Aerosolization Assembly

Abstract

A vibrating aerosolization assembly (20) for use in an aerosol generation device (10) is disclosed. The vibrating aerosolization assembly comprises an aerosolization module (21), a substantially flexible annular sealing member (22), and a substantially rigid casing (23). The aerosolization module comprises a vibratable transducer (211) and a membrane (212). The vibratable transducer is operatively coupled to the membrane so as to vibrate the membrane substantially axially in use. The sealing member is sealably coupled to a peripheral sealing area (215) of the aerosolization module. The substantially rigid casing is coupled to the sealing member. Coupling of the casing to the sealing member is limited to a retention area (221) of the sealing member. The retention area (221) is located outside the outermost periphery (D21) of the aerosolization module. The casing is more rigid than the sealing member. At least one parameter of the sealing member may be configured to mitigate against damping a vibration output of the vibratory transducer during use, the at least one parameter including one or more of a hardness of the sealing member, a Young's modulus of the sealing member, and an axial thickness of the sealing member.

Description

[Technical field]

[0001] The present disclosure relates to a vibrating aerosolization assembly for use in an aerosol generation device, as well as to a method of manufacturing the vibrating aerosolization assembly. The present disclosure also relates to an aerosol generation device including such an aerosolization assembly. [Background technology]

[0002] Known vibrating nebulizers for aerosolizing liquid aerosol-forming substrates use a membrane having a distribution of holes. The membrane is coupled to a vibrable transducer coupled to the periphery of the membrane. It is known that the transducer is enclosed and held in an annular sealing element. An electrical signal provided to the transducer is converted by the transducer into a vibration output, which induces vibration of the membrane. A liquid provided to one surface of the membrane is expelled through the holes in the membrane as a distribution of aerosol droplets by the vibration output of the transducer. However, the encapsulation and holding of the annular transducer by the sealing element may dampen the vibration output from the transducer, thereby limiting the vibration response of the membrane. As a result, the volume and velocity of the aerosol droplets emanating from the membrane may also be reduced. Therefore, the damping of the vibration output of the transducer reduces the quality of the aerosol droplet dispersion pattern emanating from the membrane.

[0003] The present disclosure is directed to the provision of a vibrating aerosolization assembly for use in an aerosol generating device that addresses one or more of the problems set forth above. Summary of the Invention

[0004] According to an aspect of the present disclosure, there is provided a vibratory aerosolization assembly for use in an aerosol generation device. The vibratory aerosolization assembly comprises an aerosolization module, a substantially flexible annular sealing member, and a substantially rigid casing. The aerosolization module comprises a vibrable transducer and a membrane. The vibrable transducer is operatively coupled to the membrane to vibrate the membrane substantially axially in use. The sealing member is sealably coupled to a peripheral sealing region of the aerosolization module. The substantially rigid casing is coupled to the sealing member. The coupling of the casing to the sealing member is limited to a retention region of the sealing member. The retention region is located outside an outermost periphery of the aerosolization module. The casing is more rigid than the sealing member. At least one parameter of the sealing member may be configured to cushion against damping a vibration output of the vibrable transducer during use, the at least one parameter comprising one or more of a hardness of the sealing member, a Young's modulus of the sealing member, and an axial thickness of the sealing member.

[0005] As used herein, the term "vibrable transducer" is used to refer to a device configured to convert energy from an initial form to a different form, where the different form includes or consists of a vibration output.

[0006] As used herein, the term "aerosol-generating device" is used to describe a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-generating device is preferably a smoking device that interacts with an aerosol-forming substrate to generate an aerosol that is inhalable directly through the user's mouth into the user's lungs.

[0007] As used herein, the term "aerosol-forming substrate" refers to a substrate made of or including an aerosol-forming material capable of releasing volatile compounds upon heating to generate an aerosol.

[0008] As used herein, the term "liquid" refers to a substance provided in liquid form, and includes a substance provided in the form of a gel.

[0009] As used herein, the term "axial thickness of the sealing member" refers to the thickness of the sealing member measured in a direction perpendicular to a plane generally defined by the membrane.

[0010] Mitigating the damping of the transducer's vibration output facilitates increasing the transducer's vibration output for a given energy input to the transducer, which in turn facilitates increasing the magnitude of the vibration membrane's displacement and thereby the quality of the aerosol droplet formation pattern generated in response to the membrane's vibration.

[0011] Ensuring that the retention area between the rigid casing and the sealing member is located outside the outermost perimeter of the aerosolization module also reduces damping of the transducer's vibrational output caused by contact between the casing and the sealing member. Locating the retention area outside the outermost perimeter of the aerosolization module allows the vibrational response of the transducer in response to a given energy input to the transducer to approach the ideal vibrational response of a completely unconstrained or free transducer.

[0012] The substantially rigid casing may form all or part of the housing of the aerosol generating device. As an example, the substantially rigid casing may be formed from a material such as a rigid plastic material (such as but not limited to polypropylene, high density polyethylene (HDPE), polyethylene terephthalate (PET), polyether ether ketone (PEEK), or polysulfone (PSU)) or a metal material (such as but not limited to aluminum). By having a retention area located outside the outermost periphery of the aerosolization module between the rigid casing and the sealing member, the constraint imposed by the casing on the sealing member occurs at a distance from the aerosolization module. As a result, damping of the vibration output of the transducer of the aerosolization module due to the casing constraining the sealing member can be minimized. The reduced damping can increase the vibration displacement of the membrane, thereby improving the quality of the aerosol droplet dispersion pattern when the liquid aerosol-forming substrate is delivered to the surface of the membrane. As used herein, the term "constraint" refers to the restriction of the movement of the sealing member.

[0013] The hardness, Young's modulus, and axial thickness of the sealing member are all parameters whose values ​​affect the extent to which the sealing member itself restricts the movement (and thereby the vibration output) of the transducer of the aerosolization module. Reducing the hardness of the sealing member will reduce the constraining effect of the sealing member on the transducer. Similarly, reducing the Young's modulus of the sealing member will also reduce the constraining effect of the sealing member on the transducer. Furthermore, reducing the axial thickness of the sealing member will also reduce the constraining effect of the sealing member on the transducer. Reducing the extent to which the sealing member restricts the movement of the transducer of the aerosolization module reduces the attenuation of the vibration output of the transducer by the sealing member. The net effect of reducing the constraint of the sealing member on the transducer is an increase in the vibration displacement of the membrane, thereby providing an aerosol droplet formation pattern of improved quality.

[0014] The membrane may be formed of any suitable material. By way of example and without limitation, the membrane may be formed of a polymeric material, thereby providing the advantage of reduced mass and inertia. However, the membrane may be formed of any other suitable material, such as a metal, semiconductor, dielectric, or ceramic material. The material may be crystalline or non-crystalline. The membrane may be a composite of two or more different materials. By way of example and without limitation, examples of membrane materials include stainless steel, palladium, silver, alloys such as Ni-Co or Ni-Pd, polyimides and polyamides, ceramics based on silicon, silicon carbide, silicon nitride, aluminum nitride, silicon oxide, aluminum oxide, or barium titanate, or combinations thereof, such as layered membranes composed of layers of silicon and silicon nitride or silicon oxide or metal. The choice of material used for the membrane may be influenced by the particular liquid aerosol-forming substrate intended to be used and aerosolized by the aerosolization module. For example, it is desirable to choose a material for the membrane that does not chemically react or decompose as a result of contact with the chosen liquid aerosol-forming substrate. By way of example only, the membrane may be formed of any of palladium, stainless steel, copper-nickel alloy, polyimide, polyamide, silicon, or aluminum nitride.

[0015] The hardness of the sealing member may preferably be within a range of 5 Shore A to 120 Shore A. More preferably, the hardness of the sealing member may be within a range of 20 Shore A to 40 Shore A.

[0016] As used herein, "Shore A" refers to the Shore A hardness scale. The Shore A hardness value of a sample of material is determined by the extent of penetration of the foot of a durometer into the sample.

[0017] The Young's modulus of the sealing member may be preferably in the range of 0.001 GPa to 1 GPa, and more preferably in the range of 0.01 GPa to 0.1 GPa.

[0018] By way of example, the sealing member may be formed from materials such as neoprene rubber, natural rubber, silicone rubber, nitrile rubber, ethylene propylene diene monomer (EPDM) rubber, styrene butadiene rubber, with silicone rubber being preferred for its biocompatibility. The hardness and Young's modulus may also be affected by any processing steps performed on the material used for the sealing member, such as the addition of one or more additives to the material selected for the sealing member.

[0019] The axial thickness of the sealing member may preferably be in the range of 1 mm to 10 mm. More preferably, the axial thickness of the sealing member may be in the range of 2 mm to 5 mm.

[0020] The Young's modulus of the substantially rigid casing is preferably in the range of 0.1 GPa to 100 GPa, or preferably in the range of 1 GPa to 10 GPa.

[0021] Advantageously, the membrane comprises an aerosol generation zone, the aerosol generation zone being provided with a plurality of nozzles for the passage of the liquid aerosol-forming substrate. The plurality of nozzles may allow a dispersion of aerosol droplets to be ejected from the nozzles when the liquid aerosol-forming substrate is provided to one surface of the vibrating membrane. The plurality of nozzles may have a diameter in the range of 1 micrometer to 20 micrometers. As used herein, the term "nozzle" is used to refer to an opening, hole or aperture through the membrane that provides a passage for the liquid aerosol-forming substrate to travel through the membrane. By way of example and without limitation, during use of the aerosolization assembly, the liquid aerosol-forming substrate may be brought into contact with a first side of the membrane. Vibration of the membrane caused by the vibration output of the transducer may cause the liquid substrate to be forced through the nozzles and emitted as an aerosol droplet forming pattern from a second (opposite) side of the membrane. The nozzles may be individually sized and arranged relative to one another to provide a predetermined aerosol droplet forming pattern.

[0022] The coupling of the casing to the sealing member may include the casing clamping opposing axial surfaces of the sealing member over at least a portion of a retention area. Clamping the sealing member may provide a more secure and reliable coupling between the casing and the sealing member. Ensuring that clamping occurs over a retention area of ​​the sealing member that is located outside the outermost periphery of the aerosolization module reduces damping of the vibration output of the transducer caused by the sealing member being clamped.

[0023] The casing may define a hole circumferentially surrounding the sealing member. An interference fit may be defined between the hole in the casing and a corresponding surface of the sealing member such that the casing radially compresses the sealing member. The interference fit between the corresponding surfaces defines all or a portion of the retention area. The use of such an interference fit radially compresses the sealing member as opposed to the axial compression of the sealing member that results from clamping opposing axial surfaces of the sealing member. The use of an interference fit may also be combined with clamping opposing axial surfaces of the sealing member.

[0024] Advantageously, the casing and sealing member may be substantially axisymmetric. The use of an axisymmetric configuration for the casing and sealing member may allow the constraining effect of the casing on the sealing member to be generally circumferentially uniform around the sealing member. The axisymmetric design may also provide a more uniform aerosol droplet formation pattern from the membrane at different circumferential positions around the membrane.

[0025] Advantageously, the retention area is substantially annular. Providing an annular retention area may enable the casing to apply a uniform circumferential constraint to the sealing member. The retention area may comprise a group of circumferentially arranged sub-areas that collectively define an annular profile. Circumferentially adjacent ones of the group of sub-areas may be circumferentially spaced apart from one another. As an example, the casing may clamp opposing axial surfaces of the sealing member by use of pairs of opposing teeth or protrusions that are circumferentially spaced apart from one another around the sealing member. Alternatively, the retention area may comprise a continuous annulus.

[0026] When the retention area is substantially annular, the ratio of the innermost diameter of the annular retention area to the outermost diameter of the aerosolization module is preferably greater than 1.5. This diameter ratio provides a sufficient radial gap between the retention area and the outermost periphery of the aerosolization module to reduce the damping effect of the casing on the vibration output of the transducer, thereby increasing the proportion of energy delivered to the transducer that is converted to vibrational displacement of the transducer, and thereby to vibrational displacement of the membrane.

[0027] The membrane is preferably circular in plan. The use of a circular membrane may be consistent with either or both of the following conditions (a) and (b).

[0028] a) the casing and the sealing member are substantially axially symmetric; b) the retention region is substantially circular;

[0029] A circular membrane may provide a more uniform aerosol droplet formation pattern from the membrane at different circumferential positions around the membrane, which may be beneficial when the aerosolization assembly forms part of an elongated cylindrical aerosol generating device intended to be used as a smoking device.

[0030] The vibratable transducer may be encapsulated within a sealing member. Encapsulation of the transducer within a sealing member not only protects the transducer from direct exposure to the liquid aerosol-forming substrate supplied for use with the aerosolization assembly, but may also provide some protection from impact damage.

[0031] Preferably, the vibratable transducer may comprise one or more piezoelectric actuators. Piezoelectric actuators are preferred as they are an energy-efficient, lightweight means of providing a vibration output from an electrical input. Piezoelectric actuators have a high efficiency of energy conversion from electrical to mechanical power. Furthermore, piezoelectric actuators are available in a wide variety of materials and shapes. In the case of a piezoelectric actuator, inputting an electrical drive signal to the piezoelectric actuator results in a mechanical output in the form of vibration. The vibration output from the transducer induces vibration of the membrane. Thus, the use of a piezoelectric actuator in or as a transducer provides an energy-efficient means of inducing vibration of the membrane. However, as an alternative to the use of a piezoelectric actuator, an actuator(s) including one or more of an electromagnetic element, a magnetostrictive element, or an electrostrictive element may also be employed in the vibratable transducer.

[0032] The one or more piezoelectric actuators may be arranged to define an annular piezoelectric actuator assembly. In one embodiment, the annular piezoelectric actuator assembly may be formed of a single annular piezoelectric actuator. Alternatively, in another embodiment, the annular piezoelectric actuator assembly may be formed of a plurality of circumferentially arranged piezoelectric actuators that collectively define an annular profile.

[0033] In a second aspect of the present disclosure, there is provided an aerosol generating device comprising a housing, a power source, control electronics, and a vibration aerosolization assembly according to any of the variations of the present disclosure. The housing includes a power source and control electronics. The control electronics is configured to control the supply of power from the power source to an aerosolization module of the vibration aerosolization assembly to activate the vibrable transducer in use. The housing is configured to hold a reservoir of liquid aerosol-forming substrate in fluid communication with a membrane of the aerosolization module.

[0034] The casing and housing may be integrally formed as a single piece. Alternatively, the casing may be structurally distinct from the housing.

[0035] The control electronics may include one or more control modules and / or processors configured for use in generating an input drive signal for the vibratable transducer, as well as any computer-readable medium storing instructions for use in generating the input drive signal. The computer-readable medium may include instructions for use in generating the input drive signal by the controller modules and / or processors. The computer-readable medium may preferably be a non-transitory computer-readable medium.

[0036] The power source is preferably rechargeable, and by way of example may include a lithium ion battery.

[0037] The housing may be sized and shaped to allow the housing to be handheld by a user. The housing is preferably an elongated housing. The elongated housing may be cylindrical in cross section. The use of an elongated housing corresponds to the geometric profile associated with a traditional cigarette.

[0038] The aerosol generating device may further comprise a cartridge. The cartridge may comprise a reservoir of liquid aerosol-forming substrate. The cartridge may be removably receivable by a housing of the aerosol generating device. The cartridge may be disposable, while the aerosol generating device may be reusable.

[0039] In a third aspect of the disclosure, a method of making a vibratory aerosolization assembly is provided. The method includes providing an aerosolization module comprising a vibratable transducer and a membrane. The vibratable transducer is operably coupled to the membrane to vibrate the membrane substantially axially during use. The method further includes sealably coupling a substantially flexible annular sealing member to a peripheral sealing region of the aerosolization module. The method further includes coupling a substantially rigid casing to the sealing member. The coupling of the casing to the sealing member is limited to a retention region of the sealing member. The retention region is located outside an outermost periphery of the aerosolization module. The casing is more rigid than the sealing member. At least one parameter of the sealing member may be configured to cushion against damping a vibration output of the vibratable transducer during use, the at least one parameter including one or more of a hardness of the sealing member, a Young's modulus of the sealing member, and an axial thickness of the sealing member.

[0040] The features of the aerosolization assembly may be as described above and in the remainder of this disclosure.

[0041] The hardness of the sealing member may preferably be within a range of 5 Shore A to 120 Shore A. More preferably, the hardness of the sealing member may be within a range of 20 Shore A to 40 Shore A.

[0042] The Young's modulus of the sealing member may be preferably in the range of 0.001 GPa to 1 GPa, and more preferably in the range of 0.01 GPa to 0.1 GPa.

[0043] The axial thickness of the sealing member may preferably be in the range of 1 mm to 10 mm. More preferably, the axial thickness of the sealing member may be in the range of 2 mm to 5 mm.

[0044] The Young's modulus of the substantially rigid casing is preferably in the range of 0.1 GPa to 100 GPa, or preferably in the range of 1 GPa to 10 GPa.

[0045] The membrane may comprise an aerosol-generation zone, the aerosol-generation zone being provided with a plurality of nozzles for the passage of the liquid aerosol-forming substrate.

[0046] The nozzles may have a diameter in the range of 1 micrometer to 20 micrometers.

[0047] Advantageously, coupling the casing to the sealing member may comprise clamping opposing axial surfaces of the sealing member to the casing over at least a portion of the retention area.

[0048] The casing may define an aperture circumferentially surrounding the sealing member. Additionally, coupling the casing to the sealing member may include defining an interference fit between the aperture of the casing and a corresponding surface of the sealing member such that the casing radially compresses the sealing member. The interference fit between the corresponding surfaces may define all or a portion of the retention area.

[0049] Preferably, the casing and the sealing member may be substantially axisymmetric.

[0050] Preferably, the retention region may be substantially annular. The retention region may further comprise a group of circumferentially disposed sub-regions that collectively define an annular profile. Circumferentially adjacent ones of the group of sub-regions may be circumferentially spaced apart from one another. Alternatively, the retention region may comprise a continuous annulus.

[0051] The ratio of the innermost diameter of the annular retention area to the outermost diameter of the aerosolization module is preferably greater than 1.5.

[0052] The membrane may be circular in plan.

[0053] Advantageously, sealably coupling the sealing member to the peripheral sealing region of the aerosolization module may include positioning a peripheral edge of the aerosolization module within an annular recess defined in the sealing member.

[0054] Alternatively, sealably coupling the sealing member to the peripheral sealing region of the aerosolization module may include overmolding a peripheral edge of the aerosolization module to form the sealing member.

[0055] The liquid aerosol-forming substrate employed may take many different forms. The following paragraphs describe various exemplary, non-limiting materials and compositions for the liquid aerosol-forming substrate.

[0056] The liquid aerosol-forming substrate may comprise nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may comprise plant-derived material. The liquid aerosol-forming substrate may comprise tobacco. The liquid aerosol-forming substrate may comprise homogenized tobacco material. The liquid aerosol-forming substrate may comprise a non-tobacco containing material. The liquid aerosol-forming substrate may comprise homogenized plant-derived material.

[0057] The liquid aerosol-forming substrate may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol upon use. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate, etc.), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). The aerosol former may be a polyhydric alcohol or a mixture thereof (such as triethylene glycol, 1,3-butanediol, glycerin, etc.). The liquid aerosol-forming substrate may include other additives and ingredients (such as flavoring agents).

[0058] The liquid aerosol-forming substrate may comprise water.

[0059] The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol former. The aerosol former may comprise glycerin. The aerosol former may comprise propylene glycol. The aerosol former may comprise both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of about 2% to about 10%. EXAMPLES

[0060] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of the other examples, embodiments, or aspects described herein.

[0061] Example 1: 1. A vibratory aerosolization assembly for use in an aerosol generation device, the vibratory aerosolization assembly comprising: an aerosolization module comprising a vibrable transducer and a membrane, the vibrable transducer operably coupled to the membrane to vibrate the membrane in a substantially axial direction in use; a substantially flexible annular sealing member, the sealing member sealably coupled to a peripheral sealing region of the aerosolization module; and a substantially rigid casing coupled to the sealing member, the coupling of the casing to the sealing member being confined to a retention region of the sealing member, the retention region being located outside an outermost periphery of the aerosolization module, the casing being stiffer than the sealing member, and at least one parameter of the sealing member configured to cushion against damping a vibration output of the vibratory transducer in use, the at least one parameter comprising one or more of a hardness of the sealing member, a Young's modulus of the sealing member, and an axial thickness of the sealing member. Example 2: The vibratory aerosolization assembly of example 1, wherein the hardness of the sealing member is in the range of 5 Shore A to 120 Shore A, or preferably in the range of 20 Shore A to 40 Shore A. Example 3: 3. The vibratory aerosolization assembly according to any one of Examples 1 or 2, wherein the Young's modulus of the sealing member is in the range of 0.001 GPa to 1 GPa, or preferably in the range of 0.01 GPa to 0.1 GPa. Example 4: The vibratory aerosolization assembly according to any one of Examples 1 to 3, wherein the axial thickness of the sealing member is in the range of 1 millimeter to 10 millimeters, or preferably in the range of 2 millimeters to 5 millimeters. Example 4a: 5. The vibratory aerosolization assembly according to any one of Examples 1 to 4, wherein the Young's modulus of the substantially rigid casing is in the range of 0.1 GPa to 100 GPa, or preferably in the range of 1 GPa to 10 GPa. Example 5: The vibrating aerosolization assembly of any one of Examples 1-4a, wherein the membrane comprises an aerosol-generation zone, the aerosol-generation zone being provided with a plurality of nozzles for passing the liquid aerosol-forming substrate. Example 6: 6. The vibrating aerosolization assembly of example 5, wherein the plurality of nozzles have a diameter in the range of 1 micrometer to 20 micrometers. Example 7: The vibratory aerosolization assembly of any one of Examples 1-6, wherein the coupling of the casing to the sealing member comprises the casing clamping opposing axial surfaces of the sealing member over at least a portion of the retention area. Example 8: A vibratory aerosolization assembly as described in any one of Examples 1 to 7, wherein the casing defines a hole that circumferentially surrounds the sealing member, and an interference fit is defined between the hole in the casing and a corresponding surface of the sealing member such that the casing radially compresses the sealing member, and the interference fit between the corresponding surfaces defines all or a portion of the retention area. Example 9: The vibratory aerosolization assembly of any one of Examples 1-8, wherein the casing and the sealing member are substantially axially symmetric. Example 10: The vibrating aerosolization assembly of any one of Examples 1-9, wherein the retention area is substantially annular. Example 11: 11. The vibratory aerosolization assembly of example 10, wherein the retention region comprises a group of circumferentially arranged subregions that collectively define an annular profile. Example 12: 12. The vibratory aerosolization assembly of example 11, wherein circumferentially adjacent ones of the group of sub-regions are circumferentially spaced apart from one another. Example 13: 12. The vibrating aerosolization assembly of any one of Examples 10 or 11, wherein the retention area comprises a continuous annular portion. Example 14: The vibrating aerosolization assembly of any one of Examples 10 to 13, wherein the ratio of the innermost diameter of the annular retaining region to the outermost diameter of the aerosolization module is greater than 1.5. Example 15: The vibrating aerosolization assembly of any one of Examples 1-14, wherein the membrane is circular in plan view. Example 16: The vibratory aerosolization assembly of any one of Examples 1-15, wherein the vibrable transducer is enclosed within a sealing member. Example 17: The vibratory aerosolization assembly of any one of Examples 1-16, wherein the vibrable transducer comprises one or more piezoelectric actuators. Example 18: The vibratory aerosolization assembly of example 17, wherein the one or more piezoelectric actuators define an annular piezoelectric actuator assembly. Example 19: The vibratory aerosolization assembly of example 18, wherein the annular piezoelectric actuator assembly is formed from a single annular piezoelectric actuator. Example 20: The vibratory aerosolization assembly of Example 18, wherein the annular piezoelectric actuator assembly is formed of a plurality of circumferentially arranged piezoelectric actuators that collectively define an annular profile. Example 21: An aerosol generating device comprising a housing, a power source, control electronics, and a vibration aerosolization assembly described in any one of Examples 1 to 20, wherein the housing includes the power source and the control electronics, the control electronics being configured to control the supply of power from the power source to an aerosolization module of the vibration aerosolization assembly so as to activate a vibrable transducer in use, and the housing being configured to hold a reservoir of liquid aerosol-forming substrate in fluid communication with a membrane of the aerosolization module. Example 22: 22. The aerosol generating device of Example 21, wherein the casing and the housing are integrally formed as a single piece. Example 23: 22. An aerosol generating device as described in Example 21, wherein the casing is structurally different from the housing. Example 24: 24. An aerosol generating device according to any one of Examples 21 to 23, further comprising a cartridge, the cartridge comprising a reservoir of liquid aerosol-forming substrate, the cartridge being removably receivable by a housing of the aerosol generating device. Example 25: A method of making a vibratory aerosolization assembly, the method comprising: providing an aerosolization module comprising a vibrable transducer and a membrane, the vibrable transducer being operably coupled to the membrane to vibrate the membrane substantially axially in use; sealably coupling a substantially flexible annular sealing member to a peripheral sealing region of the aerosolization module; and coupling a substantially rigid casing to the sealing member, the coupling of the casing to the sealing member being constrained by a retention region of the sealing member, the retention region being located outside an outermost periphery of the aerosolization module, the casing being more rigid than the sealing member, and at least one parameter of the sealing member being configured to cushion against damping a vibration output of the vibrable transducer during use, the at least one parameter comprising one or more of a hardness of the sealing member, a Young's modulus of the sealing member, and an axial thickness of the sealing member. Example 26: 26. The method according to embodiment 25, wherein the hardness of the sealing member is in the range of 5 Shore A to 120 Shore A, or preferably in the range of 20 Shore A to 40 Shore A. Example 27: 27. The method according to any one of embodiments 25 or 26, wherein the Young's modulus of the sealing member is in the range of 0.001 GPa to 1 GPa, or preferably in the range of 0.01 GPa to 0.1 GPa. Example 28: The method according to any one of embodiments 25 to 27, wherein the axial thickness of the sealing member is in the range of 1 mm to 10 mm, or preferably in the range of 2 mm to 5 mm. Example 28a: The method according to any one of Examples 25 to 28, wherein the Young's modulus of the substantially rigid casing is in the range of 0.1 GPa to 100 GPa, or preferably in the range of 1 GPa to 10 GPa. Example 29: The method of any one of Examples 25 to 28a, wherein the membrane comprises an aerosol-generation zone, the aerosol-generation zone being provided with a plurality of nozzles for passing through the liquid aerosol-forming substrate. Example 30: 30. The method of example 29, wherein the plurality of nozzles have a diameter in the range of 1 micrometer to 20 micrometers. Example 31: The method of any one of Examples 25-30, wherein coupling the casing to the sealing member comprises clamping opposing axial surfaces of the sealing member with the casing over at least a portion of a retention area. Example 32: 32. The method of any one of claims 25-31, wherein the casing defines a hole circumferentially surrounding the sealing member, and wherein coupling the casing to the sealing member defines an interference fit between the hole in the casing and a corresponding surface of the sealing member such that the casing radially compresses the sealing member, the interference fit between the corresponding surfaces defining all or a portion of the retention area. Example 33: The method of any one of Examples 25 to 32, wherein the casing and the sealing member are substantially axially symmetric. Example 34: The method according to any one of Examples 25 to 33, wherein the retention region is substantially circular. Example 35: 35. The method of example 34, wherein the retention region comprises a group of circumferentially arranged subregions that collectively define an annular profile. Example 36: 36. The method of example 35, wherein circumferentially adjacent ones of the group of subregions are circumferentially spaced apart from one another. Example 37: The method of any one of Examples 34 or 35, wherein the retention region comprises a continuous loop. Example 38: The method of any one of Examples 34 to 37, wherein the ratio of the innermost diameter of the annular retaining region to the outermost diameter of the aerosolization module is greater than 1.5. Example 39: The method according to any one of examples 25 to 38, wherein the membrane is circular in plan. Example 40: The method of any one of Examples 25 to 39, wherein sealably coupling the sealing member to the peripheral sealing region of the aerosolization module comprises positioning a peripheral edge of the aerosolization module within an annular recess defined in the sealing member. Example 41: The method of any one of Examples 25-39, wherein sealably coupling the sealing member to the peripheral sealing region of the aerosolization module comprises overmolding a peripheral edge of the aerosolization module to form the sealing member.

[0062] The embodiments will now be further described with reference to the figures. [Brief description of the drawings]

[0063] [Figure 1] FIG. 1 is a schematic diagram of a first example of an aerosol generating device according to the present disclosure. [Diagram 2] FIG. 2 is a perspective exploded view of components of a vibration aerosolization assembly according to the present disclosure. [Diagram 3] FIG. 3 is a cross-sectional three-dimensional view of the components of the vibratory aerosolization assembly of FIG. 2, with the components shown axially separated from one another. [Figure 4] FIG. 4 is a plan view of the membrane of the vibrating aerosolization assembly of FIGS. [Diagram 5] 5A and 5B show steps involved in inserting an annular portion of an aerosolization module into an annular recess of a flexible sealing member. [Figure 6]FIG. 6 is a cross-sectional three-dimensional view of the components of the vibratory aerosolization assembly of FIG. 3, except that the components are shown in a fully assembled state. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0064] FIG. 1 is a schematic diagram of a first embodiment of an aerosol generating device 10. The aerosol generating device 10 is a smoking device for generating an inhalable aerosol. The aerosol generating device 10 has an elongated cylindrical housing 11. The housing 11 includes a power source 12, a controller 13, a cartridge 14, a liquid supply assembly 15, and a vibratory aerosolization assembly 20. The controller 13 controls the supply of power from the power source 12 to the vibratory aerosolization assembly 20. In the illustrated embodiment, the power source 12 is, but is not limited to, a rechargeable lithium ion battery. The controller 13 incorporates a processor 131 and a memory module 132. The memory module 132 includes instructions accessible by the processor 131, enabling the controller 13 to control the operation of the vibratory aerosolization assembly 20. The cartridge 14 includes a reservoir 141 of a liquid aerosol-forming substrate. The liquid supply assembly 15 is located between the cartridge 14 and the vibratory aerosolization assembly 20 to supply liquid aerosol-forming substrate from a reservoir 141 to the vibratory aerosolization assembly. In the embodiment shown, the liquid supply assembly 15 is in the form of an absorbent wick, but in other embodiments, the liquid supply assembly may include a tube extending between the cartridge 14 and the vibratory aerosolization assembly 20. While FIG. 1 illustrates an embodiment in which the liquid supply assembly 15 is separate from the cartridge 14, in other embodiments, the liquid supply assembly 15 may be an integral part of the cartridge. A mouthpiece 111 is provided at one end of the housing 11. The mouthpiece 111 includes an opening 112 to allow for the exit of a dispersion of aerosol droplets 113 discharged from the vibratory aerosolization assembly 20.

[0065] 2 and 3 show exploded views of the component parts of the vibratory aerosolization assembly 20. The vibratory aerosolization assembly 20 includes an aerosolization module 21, a flexible annular sealing member 22, and a rigid casing 23. The sealing member 22 is formed of a material having a hardness in the range of 5 Shore A to 120 Shore A and a Young's modulus in the range of 0.001 GPa to 1 GPa. By way of example, the sealing member 22 may be formed of a material such as neoprene rubber, natural rubber, silicone rubber, nitrile rubber, ethylene propylene diene monomer (EPDM) rubber, styrene butadiene rubber, and the like, with silicone rubber being preferred for its biocompatibility. In the illustrated embodiment, the sealing member 22 has an axial thickness t22 of 10 millimeters, but in other embodiments, the axial thickness of the sealing member 22 may be anywhere in the range of 1 millimeter to 10 millimeters. The rigid casing 23 is a two-piece casing including a first part 231 and a second part 232. The rigid casing 23 is formed of a material having a Young's modulus in the range of 0.1 GPa to 100 GPa. However, the material selected for the rigid casing 23 will be a material having a Young's modulus greater than that of the flexible sealing member 22 to ensure that the casing is stiffer than the sealing member. By way of example, the rigid casing may be formed of a material such as a rigid plastic material (such as, but not limited to, polypropylene, high density polyethylene (HDPE), polyethylene terephthalate (PET), polyether ether ketone (PEEK), or polysulfone (PSU)) or a metal material (such as, but not limited to, aluminum). For the embodiment illustrated in the figures, the vibrating aerosolization assembly 20 is a separate component from the housing 11 and is held in place within the housing by any suitable retention means. In this manner, the vibrating aerosolization assembly 20 may be removed from the housing 11 of the device 10 and / or reinserted or replaced. However, in alternative embodiments, the rigid casing 23 may be formed integrally with the housing 11 of the aerosol generating device 10 .

[0066] The aerosolization module 21 includes a vibratable piezoelectric transducer 211 and a membrane 212. As shown in FIG. 4, the membrane 212 is circular when viewed in a plan view, i.e., along the longitudinal axis LA of the vibratory aerosolization assembly 20. The piezoelectric transducer 211 is annular and is coupled to the periphery of the membrane 212. For the illustrated embodiment, a single annular transducer 211 is used. However, in an alternative embodiment (not shown), multiple piezoelectric transducers may be circumferentially arranged to collectively define an annular transducer assembly.

[0067] As shown in FIG. 4, the membrane 212 has an aerosol-generation zone 213. A plurality of nozzles 214 are provided across the aerosol-generation zone 213 of the membrane 212. The plurality of nozzles 214 extend through a thickness t212 of the membrane 212 and have diameters in the range of 1 micrometer to 20 micrometers. The diameter of the nozzles 214 may be uniform across all of the nozzles in the aerosol-generation zone 213 or may be variable over a range (such as the range of 1 micrometer to 20 micrometers mentioned above). The membrane 212 may be formed from a polymer, metal, semiconductor, dielectric, or ceramic material. The material may be crystalline or non-crystalline. The membrane may be a composite of two or more different materials. By way of example, and not limitation, examples of membrane materials include stainless steel, palladium, silver, alloys such as Ni-Co or Ni-Pd, polyimides and polyamides, ceramics based on silicon, silicon carbide, silicon nitride, aluminum nitride, silicon oxide, aluminum oxide or barium titanate, or combinations thereof, such as layered membranes composed of layers of silicon and silicon nitride or silicon oxide or metals.

[0068] The piezoelectric transducer 211 is partially enclosed within a flexible annular sealing member 22. The aerosolization module 21 (of which the piezoelectric transducer 211 forms a part) has an outermost diameter 'D21' (see FIG. 3). A pair of electrical wires 24 are coupled to opposing axial surfaces of the transducer 211. The wires 24 pass within the interior of the housing 11 and couple to the controller 13.

[0069] In one embodiment for manufacturing the vibration aerosolization assembly 20, the sealing member 22 is first provided in the form of a ring provided with an annular recess 225 extending around the radially inner surface of the ring (see FIG. 5A). The peripheral region 215 of the transducer 211 is then positioned within the recess 225 such that the transducer 211 is partially enclosed within the sealing member 22 (see FIG. 5B). The encapsulation of the peripheral region 215 of the transducer 211 by the sealing member 22 forms a liquid-tight seal between the sealing member 22 and the transducer 211. The peripheral region 215 of the transducer 211 incorporates an electrical contact 216 for coupling with the electrical wire 24. Thus, during use of the aerosol generating device 10, the encapsulation of the peripheral region 215 of the transducer 211 within the recess 225 of the sealing member 22 inhibits contact between the electrical contact 216 and a liquid aerosol-forming substrate provided by the cartridge 14. The flexible nature of the material used for the sealing member 22 facilitates elastically deforming the sealing member to allow the peripheral region 215 of the transducer 211 to seat within the annular recess 225. In an alternative embodiment of manufacturing the vibratory aerosolization assembly 20, the flexible sealing member 22 may instead be formed by overmolding the peripheral region 215 of the transducer 211 with the sealing member material. In a further alternative embodiment, substantially all of the transducer 211 may be encapsulated by the sealing member 22, with only the membrane 212 remaining exposed. However, reducing the radial width of the transducer 211 encapsulated within the sealing member 22 will reduce vibration damping of the transducer's vibrational output by the sealing member material during use.

[0070] As mentioned above, the rigid casing 23 is a two-part casing having a first part 231 and a second part 232 (see Figs. 3 and 6). Both the first and second parts 231, 232 are annular. The second part 232 is contoured to seat inside the first part 231. The first part 231 includes an annular seat 233 and the second part 232 includes an annular protrusion 234. The seat 233 and the protrusion 234 are of equal radial width 'W'. During assembly of the vibratory aerosolization assembly 20, the sealing member 22 is positioned between the first part 231 and the second part 232. The first part 231 and the second part 232 are then moved towards each other until the sealing member 22 is clamped between the seat 233 and the protrusion 234 around the annular retention area 221, as shown in Fig. 6. The annular retention area 221 of the sealing member 22 has an innermost diameter D221 and a radial width corresponding to the radial width 'W' of the seat 233 and the protrusion 234. The rigid casing 23 defines a central opening 235 that is slightly larger than the diameter of the membrane 212. As shown in FIG. 6, the casing 23 engages the sealing member 22 some distance radially outward of the aerosolization module 21. For the illustrated embodiment, the ratio of the innermost diameter D221 of the retention area 221 of the sealing member 22 to the outermost diameter D21 of the aerosolization module 21 is 1.5: Greater than 1.

[0071] The figure shows an embodiment in which the seats 233 and protrusions 234 are in the form of corresponding annular planes. However, in an alternative embodiment (not shown), the seats 233 and protrusions 234 may instead be formed as corresponding teeth, thereby reducing the contact area between the rigid casing 23 and the sealing member 22.

[0072] In use, the controller 13 controls the supply of power from the power source 12 to the vibrating aerosolization assembly 20 according to instructions stored in the memory module 132. More specifically, the controller 13 sends an electrical drive signal to the piezoelectric transducer 211 via the electrical wires 24 coupled to the electrical contacts 216. In response to the electrical drive signal, the transducer 211 resonates at a predetermined frequency corresponding to a first resonant mode (also known as a fundamental mode). The value of this frequency varies depending on the nature of the piezoelectric transducer 211 used. In one embodiment, the first resonant mode of the transducer 211 is about 140 kHz. The vibration of the transducer 211 in turn induces vibration of the membrane 212. A liquid aerosol-forming substrate is supplied to one side of the vibrating membrane 212 from the reservoir 141 of the cartridge 14 via the liquid supply assembly 15. The vibrating action of the membrane 212 causes the liquid aerosol-forming substrate to be expelled through the nozzle 214 of the membrane 212 as a dispersion of aerosol droplets 113 (see FIG. 1 ). The dispersion of aerosol droplets 113 exits the interior of the housing 11 of the aerosol generating device 10 through the opening 112 in the mouthpiece 111. It has been found that using a resonant mode of approximately 140 kHz in combination with various other features described above reduces attenuation of the vibration output of the transducer 211.

[0073] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like, should be understood in all instances as modified by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number "A" is understood as "A" ± 10% of "A." Within this context, the number "A" may be considered to include numerical values ​​that are within the typical standard error for the measurement of the property that the number "A" modifies. The number "A" may, in some cases as used in the appended claims, deviate by the percentages recited above, provided that the amount by which "A" deviates does not materially affect the basic and novel property(ies) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. A vibrating aerosolizing assembly for use in an aerosol generator, wherein the vibrating aerosolizing assembly is an aerosolization module comprising a vibrable transducer and a membrane, wherein the vibrable transducer is operably coupled to the membrane such that it vibrates the membrane substantially axially during use, A substantially flexible annular sealing member, wherein the sealing member is sealably bonded to the peripheral sealing region of the aerosolization module, A substantially rigid casing coupled to the sealing member, wherein the coupling of the casing to the sealing member is limited to a holding region of the sealing member, and the holding region is located outside the outermost periphery of the aerosolizing module, The casing is more rigid than the sealing member, At least one parameter of the sealing member is configured to mitigate the vibration output of the vibrable transducer during use, and the at least one parameter is The hardness of the sealing member, The Young's modulus of the sealing member, and The sealing member comprises one or more of the axial thicknesses, A vibratory aerosolized assembly, wherein the casing defines a hole surrounding the sealing member in the circumferential direction, and an interference fit is defined between the hole in the casing and a corresponding surface of the sealing member such that the casing compresses the sealing member radially, and the interference fit between the corresponding surfaces defines all or part of the retaining area.

2. The vibrating aerosolizing assembly according to claim 1, wherein the membrane comprises an aerosol generating zone, and the aerosol generating zone is provided with a plurality of nozzles for passing a liquid aerosol forming substrate through.

3. The vibratory aerosolization assembly according to claim 1, wherein the coupling of the casing to the sealing member comprises the casing clamping the opposing axial surface of the sealing member over at least a portion of the holding area.

4. The vibratory aerosolization assembly according to claim 1, wherein the casing and the sealing member are substantially axially symmetric.

5. The vibratory aerosolizing assembly according to claim 1, wherein the holding region is substantially annular.

6. The vibratory aerosolizing assembly according to claim 5, wherein the holding region comprises a group of sub-regions arranged in the circumferential direction that collectively define an annular profile, and the circumferentially adjacent sub-regions of the group are spaced apart from each other in the circumferential direction.

7. The vibrating aerosolized assembly according to claim 6, wherein the holding region comprises a continuous annular portion.

8. The vibratory aerosolization assembly according to claim 1, wherein the membrane is circular in a planar shape.

9. The vibrating aerosol assembly according to claim 1, wherein the vibrable transducer is enclosed within the sealing member.

10. The vibrating aerosol assembly according to claim 1, wherein the vibrable transducer comprises one or more piezoelectric actuators.

11. Aerosol generator, Housing and Power supply and Control electronic circuits, A vibrating aerosolization assembly according to any one of claims 1 to 10, comprising Aerosol generator, wherein the housing includes the power supply and the control electronic circuit, the control electronic circuit is configured to control the supply of power from the power supply to the aerosolizing module of the vibrating aerosolizing assembly in order to activate the vibrable transducer when in use, and the housing is configured to hold a storage section for a liquid aerosol-forming substrate that is in fluid communication with the membrane of the aerosolizing module.

12. The aerosol generating apparatus according to claim 11, wherein the casing and the housing are integrally formed as a single component.

13. The aerosol generating apparatus according to claim 11, wherein the casing is structurally different from the housing.

14. A method for producing a vibrating aerosolized assembly, wherein the method is To provide an aerosolization module comprising a vibrable transducer and a membrane, wherein the vibrable transducer is operably coupled to the membrane such that it vibrates the membrane substantially axially during use. A substantially flexible annular sealing member is sealedly bonded to the peripheral sealing region of the aerosolization module, A substantially rigid casing is bonded to the sealing member, wherein the bond of the casing to the sealing member is limited to a holding region of the sealing member, and the holding region is located outside the outermost periphery of the aerosolizing module. The casing is more rigid than the sealing member, At least one parameter of the sealing member is configured to mitigate the vibration output of the vibrable transducer during use, and the at least one parameter is The hardness of the sealing member, The Young's modulus of the sealing member, and The sealing member comprises one or more of the axial thicknesses, A method wherein the casing defines a hole surrounding the sealing member in a circumferential direction, and coupling the casing to the sealing member includes defining an interference fit between the hole in the casing and a corresponding surface of the sealing member such that the casing compresses the sealing member radially, and the interference fit between the corresponding surfaces defines all or part of the retaining area.

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