively permit and prevent access to the receptacle 38. The flow channel 44 is provided in the body of the housing 36. The mouthpiece 34 is positioned at the end of the flow channel 44 and can be integral with or attached to the body of the housing 36. In an alternative embodiment, the flow channel 44 can form part of the cartridge 20 of the inhalation device (rather than the housing 36), or can be separated from both the cartridge 20 of the inhalation device and the housing 36.

[0090] When the cartridge 20 of the inhalation device is removably received in the housing 36, as Figure 2 and 3As shown, the end of the cartridge 26 outside the second sub-chamber 30 is positioned beside the heating element 42 and aligned with the flow channel 44. The housing 36 may include one or more location features, such as rods, walls, or clips, for positioning the inhalation device cartridge 20 in the correct position and orientation within the receptacle 38. Additionally, the asymmetrical shape of the inhalation device cartridge 20 helps to ensure its correct positioning and orientation within the receptacle 38. The inhalation device cartridge 20 and the receptacle may be correspondingly shaped to provide a mating fit (e.g., a push fit) between the inhalation device cartridge 20 and the receptacle, such that the inhalation device cartridge 20 is correctly positioned within the receptacle 38.

[0091] When the door 40 is closed ( Figure 4 ), the exposed end of the cartridge 26, the outer component 46 of the second sub-chamber 30, and the heating element 42 are sandwiched between the first containment component 48 and the second containment component 50 to form a cavity 52 between the first containment component 48 and the second containment component 50. The cavity 52 is in fluid communication with the flow channel 44, such that fluid can flow from the cavity 52 to the flow channel 44. The outer component 46 of the second sub-chamber 30 sandwiched between the first containment component 48 and the second containment component 50 helps to seal the cavity 52 relative to the remainder of the receptacle 38.

[0092] The first containment component 48 is attached to the body of the housing 36, while the second containment component 50 is attached to the door 40 of the housing 36. In alternative embodiments, the first containment component 48 may be integral with the body of the housing 36, and / or the second containment component 50 may be integral with the door 40 of the housing 36. The containment components 48, 50 are preferably made of silicone or another elastic material, which provides excellent sealing properties due to its ability to absorb tolerances or manufacturing variations.

[0093] In the illustrated embodiment, the heating element 42 is disposed in the first containment component 48, but in other embodiments, it may be disposed in the second containment component 50.

[0094] In other embodiments, the entire receptacle 38 may be sealed relative to the exterior of the housing 36.

[0095] The door 40 acts as a seal breaker for rupturing the frangible seal 24. Specifically, the door 40 and the receptacle 38 can be shaped and sized such that the door 40 itself, when closed, is capable of squeezing the first sub-chamber 28 to apply pressure to the first sub-chamber 28, thereby accumulating an internal pressure inside the first sub-chamber 28. Once sufficient internal pressure has accumulated inside the first sub-chamber 28, the internal pressure will push outwards on the layers of the polypropylene film until the bond at the frangible seal 24 begins to weaken. This ultimately results in the separation of the layers of the polypropylene film at the frangible seal 24 and, thereby, the rupture of the frangible seal 24. In this way, the seal breaker provides a controlled way to rupture the frangible seal 24.

[0096] Alternative designs of the seal breaker are envisioned, and non-limiting examples thereof are described throughout the specification.

[0097] In one embodiment, the door 40 can be deformable such that the door 40, when closed, can be pushed to apply pressure to the first sub-chamber 28 in order to rupture the frangible seal 24.

[0098] In another embodiment, the seal breaker can be in the form of a protrusion 54 formed on the inner surface of the door 40, as Figure 3 shown. When a thrust is applied to the closed door 40 and thus to the protrusion 54, the protrusion 54 in turn applies pressure to the first sub-chamber 28 in order to rupture the frangible seal 24. Optionally, the protrusion 54 can be sized such that closing the door 40 is sufficient to apply pressure to the first sub-chamber 28 in order to rupture the frangible seal, without the need for an additional thrust.

[0099] As Figure 6 (a) shows, a protrusion 56 in the form of a bump or rib can be formed in the receptacle 38. The bump or rib 56 is positioned in the receptacle 38 such that when the protrusion on the door 40 is pushed relative to the first sub-chamber 28, the outer rim 58 of the inhalation device cartridge 20 rests on the bump or rib 56, as Figure 6 (b) shows. Thus, the inhalation device cartridge 20 is bent between the bump or rib 56 and the protrusion 54 on the door 40, which helps to separate the layers of the polypropylene film at the frangible seal 24 in order to increase the size of the opening formed by the unsealed frangible seal 24.

[0100] The battery 37 is stored in a compartment inside the housing 36 and is used to power the heating element 42 and the pressure sensor 60 disposed in the first containment member 48. Optionally, the battery 37 can be used to power a controller (such as a microcontroller) for controlling the heating element 42.

[0101] Non-limiting examples of methods of using the inhalation device cartridge 20 are described below.

[0102] Initially, a membrane is removed from an end of the cartridge 26 that is external to the second sub-chamber 30 to create an exposed cartridge end. Next, before closing the door 40, the inhalation device cartridge 20 is placed in the receptacle 38 in its intended position and orientation. It may be necessary to remove a used inhalation device cartridge 20 from the receptacle 38 before inserting the inhalation device cartridge 20 into the receptacle 38.

[0103] Next, the door 40 is closed, which causes an internal pressure build-up in the first sub-chamber 28 and thereby causes the frangible seal 24 to rupture. This establishes a fluid connection between the first sub-chamber 28 and the second sub-chamber 30 to allow the liquid aerosol precursor in the first sub-chamber 28 to enter the second chamber and thereby wet the cartridge 26. Thereafter, the liquid aerosol precursor diffuses throughout the cartridge 26 by capillary action.

[0104] The heating element 42 is controlled to heat the liquid aerosol precursor in the cartridge 26 to produce an inhaled aerosol that diverges from the cartridge 26. In this way, the cartridge 26 and the heating element 42 together act as an atomizer for producing an inhaled aerosol from the liquid aerosol precursor.

[0105] The flow channel 44 then directs the inhaled aerosol from the cartridge 26 to the mouthpiece 34 such that a user can inhale the inhaled aerosol through the mouthpiece 34. Specifically, the housing 36 includes an air duct 62 that is configured to connect the exterior of the housing 36 to the cavity 52 between the first containment member 48 and the second containment member 50. This forms an air path 64 that includes the air duct 62, the cavity 52, the flow channel 44, and the mouthpiece 34 through which air can flow from the exterior of the housing 36 into the air duct 62, through the cavity, through the flow channel 44, and through the mouthpiece 34 in that order when the user sucks on the mouthpiece 34. This facilitates the flow of the inhaled aerosol from the cartridge 26 to the mouthpiece 34.

[0106] When the inhalation device cartridge 20 is located in the electronic cigarette 22 ( Figure 5 ), a pressure change occurs inside the sealed cavity 52 between the first containment member 48 and the second containment member 50 when the user sucks on the mouthpiece 34. The pressure sensor 60 is configured to detect the pressure change inside the cavity 52 and thereby trigger the activation of the heating element 42 upon detection of the pressure change. In this way, the heating element 42 is controlled to heat the liquid aerosol precursor in the cartridge 26 to produce an inhaled aerosol.

[0107] When the inhalation device cartridge 20 is not located in the electronic cigarette 22 ( Figure 7)When it is in this state, the cavity 52 is not sealed relative to the receptacle 38, which means that air can flow freely between the cavity 52 and the rest of the receptacle 38. Therefore, due to the insufficient pressure change inside the cavity 52 between the first containment member 48 and the second containment member 50 when the user sucks on the mouthpiece 34, the activation of the heating element 42 is not triggered by the pressure sensor. This ensures that the heating element 42 cannot be activated when the inhalation device cartridge 20 is not located in the electronic cigarette 22.

[0108] Once the liquid aerosol precursor is used up, the inhalation device cartridge 20 can be removed from the receptacle 38 and replaced with a new inhalation device cartridge 20.

[0109] The configuration of the present invention, in particular the formation of the first sub-chamber 28 and the second sub-chamber 30 and the frangible seal 24 in the membrane material, makes the closed-system electronic cigarette 22 more compact and lighter in weight compared to conventional electronic cigarettes, with fewer components, and is cheaper and less wasteful. Additionally, since it includes the core 26 and is capable of forming a fluid connection between the first sub-chamber 28 and the second sub-chamber 30 when the frangible seal 24 is ruptured, the inhalation device cartridge 20 is in a ready-to-use state. Furthermore, the configuration of the first sub-chamber 28, the second sub-chamber 30, and the frangible seal 24 of the present invention allows for the design control of the inhalation device cartridge 20 to manage the use of the stored liquid aerosol precursor and thus reduce waste.

[0110] Conversely, conventional cartridges for closed-system electronic cigarettes contain multiple components, including a heating element, a metal connector, a core, and nicotine liquid, which are contained in a rigid plastic assembly with a shell. Due to the number of components involved and the types of materials used, this method is costly and generates a large amount of landfill waste.

[0111] Reference is made below to Figure 8 a non-limiting example of a method for manufacturing the inhalation device cartridge 20.

[0112] In step 100, a plurality of cavities are formed in the first layer of the polypropylene film, where each pair of cavities corresponds to the first sub-chamber 28 and the second sub-chamber 30 of an individual inhalation device cartridge 20. The cavities can be formed using thermoforming (such as vacuum forming or pressure forming).

[0113] In step 102, the liquid aerosol precursor is dispensed into each cavity corresponding to the first sub-chamber 28 of an individual inhalation device cartridge 20. The corresponding core 26 is placed in each cavity corresponding to the second sub-chamber 30 of an individual inhalation device cartridge 20.

[0114] In step 104, the second layer of the polypropylene film is then placed over the first layer of the polypropylene film. The two layers of the polypropylene film are then joined together by heat sealing, thereby forming a first sub-chamber 28 and a second sub-chamber 30 and a frangible seal 24 in the process.

[0115] Next, in step 106, a die is then used to create perforation lines in the joined layers of the polypropylene film to produce the packaging for the inhalation device cartridge 20, wherein the inhalation device cartridges 20 are detachably attached to each other by the perforation lines. Alternatively, a die can be used to cut through the joined layers of the polypropylene film to produce individual inhalation device cartridges 20 that are detached from each other. Alternatively, a laser can be used instead of a die. The laser can be used to scribe the surface to create tear lines instead of penetrating the surface to create perforation lines. Other means of creating tear lines, cut lines or perforation lines in the joined layers of the polypropylene film can be used.

[0116] Die cutting, laser cutting or other cutting or marking techniques can be used to add perforations, notches, cuts or markings to provide information about the inhalation device cartridge 20. The information may be for the consumer or the manufacturer and can indicate the type, flavor and / or strength of the liquid aerosol precursor used.

[0117] Particularly due to the formation of the first sub-chamber 28 and the second sub-chamber 30 and the frangible seal 24 in the film or sheet material, and due to the reduction in the number of components of the inhalation device cartridge 20, the foregoing manufacturing steps permit the end-to-end manufacture of the inhalation device cartridge 20 using a single production line. The single production line includes a thermoforming machine, a liquid aerosol precursor dispensing station, a core placement machine, a heat sealing device and a die cutting machine. Thus, high-speed and cost-effective production can be achieved in a single location.

[0118] Conversely, conventional inhalation device cartridges require multiple manufacturing lines that include metal die casting, lathes, plastic injection molding, etc. These require large and specialized manufacturing facilities that are typically distributed around the world, thus requiring expensive and time-consuming transportation of components between manufacturing locations.

[0119] The listing or discussion of an apparently previously published document or apparently previously published information in this specification should not necessarily be taken as an admission that the document or information is part of the prior art or is common general knowledge.

[0120] Unless the context otherwise indicates, preferences and choices for a given aspect, feature or parameter of the present invention should be considered to be disclosed in combination with any and all preferences and choices for all other aspects, features and parameters of the present invention.

Claims

1. An inhaler cartridge, comprising a chamber and a core, the chamber being formed of a membrane or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, and the chamber houses the core.

2. The inhaler cartridge according to claim 1, wherein the inhaler cartridge contains a liquid aerosol precursor stored in the reservoir.

3. The inhaler cartridge according to claim 2, wherein the liquid aerosol precursor comprises an e-cigarette substance.

4. The inhaler cartridge according to claim 2 or claim 3, wherein the liquid aerosol precursor comprises nicotine, a psychoactive substance, a non-psychoactive substance, a nicotine-free substance, and / or a derivative thereof.

5. The inhaler cartridge according to any one of the preceding claims, wherein the chamber is formed of at least two bonded layers of the membrane or sheet material.

6. The inhaler cartridge according to any one of the preceding claims, wherein the chamber is formed as a planar or substantially planar chamber.

7. The inhaler cartridge according to any one of the preceding claims, wherein the chamber is shaped and / or sized such that the inhaler cartridge has an asymmetrical shape.

8. The inhaler cartridge according to any one of the preceding claims, wherein the chamber comprises a first sub-chamber and a second sub-chamber, and wherein the inhaler cartridge comprises a seal, the first sub-chamber and the second sub-chamber being separated by the seal that can be ruptured to fluidly connect the first sub-chamber and the second sub-chamber, wherein the first sub-chamber defines the reservoir for storing the liquid aerosol precursor, and the second sub-chamber houses the core.

9. The inhaler cartridge according to claim 8, wherein the seal is formed of the membrane or sheet material.

10. The inhaler cartridge according to claim 9, wherein the seal is formed of at least two bonded layers of the membrane or sheet material.

11. The inhaler cartridge according to any one of claims 8 to 10, wherein the seal is a frangible seal or a single-use seal.

12. The inhaler cartridge according to any one of claims 8 to 10, wherein the seal can be resealed to separate the first sub-chamber and the second sub-chamber.

13. The inhaler cartridge according to any one of the preceding claims, wherein the core is encapsulated in a removable cap.

14. The inhaler cartridge according to any one of the preceding claims, wherein one or more support ribs are formed in the membrane or sheet material.

15. A kit for an inhaler cartridge, the kit comprising a chamber and a core, the chamber being formed of a membrane or sheet material, wherein the chamber defines a reservoir for storing a liquid aerosol precursor, the chamber and the core being combinable to form an inhaler cartridge according to any one of the preceding claims.

16. A package for an inhaler cartridge, which comprises a plurality of inhaler cartridges, each inhaler cartridge being detachably attached to at least one other inhaler cartridge, and each inhaler cartridge conforming to any one of claims 1 to 14.

17. The package for an inhaler cartridge according to claim 16, wherein each inhaler cartridge is separated from the at least one other inhaler cartridge by a tear line, a cut line or a perforation line.

18. An inhaler for dispensing an inhalable aerosol, the inhaler comprising a mouthpiece, a housing and a replaceable inhaler cartridge, the inhaler cartridge conforming to any one of claims 1 to 14, the inhaler cartridge being detachably received in the housing, and the inhaler comprising a flow channel configured to direct the aerosol from the core to the mouthpiece during use.

19. The inhaler according to claim 18, wherein the inhaler is an electronic cigarette or a vaping device.

20. The inhaler according to claim 18 or claim 19, which comprises a heating element for heating the core.

21. The inhaler according to claim 20, which comprises a pressure sensor configured to detect the pressure inside a cavity formed by receiving the inhaler cartridge in the housing, the cavity being in fluid communication with the flow channel, wherein the pressure sensor is configured to trigger the activation of the heating element when it detects a pressure change inside the cavity exceeding a predefined threshold.

22. The inhaler according to any one of claims 18 to 21, when appended to any one of claims 8 to 12, wherein the housing comprises a seal breaker configured to apply pressure to the inhaler cartridge during use to break the seal.

23. The inhaler according to claim 22, wherein the seal breaker is pushable to apply pressure to the inhaler cartridge to break the seal.

24. The inhaler according to claim 22 or claim 23, wherein the seal breaker is configured to apply pressure to the first sub-chamber and / or the seal during use to break the seal.

25. The inhaler according to any one of claims 22 to 24, wherein the housing comprises one or more protrusions arranged to engage with the inhaler cartridge such that when the seal breaker applies pressure to the inhaler cartridge to break the seal, the inhaler cartridge bends between the one or more protrusions and the seal breaker.

26. A method of manufacturing an inhaler cartridge according to any one of claims 1 to 14, the method comprising the steps of: using a film or sheet material to form the chamber of the inhaler cartridge; providing a liquid aerosol precursor in the chamber; [[ID= 27. A method of manufacturing a package for an inhaler cartridge according to claim 16 or claim 17, the method comprising the steps of: using a film or sheet material to form a chamber for each inhaler cartridge; providing a corresponding liquid aerosol precursor in the chamber of each inhaler cartridge; arranging a corresponding core to be received by the chamber of each inhaler cartridge; configuring the film or sheet material such that each inhaler cartridge is detachably attached to at least one other inhaler cartridge.

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