Aerosolizing system with replaceable capsule

Abstract

An aerosol generating system (1) and device comprising: a main body (3) housing a power supply (10); a mouthpiece portion (2) releasably secured to the main body (3) and configured for housing a consumable (4); an aerosol unit (29) configured to be releasably secured within the main body (3) and electrically connected to the power supply (10), the aerosol unit (29) comprising: an aerosol generator (7) for generating an aerosol; and a wicking component (6) configured for receipt in an outlet of the consumable (4) and for providing fluid communication between the outlet of the consumable (4) and the aerosol generator (7); wherein an airflow passage extends between an upstream inlet of the aerosol unit (29) and a downstream outlet (11) of the mouthpiece portion (2).

Description

[0001] AEROSOLIZING SYSTEM WITH REPLACEABLE CAPSULE

[0002] This invention relates to an aerosolizing system with replaceable capsules. The capsules are intended to contain a liquid formulation. The aerosolizing system is intended to aerosolize the liquid formulation contained within the capsule. A user may then inhale upon the aerosolizing system to cause the aerosol to flow into their mouth and lungs.

[0003] Such aerosolizing systems are well known. For instance, electronic cigarettes aerosolize liquid containing nicotine. Other aerosolizing systems may be used for aerosolizing medicant for patients to inhale.

[0004] Aerosolizing systems with replaceable capsules, also known as cartridges or pods, are also well known. In particular, electronic cigarettes are combined with capsules containing a nicotine liquid formulation, a heater for vaporizing the liquid, and a wick for transporting the liquid to the heater. Such electronic cigarette capsules are typically complicated in their construction, containing many parts such as the liquid tank, a mouthpiece, a wick, a heater, and a bottom cap. This makes the capsules complicated and expensive to manufacture. In addition, such capsules are single-use. Once all the liquid has been aerosolized, the empty capsule is discarded. This is not sustainable or environmentally friendly because the wick and heater are discarded. These components often contain expensive and scarce materials such as ceramics and metals.

[0005] Such electronic cigarette capsules are also susceptible to leakage. They contain an air inlet hole and an aerosol outlet hole, both in communication with the e-liquid storage tank through a wicking component. As such, there is a high tendency for non-aerosolized liquid to leak out of the inlet or outlet of the capsule. This is a nuisance for the user but also can be dangerous, as liquid nicotine can be toxic when absorbed or ingested.

[0006] Furthermore, the wicking process within an electronic cigarette capsule can be very inconsistent, resulting in the aerosol being generated also being inconsistent. This is a result of the components used for wicking the liquid having inconsistent wicking properties. This is due to the wicking materials used, such as cotton, silica, porous ceramic, etc. It is also due to the wide manufacturing tolerances of wicking components being made with such inconsistent materials.

[0007] Various embodiments of liquid capsules have previously been disclosed, for example, in WO2017167513 and W02020193659, where the wicking and heating components have been removed from the capsule. However, such embodiments do not solve the problem of potential leakage from the pod or wick. Nor do they address the fragile nature of the wicking components, the inconsistency of the wicking properties, and consequently, the inconsistent resultant aerosol. In addition, they do not address the relatively short life expectancy of the various heater components for aerosolization, such as resistive wire coils or resistive heater tracks.

[0008] The present invention intends to overcome the shortcomings of existing aerosolizing systems with replaceable capsules. The capsule that is the subject of this invention does not contain a wicking, heating, or aerosolizing component. The aerosolizing unit is instead contained within the aerosolizing system itself. As such, the capsule is much simpler and cheaper to manufacture. This also makes the single-use capsule much more sustainable and environmentally friendly. Recycling the capsule will be much easier and cheaper than currently known capsules.

[0009] Furthermore, the aerosolization process is much more consistent and repeatable, with no wicking component within the capsule. This improves the user experience and, in medical applications, helps the aerosolization system comply with delivered dose uniformity requirements.

[0010] The capsule is intended to be a hermetically sealed unit until the point at which it is engaged within the aerosolization system. This ensures there is no leakage of the liquid contained within the capsule during storage and transit, drastically improving the experience and safety of the user.

[0011] The replaceable capsule of this invention consists of a liquid holding tank and an end cap that is hermetically sealed to the tank once it has been filled with liquid. One end of the capsule is shaped to fit over a protrusion within the aerosolization system. This end of the capsule contains a removable section. The removable section is an integral part of the liquid holding tank and is designed such that the protrusion within the device will break the removable section free from the tank, thus creating an opening through which the liquid can pass into the aerosolization system for aerosolization.

[0012] An alternative embodiment of the capsule would contain a removable sealing bung instead of an integral removable section. In this embodiment, the protrusion would push the sealing bung into the inside of the capsule, breaking the seal and creating an opening through which the liquid can pass into the aerosolization system for aerosolization. The protrusion within the aerosolization system contains one or more internal channels. These channels are shaped and dimensioned such that they exert a capillary action upon the liquid in the capsule, drawing the liquid into the aerosolization unit within the aerosolization system. A ventilation feature may be required between the replaceable capsule and the protrusion. Such a feature may take the form of a channel, notch, or any other suitably formed feature. The purpose of the ventilation feature is to allow air to vent into the capsule to replace any liquid that is drawn out of the capsule for aerosolization.

[0013] The aerosolization unit within the aerosolization system preferably consists of an ultrasonic vibrating mesh, such as is common in currently known medical nebulizers. Alternatively, the aerosolization unit may consist of a conventional electronic cigarette wick and heater combination, such as a porous ceramic wick and resistive heater wire or track.

[0014] The aerosolization unit is connected to the capsule by the aforementioned protrusion, which draws liquid from the capsule to the point of aerosolization. The materials, shape, form, and dimensions of the capsule and of the protrusion are such that liquid does not leak externally from the capsule or aerosolization system, ensuring all liquid is aerosolized for the user to inhale.

[0015] Furthermore, the aerosolization system consists of a self-contained aerosolization unit that can be detachably removed from the aerosolization system. When attached to the aerosolization system, electrical contacts electrically connect the aerosolization unit to the source of electrical power within the device, such as a rechargeable battery. However, the electrical contact is broken when the aerosolization unit is removed.

[0016] The aerosolization unit is locked into position in the aerosolization system by means of mechanical engagement. The mechanical engagement rigidly holds the aerosolization unit in place but can also be easily disengaged when required. The aerosolization unit is easily removable so that it can either be replaced by a new aerosolization unit after a period of use or preferably so that it can be cleaned periodically and replaced for further use.

[0017] A location feature within the aerosolization system will correspond to an engaging feature on the aerosolization unit. This ensures the correct orientation and positioning of the aerosolization unit within the aerosolization system so that it can be easily removed and replaced correctly every time. The aerosolization unit consists of an assembly of components that permanently encase the aerosolization technology, which preferably would be an ultrasonic vibrating mesh nebulizer, but alternatively could be a porous ceramic wick with resistive heating or another such suitable aerosolization technology.

[0018] The aerosolization unit consists of the protrusion for interfacing with the liquid capsule, the internal channels for drawing the liquid from the liquid capsule to the aerosolization technology, and a capillary chamber that stores the liquid in proximity to the aerosolization technology in preparation for it to be aerosolized. The materials, shape, form, dimensions, and surface texture of the capillary chamber are configured in such a way as to ensure the optimum volume of liquid is presented to the aerosolization technology at any one time regardless of the orientation of the aerosolization system, such that the aerosolization technology will always produce a repeatable and consistent aerosol for the user to inhale. The materials, shape, form, dimensions, and surface texture of the capillary chamber may require optimization for different variants of liquid, dependent on the physical parameters of the liquid, such as viscosity, surface tension, contact angle, density, etc.

[0019] When the aerosolization unit is in place within the aerosolization system, it forms an aerosolization chamber with the device. This is the area on the opposite side of the aerosolization technology to the capillary chamber. The aerosolization chamber is where the aerosol is formed and then drawn up through the mouthpiece when a user inhales. The electrical contacts for the aerosolization unit may also be housed within the aerosolization chamber.

[0020] It is the intention of this invention that the replaceable capsule remains connected to the protrusion of the aerosolization unit and hence the entirety of the aerosolization system until all the liquid from the capsule has been drawn into the aerosolization unit and aerosolized. However, it may be possible for the user to remove the capsule from the aerosolization system before all the liquid is aerosolized. As such, removing the capsule whilst liquid remains inside is possible. To prevent any remaining liquid from leaking from the open end of the capsule, the material, shape, form, dimensions, and surface texture of the open end of the capsule are configured such that the physical parameters of the liquid prevent it from leaking. This will rely upon the viscosity, surface tension, contact angle, and density of the liquid in combination with the material, shape, form, dimensions, and surface texture of the open end of the capsule.

[0021] The replaceable capsule is held in position by means of a separate mouthpiece that attaches to the main body of the aerosolization system, keeping the capsule in position. The aerosol produced by the aerosolization unit is drawn up through the inside of the mouthpiece when the user inhales and exits the open end of the mouthpiece and into the user’s mouth.

[0022] The mouthpiece's internal surfaces, combined with the external surfaces of the capsule, form the passage through which the aerosol is drawn to the open end of the mouthpiece and into the user’s mouth. Consequently, either the internal surfaces of the mouthpiece or the external surfaces of the capsule, or both, may be designed to optimize the aerosol flow path.

[0023] In addition, the external surfaces of the aerosolization unit will have features to allow the aerosol to flow from the aerosol chamber to the flow path between the mouthpiece and capsule.

[0024] It is possible that condensation may form on the internal surfaces of the mouthpiece or the external surfaces of the capsule as the aerosol is drawn through it. To prevent any liquid droplets of condensation from being drawn from the mouthpiece into the user’s mouth, the inside of the mouthpiece may contain an absorbent component. Such an absorbent component may then absorb droplets and prevent them from traveling out of the mouthpiece. Such an absorbent component would be replaceable, such that if it became fully saturated, it would be replaced with a fresh absorbent component. Preferably, the absorbent component would be attached to the replaceable capsule and, as such, would be replaced by default when a new capsule is inserted. The absorbent component may permanently connect with the replaceable capsule or may be detachable from it.

[0025] The action of attaching the mouthpiece to the aerosolization system could simultaneously push the capsule onto the protrusion and break the removable section of the capsule or push the sealing bung into the capsule to allow liquid to be drawn into the aerosolization unit. Alternatively, the capsule could be pushed onto the protrusion by the user independently of the mouthpiece, with the mouthpiece being attached after the capsule has interfaced with the aerosolization unit.

[0026] Once in place, the replaceable capsule is pressed onto a seal on the top face of the aerosolization unit by the mouthpiece. This seal ensures that no liquid leaks from the capsule into the mouthpiece cavity, and all liquid is drawn into the capillary chamber.

[0027] An embodiment of this invention relies on the aerosolization system being activated when airflow is detected. The airflow will be the result of a user inhaling on the device. The aerosolization system will detect the airflow by means of a pressure sensor, flow sensor, or other electrical or mechanical means. Once airflow is detected, electrical power from the rechargeable battery or other power source will be applied to the aerosolization unit by means of the electrical contacts. As a result, aerosol will be generated in the aerosolization chamber and drawn through the mouthpiece into the user’s mouth.

[0028] Another embodiment of this invention will include a locking feature that secures the outer case of the aerosolization system. The outer case may be required to protect the internal components of the aerosolization system, such as the aerosolization unit, the battery, the electronics, etc. The aforementioned locking feature will be easily unlocked by the user using a simple tool to allow the outer case to be removed. As such, if required, the battery can be removed and replaced. In addition, the removal of the outer case could result in the mechanical engagement that locks the aerosolization unit in place being released, allowing the aerosolization unit to be removed.

[0029] In accordance with a first aspect of the present invention there is an aerosol generating device comprising: a main body housing a power supply; a mouthpiece portion releasably secured to the main body and configured for housing a consumable; an aerosol unit configured to be releasably secured within the main body and electrically connected to the power supply, the aerosol unit comprising: an aerosol generator for generating an aerosol; and a wicking component configured for receipt in an outlet of the consumable and for providing fluid communication between the outlet of the consumable and the aerosol generator; wherein an airflow passage extends between an upstream inlet of the aerosol unit and a downstream outlet of the mouthpiece portion.

[0030] It is preferred that the wicking component is elongate.

[0031] It is also preferred that the wicking component comprises at least one internal fluid channel.

[0032] In addition, it is preferred that the aerosol unit comprises a capillary chamber in fluid communication with the at least one internal fluid channel.

[0033] It is preferred that the capillary chamber is configured to hold a consumable liquid in contact with the aerosol generator using capillary action.

[0034] It is also preferred that the aerosol generator comprises an ultrasonic vibrating mesh.

[0035] Alternatively, the aerosol generator comprises a resistive heater. Preferably, the aerosol unit further comprises an aerosol chamber in which the aerosol is formed.

[0036] It is also preferred that the mouthpiece houses an absorbent component in the airflow passage.

[0037] Further still, it is preferred that the airflow passage extends through an internal bore formed in the absorbent component.

[0038] In addition, it is preferred that the device comprises a sensor means, and preferably, the device is configured to supply electrical power to the aerosol generator in response to sensing of a defined condition by the sensor means.

[0039] It is preferred that the sensor means is an air flow sensor or a pressure sensor.

[0040] In addition, it is preferred that the aerosol unit is provided with a seal formed around a base of the wicking component.

[0041] It is also preferred that the elongate wicking component comprises a venting recessed portion formed in an outer surface along its length.

[0042] In addition, it is preferred that the aerosol unit is releasably secured within the main body by a snap-fit mechanism.

[0043] In accordance with a second aspect of the invention, there is a system comprising an aerosol generating device as in the first aspect, further comprising a consumable.

[0044] Preferably, the consumable is comprised of a tank for holding the consumable liquid, and wherein the tank is hermetically sealed at its upper end by an end cap.

[0045] It is also preferred that the tank comprises a removeable portion formed at its lower end.

[0046] In addition, it is preferred that the removeable portion is configured to engage the wicking component and detach from the tank upon application of a force that is above a predetermined threshold. Preferably, the tank comprises a hollow guiding portion that extends around the periphery of the removeable portion.

[0047] It is preferred that the hollow guiding portion is configured to receive the wicking component.

[0048] In addition, it is preferred that upon insertion of the consumable into the main body, an outer peripheral edge of the hollow guiding portion is configured to engage the seal.

[0049] Preferably, the consumable comprises an airflow recess formed on an outer face of the tank.

[0050] Further still, it is preferred that the absorbent material is releasably coupled to the end cap.

[0051] Preferably, the consumable is comprised of a plastics or polymer material.

[0052] It is also preferred that the removable portion is integrally formed with the tank.

[0053] Embodiments of this invention are now described, by way of example, with reference to the following drawings:

[0054] Figures 1A and 1 B show a schematic perspective view and a cross-sectional view of an aerosolization system in an embodiment of the present invention;

[0055] Figure 2 shows an exploded view of an aerosolization system, including a replaceable liquid capsule and a mouthpiece;

[0056] Figure 3 shows an exploded view of an aerosolization system, including a replaceable liquid capsule, an absorbent component, and a mouthpiece;

[0057] Figure 4 shows an exploded cross-sectional view of an aerosolization system, including a replaceable liquid capsule, an absorbent component, a mouthpiece, and an aerosolization unit;

[0058] Figures 5A and 5B show a cross-sectional view of a capsule with an integral removable section being broken by a protrusion;

[0059] Figures 6A and 6B show a cross-sectional view of a capsule with a sealing bung being pushed into the capsule by a protrusion; Figure 7 shows a cross-sectional view of a capsule engaged with an aerosolization system without an absorbent component in the mouthpiece;

[0060] Figure 8 shows a cross-sectional view of a capsule engaged with an aerosolization system with an absorbent component in the mouthpiece and an airflow path between the capsule and mouthpiece;

[0061] Figure 9 shows a cross-sectional view of a capsule engaged with an aerosolization system, including the construction of the aerosolization unit;

[0062] Figure 10 shows a schematic perspective view of a capsule with an absorbent component attached;

[0063] Figure 11 shows a schematic perspective view of a capsule without an absorbent component attached;

[0064] Figure 12 shows a cross-sectional view of a capsule with an integral removable section;

[0065] Figure 13 shows a cross-sectional close-up view of an integral removable section;

[0066] Figure 14 shows a cross-sectional view of a capsule with a sealing bung;

[0067] Figure 15 shows a cross-sectional close-up view of a capsule open end with the integral removable section or sealing bung removed;

[0068] Figure 16 shows a schematic perspective view of an aerosolization unit housed within an aerosolization system;

[0069] Figure 17 shows a top view of an aerosolization unit housed within an aerosolization system;

[0070] Figures 18 and 19 show a schematic perspective view of an aerosolization unit removed from an aerosolization system;

[0071] Figure 20 shows a schematic perspective view of an aerosolization system with the capsule, mouthpiece, and aerosolization unit removed; Figure 21 shows a top view of an aerosolization system with the capsule, mouthpiece, and aerosolization unit removed;

[0072] Figure 22 shows a cross-sectional view of a mechanical locking mechanism for an aerosolization unit within an aerosolization system;

[0073] Figure 23 shows a schematic perspective view of an aerosolization system with the outer case removed;

[0074] Figures 24A and 24B show a cross-sectional view of an aerosolization unit being unlocked and removed from an aerosolization system;

[0075] Figures 25A and 25B show a schematic perspective view of an aerosolization unit;

[0076] Figure 26 shows an exploded view of an aerosolization unit;

[0077] Figure 27A shows a cross-sectional view of an aerosolization unit containing an ultrasonic vibrating mesh aerosolization technology;

[0078] Figure 27B shows a cross-sectional view of an aerosolization unit containing a porous ceramic wick and resistive heater aerosolization technology;

[0079] Figures 28A, 28B, 28C, 28D, 28E, 28F, 28G, 28H, and 28I show schematic perspective views of various embodiments of aerosolization unit protrusions, including various geometries for internal channels and venting features;

[0080] Figure 29 shows a close-up schematic perspective view of an outer case locking feature;

[0081] Figure 30 shows a schematic perspective view of an outer case being removed and revealing a locking mechanism;

[0082] Figure 31 shows a schematic perspective view of an outer case being removed and revealing a battery and battery compartment;

[0083] Figure 32 shows a schematic perspective view of an outer case removed and the removal of a battery. Figure 1A shows an aerosolization system 1 according to an embodiment of the present invention having a mouthpiece 2 and main body 3.

[0084] Figure 1 B shows that the main body 3 consists of, amongst other components, a battery 10, an internal chassis 9, and an outer case 8. An aerosolization unit 29 is housed within the main body 3. Contained within the mouthpiece 2 is a replaceable capsule 4 and an absorbent component 5.

[0085] Figures 2 and 3 show embodiments of an aerosolization system 1 , with a mouthpiece 2, replaceable capsule 4, absorbent component 5, and main body 3 in an exploded view.

[0086] Figure 4 shows an embodiment of a mouthpiece 2 with the open end 11 where the aerosol is drawn out into the user’s mouth. The absorbent component 5 is cylindrical in shape with an internal bore 12 through which the aerosol is intended to flow, whilst any droplets are absorbed within the absorbent component 5 before they reach the user’s mouth.

[0087] The absorbent component 5 is attached to the replaceable capsule 4 by means of the end cap 14. The end cap 14 is hermetically sealed to the liquid holding tank 13 with an interference fit, ultrasonic welding, sealant, or another suitable sealing method. Integral to the structure of the liquid holding tank 13 is the removable section 15. The removable section 15 is formed as an integral part of the liquid holding tank 13 as an injection moulded component or similar manufacturing process. The materials of the replaceable capsule 4 components are preferably plastic or polymer, such that they can be moulded in high volume at low cost and contain the relevant features and detail. In particular, the removable section 15 will be integrally moulded to the liquid holding tank 13 and connected to the liquid holding tank 13 by means of continuous integral breakable features 24, which also form part of the plastic moulding.

[0088] The protrusion 6 is a feature of the aerosolization unit 29, which contains one or more internal channels 40 to draw liquid from the replaceable capsule 4 to the capillary chamber 18. The capillary chamber 18 is dimensioned and shaped in such a way as to hold liquid by means of capillary action against the ultrasonic vibrating mesh 7, regardless of the orientation of the aerosolization system 1.

[0089] Figures 5A and 5B show how the replaceable capsule 4 with a removable section 15 is inserted into the main body 3. As the exit tube 16 of the replaceable capsule 4 is pushed down over the protrusion 6, either by the user or by means of the mouthpiece 2 being attached to the main body 3, the protrusion 6 exerts a force on the removable section 15 to such an extent that the removable section 15 becomes detached from the liquid holding tank 13. A clamping feature 19 included as part of the mouthpiece 2 interfaces with the end cap 14 of the replaceable capsule 4, exerting a downward force as the mouthpiece 2 is attached to the main body 3. This downward force is enough for the protrusion 6 to break the removable section 15 and open the replaceable capsule 4 such that the liquid contained within can be drawn down the internal channels 40 of the protrusion 6 by means of capillary action.

[0090] The exit tube 16 is dimensioned such that it fits neatly over the protrusion 6, helping to guide the replaceable capsule 4 over the protrusion 6. Once in position, the exit tube 16 is compressed against the seal 17 of the aerosolization unit, such that no liquid can leak passed the interface, and all liquid is drawn down the internal channels 40 to the capillary chamber 18.

[0091] Below the ultrasonic vibrating mesh 7 can be found the aerosolization chamber 21 where the aerosol is formed by the ultrasonic vibrating mesh 7 before it is drawn up and out via the mouthpiece 2 into the user’s mouth.

[0092] Figures 6A and 6B show an alternative embodiment of the replaceable capsule 4, wherein the removable section 15 has been replaced by a sealing bung 20. As in the aforementioned embodiment, when the replaceable capsule 4 is inserted over the protrusion 6, the sealing bung 20 is pushed by the protrusion 6 into the liquid holding tank 13 allowing liquid to be drawn from the replaceable capsule 4 down the internal channels 40 of the protrusion 6.

[0093] Figure 7 shows an embodiment where the absorbent component 5 is not present within the mouthpiece 2.

[0094] Figure 8 shows an embodiment of the replaceable capsule 4 where the outer wall of the liquid holding tank 13 contains an airflow channel 22, which helps direct aerosol from the aerosolizing chamber 21 to the open end 11 of the mouthpiece 2.

[0095] Figure 9 shows the aerosolization chamber 21 and the electrical contacts 23 contained therein. The electrical contacts 23 may take the form of flexible electrical connectors, such as pogo pins or spring contacts, which enable the aerosolization unit 29 to be detachably removed and reattached without the need for permanent electrical contacts or wires connecting the aerosolizing unit 29 to the main body 3. Figures 10 and 11 show embodiments of the replaceable capsule 4, with an external airflow channel 22, with and without an absorbent component 5 respectively.

[0096] Figure 12 shows a cross-sectional view of an embodiment of a replaceable capsule 4 and how the various components interact. The removable section 15 can be seen in close up detail in Figure 13, whereby the removable section 15 is integrally attached to the liquid holding tank 13 by a continuous breakable feature 24. When the exit tube 16 of the replaceable capsule 4 is inserted over the protrusion 6 and a force is exerted, the protrusion breaks the breakable feature 24 and pushes the removable section 15 into the liquid holding tank 13, thus allowing liquid to be drawn down the internal channels 40 towards the capillary chamber 18.

[0097] Similarly, Figure 14 shows an embodiment of the replaceable capsule 4 with a sealing bung 20 in place of a removable section 15. The protrusion 6 pushes the sealing bung 20 into the liquid holding tank 13, thus allowing liquid to be drawn down the internal channels 40 towards the capillary chamber 18.

[0098] Figure 15 shows a close-up view of the exit tube 16 of the replaceable capsule 4 once the removable section 15 or sealing bung 20 has been removed. If the replaceable capsule 4 is removed from the aerosolization system 1 whilst liquid still remains in the liquid holding tank 13, the material, shape, form, dimensions, and surface texture of the exit tube 16, capsule opening 26, and capsule exit walls 26 are all such that liquid should not leak out of the exit tube 16 by virtue of viscosity, surface tension, contact angle, density, etc. For instance, the capsule opening 25 and exit tube 16 diameter may be between 2mm and 6mm, and more preferably between 3mm and 5mm. The length of the exit tube 16 may be between 2mm and 12mm long and, more preferably, between 4mm and 8mm long. The angle to the vertical plane of the capsule exit walls 26 may be between 10 degrees and 80 degrees, and more preferably between 30 degrees and 60 degrees.

[0099] Figures 16 and 17 show an embodiment of the aerosolization system 1 without the mouthpiece 2 and replaceable capsule 4. It shows the aerosolization unit 29 in place within the main body 3. A location feature 27 in the main body 3 helps locate and position the aerosolization unit 29 in the correct orientation within the main body 3. A corresponding engagement feature 34 in the aerosolization unit 20 engages with the location feature 27. In addition, multiple aerosol channels 28 are formed between the outer surfaces of the aerosolization unit 29 and the inner surfaces of the internal chassis 9 within the main body 3. These aerosol channels 28 allow the aerosol that is generated in the aerosolization chamber 21 to flow to the mouthpiece 2 and through the open end 11 into the user’s mouth. Figures 18, 19, 20 and 21 show an embodiment of the aerosolization unit 29 and the area where it is located within the main body 3. With the aerosolization unit 29 removed, the electrical contacts 23 can be clearly seen in the main body 3. In addition to the location feature 27 engaging with the engagement feature 34, the aerosolization unit is positioned to rest upon one or more supports 32 as part of the internal chassis 9. Also included in the internal chassis 9 are one or more locking features 33, which lock the aerosolization unit 29 in place. Such locking features 33 need to be disengaged before the aerosolization unit 29 can be removed for cleaning or replacement.

[0100] Figure 22 shows a cross-sectional embodiment of the aerosolization unit 29 within the main body 3. In particular, an embodiment of the locking features 33 can be seen. The locking features 33 are formed as an integral part of the internal chassis 9. When the outer case 8 is present, the locking features 33 engage with the aerosolization unit 29 such that it cannot be removed from the main body 3. The aerosolization unit 29 consists of a top flange 30, a gasket 35, an ultrasonic vibrating mesh 7, and a bottom flange 31. In this embodiment, the top flange 30 and bottom flange 31 combine together to form a retention feature 37 that the locking feature 33 engages with to lock the aerosolization unit 29 in place. In addition, the top flange 30, gasket 35, and ultrasonic vibrating mesh 7 combine to form the capillary chamber 18, where liquid is held by capillary action prior to aerosolization.

[0101] Figure 23 shows an embodiment of the aerosolization system 1 with the outer case 8 removed such that the internal chassis 9 is visible along with a battery 10 and the locking features 33.

[0102] Figures 24A and 24B show an embodiment of the invention when the outer case 8 has been removed. As such, the locking features 33 are free to move and no longer exert the retention on the aerosolization unit 29 as they did when the outer case 8 was present. Therefore the aerosolization unit 29 is no longer locked in position and can be removed for cleaning or replacement.

[0103] Figures 25A and 25B show in more detail the aforementioned features of an embodiment of the aerosolization unit 29. In particular, Figure 25B shows the electrical contact holes 38 that mate with the electrical contacts 23 of the main body 3 in order to supply power to the aerosolization technology 7.

[0104] Figure 26 shows an exploded view of an embodiment of the aforementioned aerosolization unit 29. Figure 27A shows a cross-sectional view of an embodiment of the aerosolization unit 29 wherein the aerosolization technology is an ultrasonic vibrating mesh 7 as commonly found in medical nebulizers.

[0105] Figure 27A shows a cross-sectional view of an embodiment of the aerosolization unit 29 wherein the aerosolization technology is a porous ceramic heater 39 as commonly found in electronic cigarettes.

[0106] Figures 28A, 28B, 28C, 28D, 28E, 28F, 28G, 28H, and 281 show various embodiments of the protrusion 6. These are just some examples of the possible profiles of the protrusion 6 used to break the removable section 15 or push the sealing bung 20 out of place. In addition, various embodiments of internal channels 40 can be seen for drawing the liquid from the replaceable capsule 4 towards the capillary chamber 18. If required, a venting channel 41 can be added to the protrusion 6 to allow air into the replaceable capsule 4 to replace any liquid that has been drawn out and aerosolized.

[0107] Figures 29, 30, 31 and 32 show an embodiment of the invention whereby the outer case 8 can be locked and released from the internal chassis 9. One embodiment of the aerosolization system 1 requires the outer case 8 to be removed in order to remove both the aerosolization unit 29 and the battery 10. Such an embodiment consists of a locking tab 43 that is integral to the internal chassis 9 by means of a cantilever 45. The locking tab 43 of the internal chassis 9 engages with the locking recess 44 of the outer case 8. If the locking tab 43 is depressed by the user, by the means of a pin, needle, pen, or another similar tool, the locking tab 43 then disengages from the locking recess 44 by deflection of the cantilever 45, allowing the outer case 8 to slide off the internal chassis 9.

[0108] The above description explains certain embodiments of the inventions. However, other embodiments not described but obvious and apparent to those skilled in the mechanical arts, electrical arts, and aerosol generation or related fields are intended to be within the scope of this invention and the associated claims.

Claims

CLAIMS1. An aerosol generating device comprising: a main body housing a power supply; a mouthpiece portion releasably secured to the main body and configured for housing a consumable; an aerosol unit configured to be releasably secured within the main body and electrically connected to the power supply, the aerosol unit comprising: an aerosol generator for generating an aerosol; and a wicking component configured for receipt in an outlet of the consumable and for providing fluid communication between the outlet of the consumable and the aerosol generator; wherein an airflow passage extends between an upstream inlet of the aerosol unit and a downstream outlet of the mouthpiece portion.

2. The aerosol generating device of claim 1 , wherein the wicking component is elongate.

3. The aerosol generating device of any preceding claim, wherein the wicking component comprises at least one internal fluid channel.

4. The aerosol generating device of claim 3, wherein the aerosol unit comprises a capillary chamber in fluid communication with the at least one internal fluid channel.

5. The aerosol generating device of claim 4, wherein the capillary chamber is configured to hold a consumable liquid in contact with the aerosol generator using capillary action.

6. The aerosol generating device of any of the preceding claims, wherein the aerosol generator comprises an ultrasonic vibrating mesh.

7. The aerosol generating device of claim 5, wherein the aerosol generator comprises a resistive heater.

8. The aerosol generating device of any of the preceding claims, wherein the aerosol unit further comprises an aerosol chamber in which the aerosol is formed.

9. The aerosol generating device of any preceding, wherein the mouthpiece houses an absorbent component in the airflow passage.

10. The aerosol generating device of claim 9, wherein the airflow passage extends through an internal bore formed in the absorbent component.

11. The aerosol generating device of any preceding claim, wherein the device comprises a sensor means.

12. The aerosol generating device of claim 11 , wherein the device is configured to supply electrical power to the aerosol generator in response to sensing of a defined condition by the sensor means.

13. The aerosol generating device of claim 13, wherein the sensor means is an air flow sensor.

14. The aerosol generating device of claim 13, wherein the sensor means is a pressure sensor.

15. The aerosol generating device of any preceding claim, wherein the aerosol unit is provided with a seal formed around a base of the wicking component.

16. The aerosol generating device of any claims 2 to 15, wherein the elongate wicking component comprises a venting recessed portion formed in an outer surface along its length.

17. The aerosol generating device of any preceding claims, wherein the aerosol unit is releasably secured within the main body by a snap-fit mechanism.

18. A system comprising an aerosol generating device as claimed in any preceding claim, further comprising a consumable.

19. The system of claim 18, wherein the consumable is comprised of a tank for holding the consumable liquid, and wherein the tank is hermetically sealed at its upper end by an end cap.

20. The system of claim 19, wherein the tank comprises a removable portion formed at its lower end.

21. The system of claim 20, wherein the removable portion is configured to engage the wicking component and detach from the tank upon application of a force that is above a predetermined threshold.

22. The system of any claims 18 to 21, wherein the tank comprises a hollow guiding portion that extends around the periphery of the removable portion.

23. The system of claim 22, wherein the hollow guiding portion is configured to receive the wicking component.

24. The system of any claims 22 to 23, wherein upon insertion of the consumable into the main body, an outer peripheral edge of the hollow guiding portion is configured to engage the seal.

25. The system of any claims 18 to 24, wherein the consumable comprises an airflow recess formed on an outer face of the tank.

26. The system of any claims 18 to 25, wherein the absorbent material is releasably coupled to the end cap.

27. The system of any claims 18 to 26, wherein the consumable is comprised of a plastics or polymer material.

28. The system of any claims 18 to 27, wherein the removable portion is integrally formed with the tank.

Images