Aerosolizing system and replaceable capsule with an integral absorbent pad

Abstract

A consumable (4) for an aerosol generating device comprising: an upper body portion housing a liquid holding tank (14); and a lower body portion (46) comprising: an absorbent pad (48) for holding a li

Description

The present application claims the benefit of priority to and incorporates by reference herein the entirety of UK patent application number GB2312051.2 filed on 7 August 2023. This invention relates to an aerosolizing system and replaceable capsules with an integral absorbent pad. The capsules are intended to contain a liquid formulation. The aerosolizing system is intended to aerosolize the liquid formulation contained within the capsule. The integral absorbent pad is intended to present the liquid formulation to the aerosolizing technology. A user may then inhale upon the aerosolizing system to cause the aerosol to flow into their mouth and lungs. 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. 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. 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. 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. Various embodiments of liquid capsules have previously been disclosed, for example, in WO2017167513 and WO2020193659, 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. Not 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. The invention that is the subject of UK patent application number GB2312051.2 intends to overcome the shortcomings of existing aerosolizing systems with replaceable capsules. The capsule that is the subject of the UK patent application number GB2312051.2 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. 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. 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. The replaceable capsule that is the subject of UK patent application number GB2312051.2 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. The subject of this present invention contains many of the features described within UK patent application number GB2312051.2, such as a hermetically sealed liquid capsule; an integrally formed removable section of said capsule; a protrusion containing internal channels for exerting a capillary action on the liquid contained within the capsule; and a self-contained aerosolization unit that can be detachably removed from the aerosolization system. Where this present invention differs is that the protrusion containing the internal channels is an integral part of the capsule itself, added to which is an absorbent pad that is saturated with the liquid formulation once the removable section of the capsule has been removed. The protrusion feature containing the internal channels forms part of a moveable liquid transport component. This component is attached to the hermetically sealed capsule by means of locking features and locking recesses. The moveable liquid transport component has an absorbent pad permanently attached to the face opposite to the aforementioned protrusions. The internal channels run the full length of the moveable liquid transport component, transporting liquid from the hermetically sealed capsule to the absorbent pad, once the removable section has been removed. The absorbent pad becomes saturated with liquid as it is drawn down the internal channels by capillary action from the capsule. The saturated absorbent pad is in communication with the aerosolization technology, which is preferably an ultrasonic vibrating piezo mesh, or an ultrasonic vibrating piezo solid disc. The liquid within the absorbent pad can then be aerosolized by the vibrating action of either the ultrasonic vibrating piezo mesh or the ultrasonic vibrating piezo solid disc. The purpose of the absorbent pad is to hold sufficient liquid in close proximity to the ultrasonic vibrating technology such that sufficient aerosol can be generated when a user puffs on the device. The absorbent pad also ensures that there is not too much liquid present, which may result in unwanted leakage or flooding or over-loading of the ultrasonic vibrating technology to the extent that the device does not perform as intended. In UK patent application number GB2312051.2 there is a capillary chamber that contains a volume of liquid behind the ultrasonic vibrating piezo mesh. This volume of liquid is then drawn through the holes of the mesh when it vibrates and therefore aerosolizes the liquid. However, this approach of a volume of liquid in a capillary chamber would not work for an ultrasonic vibrating piezo solid disc, as the liquid cannot pass through the solid disc. This is where the saturated absorbent pad has an advantage, as the aerosolization can occur on the same side of the solid disc that the liquid is present, and the liquid does not need to pass through to the other side of the disc, as it does in the case of the piezo mesh. Another advantage of the absorbent pad in this present invention is that it is permanently attached to the liquid capsule itself. Therefore, once the capsule is empty of liquid, the capsule along with the integral absorbent pad can be removed from the device and discarded or recycled. So each time a new capsule is inserted into the device, it comes with a fresh absorbent pad. This ensures that the longevity of the absorbent pad only needs to be as long as the liquid lasts within each capsule. It is intended that the absorbent pad is permanently attached to the capsule, via the moveable liquid transport component, by means of bonding, and most preferably by ultrasonically welding the absorbent pad to the plastic component of the capsule. Embodiments of this invention are now described, by way of example, with reference to the following drawings: Figures 1A and IB show a schematic perspective view and a cross-sectional view of an aerosolization system in an embodiment of the present invention; Figure 2 shows an exploded view of an aerosolization system, including a replaceable liquid capsule and a mouthpiece; Figure 3 shows an exploded view of an aerosolization system, including a replaceable liquid capsule, an absorbent component, and a mouthpiece; 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; Figures 5A and 5B show a cross-sectional view of a liquid capsule being inserted into the mouthpiece; Figures 6A and 6B show a cross-sectional view of a liquid capsule with an integral removable section being broken by a protrusion; Figure 7 shows a cross-sectional view of a liquid capsule engaged with an aerosolization system before the removable section has been removed; Figure 8 shows a cross-sectional view of a liquid capsule engaged with an aerosolization system after the removable section has been removed; Figure 9 shows a view of the liquid capsule before the moveable liquid transport component has removed the removable section within the capsule; Figure 10 shows a view of the liquid capsule after the moveable liquid transport component has removed the removable section within the capsule; Figure 11 shows a cross section of the liquid capsule before the moveable liquid transport component has removed the removable section within the capsule; Figure 12 shows a close up cross-sectional view of the integral removable section; Figure 13 shows a cross section of the liquid capsule after the moveable liquid transport component has removed the removable section within the capsule; Figure 14 shows an exploded view of the liquid capsule; Figure 15 shows an exploded view of the liquid capsule; Figure 16 shows an exploded view of the sub-assemblies of the liquid capsule Figure 17 shows an assembled view of the liquid capsule; Figures 18 shows a cross section of the liquid capsule before the moveable liquid transport component has removed the removable sections within the capsule; Figure 19 shows a cross section of the liquid capsule after the moveable liquid transport component has removed the removable sections within the capsule; Figure 20 shows a cross section of the liquid capsule after the moveable liquid transport component has removed the removable sections within the capsule; Figure 21 shows a view of the moveable liquid transport component with a single protrusion for use with the piezo mesh; Figure 22 shows a view of the moveable liquid transport component with two protrusions for use with the piezo solid disc; Figure 23 shows a view of the moveable liquid transport component with two protrusions for use with the piezo solid disc, and the ultrasonic weld protrusions where the absorbent pad would be attached; Figures 24 shows a view of the moveable liquid transport component with a single protrusion for use with the piezo solid disc, and the ultrasonic weld protrusions where the absorbent pad would be attached; Figures 25 shows the aerosolization unit within the device; Figure 26 shows the aerosolization unit removed from the device; Figure 27 shows the recess within the device where the aerosolization unit fits; Figure 28 shows the piezo solid disc aerosolization unit locked in place within the device; Figure 29 shows the piezo mesh aerosolization unit locked in place within the device; Figures 30A, 30B, 30C, 30D, 30E, 30F, 30G, 30H, and 301 show schematic perspective views of various embodiments of moveable liquid transport component protrusions, including various geometries for internal channels and venting features; Figure 1A shows an aerosolization system 1 according to an embodiment of the present invention having a mouthpiece 2 and main body 3. Figure IB 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. 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. 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. The absorbent component 5 is attached to the replaceable capsule 4 by means of an interference fit with the liquid holding tank 13. 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 end cap 14 is the removable section 15. The removable section 15 is formed as an integral part of the end cap 14 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 end cap 14 and connected to the end cap 14 by means of continuous integral breakable features 24, which also form part of the plastic moulding. The protrusion 6 is a feature of the moveable liquid transport component 46, which contains one or more internal channels 40 to draw liquid from the liquid holding tank 13 to the absorbent pad 48. The absorbent pad 48 becomes saturated with liquid which is then presented to the surface of the ultrasonic vibrating piezo mesh 53, or the ultrasonic vibrating piezo solid disc 52, regardless of the orientation of the aerosolization system 1. Figures 5A and 5B show how the replaceable capsule 4 is inserted into the mouthpiece 2. A ledge feature 55 on the liquid holding tank 13 butts up against the clamping feature 19 of the mouthpiece 2. Figures 6A and 6B show the mouthpiece 2 being attached to the main body 3, and the moveable liquid transport component 46 being pushed towards the end cap 14. The protrusion 6 exerts a force on the removable section 15 to such an extent that the removable section 15 becomes detached from the end cap 14. A clamping feature 19 included as part of the mouthpiece 2 interfaces with the ledge feature 55 of the liquid holding tank 13 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. Once the mouthpiece 2 is fully attached to the main body 3, the moveable liquid transport component 46 will have fully sandwiched the seal 17, ensuring no liquid can leak between the replaceable capsule 4 and the aerosolization unit 29. Below the ultrasonic vibrating piezo mesh 53 can be found the aerosolization chamber 21 where the aerosol is formed by the ultrasonic vibrating piezo mesh 53 before it is drawn up and out via the mouthpiece 2 into the user's mouth. Figure 7 shows a cross section of the replaceable capsule 4 once it has been inserted into the aerosolization system 1 and the mouthpiece 2 has been attached, but not fully tightened into position. Figure 8 shows a cross section of the replaceable capsule 4 once it has been inserted into the aerosolization system 1 and the mouthpiece 2 has been fully tightened into position, such that the removable section 15 has become detached from the end cap 14. Figure 9 shows the replaceable capsule 4 whereby the liquid holding tank 13, now containing liquid, has been permanently attached to the end cap 14 by some form of bonding, preferably ultrasonic welding, thereby creating a liquid holding capsule that is hermetically sealed. An absorbent component 5 is attached to the liquid holding tank 13, preferably by means of interference fit. The moveable liquid transport component 46 is attached to the end cap 14 by means of one or more locking features 47 that engage with an associated locking recess 50. The locking feature 47 and locking recess 50 are designed such that the moveable liquid transport component 46 can move along the axis of the replaceable capsule 4, such that once inserted into the aerosolization system 1 the protrusion 6 will push into and remove the removable section 15 of the end cap 14. Figure 10 shows the replaceable capsule 4 once the moveable liquid transport component 46 has been pushed into the end cap 14 and removed the removable section 15 of the end cap 14. Figures 11 and 12 show a cross section of the replaceable capsule 4, and in particular the detail of the removable section 15 and the breakable features 24 that ensure the removable section 15 is an integrally formed part of the end cap 14. Figure 13 show a cross section of the replaceable capsule 4 once the protrusion 6 of the moveable liquid transport component 46 has removed the removable section 15 of the end cap 14. Figures 14 and 15 show and exploded view of all the components of the replaceable capsule 4, including the absorbent pad 48 which is permanently attached to the moveable liquid transport component 46. Figures 16 and 17 show how the components and sub-assemblies of the replaceable capsule 4 come together to form the final product. Figures 18, 19, and 20 show an alternative embodiment of the replaceable capsule 4, in the case where the aerosolization unit 29 utilises an ultrasonic vibrating piezo solid disc 52, instead of an ultrasonic vibrating piezo mesh 53. In the case of the ultrasonic vibrating piezo solid disc 52, the aerosolization chamber 21 sits above, rather than below, the aerosolization unit 29. The absorbent pad 48 is saturated with liquid, which is aerosolized once the ultrasonic vibrating piezo solid disc 52 starts vibrating. In this case, the liquid within the absorbent pad 48 is sitting on top of the ultrasonic vibrating piezo solid disc 52. The aerosol is formed in the aerosolization chamber 21 above the ultrasonic vibrating piezo solid disc 52 and is then drawn up the central airway 51 and out through the mouthpiece 2. The central airway 51 is formed as part of the liquid holding tank 13, and as such the liquid is stored in the liquid holding tank 13 with the central airway 51 passing through the middle. Figure 21 shows an embodiment of the moveable liquid transport component 46 with a single protrusion 6 in the centre and two locking features 47 at the circumference. This embodiment would be used in conjunction with the ultrasonic vibrating piezo mesh. Figure 22 shows an embodiment of the moveable liquid transport component 46 with two outer protrusions 6 and two locking features 47. This moveable liquid transport component 46 has a central recess 54 which, once inserted into the aerosolization system 1 helps form the aerosolization chamber 21. This central recess 54 lines up with the central airway 51 of the liquid holding tank 13 to allow for a route by which generated aerosol can be drawn from the mouthpiece 2. Figures 23 and 24 show the two aforementioned embodiments of moveable liquid transport components 46, with an example of ultrasonic weld protrusions 49 on the underside. These ultrasonic weld protrusions 49 are one possible method for permanently attaching the absorbent pad 48 to the moveable liquid transport component 46. During the ultrasonic welding process, these ultrasonic weld protrusions 49 would melt and then permanently bond to the material of the absorbent pad 48, thus ensuring a permanent bond. Figures 25 and 26 show how the aerosolization unit 29 can be attached and oriented within the main body 3. Figure 27 shows the electrical contacts 23 within the aerosolization system 1 that will connect to the aerosolization unit 29. It also shows the locking features 33 and location features 27 required to orient and lock the aerosolization unit 29 in place. Figure 28 shows the locking features 33 and electrical contacts 23 for an aerosolization unit 29 that contains an ultrasonic vibrating piezo solid disc 52 arrangement. Figure 29 shows the locking features 33 and electrical contacts 23 for an aerosolization unit 29 that contains an ultrasonic vibrating piezo mesh 53 arrangement. Figures 30A, 30B, 30C, 30D, 30E, 30F, 30G, 30H, and 301 show various embodiments of the protrusion 6 as part of the moveable liquid transport component 46. These are just some examples of the possible profiles of the protrusion 6 used to break the removable section 15 of the end cap 14. In addition, various embodiments of internal channels 40 can be seen for drawing the liquid from the liquid holding tank 13 towards the absorbent pad 48. 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. 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

10 07 251. A consumable for an aerosol generating device comprising: an upper body portion housing a liquid holding tank; and5 a lower body portion comprising:an absorbent pad for holding a liquid against an aerosol generator; anda wicking component configured for receipt in an outlet of the liquid holding tank and for providing fluid communication between the outlet of the liquid holding tank and the absorbent pad, wherein the lower body portion is moveable relative to the10 upper body portion between a first, extended position in which the wicking componentis not in fluid communication with the liquid holding tank and a second retracted position, in which the wicking component is in fluid communication with the liquid holding tank.15 2. The consumable of claim 1, wherein the liquid holding tank comprises a removable portionformed at its lower end.

3. The consumable of claim 2, wherein the removable portion is configured to engage the wicking component and detach from the liquid holding tank when the lower body portion is moved into20 the second, retracted position.

4. The consumable of any preceding claim, wherein the wicking component forms an elongate protrusion.25 5. The consumable of any preceding claim, wherein the removeable portion is integrally formedwith liquid holding tank.

6. The consumable of any preceding claim, wherein the removable portion covers the outlet in the liquid holding tank.

307. The consumable of any preceding claim, wherein the upper body portion comprises a hollow guiding portion that extends around the periphery of the outlet.

8. The consumable of claim 7, wherein the hollow guiding portion is configured to receive the 35 wicking component.

9. The consumable of any preceding claim, wherein the wicking component comprises a venting recessed portion formed in an outer surface along its length.10 07 2510. The consumable of any preceding claim, wherein the upper body portion comprises an airflow passage.5 11. The consumable of claim 10, wherein the consumable comprises an airflow recess formed onan outer face of the upper body portion, wherein the airflow recess is in fluid communication with the airflow passage.

12. The consumable of claim 10, wherein the holding tank comprises an internal airway in fluid 10 communication with the airflow passage.

13. The consumable of claim 11 or 12, further comprising an absorbent component releasably secured in the airflow passage.15 14. Wherein the airflow passage extends through an internal bore formed in the absorbentcomponent.

15. The consumable of any preceding claim, wherein the wicking component comprises an internal channel fordrawing liquid from the liquid holding tank to the absorbent pad.2016. The consumable of claim 15, wherein the wicking component comprises a plurality of internal channels.

17. The consumable of any preceding claim, wherein the lower body portion comprises a plurality25 of wicking components, each for receipt in a corresponding outlet of the liquid holding tank.

18. The consumable of any preceding claim, wherein the consumable is comprised of a plastics or polymer material.30 19. The consumable of any preceding claim, wherein the absorbent pad is ultrasonically welded tothe lower body portion.

20. The consumable of any preceding claim, wherein the liquid holding tank is hermetically sealed and comprises an end cap that is ultrasonically welded at an open end of the tank.

21. 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 the consumable of any of claims 1 to 20; andan aerosol unit configured to be releasably secured within the main body and electrically connected to the power supply, the aerosol unit comprising;5 an aerosol generator for generating an aerosol; andan aerosol chamber in fluid communication with the aerosol generator;wherein an airflow passage extends between an upstream outlet of the aerosol chamber and a downstream outlet of the mouthpiece portion.10 22. The aerosol generating device of claim 21, wherein the absorbent pad is configured to hold aconsumable liquid in contact with the aerosol generator.

23. The aerosol generating device of any of claims 21 to 22, wherein the aerosol generator is an ultrasonic vibrating piezo mesh.1524. The aerosol generating device of any of claims 21 to 22, wherein the aerosol generator is an ultrasonic piezo solid disc.

25. The aerosol generating device of any claims 21 to 24, wherein the mouthpiece portion is 20 configured such that on assembly of the mouthpiece portion to the main body, the lower bodyportion of the consumable is urged into the second, retracted position.10 07 252530A

Images