A cartridge and a cartomizer for a vapor inhalation device and method for producing the same

Abstract

The present disclosure provides a cartridge (10) for a vapor inhalation device. The cartridge (10) comprises: a reservoir body (12); an insert (16) abutting the reservoir body (12), such that a reservoir is defined by the reservoir body (12) and the insert (16); the insert (16) having at least one outlet channel (16a, 16b) for allowing liquid to flow out of the reservoir. A portion of the insert (16) between the outlet channel (16a, 16b) and the reservoir body (12) defines a rim (R') of the at least one outlet channel (16a, 16b). The rim (R') is configured to promote flow of liquid from the reservoir into the at least one outlet channel (16a, 16b). A method of manufacturing a cartridge is also disclosed.

Description

[Technical Field]

[0001] The present invention relates generally to a cartridge for a vapor inhalation device. A method of manufacturing a cartridge is also provided.[Background]

[0002] Vapor inhalation devices, also referred to as aerosol generation devices or aerosol inhalation devices, such as vaping devices and aerosol inhalers, are known. Such vapor inhalation devices are hand-held devices and conventionally include a power supply, and liquid-filled cartridge and an atomizer / heater intended to generate the aerosol. The liquid is heated by the atomizer / heater in order to generate an aerosol (that is, a vapour) that may be inhaled by the user. Suitable liquids for vapor inhalation devices are commonly called "eliquids". There are many different eliquids that are commercially available. A typical e-liquid may be composed of propylene glycol and glycerin. optionally also including one or more of flavorings, nicotine. However, many other formulations are possible. Eliquids are designed so as to form a vapor after contacting an atomizer / heater, where the vapor has desired properties such as a particular flavor and mouth-feel when inhaled by a user.

[0003] Vapor inhalation devices are generally designed to be reusable. By way of example, a reusable vapor inhalation device may include features such as a rechargeable power source. The cartridge is then generally designed as a consumable product that is detachable or removable from the vapor inhalation device and replaceable.

[0004] The atomizer / heater can be provided in the cartridge containing the liquid, the cartridge is connectable to the vapor inhalation device that contains the power supply, such that these together provide a functional vapor inhalation device.[Summary of the Invention] [Technical Problem]

[0005] A cartridge for a vapor inhalation device contains a liquid in a reservoir. At least one outlet channel is provided for allowing flow of the liquid to flow out from the reservoir, e.g. to an atomizer / heater. Due to surface tension of the liquid, it has been found that, when a cartridge is nearly empty, liquid will gather around the rim of the outlet channel(s) and will not flow into the outlet channel(s). That is, surface tension may cause the liquid to pool around the outlet, particularly in narrow corners of the reservoir, and not flow through the outlet channel(s). This can result in wasted liquid product.

[0006] Some cartridges have a translucent or transparent window therein or the body of the cartridge can be made at least in part of a translucent or transparent material, for example, so that a user can visually identify how much liquid is left in the reservoir. The window will typically allow viewing down to an end of the reservoir that contains the outlet channel(s) so that are user can see when the liquid level is low. Surface tension of the liquid can cause the liquid to gather around the rim of the outlet channel(s) and may also creep up the walls of the reservoir body. The user may receive a false impression of how much liquid remains in the cartridge and in any case the user may see liquid remaining inside the cartridge even if the aerosol generating device already detected that the cartridge is empty.[Summary of the Solution]

[0007] The present invention is intended to address one or more of the above technical problems.

[0008] In particular, in view of the limitations discussed above, the present inventors have devised, a cartridge for a vapor inhalation device, the cartridge comprising: a reservoir body; an insert abutting the reservoir body, such that a reservoir is defined by the reservoir body and the insert; the insert having at least one outlet channel for allowing liquid to flow out of the reservoir, wherein a portion of the insert between the outlet channel and the reservoir body defines a rim of the at least one outlet channel, wherein the rim is configured to promote flow of liquid from the reservoir into the at least one outlet channel.

[0009] That is, the rim is the portion of the insert that both a) faces toward the reservoir and b) extends from the outer edge of each outlet channel to the reservoir body (i.e., to where the insert meets contacts the reservoir body). Having the rim configured to promote flow of liquid from the reservoir into the at least one outlet channel helps to avoid wasted liquid product.

[0010] The rim may be provided with a constructional configuration that facilitates flow of liquid into the outlet channel. In other words, the rim can be configured to inhibit the adhesion of liquid to the rim. That is, it is the trapping of liquid on the rim, particularly in narrow corners where the rim meets the reservoir body, that prevents the free flow of liquid into the outlet channel.

[0011] Advantageously, in the cartridge according to the invention, the rim is configured to promote flow of liquid form the reservoir to the at least one outlet channel, thus avoiding that the liquid is trapped on the rim, particularly in narrow corners where the rim meets the reservoir body.

[0012] This will also reduce / avoid the generation of dry puff, i.e. when the user starts a puffing action even if there is no liquid in the reservoir and in particular in the wick and / or heater. In particular, in known cartridges, the liquid trapped on the rim could convey to the user a false impression of how much liquid remains in the cartridge, but there is not enough / no liquid in the wick and / or heater to generate a complete puff. In the flow of the liquid towards the outlet channel is promoted, thus reducing the risk of generating a dry puff that is an unpleasant experience for the user.

[0013] According to an aspect, the insert may have multiple outlet channels. For example, the insert may have two outlet channels. Where there are multiple outlet channels, the rim may still be defined as the portion of the insert that is between at least one outlet channel and the reservoir body.

[0014] The rim may comprise one or more channelling features configured to promote flow of fluid into the at least one outlet channel.

[0015] This may provide one configuration by which flow from the reservoir into the outlet channel(s) may be promoted.

[0016] The channelling features may comprise one or more slots. The undesirable gathering of liquid can preferentially occur on smooth surfaces. By disrupting the otherwise-smooth surface of the rim between the outlet channel(s) and the reservoir body by providing slots, flow of liquid into the outlet channel(s) can be promoted. Without being bound by any particular theory, the slots may, for example, provide a flowpath along which liquid will wick towards the outlet channel.

[0017] One or more slots (for example, two or more slots) may be formed in the rim, each slot opening out into one of the at least one outlet channel. Having a plurality of slots may further reduce the presence of otherwise smooth surfaces of the rim that could provide gathering-places for liquid. Each slot may be formed at a location where liquid would otherwise preferentially gather when the reservoir is nearly empty.

[0018] The rim may comprise a sloped surface, sloping towards the at least one outlet channel. The slope may promote liquid flow into the outlet channel(s) by simple action of gravity (when the cartridge is held in an appropriate orientation). The slope may also reduce the angle between the rim surface and the outlet channel which may promote flow into the outlet channel. The slope may also increase the angle between the rim surface and the reservoir body, thereby reducing the formation of narrow corners where liquid may otherwise preferentially gather.

[0019] The cartridge may comprise a transparent or translucent window for allowing visual inspection of a liquid level in the reservoir in a region encompassing a portion of the reservoir adjacent the rim. The window may be formed by forming a portion of, or the entire, reservoir body out of a translucent or transparent material. The window may allow the user to see how much liquid remains in the reservoir. In conjunction with the aforementioned feature of the rim being configured to promote flow of liquid from the reservoir into the outlet channel, this may help avoid giving the user a false impression of how much liquid remains in the cartridge when it is nearly empty.

[0020] The rim / slope may be coated with a coating that is hydrophobic and / or oleophobic. This coating may be provided instead of, or in addition to, the slots. The coating provides another way by which flow of liquid into the outlet channel may be promoted, by reducing the tendency of the last drops of liquid in a nearly-empty reservoir to stick to the rim / slope. Again, this helps preventing wasted product. Alternatively or additionally, the insert may be formed of a material that is hydrophobic and / or oleophobic.

[0021] The insert may be made of silicone or may comprise a silicone outer layer that forms at least the rim. Silicone may provide a good liquid-tight seal between the insert and reservoir body and thus prevent undesirable leakage of liquid.

[0022] According to an aspect, the cartridge comprises a heater and the outlet channel allows fluid to flow from the reservoir to the heater.

[0023] According to an aspect, the cartridge comprises a heater holder. The heater holder may be formed integrally with the insert (e.g. may be formed of the same material) or may be formed as a separate element, preferably of a separate material, and connected to the insert. For example, a cover (e.g. of silicone) may be moulded around the heater holder to produce the insert.

[0024] The insert may be formed on the heater holder as a silicone outer layer, wherein the silicone outer layer forms the rim.

[0025] According to an aspect, there is provided a method of manufacturing a cartridge, the method comprising: forming an insert having an outlet channel, inserting the insert into an end of a reservoir body; wherein a portion of the insert between the outlet channel and the reservoir body defines a rim of the outlet channel, wherein forming the insert includes configuring the rim to promote flow of liquid into the outlet channel.

[0026] Forming the insert may comprise forming one or more channelling features on the rim, the one or more channelling features configured to promote flow of fluid into the outlet channel. The channelling features may provide one way of promoting flow into the outlet channel, particularly for promoting flow of the last amounts of liquid in a nearly-empty reservoir.

[0027] The channelling features may comprise one or more slots. Without being bound by any particular theory, the slots may, for example, provide a flow path along which liquid will wick towards the outlet channel.

[0028] One or more slots (for example, two or more slots) may be formed in the rim, each slot opening out into one of the at least one outlet channel. Each slot may be formed at a location where liquid would otherwise preferentially gather when the reservoir is nearly empty.

[0029] The method may include forming the rim as having a sloped surface, sloping towards the outlet channel. The slope may promote liquid flow into the outlet channel by simple action of gravity (when the cartridge is held in an appropriate orientation). The slope may also reduce the angle between the rim surface and the outlet channel which may promote flow into the outlet channel.

[0030] The step of forming the insert may include applying a coating that is hydrophobic and / or oleophobic to portions of the insert that form the rim when the insert is inserted into the end of the reservoir body. The coating provides another way by which flow of liquid into the outlet channel may be promoted, by reducing the tendency of the last drops of liquid in a nearly-empty reservoir to stick to the rim. Again, this helps prevent wasted product. Alternatively or additionally, the insert may be formed of a material that is hydrophobic and / or oleophobic.[Brief Description of the Drawings]

[0031] Figure 1 shows a perspective view of a known design of cartridge; Figure 2 shows a cross-sectional view of a new design of cartridge; Figure 3 shows a perspective view of an insert for a cartridge; and Figure 4 shows a cutaway perspective view of the insert of Figure 3; Figures 5A and B show views of another insert for a cartridge; and Figure 6 shows a flow-chart for a method of making a cartridge. [Detailed Description]

[0032] In the field of vapor inhalation devices, a cartridge has a reservoir is intended to store the liquid for the aerosol generation. According to different possible embodiments, an atomizer (or heater) can be directly provided in the cartridge, or alternatively in the device. The following discussion is given in view of a cartridge including an atomizer / heater, but the skilled reader will understand that this discussion applies equally to a cartridge not provided with an internal atomizer / heater, except for parts of discussion relating to the heater / atomizer.

[0033] Figure 1 is a schematic view of a cartridge 50 known in the art. The cartridge 50 comprises a reservoir body 12 that , in use, connects to an end of a vapor inhalation device 14. An insert 15 in inserted into the reservoir body 12. The reservoir body 12 substantially defines a reservoir for storing liquid, such as eliquid, and the insert 15 forms one end of the reservoir. The insert 15 has two outlet channels 15a,b that are provided to allow fluid to flow out of the reservoir and towards a heater 20. The heater 20 can be mounted in a heater holder 18. The insert 15 sits atop the heater holder 18 and thus sits between the reservoir and the heater holder 18. The heater 20 may be arranged such that, when the cartridge 50 is connected to a vapor inhalation device, the heater 20 can receive electrical power from a battery of the vapor inhalation device, for heating the heater 20.

[0034] The insert 15 has an outer surface 15c that abuts against the reservoir body 12 to provide a fluid-tight seal that prevents liquid in the reservoir from leaking out between the reservoir body 12 and the insert 15.

[0035] The outlet channels 15a,b of the insert 15 are at least partially aligned with corresponding flow channels formed in the heater holder 18, such that liquid that passes through the outlet channels 15a,b flows into the flow channels and thus arrive at the heater 20.

[0036] A central tube 24 is formed through the body of the reservoir for providing a fluid flow path from the heater 20 to a device outlet 24a of the cartridge 50. In use, a user sucks upon the device outlet 24a.

[0037] Liquid flows out of the reservoir via the two outlet channels 15a,b and through the heater holder 18, whereupon the liquid comes into contact with the heater 20. Usually a wick is arranged to convey the liquid to the heater. According to an embodiment a ceramic wick is provided. The heater, e.g., an electric heater, is arranged close to or in direct contact with the wick. For example an electric heater, and in particular an electric wire or filament can be printed on a surface of the ceramic wick.

[0038] The heater 20 is heated using electrical power from the vapor inhalation device. The heater 20 rapidly heats the liquid to form a vapor. The cartridge 50 is additionally provided with one or more air inlet channels such that, when a user sucks on the outlet 24a, air is pulled through the cartridge 50 and mixes with the vapor formed at the heater 20, so that the user inhales an airflow carrying the vapor. The vapor flows along the central tube 24 and is inhaled by the user via the device outlet 24a.

[0039] In some cases, a user will press a button to energize the heater 20 when they suck on the device outlet 24a. In other cases, a pressure sensor in the device (either in the cartridge or in the vapor inhalation device) detects a change in pressure resulting from a user sucking on the device outlet 24a, and the heater 20 is heated based on this detected change of pressure.

[0040] A portion of the insert 15 between each outlet channel 15a,b and the reservoir body 12 defines a rim of the outlet channel. The rim is generally marked by arrows R in Figure 1. In this known design of cartridge 50, the rim R provides a space in which liquid gathers when the reservoir is nearly empty. Surface tension of the liquid typically encourages the liquid to gather on the rim R and to collect in the corners formed where the reservoir body 12 meets the insert 15. This surface tension may prevent the liquid from entering the outlet channels 15a,b. Surface tension (wetting) may also cause the liquid to partially climb up the reservoir body 12 as well. It has been found that liquid that is stuck in this way will not freely flow into the outlet channels 15a,b. As such, a cartridge 50 may be disposed before it is completely empty, because liquid collecting on the rim is not passing through the outlet channels 15a,b towards the heater 20.

[0041] Figure 2 shows a zoomed-in view of a cartridge 10 according to the present invention. This cartridge 10 has several features in common with the known cartridge 100 of Figure 1 and, in the following description, like features will have like reference numerals.

[0042] The cartridge 10 of Figure 2 has a reservoir body 12, an outer casing, a heater holder 18, and a heater (or atomizer) 20. A central tube 24 is formed through the body of the reservoir for providing a fluid flow path from the heater 20 to a device outlet 24a of the cartridge 10. The heater 20 can be mounted in a heater holder 18. An insert 16 sits atop the heater holder 18 and thus sits between the reservoir and the heater holder 18. Other embodiments are possible, wherein the heater holder is not provided and the insert is arranged between the reservoir and the heater, preferably between the reservoir and a wick (e.g. a ceramic wick) that that is associated with the heater. The heater 20 may be arranged such that, when the cartridge 10 is connected to a vapor inhalation device, the heater 20 can receive electrical power from a battery of the vapor inhalation device, for heating the heater 20.

[0043] During construction of the cartridge, the insert 16 in inserted into the reservoir body 12 and the insert 16 forms one end of the reservoir. That is, the reservoir is defined by the reservoir body 12 and the insert 16. The insert 16 has two outlet channels 16a,b that are provided to allow fluid to flow out of the reservoir towards the heater 20. The central tube 24 extends from the heater 20, up through the center of the reservoir, to the outlet 24a.

[0044] A portion of the insert 16 between each outlet channel 16a,b and the reservoir body 12 defines a rim R' of the outlet channels 16a,b. Different from the insert 15, described above, the insert 16 has multiple channeling features formed in the rim R'. In Figures 2-4, these channeling features are slots 22a-f. These slots 22a-f break up the otherwise-flat surface of the rim R and promote fluid to flow into the outlet channels 16a,b. That is, these slots 22a-f may encourage wicking of fluid that would otherwise stick to the rim to instead flow through the outlet channels 16a,b.

[0045] Each slot 22a-f opens into a respective one of the channels 16a,b. That is, slots 22a, 22c and 22d open into outlet channel 16a, and slots 22b, 22e, 22f each open into outlet channel 16b. The slots 22a-f thereby encourage fluid that would otherwise sit on (adhere to) the rim R', to flow into the outlet channels 16a,b.

[0046] In Figure 3, the slots 22a-f are formed in the narrower corners that exist in the reservoir. That is, when the insert 16 shown in Figure 3 is inserted into a reservoir body, these areas have narrow corners where the reservoir body meets the insert 16. The reservoir body 12 has a cross-sectional shape of a flattened oval to match the generally oval shape of the insert as shown in Figure 3. This shape means that narrow corners are formed at either end of the major axis of the oval shape, where the reservoir body 12 meets the insert 16. Further, the central tube 24 extends up through a center of the reservoir body 12 and fills a substantial portion of the minor axis of the aforesaid oval cross-sectional shape. As such, narrow corners also form in the small gap between the central tube 24 and the reservoir body 12, where the reservoir body 12 meets the insert 16. These narrow corners are particularly prone to collecting liquid when the reservoir is nearly empty. As such, forming the slots 22a-f in these corners helps to promote flow of the last bits of the liquid in the reservoir into the outlet channels 16a,b. These slots 22a-f therefore reduce the amount of unusable liquid of a given cartridge 10.

[0047] Figure 3 shows a perspective view of the insert 16 shown in Figure 2. Figure 2 depicts a side view such that only slots 22a and 22b are visible in Figure 2, whereas figure 3 shows further slots 22c-e that are formed around the outlet channels 16a,b. The slots 22a-f are formed in areas where, when the insert 16 is inserted into a reservoir body 12, narrow corners are formed. The insert 16 has an outer edge 16c that seals against the reservoir body 12 when the insert 16 is inserted into said reservoir body 12. The outer edge 16c shown in Figure 3 has ridges which may help to promote fluid-tight sealing between the insert 16 and the reservoir body 12. The insert 16 has a central hole 26 that either surrounds the central tube 24 or connects to an end of the central tube 24. The central hole 26 is for allowing vapor from the heater 20 to pass through central tube 24 to the device outlet 24a.

[0048] The insert 16 may be made of any suitable material. For example, the insert may be made of silicone.

[0049] The insert 16 may be connected to a heater holder 18. For example, the insert 16 may be moulded around and / or placed onto at least part of the heater holder 18. In this setup, a cartridge 10 is formed when the insert 16, heater holder 18, and heater 20 are inserted as one unit into the reservoir body 12. The cartridge 10 may then be connected to a vapor inhalation device (e.g., device 14) having a power source, such as a (rechargeable) battery, that is for powering the heater 20.

[0050] Figure 4 depicts a cutaway perspective view of the insert 16 of Figure 3. Slot 22a, at an end of the slot 22a nearest the reservoir body 12, has a base surface 22a1 that has a relatively steep slope extending down from the otherwise-flat surface of the rim R'. At an end of the slot 22a that opens into the outlet 16a, the base surface 22a1 of the slot 22a is almost flat, i.e. is almost parallel to the surface of the rim R'. The curved base surface 22a1 of the slot helps encourage flow of liquid through the slot and into the outlet channel 16a. The slot 22a has vertical sidewalls 22a2 (only one shown in the view of Figure 4, the other sidewall having been cut away to show the base surface 22a1). Other slots may be formed in the same way. Thus, for example, slot 22b has a curved base surface 22b1 and vertical sidewalls 22b2

[0051] Other shapes of slots are envisaged. For example, a slot may have a rectilinear or triangular shape having a flat base surface. Alternatively, a slot may have curved surfaces on all sides to form a bowl-shape.

[0052] Figures 5A and 5B depict a different possible embodiment of an insert 16 wherein the rim has sloped sides, sloping down towards each of the outlet channels 16a,16b. Figure 5A is a perspective view of the insert 16 where one outlet channel 16a has sloped sides 16as and the other outlet channel 16b also has sloped sides 16bs. Figure 5B shows a cutaway side view of the insert 16, in which the sloped sides 16as,16bs may be seen. In this manner, the rim comprises at least one sloped surface (where two such sloped surfaces are shown in Figure 5A and in Figure 5B), sloping down towards the at least one outlet channel. The sloped surface(s) reduce the angle between the rim and outlet channel 16a,b, which can encourage flow over the rim and into the respective outlet channel 16a,b. The sloped surface can also increase the angle between the reservoir body and the rim, and thereby reduce the formation of narrow corners that can otherwise form where the rim meets the reservoir body 12. As shown in Figure 5B, the topmost part of the sloped surface, distal from the outlet channel 16a,b may have an apex followed by a short slope S on a side distant from the outlet channel. This may help in inserting the insert 16 into the reservoir body 12, without providing much space where liquid might undesirably pool.

[0053] The cartridge 10 may comprise a transparent or translucent window for allowing visual inspection of a liquid level in the reservoir. In some examples, the entire reservoir body 12 may be transparent or translucent in which cases the whole reservoir body 12 is considered to form the window. In other examples, the reservoir body 12 may be formed of an opaque material having a transparent or translucent window formed therein.

[0054] The window allows visual inspection of the fluid level in the reservoir at least in a region adjacent the rim R'. That is, the window allows a user to at least see the rim and some distance thereabove to assess whether liquid remains in the reservoir. Where the reservoir body 12 is made of transparent or translucent material, the window may allow inspection of the entire reservoir, e.g. to see how full it is.

[0055] The rim R' may be coated with a coating X that is hydrophobic and / or oleophobic. Alternatively, the insert 16 may be made of a material that is inherently hydrophobic and / or oleophobic. The coating X may be used in addition to or instead of any of the slots 22a-f described hereinabove. In this description, the terms hydrophobic and oleophobic take their normal meanings. That is, "hydrophobic" means that a drop of water on the coating X will form a contact angle >90 degrees. "Oleophobic" means that a drop of oil on the coating X will form a contact angle >90 degrees. Some coatings or materials may be both oleophobic and hydrophobic.

[0056] Figure 6 is a flowchart of a method 100 of manufacturing a cartridge. The method 100 comprises the following steps: Step 102: forming an insert 16 having an outlet channel, wherein forming the insert includes: Step 104: configuring the rim to promote flow of liquid into the channel; and Step 106: inserting the insert 16 into an end of a reservoir body 12.

[0057] As before, a portion of the insert between the outlet channel and the reservoir body defines a rim of the outlet channel. The insert 16 formed by this method may be any of the designs of insert 16 described hereinabove. That is: Step 104 of configuring the rim to promote flow of liquid into the channel may include forming one or more slots (e.g. slots 22a-f) in the insert 16. Step 104 may alternatively or additionally include applying a coating that is hydrophobic and / or oleophobic to the insert 16. Step 102 may alternatively or additionally include forming the insert 16 of a material that is hydrophobic and / or oleophobic. In this case, Step 104 is inherently performed by performing Step 102. That is, the fact that the material is hydrophobic and / or oleophobic inherently configures the rim to promote flow of liquid into the channel.

[0058] The reservoir body 12 may be the reservoir body described hereinabove.

[0059] Figure 6 may also be considered to be a flowchart of a method 100 of manufacturing a cartridge (e.g. the cartridge 10 described hereinabove), with the additional limitations that cartridge 10 includes a heater holder 18 comprising a heater 20, and wherein the outlet channel 16a,b allows fluid to flow from the reservoir to the heater 20.[List of Reference Signs]

[0060] 10cartridge 12reservoir body 14vapor inhalation device 15insert (prior art) 15a,boutlet channels of insert 15 15couter edge of insert 15 16insert 16a,boutlet channels of insert 16 16couter edge of insert 16 18heater holder 20heater 21end cap 22a-fslots 24central tube 24adevice outlet 26central hole (of insert 16) 50cartridge (prior art) 100method 102step of forming an insert 104step of configuring a rim of the insert 106step of inserting the insert

Examples

Embodiment Construction

[0032]In the field of vapor inhalation devices, a cartridge has a reservoir is intended to store the liquid for the aerosol generation. According to different possible embodiments, an atomizer (or heater) can be directly provided in the cartridge, or alternatively in the device. The following discussion is given in view of a cartridge including an atomizer / heater, but the skilled reader will understand that this discussion applies equally to a cartridge not provided with an internal atomizer / heater, except for parts of discussion relating to the heater / atomizer.

[0033]Figure 1 is a schematic view of a cartridge 50 known in the art. The cartridge 50 comprises a reservoir body 12 that , in use, connects to an end of a vapor inhalation device 14. An insert 15 in inserted into the reservoir body 12. The reservoir body 12 substantially defines a reservoir for storing liquid, such as eliquid, and the insert 15 forms one end of the reservoir. The insert 15 has two outlet channels 15a,b that...

[Technical Field]

[0001] The present invention relates generally to a cartridge for a vapor inhalation device. A method of manufacturing a cartridge is also provided.[Background]

[0002] Vapor inhalation devices, also referred to as aerosol generation devices or aerosol inhalation devices, such as vaping devices and aerosol inhalers, are known. Such vapor inhalation devices are hand-held devices and conventionally include a power supply, and liquid-filled cartridge and an atomizer / heater intended to generate the aerosol. The liquid is heated by the atomizer / heater in order to generate an aerosol (that is, a vapour) that may be inhaled by the user. Suitable liquids for vapor inhalation devices are commonly called "eliquids". There are many different eliquids that are commercially available. A typical e-liquid may be composed of propylene glycol and glycerin. optionally also including one or more of flavorings, nicotine. However, many other formulations are possible. Eliquids are designed so as to form a vapor after contacting an atomizer / heater, where the vapor has desired properties such as a particular flavor and mouth-feel when inhaled by a user.

[0003] Vapor inhalation devices are generally designed to be reusable. By way of example, a reusable vapor inhalation device may include features such as a rechargeable power source. The cartridge is then generally designed as a consumable product that is detachable or removable from the vapor inhalation device and replaceable.

[0004] The atomizer / heater can be provided in the cartridge containing the liquid, the cartridge is connectable to the vapor inhalation device that contains the power supply, such that these together provide a functional vapor inhalation device.[Summary of the Invention] [Technical Problem]

[0005] A cartridge for a vapor inhalation device contains a liquid in a reservoir. At least one outlet channel is provided for allowing flow of the liquid to flow out from the reservoir, e.g. to an atomizer / heater. Due to surface tension of the liquid, it has been found that, when a cartridge is nearly empty, liquid will gather around the rim of the outlet channel(s) and will not flow into the outlet channel(s). That is, surface tension may cause the liquid to pool around the outlet, particularly in narrow corners of the reservoir, and not flow through the outlet channel(s). This can result in wasted liquid product.

[0006] Some cartridges have a translucent or transparent window therein or the body of the cartridge can be made at least in part of a translucent or transparent material, for example, so that a user can visually identify how much liquid is left in the reservoir. The window will typically allow viewing down to an end of the reservoir that contains the outlet channel(s) so that are user can see when the liquid level is low. Surface tension of the liquid can cause the liquid to gather around the rim of the outlet channel(s) and may also creep up the walls of the reservoir body. The user may receive a false impression of how much liquid remains in the cartridge and in any case the user may see liquid remaining inside the cartridge even if the aerosol generating device already detected that the cartridge is empty.[Summary of the Solution]

[0007] The present invention is intended to address one or more of the above technical problems.

[0008] In particular, in view of the limitations discussed above, the present inventors have devised, a cartridge for a vapor inhalation device, the cartridge comprising: a reservoir body; an insert abutting the reservoir body, such that a reservoir is defined by the reservoir body and the insert; the insert having at least one outlet channel for allowing liquid to flow out of the reservoir, wherein a portion of the insert between the outlet channel and the reservoir body defines a rim of the at least one outlet channel, wherein the rim is configured to promote flow of liquid from the reservoir into the at least one outlet channel.

[0009] That is, the rim is the portion of the insert that both a) faces toward the reservoir and b) extends from the outer edge of each outlet channel to the reservoir body (i.e., to where the insert meets contacts the reservoir body). Having the rim configured to promote flow of liquid from the reservoir into the at least one outlet channel helps to avoid wasted liquid product.

[0010] The rim may be provided with a constructional configuration that facilitates flow of liquid into the outlet channel. In other words, the rim can be configured to inhibit the adhesion of liquid to the rim. That is, it is the trapping of liquid on the rim, particularly in narrow corners where the rim meets the reservoir body, that prevents the free flow of liquid into the outlet channel.

[0011] Advantageously, in the cartridge according to the invention, the rim is configured to promote flow of liquid form the reservoir to the at least one outlet channel, thus avoiding that the liquid is trapped on the rim, particularly in narrow corners where the rim meets the reservoir body.

[0012] This will also reduce / avoid the generation of dry puff, i.e. when the user starts a puffing action even if there is no liquid in the reservoir and in particular in the wick and / or heater. In particular, in known cartridges, the liquid trapped on the rim could convey to the user a false impression of how much liquid remains in the cartridge, but there is not enough / no liquid in the wick and / or heater to generate a complete puff. In the flow of the liquid towards the outlet channel is promoted, thus reducing the risk of generating a dry puff that is an unpleasant experience for the user.

[0013] According to an aspect, the insert may have multiple outlet channels. For example, the insert may have two outlet channels. Where there are multiple outlet channels, the rim may still be defined as the portion of the insert that is between at least one outlet channel and the reservoir body.

[0014] The rim may comprise one or more channelling features configured to promote flow of fluid into the at least one outlet channel.

[0015] This may provide one configuration by which flow from the reservoir into the outlet channel(s) may be promoted.

[0016] The channelling features may comprise one or more slots. The undesirable gathering of liquid can preferentially occur on smooth surfaces. By disrupting the otherwise-smooth surface of the rim between the outlet channel(s) and the reservoir body by providing slots, flow of liquid into the outlet channel(s) can be promoted. Without being bound by any particular theory, the slots may, for example, provide a flowpath along which liquid will wick towards the outlet channel.

[0017] One or more slots (for example, two or more slots) may be formed in the rim, each slot opening out into one of the at least one outlet channel. Having a plurality of slots may further reduce the presence of otherwise smooth surfaces of the rim that could provide gathering-places for liquid. Each slot may be formed at a location where liquid would otherwise preferentially gather when the reservoir is nearly empty.

[0018] The rim may comprise a sloped surface, sloping towards the at least one outlet channel. The slope may promote liquid flow into the outlet channel(s) by simple action of gravity (when the cartridge is held in an appropriate orientation). The slope may also reduce the angle between the rim surface and the outlet channel which may promote flow into the outlet channel. The slope may also increase the angle between the rim surface and the reservoir body, thereby reducing the formation of narrow corners where liquid may otherwise preferentially gather.

[0019] The cartridge may comprise a transparent or translucent window for allowing visual inspection of a liquid level in the reservoir in a region encompassing a portion of the reservoir adjacent the rim. The window may be formed by forming a portion of, or the entire, reservoir body out of a translucent or transparent material. The window may allow the user to see how much liquid remains in the reservoir. In conjunction with the aforementioned feature of the rim being configured to promote flow of liquid from the reservoir into the outlet channel, this may help avoid giving the user a false impression of how much liquid remains in the cartridge when it is nearly empty.

[0020] The rim / slope may be coated with a coating that is hydrophobic and / or oleophobic. This coating may be provided instead of, or in addition to, the slots. The coating provides another way by which flow of liquid into the outlet channel may be promoted, by reducing the tendency of the last drops of liquid in a nearly-empty reservoir to stick to the rim / slope. Again, this helps preventing wasted product. Alternatively or additionally, the insert may be formed of a material that is hydrophobic and / or oleophobic.

[0021] The insert may be made of silicone or may comprise a silicone outer layer that forms at least the rim. Silicone may provide a good liquid-tight seal between the insert and reservoir body and thus prevent undesirable leakage of liquid.

[0022] According to an aspect, the cartridge comprises a heater and the outlet channel allows fluid to flow from the reservoir to the heater.

[0023] According to an aspect, the cartridge comprises a heater holder. The heater holder may be formed integrally with the insert (e.g. may be formed of the same material) or may be formed as a separate element, preferably of a separate material, and connected to the insert. For example, a cover (e.g. of silicone) may be moulded around the heater holder to produce the insert.

[0024] The insert may be formed on the heater holder as a silicone outer layer, wherein the silicone outer layer forms the rim.

[0025] According to an aspect, there is provided a method of manufacturing a cartridge, the method comprising: forming an insert having an outlet channel, inserting the insert into an end of a reservoir body; wherein a portion of the insert between the outlet channel and the reservoir body defines a rim of the outlet channel, wherein forming the insert includes configuring the rim to promote flow of liquid into the outlet channel.

[0026] Forming the insert may comprise forming one or more channelling features on the rim, the one or more channelling features configured to promote flow of fluid into the outlet channel. The channelling features may provide one way of promoting flow into the outlet channel, particularly for promoting flow of the last amounts of liquid in a nearly-empty reservoir.

[0027] The channelling features may comprise one or more slots. Without being bound by any particular theory, the slots may, for example, provide a flow path along which liquid will wick towards the outlet channel.

[0028] One or more slots (for example, two or more slots) may be formed in the rim, each slot opening out into one of the at least one outlet channel. Each slot may be formed at a location where liquid would otherwise preferentially gather when the reservoir is nearly empty.

[0029] The method may include forming the rim as having a sloped surface, sloping towards the outlet channel. The slope may promote liquid flow into the outlet channel by simple action of gravity (when the cartridge is held in an appropriate orientation). The slope may also reduce the angle between the rim surface and the outlet channel which may promote flow into the outlet channel.

[0030] The step of forming the insert may include applying a coating that is hydrophobic and / or oleophobic to portions of the insert that form the rim when the insert is inserted into the end of the reservoir body. The coating provides another way by which flow of liquid into the outlet channel may be promoted, by reducing the tendency of the last drops of liquid in a nearly-empty reservoir to stick to the rim. Again, this helps prevent wasted product. Alternatively or additionally, the insert may be formed of a material that is hydrophobic and / or oleophobic.[Brief Description of the Drawings]

[0031] Figure 1 shows a perspective view of a known design of cartridge; Figure 2 shows a cross-sectional view of a new design of cartridge; Figure 3 shows a perspective view of an insert for a cartridge; and Figure 4 shows a cutaway perspective view of the insert of Figure 3; Figures 5A and B show views of another insert for a cartridge; and Figure 6 shows a flow-chart for a method of making a cartridge. [Detailed Description]

[0032] In the field of vapor inhalation devices, a cartridge has a reservoir is intended to store the liquid for the aerosol generation. According to different possible embodiments, an atomizer (or heater) can be directly provided in the cartridge, or alternatively in the device. The following discussion is given in view of a cartridge including an atomizer / heater, but the skilled reader will understand that this discussion applies equally to a cartridge not provided with an internal atomizer / heater, except for parts of discussion relating to the heater / atomizer.

[0033] Figure 1 is a schematic view of a cartridge 50 known in the art. The cartridge 50 comprises a reservoir body 12 that , in use, connects to an end of a vapor inhalation device 14. An insert 15 in inserted into the reservoir body 12. The reservoir body 12 substantially defines a reservoir for storing liquid, such as eliquid, and the insert 15 forms one end of the reservoir. The insert 15 has two outlet channels 15a,b that are provided to allow fluid to flow out of the reservoir and towards a heater 20. The heater 20 can be mounted in a heater holder 18. The insert 15 sits atop the heater holder 18 and thus sits between the reservoir and the heater holder 18. The heater 20 may be arranged such that, when the cartridge 50 is connected to a vapor inhalation device, the heater 20 can receive electrical power from a battery of the vapor inhalation device, for heating the heater 20.

[0034] The insert 15 has an outer surface 15c that abuts against the reservoir body 12 to provide a fluid-tight seal that prevents liquid in the reservoir from leaking out between the reservoir body 12 and the insert 15.

[0035] The outlet channels 15a,b of the insert 15 are at least partially aligned with corresponding flow channels formed in the heater holder 18, such that liquid that passes through the outlet channels 15a,b flows into the flow channels and thus arrive at the heater 20.

[0036] A central tube 24 is formed through the body of the reservoir for providing a fluid flow path from the heater 20 to a device outlet 24a of the cartridge 50. In use, a user sucks upon the device outlet 24a.

[0037] Liquid flows out of the reservoir via the two outlet channels 15a,b and through the heater holder 18, whereupon the liquid comes into contact with the heater 20. Usually a wick is arranged to convey the liquid to the heater. According to an embodiment a ceramic wick is provided. The heater, e.g., an electric heater, is arranged close to or in direct contact with the wick. For example an electric heater, and in particular an electric wire or filament can be printed on a surface of the ceramic wick.

[0038] The heater 20 is heated using electrical power from the vapor inhalation device. The heater 20 rapidly heats the liquid to form a vapor. The cartridge 50 is additionally provided with one or more air inlet channels such that, when a user sucks on the outlet 24a, air is pulled through the cartridge 50 and mixes with the vapor formed at the heater 20, so that the user inhales an airflow carrying the vapor. The vapor flows along the central tube 24 and is inhaled by the user via the device outlet 24a.

[0039] In some cases, a user will press a button to energize the heater 20 when they suck on the device outlet 24a. In other cases, a pressure sensor in the device (either in the cartridge or in the vapor inhalation device) detects a change in pressure resulting from a user sucking on the device outlet 24a, and the heater 20 is heated based on this detected change of pressure.

[0040] A portion of the insert 15 between each outlet channel 15a,b and the reservoir body 12 defines a rim of the outlet channel. The rim is generally marked by arrows R in Figure 1. In this known design of cartridge 50, the rim R provides a space in which liquid gathers when the reservoir is nearly empty. Surface tension of the liquid typically encourages the liquid to gather on the rim R and to collect in the corners formed where the reservoir body 12 meets the insert 15. This surface tension may prevent the liquid from entering the outlet channels 15a,b. Surface tension (wetting) may also cause the liquid to partially climb up the reservoir body 12 as well. It has been found that liquid that is stuck in this way will not freely flow into the outlet channels 15a,b. As such, a cartridge 50 may be disposed before it is completely empty, because liquid collecting on the rim is not passing through the outlet channels 15a,b towards the heater 20.

[0041] Figure 2 shows a zoomed-in view of a cartridge 10 according to the present invention. This cartridge 10 has several features in common with the known cartridge 100 of Figure 1 and, in the following description, like features will have like reference numerals.

[0042] The cartridge 10 of Figure 2 has a reservoir body 12, an outer casing, a heater holder 18, and a heater (or atomizer) 20. A central tube 24 is formed through the body of the reservoir for providing a fluid flow path from the heater 20 to a device outlet 24a of the cartridge 10. The heater 20 can be mounted in a heater holder 18. An insert 16 sits atop the heater holder 18 and thus sits between the reservoir and the heater holder 18. Other embodiments are possible, wherein the heater holder is not provided and the insert is arranged between the reservoir and the heater, preferably between the reservoir and a wick (e.g. a ceramic wick) that that is associated with the heater. The heater 20 may be arranged such that, when the cartridge 10 is connected to a vapor inhalation device, the heater 20 can receive electrical power from a battery of the vapor inhalation device, for heating the heater 20.

[0043] During construction of the cartridge, the insert 16 in inserted into the reservoir body 12 and the insert 16 forms one end of the reservoir. That is, the reservoir is defined by the reservoir body 12 and the insert 16. The insert 16 has two outlet channels 16a,b that are provided to allow fluid to flow out of the reservoir towards the heater 20. The central tube 24 extends from the heater 20, up through the center of the reservoir, to the outlet 24a.

[0044] A portion of the insert 16 between each outlet channel 16a,b and the reservoir body 12 defines a rim R' of the outlet channels 16a,b. Different from the insert 15, described above, the insert 16 has multiple channeling features formed in the rim R'. In Figures 2-4, these channeling features are slots 22a-f. These slots 22a-f break up the otherwise-flat surface of the rim R and promote fluid to flow into the outlet channels 16a,b. That is, these slots 22a-f may encourage wicking of fluid that would otherwise stick to the rim to instead flow through the outlet channels 16a,b.

[0045] Each slot 22a-f opens into a respective one of the channels 16a,b. That is, slots 22a, 22c and 22d open into outlet channel 16a, and slots 22b, 22e, 22f each open into outlet channel 16b. The slots 22a-f thereby encourage fluid that would otherwise sit on (adhere to) the rim R', to flow into the outlet channels 16a,b.

[0046] In Figure 3, the slots 22a-f are formed in the narrower corners that exist in the reservoir. That is, when the insert 16 shown in Figure 3 is inserted into a reservoir body, these areas have narrow corners where the reservoir body meets the insert 16. The reservoir body 12 has a cross-sectional shape of a flattened oval to match the generally oval shape of the insert as shown in Figure 3. This shape means that narrow corners are formed at either end of the major axis of the oval shape, where the reservoir body 12 meets the insert 16. Further, the central tube 24 extends up through a center of the reservoir body 12 and fills a substantial portion of the minor axis of the aforesaid oval cross-sectional shape. As such, narrow corners also form in the small gap between the central tube 24 and the reservoir body 12, where the reservoir body 12 meets the insert 16. These narrow corners are particularly prone to collecting liquid when the reservoir is nearly empty. As such, forming the slots 22a-f in these corners helps to promote flow of the last bits of the liquid in the reservoir into the outlet channels 16a,b. These slots 22a-f therefore reduce the amount of unusable liquid of a given cartridge 10.

[0047] Figure 3 shows a perspective view of the insert 16 shown in Figure 2. Figure 2 depicts a side view such that only slots 22a and 22b are visible in Figure 2, whereas figure 3 shows further slots 22c-e that are formed around the outlet channels 16a,b. The slots 22a-f are formed in areas where, when the insert 16 is inserted into a reservoir body 12, narrow corners are formed. The insert 16 has an outer edge 16c that seals against the reservoir body 12 when the insert 16 is inserted into said reservoir body 12. The outer edge 16c shown in Figure 3 has ridges which may help to promote fluid-tight sealing between the insert 16 and the reservoir body 12. The insert 16 has a central hole 26 that either surrounds the central tube 24 or connects to an end of the central tube 24. The central hole 26 is for allowing vapor from the heater 20 to pass through central tube 24 to the device outlet 24a.

[0048] The insert 16 may be made of any suitable material. For example, the insert may be made of silicone.

[0049] The insert 16 may be connected to a heater holder 18. For example, the insert 16 may be moulded around and / or placed onto at least part of the heater holder 18. In this setup, a cartridge 10 is formed when the insert 16, heater holder 18, and heater 20 are inserted as one unit into the reservoir body 12. The cartridge 10 may then be connected to a vapor inhalation device (e.g., device 14) having a power source, such as a (rechargeable) battery, that is for powering the heater 20.

[0050] Figure 4 depicts a cutaway perspective view of the insert 16 of Figure 3. Slot 22a, at an end of the slot 22a nearest the reservoir body 12, has a base surface 22a1 that has a relatively steep slope extending down from the otherwise-flat surface of the rim R'. At an end of the slot 22a that opens into the outlet 16a, the base surface 22a1 of the slot 22a is almost flat, i.e. is almost parallel to the surface of the rim R'. The curved base surface 22a1 of the slot helps encourage flow of liquid through the slot and into the outlet channel 16a. The slot 22a has vertical sidewalls 22a2 (only one shown in the view of Figure 4, the other sidewall having been cut away to show the base surface 22a1). Other slots may be formed in the same way. Thus, for example, slot 22b has a curved base surface 22b1 and vertical sidewalls 22b2

[0051] Other shapes of slots are envisaged. For example, a slot may have a rectilinear or triangular shape having a flat base surface. Alternatively, a slot may have curved surfaces on all sides to form a bowl-shape.

[0052] Figures 5A and 5B depict a different possible embodiment of an insert 16 wherein the rim has sloped sides, sloping down towards each of the outlet channels 16a,16b. Figure 5A is a perspective view of the insert 16 where one outlet channel 16a has sloped sides 16as and the other outlet channel 16b also has sloped sides 16bs. Figure 5B shows a cutaway side view of the insert 16, in which the sloped sides 16as,16bs may be seen. In this manner, the rim comprises at least one sloped surface (where two such sloped surfaces are shown in Figure 5A and in Figure 5B), sloping down towards the at least one outlet channel. The sloped surface(s) reduce the angle between the rim and outlet channel 16a,b, which can encourage flow over the rim and into the respective outlet channel 16a,b. The sloped surface can also increase the angle between the reservoir body and the rim, and thereby reduce the formation of narrow corners that can otherwise form where the rim meets the reservoir body 12. As shown in Figure 5B, the topmost part of the sloped surface, distal from the outlet channel 16a,b may have an apex followed by a short slope S on a side distant from the outlet channel. This may help in inserting the insert 16 into the reservoir body 12, without providing much space where liquid might undesirably pool.

[0053] The cartridge 10 may comprise a transparent or translucent window for allowing visual inspection of a liquid level in the reservoir. In some examples, the entire reservoir body 12 may be transparent or translucent in which cases the whole reservoir body 12 is considered to form the window. In other examples, the reservoir body 12 may be formed of an opaque material having a transparent or translucent window formed therein.

[0054] The window allows visual inspection of the fluid level in the reservoir at least in a region adjacent the rim R'. That is, the window allows a user to at least see the rim and some distance thereabove to assess whether liquid remains in the reservoir. Where the reservoir body 12 is made of transparent or translucent material, the window may allow inspection of the entire reservoir, e.g. to see how full it is.

[0055] The rim R' may be coated with a coating X that is hydrophobic and / or oleophobic. Alternatively, the insert 16 may be made of a material that is inherently hydrophobic and / or oleophobic. The coating X may be used in addition to or instead of any of the slots 22a-f described hereinabove. In this description, the terms hydrophobic and oleophobic take their normal meanings. That is, "hydrophobic" means that a drop of water on the coating X will form a contact angle >90 degrees. "Oleophobic" means that a drop of oil on the coating X will form a contact angle >90 degrees. Some coatings or materials may be both oleophobic and hydrophobic.

[0056] Figure 6 is a flowchart of a method 100 of manufacturing a cartridge. The method 100 comprises the following steps: Step 102: forming an insert 16 having an outlet channel, wherein forming the insert includes: Step 104: configuring the rim to promote flow of liquid into the channel; and Step 106: inserting the insert 16 into an end of a reservoir body 12.

[0057] As before, a portion of the insert between the outlet channel and the reservoir body defines a rim of the outlet channel. The insert 16 formed by this method may be any of the designs of insert 16 described hereinabove. That is: Step 104 of configuring the rim to promote flow of liquid into the channel may include forming one or more slots (e.g. slots 22a-f) in the insert 16. Step 104 may alternatively or additionally include applying a coating that is hydrophobic and / or oleophobic to the insert 16. Step 102 may alternatively or additionally include forming the insert 16 of a material that is hydrophobic and / or oleophobic. In this case, Step 104 is inherently performed by performing Step 102. That is, the fact that the material is hydrophobic and / or oleophobic inherently configures the rim to promote flow of liquid into the channel.

[0058] The reservoir body 12 may be the reservoir body described hereinabove.

[0059] Figure 6 may also be considered to be a flowchart of a method 100 of manufacturing a cartridge (e.g. the cartridge 10 described hereinabove), with the additional limitations that cartridge 10 includes a heater holder 18 comprising a heater 20, and wherein the outlet channel 16a,b allows fluid to flow from the reservoir to the heater 20.[List of Reference Signs]

[0060] 10cartridge 12reservoir body 14vapor inhalation device 15insert (prior art) 15a,boutlet channels of insert 15 15couter edge of insert 15 16insert 16a,boutlet channels of insert 16 16couter edge of insert 16 18heater holder 20heater 21end cap 22a-fslots 24central tube 24adevice outlet 26central hole (of insert 16) 50cartridge (prior art) 100method 102step of forming an insert 104step of configuring a rim of the insert 106step of inserting the insert

Examples

Embodiment Construction

[0032]In the field of vapor inhalation devices, a cartridge has a reservoir is intended to store the liquid for the aerosol generation. According to different possible embodiments, an atomizer (or heater) can be directly provided in the cartridge, or alternatively in the device. The following discussion is given in view of a cartridge including an atomizer / heater, but the skilled reader will understand that this discussion applies equally to a cartridge not provided with an internal atomizer / heater, except for parts of discussion relating to the heater / atomizer.

[0033]Figure 1 is a schematic view of a cartridge 50 known in the art. The cartridge 50 comprises a reservoir body 12 that , in use, connects to an end of a vapor inhalation device 14. An insert 15 in inserted into the reservoir body 12. The reservoir body 12 substantially defines a reservoir for storing liquid, such as eliquid, and the insert 15 forms one end of the reservoir. The insert 15 has two outlet channels 15a,b that...

Claims

1. A cartridge for a vapor inhalation device, the cartridge comprising: a reservoir body; an insert abutting the reservoir body, such that a reservoir is defined by the reservoir body and the insert; the insert having at least one outlet channel for allowing liquid to flow out of the reservoir, wherein a portion of the insert between the outlet channel and the reservoir body defines a rim of the outlet channel, wherein the rim is configured to promote flow of liquid from the reservoir into the at least one outlet channel.

2. The cartridge of claim 1, wherein the rim comprises one or more channelling features configured to promote flow of fluid into the at least one outlet channel.

3. The cartridge of claim 2, wherein the channelling features comprise one or more slots.

4. The cartridge of claim 3, wherein one or more slots are formed in the rim, each slot opening out into one of the at least one outlet channel.

5. The cartridge of any preceding claim, wherein the rim comprises a sloped surface, sloping towards one of the at least one outlet channel.

6. The cartridge of any preceding claim, wherein the cartridge comprises a transparent or translucent window for allowing visual inspection of a liquid level in the reservoir in a region encompassing a portion of the reservoir adjacent the rim, optionally wherein the reservoir is formed from a translucent or transparent material to provide the window.

7. The cartridge of any preceding claim, wherein the rim is coated with a coating that is hydrophobic and / or oleophobic.

8. The cartridge of any preceding claim, wherein the insert is made of silicone or comprises a silicone outer layer that forms at least the rim.

9. The cartridge of any preceding claim, comprising a heater, and wherein the outlet channel allows fluid to flow from the reservoir to the heater.

10. The cartridge according to claim 9, wherein the insert is arranged on a heater holder, preferably as a silicone outer layer, wherein the silicone outer layer forms the rim.

11. A method of manufacturing a cartridge, the method comprising: forming an insert having at least one outlet channel, and inserting the insert into an end of a reservoir body; wherein a portion of the insert between the at least one outlet channel and the reservoir body defines a rim of the at least one outlet channel, wherein forming the insert includes configuring the rim to promote flow of liquid into the at least one outlet channel.

12. The method according to claim 11, wherein forming the insert comprises forming one or more channelling features on the rim, the one or more channelling features configured to promote flow of fluid into the at least one outlet channel.

13. The method according to claim 12, wherein the channelling features comprise one or more slots.

14. The method according to claim 13, wherein one or more slots are formed in the rim, each slot opening out into an outlet channel of the at least one outlet channel.

15. The method according to any of claims 11-14, wherein the step of forming the insert includes applying a coating that is hydrophobic and / or oleophobic to portions of the insert that form the rim when the insert is inserted into the end of the reservoir body.

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