A removeable cartridge for a vapour generating device

Abstract

A removeable cartridge (10) for a vapour generating device (12) comprises a liquid store (14) for holding a vapour generating liquid and a vaporisation assembly (15). The vaporisation assembly (15) comprises a vapour generation area (19). The vapour generation area (19) comprises a vaporisation chamber (16) and a porous liquid transfer element (18) associated with the vaporisation chamber (16). The porous liquid transfer element (18) is configured to hold and transfer vapour generating liquid from the liquid store (14). The removeable cartridge (10) further comprises a vapour outlet channel (24) fluidly connected to the vaporisation chamber (16), and a cartridge housing (26). The cartridge housing (26) comprises a frangible line (46) defining a first housing portion (42) and a second housing portion (44). The frangible line (46) is arranged to facilitate separation of the first and second housing portions (42, 44).

Description

[0001] A REMOVEABLE CARTRIDGE FOR A VAPOUR GENERATING DEVICE

[0002] Technical Field

[0003] The present disclosure relates generally to a removeable cartridge for a vapour generating device configured to heat a vapour generating liquid to generate a vapour which cools and condenses to form an aerosol for inhalation by a user of the device.

[0004] Technical Background

[0005] The term vapour generating device (or more commonly electronic cigarette or e-cigarette) refers to a handheld electronic device that is intended to simulate the feeling or experience of smoking tobacco in a traditional cigarette. Electronic cigarettes work by causing a vapour generating liquid (or so called “e-liquid”) to be heated to generate a vapour that cools and condenses to form an aerosol which is then inhaled by the user.

[0006] In some arrangements, the vapour generating liquid is held in a liquid store of a removable cartridge receivable in the vapour generating device. A shortcoming of such arrangements is that removable cartridges can be difficult to recycle, for instance, because of plastic components which can be difficult to recycle.

[0007] There is, therefore, a need to address this shortcoming.

[0008] Summary of the Disclosure

[0009] According to a first aspect of the present disclosure, there is provided a removeable cartridge for a vapour generating device, wherein the removeable cartridge comprises: a liquid store for holding a vapour generating liquid; a vaporisation assembly, the vaporisation assembly comprising: a vapour generation area, the vapour generation area comprising a vaporisation chamber and a porous liquid transfer element associated with the vaporisation chamber, wherein the porous liquid transfer element is configured to hold and transfer vapour generating liquid from the liquid store; and a thermal interface material arranged to thermally couple, in use, the vapour generation area and a heater comprised in the vapour generating device; the removeable cartridge further comprising: a vapour outlet channel fluidly connected to the vaporisation chamber; and a cartridge housing, wherein the cartridge housing comprises a frangible line defining a first housing portion and a second housing portion, wherein the frangible line is arranged to facilitate separation of the first and second housing portions.

[0010] According to a second aspect of the present disclosure, there is provided a removeable cartridge for a vapour generating device, wherein the removeable cartridge comprises: a liquid store for holding a vapour generating liquid; a vaporisation assembly comprising: a vapour generation area, the vapour generation area comprising a vaporisation chamber and a porous liquid transfer element associated with the vaporisation chamber, wherein the porous liquid transfer element is configured to hold and transfer vapour generating liquid from the liquid store; the removeable cartridge further comprising: a vapour outlet channel fluidly connected to the vaporisation chamber; and a cartridge housing, wherein the cartridge housing comprises a frangible line defining a first housing portion and a second housing portion, wherein the frangible line is arranged to facilitate separation of the first and second housing portions.

[0011] Removable cartridges according to examples of the disclosure can readily be recycled by separation of the first and second housing portions at the frangible line. The first and second housing portions can therefore be recycled or disposed of separately.

[0012] Possibly, the removeable cartridge comprises an insert having a non-metallic body, wherein the vapour generation area is nested in the insert. An insert having a non-metallic body can be mass produced, for instance, by injection moulding.

[0013] Possibly, the vapour generation area comprises a base, the base being provided by the thermal interface material. The thermal interface material may contact the porous liquid transfer element associated with the vaporisation chamber. Possibly, the porous liquid transfer element comprises castellations, wherein the thermal interface material contacts the castellations. The arrangement of the thermal interface material and porous liquid transfer element ensures heat transfer to the vapour generation area with minimal heat loss. The castellations ensure proper vape generation and prevent vape cumulation below the porous liquid transfer element. Possibly, the removeable cartridge comprises an airflow channel, wherein the airflow channel comprises an air inlet through which ambient air can flow into the airflow channel and an air outlet through which ambient air can flow out of the airflow channel into the vaporisation chamber to facilitate vaporisation of vapour generating liquid. The removeable cartridge has a cartridge axis Y, wherein the airflow channel may extend perpendicular to the cartridge axis Y. The airflow channel may extend through the insert.

[0014] Possibly, the removeable cartridge comprises a leakage trap associated with the airflow channel, wherein the leakage trap comprises: a liquid drain in the airflow channel through which liquid can drain from the airflow channel; and a liquid absorber, wherein the liquid absorber is arranged to absorb liquid drained through the liquid drain from the airflow channel.

[0015] Possibly, the liquid store and the vapour outlet channel are associated with the first housing portion, and the vaporisation assembly is associated with the second housing portion. The cartridge housing and the vapour outlet channel may be formed of aluminium.

[0016] Accordingly, non-metallic, e.g., plastic components can be provided only in the second housing portion, and this can be disposed of or recycled separately from the first housing portion which can comprise only metal components, e.g., aluminium components. In some embodiments, the plastic components can be removed from the second housing portion before its recycling. The removing of the plastic components can be easily done after separation of the first and second housing portions.

[0017] The removeable cartridge may have a substantially cuboidal shape. A cuboidal shaped removeable cartridge can be better stacked by utilising more of the packing space available, for instance, on a pallet or container. This improves transport efficiency and therefore reduces CO2 emissions. Additionally, after separation of the first and second housing portions, these portions can be easily transported for recycling due to the cuboidal shape.

[0018] According to a third aspect of the present disclosure, there is provided a vapour generating system, the vapour generating system comprising: a vapour generating device and a removable cartridge, wherein the removable cartridge comprises: a liquid store for holding a vapour generating liquid; a vaporisation assembly, the vaporisation assembly comprising: a vapour generation area, the vapour generation area comprising a vaporisation chamber and a porous liquid transfer element associated with the vaporisation chamber, wherein the porous liquid transfer element is configured to hold and transfer vapour generating liquid from the liquid store; and a thermal interface material; the removeable cartridge further comprising: a vapour outlet channel fluidly connected to the vaporisation chamber; and a cartridge housing, wherein the cartridge housing comprises a frangible line defining a first housing portion and a second housing portion, wherein the frangible line is arranged to facilitate separation of the first and second housing portions, wherein the vapour generating device comprises: a device housing defining a chamber configured to operably receive the removeable cartridge; and a heater, wherein the heater contacts the thermal interface material of the removeable cartridge when the removeable cartridge is operably received in the chamber to thermally couple the heater and the vapour generation area.

[0019] Possibly, the vapour generating device comprises: a force generating mechanism, the force generating mechanism being configured to cause the heater of the vapour generating device and the thermal interface material of the removable cartridge to be forced together when the removeable cartridge is operably received in the chamber. The removeable cartridge is internally loaded in the vapour generating device by virtue of the force generating mechanism.

[0020] According to a fourth aspect of the present disclosure, there is provided a method of manufacturing a removeable cartridge for a vapour generating device, the method comprising: deep drawing and / or stretch drawing a first sheet material to form a cartridge housing, the cartridge housing providing a liquid store; forming a frangible line in the cartridge housing, the frangible line defining a first housing portion and a second housing portion; deep drawing and / or stretch drawing a second sheet material to form a vapour outlet channel; connecting the vapour outlet channel to the cartridge housing; filling the liquid store with a vapour generating liquid; providing a vaporisation assembly, the vaporisation assembly comprising: a vapour generation area, the vapour generation area comprising a vaporisation chamber and a porous liquid transfer element associated with the vaporisation chamber, wherein the porous liquid transfer element is configured to hold and transfer vapour generating liquid from the liquid store; and a thermal interface material arranged to thermally couple, in use, the vapour generation area and a heater comprised in the vapour generating device; the method further comprising: applying a capping end portion to the cartridge housing to encase the liquid store, the vapour outlet channel and the vaporisation assembly.

[0021] The method may comprise forming the frangible line in the cartridge housing using a tool, wherein the tool comprises a rotatable blade, wherein the method comprises: receiving the removeable cartridge in a rotatable cartridge holder; urging the rotatable blade against the cartridge housing; and rotating the removeable cartridge by the rotatable cartridge holder to cause the rotatable blade to form the frangible line in the cartridge housing by a cutting action.

[0022] According to a fifth aspect of the present disclosure, there is provided a vapour generating device, the vapour generating device comprising: a housing defining a chamber configured to operably receive a removeable cartridge according to any of the preceding paragraphs; and a heater, wherein the heater is configured to contact a thermal interface material of the removeable cartridge when the removeable cartridge is operably received in the chamber to thermally couple the heater and the vapour generation area of the removeable cartridge.

[0023] According to a sixth aspect of the present disclosure, there is provided a method of recycling a removeable cartridge according to any of the preceding paragraphs, wherein the method comprises: locating the removeable cartridge in an adapter comprising a first adapter part and a second adapter part, wherein the first adapter part receives the first housing portion, and the second adapter part receives the second housing portion; and rotating the first adapter part and / or the second adapter part about a rotation line causing the cartridge housing to break along the frangible line and the first and second housing portions to separate.

[0024] The method may comprise rotating the second adapter part relative to the first adapter part, wherein the first adapter part remains stationary. Alternatively, the method may comprise rotating the first adapter part relative to the second adapter part, wherein the second adapter part remains stationary. Alternatively, the method may comprise simultaneously rotating both the first and second adapter parts in opposite directions.

[0025] According to a seventh aspect of the present disclosure, there is provided an adapter for use in recycling a removeable cartridge according to any of the preceding paragraphs, wherein the adapter comprises a first adapter part and a second adapter part, wherein the first adapter part and / or the second adapter part are rotatable about a rotation line.

[0026] The first adapter part and / or the second adapter part may comprise a handle portion. The first adapter part and / or the second adapter part may comprise a pair of handles portions. The pair of handle portions may extend radially in opposite directions from the first adapter part or may extend radially in opposite directions from the second adapter part.

[0027] Possibly, the longitudinal extension of the first adapter part is greater than the one of the second adapter part.

[0028] Brief Description of the Drawings

[0029] Figure 1 is a diagrammatic view of a vapour generating system including a vapour generating device and a removeable cartridge;

[0030] Figure 2 is a diagrammatic perspective view of the vapour generating system of Figure 1 showing the vapour generating device and the removeable cartridge in a separated condition; Figure 3 is a diagrammatic perspective view of the vapour generating device of Figure 2;

[0031] Figure 4 is a diagrammatic perspective view of the removeable cartridge of Figure 2; Figure 5 is a diagrammatic cross-sectional view of the removeable cartridge of Figure 2 received in the vapour generating device, but with only a heater of the vapour generating device shown;

[0032] Figure 6 is a diagrammatic perspective view of the removeable cartridge of Figure 2 and the heater of the vapour generating device shown in Figure 5;

[0033] Figure 7 is a diagrammatic perspective exploded view of the removeable cartridge of Figure 2; Figure 8 is a diagrammatic perspective view of the removeable cartridge of Figure 2 with first and second housing portions separated;

[0034] Figure 9 is a diagrammatic perspective view of the heater of the vapour generating device of Figure 2;

[0035] Figure 10 is a diagrammatic perspective view of a magnification of an end of a vapour outlet channel of the removeable cartridge of Figure 2;

[0036] Figure 11 is a diagrammatic cross-sectional perspective view of a magnification of part of the removeable cartridge of Figure 2;

[0037] Figure 12 is a diagrammatic perspective exploded view of some components of the removeable cartridge of Figure 2;

[0038] Figure 13 is a diagrammatic perspective view of the insert of the removeable cartridge of Figure 2;

[0039] Figure 14 is a diagrammatic cross-sectional perspective view of the insert of Figure 13;

[0040] Figure 15 is a diagrammatic perspective exploded view of the removeable cartridge of Figure 2 with the capping end portion shown separated;

[0041] Figures 16A and 16B are diagrammatic perspective views of arrangements in a typical process involved in recycling the removeable cartridge of Figure 2;

[0042] Figures 17A to 17D are diagrammatic perspective views of arrangements in another typical process involved in recycling the removeable cartridge of Figure 2;

[0043] Figures 18 A to 18E are diagrammatic perspective views of arrangements in an example method of forming a cartridge housing of the removable cartridge of Figure 2;

[0044] Figures 19Ato 19C are diagrammatic perspective views of arrangements in an example method of forming a frangible line in the cartridge housing of Figure 18; and

[0045] Figure 20A and 20B are diagrammatic perspective views magnifications of arrangements in the method of Figures 19A to 19C. Detailed Description of Embodiments

[0046] Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0047] Referring initially to Figures 1 to 4, there is shown a vapour generating system 100. In the illustrated example, the vapour generating system 100 comprises a vapour generating device 12 and a removeable cartridge 10 configured to be used with the vapour generating device 12.

[0048] In the illustrated example, the removeable cartridge 10 has a substantially cuboidal shape. A cuboidal shaped removeable cartridge 10 (i.e., square shaped) can be better stacked by utilising more of the packing space available (i.e., can better fill the volume available), for instance, on a pallet or container. This improves transport efficiency and therefore reduces CO2 emissions.

[0049] In some examples, the thickness of the removeable cartridge 10 may be from 0.15mm to 0.45mm. Preferably, the removeable cartridge 10 has a thickness of 0.3mm.

[0050] In some examples, the width of the removeable cartridge 10 may be from 6.5mm to 19.5mm. Preferably, the removeable cartridge 10 may have a width of 13mm.

[0051] The height of the removeable cartridge 10 can be varied. In some examples, the removeable cartridge 10 may have a height of from 13.45mm to 40.35mm. Preferably, the removeable cartridge 10 may have a height of 26.90mm.

[0052] The removeable cartridge 10 may have a substantially prismatic shape. Other shapes are, however, entirely within the scope of the present disclosure.

[0053] The vapour generating device 12 comprises a device housing 54 defining a chamber 56 configured to operably receive the removeable cartridge 10. The removeable cartridge 10 is releasably connectable to the vapour generating device 12 by a releasable connection. The releasable connection can, for example, be a snap-fit connection, a press-fit connection, or alternatively, a magnetic connection, a threaded connection or a bayonet connection. The releasable connection of the illustrated example provides a force generating mechanism 90, as described below. An opening mechanism of the vapour generating device 12 allows the insertion or removal of the removeable cartridge 10 into and from the vapour generating device 10. The opening mechanism comprises a hinged door 55 providing access to the chamber 56. The chamber 56 may be referred to as a pod bay or cartridge bay.

[0054] In the illustrated example, the vapour generating device 12 comprises a mouthpiece 72. In other examples, the removable cartridge 10 can form a mouthpiece or a separate mouthpiece can be provided.

[0055] The vapour generating device 12 may be elongated and have a substantially cylindrical shape which resembles a cigarette or cigar. Other shapes are, however, entirely within the scope of the present disclosure.

[0056] The term vapour generating device 12 (or more commonly electronic cigarette or e-cigarette) refers to a handheld electronic device that is intended to simulate the feeling or experience of smoking tobacco in a traditional cigarette. Electronic cigarettes work by causing a vapour generating liquid to be heated to generate a vapour that cools and condenses to form an aerosol which is then inhaled by the user. Accordingly, using e-cigarettes is also sometimes referred to as “vaping”. Vapour generating liquid is sometimes referred to as e-liquid.

[0057] In general terms, a vapour is a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms ‘aerosol’ and ‘vapour’ may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.

[0058] The vapour generating liquid may comprise polyhydric alcohols and mixtures thereof such as glycerine or propylene glycol. The vapour generating liquid may contain nicotine. The vapour generating liquid may also comprise flavourings such as e.g., tobacco, menthol, or fruit flavour.

[0059] The removeable cartridge 10 comprises a cartridge housing 26 having a proximal end 60 and a distal end 62. The cartridge housing provides an external casing 28. In some examples, the cartridge housing 26 is formed of aluminium. The cartridge housing 26 may be substantially formed of aluminium. The cartridge housing 26 may be exclusively formed of aluminium for example using deep drawing. In some examples, the cartridge housing 26 has a wall thickness of from 0.15 mm to 0.2 mm.

[0060] In some examples, the removeable cartridge 10 may be substantially formed of aluminium, that is, taken as a whole the material most prevalent in and of the removeable cartridge 10 is aluminium. In such examples, components made of other materials, for instance plastics, may also be present in the removeable cartridge 10.

[0061] The cartridge housing 26 has an exterior surface sized and shaped for operable insertion into a vapour generating device 12 according to examples of the disclosure.

[0062] In the illustrated example, the vapour generating device 12 includes a controller 64. The vapour generating device 12 includes a user interface 66 for controlling the operation of the vapour generating device 12 via the controller 64 and / or for displaying information. In some examples, the user interface 66 may be comprised in a separate device such as a mobile device.

[0063] The controller 64 may be configured to detect the initiation of use of the vapour generating device 12 in response to a user input, such as a button press to activate the vapour generating device 12, or in response to a detected airflow through the vapour generating device 12. As will be understood by one of ordinary skill in the art, an airflow through the vapour generating device 12 is indicative of a user inhalation or ‘puff. The vapour generating device 12 may, for example, include a puff detector (not shown), such as an airflow sensor, to detect an airflow through the vapour generating device 12.

[0064] The controller 64 includes electronic circuitry 68. The vapour generating device 12 includes a power source 70, such as a battery. The power source 70 and the electronic circuitry 68 may be configured to operate at a high frequency. The power source 70 and the electronic circuitry 68 may be configured to operate at a frequency of between approximately 80 kHz and 500 kHz, possibly between approximately 150 kHz and 250 kHz, and possibly at approximately 200 kHz. The power source 70 and the electronic circuitry 68 could be configured to operate at a higher frequency, for example in the MHz range, if required. In some examples, the vapour generating device 12 may include a heater 22, as described below. The heater 22 is configured to electrically couple to the power source 70 to receive a current flow.

[0065] With reference to Figures 5 to 15, the removeable cartridge 10 comprises a liquid store 14 for containing, i.e., for holding or storing, a vapour generating liquid. Accordingly, the liquid store

[0066] 14 is configured for containing therein a vapour generating liquid. The liquid store 14 is sized and shaped to allow consumption of substantially all of the vapour generating liquid in use by heating the vapour generating liquid by the heater 22 without burning the vapour generating liquid. The liquid store 14 provides a liquid reservoir. In some examples, the liquid store 14 holds a liquid volume of 1.7 ml. The liquid store 14 may hold a liquid volume of from 1 ml to 3 ml.

[0067] In the illustrated example, the liquid store 14 extends generally between the proximal end 60 and the distal end 62 of the cartridge housing 26.

[0068] The removeable cartridge 10 comprises a vapour outlet channel 24. The vapour outlet channel 24 is fluidly connected to the proximal end 60. The vapour outlet channel 24 has a vapour outlet 61 fluidly connected to an opening 65 in the cartridge housing 26. In use, the vapour outlet 61 is fluidly connected to the mouthpiece 72 of the vapour generating device 12. In the illustrated example, the liquid store 14 surrounds, and coextends with, the vapour outlet channel 24.

[0069] In some examples, the vapour outlet channel 24 is formed of aluminium. The vapour outlet channel 24 may be substantially formed of aluminium. In some examples, the vapour outlet channel 24 comprises a chimney formed or substantially formed of aluminium. The vapour outlet channel 24 may be formed exclusively of aluminium.

[0070] The removeable cartridge comprises a vaporisation assembly 15. The vaporisation assembly

[0071] 15 comprises a vapour generation area 19.

[0072] The vapour generation area 19 comprises a vaporisation chamber 16. The vapour outlet channel 24 is fluidly connected to the vaporisation chamber 16. The vapour outlet channel 24 is aligned with, and fluidly connected to, the vaporisation chamber 16 such that, in use, vapour generated by heating the vapour generating liquid cools and condenses to form an aerosol that can be inhaled by a user, for instance, through the mouthpiece 72 of the vapour generating device 12.

[0073] The vapour generation area 19 further comprises a porous liquid transfer element 18, also called wick, associated with the vaporisation chamber 16. The porous liquid transfer element 18 is configured to hold and transfer vapour generating liquid from the liquid store 14.

[0074] The vaporisation chamber 16 and the porous liquid transfer element 18 therefore provide the vapour generation area 19.

[0075] In the illustrated example, the porous liquid transfer element 18 is toroidal and comprises a hollow core and a base. The porous liquid transfer element 18 may be substantially disk shaped.

[0076] The porous liquid transfer element 18 is arranged to hold and transfer vapour generating liquid from the liquid store 14 by capillary action. The porous liquid transfer element 18 is positioned outside the inner volume of the liquid store 14, and more particularly beneath the liquid store 14. An advantage of this arrangement is that it allows the delivery of liquid to the porous liquid transfer element 18 to be carefully controlled whilst minimising heat transfer from the porous liquid transfer element 18 to the vapour generating liquid in the liquid store 14. The porous liquid transfer element 18 includes an outer surface, i.e., an in-use top side 88, which is exposed to an inner space of the liquid store 14.

[0077] In the illustrated example, the vaporisation chamber 16 is substantially cylindrical and centrally positioned. The vaporisation chamber 16 is aligned with, and fluidly connected to, the vapour outlet channel 24. The vaporisation chamber 16 provides a route which allows vapour generated by heating the vapour generating liquid to be transferred into the vapour outlet channel 24 where it cools and condenses to form an aerosol that can be inhaled by a user. The vapour generated in the vaporisation chamber 16 may cool and condense to form an aerosol as it flows along the vapour outlet channel 24, from the vaporisation chamber 16 towards an end of the vapour outlet channel 24. Efficient vapour generation is thereby assured. In particular, in use, a continuous process is achieved in which vapour generating liquid from the liquid store 14 is continuously absorbed by the porous liquid transfer element 18 and heated by the heater 22 to generate a vapour in the vaporisation chamber 16. The porous liquid transfer element 18 comprises a capillary material, such as a porous ceramic material. Accordingly, the porous liquid transfer element 18 may be a porous ceramic wick. In other examples, the porous liquid transfer element 18 comprises or is formed of glass, plastics (e.g., high temperature plastics), or foam (e.g., high temperature foam, for instance neoprene foam). The material of the porous liquid transfer element 18 may be configured to withstand temperatures of at least 400°C without any change of shape or material properties. The material of the porous liquid transfer element 18 may be non-conductive.

[0078] In some examples, the vaporisation assembly 15 may further comprise a thermal interface material 20 arranged to thermally couple, in use, the vapour generation area 19 and the heater 22 comprised in the vapour generating device 12 to produce vapour from the vapour generating liquid contained in the liquid store 14. In the illustrated example, the heater 22 is configured to electrically couple to the power source 70 to receive a current flow and heat the vapour generating liquid to form an aerosol. In use, the heater is arranged in thermal proximity to the vapour generation area 19 to heat and vaporise the vapour generating liquid held in the porous liquid transfer element 18. The thermal interface material 20 is disposed below the porous liquid transfer element 18, in use.

[0079] The arrangement of the thermal interface material 20 and porous liquid transfer element 18 ensures heat transfer to the vapour generation area 19 with minimal heat loss.

[0080] The thermal interface material 20 may be formed of a metal. The thermal interface material 20 may comprise stainless steel, tungsten (such as tungsten foil), titanium (such as titanium foil), or poly ether ether ketone (PEEK) (such as PEEK foil). The thermal interface material 20 may be formed of stainless steel or tungsten. The thermal interface material 20 may have a thickness of from 10 to 25 microns. In the illustrated example, the thermal interface material 20 is planar. The thermal interface material 20 may be a membrane.

[0081] The vapour generation area 19 comprises a base 32. In the illustrated example, the base 32 is provided by the thermal interface material 20. In use the heater 22 contacts the thermal interface material 20 of the removeable cartridge 10 when the removeable cartridge 10 is operably received in the chamber 56 to thermally couple the heater 22 and the vapour generation area 19. In use, the heater 22 therefore contacts the base 32 of the vapour generation area 19. The heater 22 includes a heating face 74 dimensioned to correspond to a heatable face 76 of the thermal interface material 20. In the illustrated example, the heating face 74 of the heater 22 and the heatable face 76 of the thermal interface material 20 are disk shaped, and may have a diameter of 3 mm. The heater 22 may be a ceramic heater. The heater 22 may have a lapped top surface, i.e., the heating face 74 may be a lapped top. The heating face 74 may have a contact surface treatment ensuring good surface flatness and good contact with the thermal interface material 20.

[0082] In use, the heating face 74 of the heater 22 contacts the corresponding heatable face 76 of the thermal interface material 20. With this arrangement, in use there is no gap between the heater 22 and the thermal interface material 20. Thus, heat can be readily conducted from the heater 22 to the thermal interface material 20 thereby improving vapour generation and energy efficiency.

[0083] With reference in particular to Figure 9, in the illustrated example the heater 22 is supported in the device 12 by a rigid support member 78. The rigid support member 78 comprises ceramic or Macor. In the illustrated example, the rigid support member 78 comprises a pair of cut-out portions 80 arranged opposite one another. Accordingly, in some examples the rigid support member 78 comprises a cut-out portion 80 or a plurality of cut-out portions 80. The cut-out portion 80 or cut-out portions 80 minimize contact with the rigid support member 78 and therefore minimize heat loss from the heater 22. The cut-out potions 80 may be machined into rigid support member 78.

[0084] In the illustrated example, the thermal interface material 20 contacts the porous liquid transfer element 18 associated with the vaporisation chamber 16. Accordingly, the porous liquid transfer element 18 is in thermal contact with the thermal interface material 20.

[0085] In the illustrated example, the porous liquid transfer element 18 comprises castellations 34. The thermal interface material 20 contacts the castellations 34. The castellations 34 are provided by a plurality of indentations 82, i.e., cut-out portions. The indentations 82 are provided on only one face 84 of the porous liquid transfer element 18, which is an in-use underside of the porous liquid transfer element 18. Accordingly, the castellations 34 are provided on only one face 84 of the porous liquid transfer element 18. The face 84 of the porous liquid transfer element 18 comprising castellations 34 contacts the thermal interface material 20. The castellations 34 provide airflow channels 86. In the illustrated example, the other face 88 of the porous liquid transfer element 18, i.e., the in-use top side, is substantially flat.

[0086] The castellations 34 ensure proper vape generation and prevent vape cumulation below the porous liquid transfer element 18.

[0087] Referring to Figure 2 in particular, in some examples the vapour generating device 12 comprises a force generating mechanism 90. The force generating mechanism 90 provides a releasable connection configured to cause the heater 22 of the vapour generating device 12 and the thermal interface material 20 of the removable cartridge 10 to be forced together when the removeable cartridge 10 is operably received in the chamber 56 of the vapour generating device 12. In use, the heater 22 therefore presses against the thermal interface material 20.

[0088] The force generating mechanism 90 is configured to apply a mechanical load (e.g., a mechanical force) to the thermal interface material 20. The heater 22 and the thermal interface material 20 are in compression based on the mechanical force applied.

[0089] The force generating mechanism 90 comprises a force generator 92. In the illustrated example, the force generator 92 comprises a plurality of coiled springs 94 arranged about the rigid support member 78. The force generator 92 is configured to cause the heater 22 and the thermal interface material 20 of the removable cartridge 10 to be forced together with a force of at least 20N when the removeable cartridge 10 is operably received in the chamber 56.

[0090] The removeable cartridge 10 is internally loaded in the vapour generating device 10 by virtue of the force generating mechanism 90. In some examples, a good contact between the heater 22 and the removeable cartridge 10 is achieved by a force of 20N.

[0091] As best shown in Figures 5 and 14, in some examples the removeable cartridge 20 comprises an airflow channel 36. The airflow channel 36 comprises an air inlet 38 through which ambient air can flow into the airflow channel 36 and an air outlet 40 through which ambient air can flow out of the airflow channel 36 into the vaporisation chamber 16 to facilitate vaporisation of vapour generating liquid. The vaporisation of the vapour generating liquid is facilitated by the addition of air from the surrounding environment through the air inlet 38. The flow of air and / or vapour may be aided by negative pressure created by a user drawing air through the device 12.

[0092] The removeable cartridge 10 has a cartridge axis Y. The airflow channel 36 extends perpendicular to the cartridge axis Y.

[0093] In the illustrated example, the removeable cartridge 10 comprises two airflow channels 36, wherein each airflow channel 36 comprises an air inlet 38 through which ambient air can flow into the airflow channel 36 and an air outlet 40 through which ambient air can flow out of the airflow channel 36 into the vaporisation chamber 16 to facilitate vaporisation of vapour generating liquid. The air outlets 40 of the two airflow channels 36 face one another across the vaporisation chamber 16. Each airflow channel 36 extends perpendicular to the cartridge axis Y. The two airflow channels 36 extend perpendicular to the cartridge axis Y in opposite directions. Accordingly, a horizontal airflow path is provided.

[0094] In use, air entering the air inlets 38 carries vapour generated through the vapour outlet channel 24 for inhalation by a user.

[0095] The air inlets 38 and / or air outlets 40 may have a diameter of 0.5 mm, and may be formed by drilling.

[0096] In the illustrated example, the removeable cartridge 10 comprises an insert 30 having a non- metallic body 31. The vapour generation area 19 is nested in the insert 30.

[0097] As best shown in Figure 12, the insert comprises an opening 49. The porous liquid transfer element 18 is disposed in the opening 49. The insert 30 provides a support for the porous liquid transfer element 18.

[0098] In some examples, the airflow channel 36 extends through the insert 30. In such examples, the air inlet 38 is provided in the cartridge housing 26 and opens into the airflow channel 36 comprised in the insert 30. In the illustrated example, each of the two airflow channels 36 extend through the insert 30. The airflow channels 36 are comprised in the insert 30. The respective air inlets 38 are provided on opposites sides of the cartridge housing 26 and open into the respective airflow channels 36 comprised in the insert 30.

[0099] Accordingly, a horizontal airflow path is provided through the insert 30.

[0100] The non-metallic body 31 of the insert 30 may comprise plastics, which may be polyimide- based plastics. The non-metallic body 31 may comprise Vespel®. The non-metallic body 31 may be formed of plastics. The non-metallic body 31 may be formed of polyimide-based plastics. The non-metallic body 31 may be formed of Vespel®. The non-metallic body 31 may comprise any other suitable material capable of withstanding high temperatures e.g., about 300°C, for example, Torlon or PEEK. The non-metallic body 31 may be manufactured by injection moulding, which allows mass production.

[0101] As best illustrated in Figure 14, in the illustrated example the thermal interface material 20 is arranged in the insert 30. The thermal interface material 20 may be over-moulded into the non- metallic body 31 of the insert 30 during injection moulding. The thermal interface material 20 is comprised in the insert 30. The insert 30 therefore comprises the thermal interface material 20.

[0102] In the illustrated example, the insert 30 is disposed in the cartridge housing 26 below the liquid store 14.

[0103] The insert 30 provides a sealing element 33 which sealingly closes off the liquid store 14 to retain the vapour generating liquid in the liquid store 14. The insert 30 is therefore a partition. The in-use top side 88 of the porous liquid transfer element 18 is exposed to the inner space of the liquid store 14. Vapour generating liquid is thereby absorbed into the porous liquid transfer element 18 via the in-use top side 88.

[0104] In some examples, the removeable cartridge 10 comprises a leakage trap 48 associated with the airflow channel 36. The leakage trap 48 comprises a liquid drain 50 in the airflow channel 36 through which liquid can drain from the airflow channel 36. The leakage trap 48 further comprises a liquid absorber 52. The liquid absorber 52 is arranged to absorb liquid drained through the liquid drain 50 from the airflow channel 36.

[0105] The liquid drain 50 comprises an aperture in the airflow channel 36 through which liquid can drain. The liquid absorber 52 is in fluid communication with the liquid drain 50. The liquid absorber 52 may be a foam material.

[0106] In the illustrated example, a leakage trap 48 is provided comprising a plurality of liquid drains 50 in the airflow channel 36. The leakage trap 48 comprises two liquid drains 50 in the airflow channel 36.

[0107] In the illustrated example, the removable cartridge 10 comprises a leakage trap 48 associated with each airflow channel 36, wherein each leakage trap 48 comprises a plurality of liquid drains 50. Each leakage trap 48 comprises two liquid drains 50 in a respective airflow channel 36. The liquid absorber 52 is arranged to absorb liquid exiting each respective airflow channel 36 through respective liquid drains 50. The liquid absorber 52 is in fluid communication with the liquid drains 50 in each airflow channel 36.

[0108] In the illustrated example, the insert 30 comprises the liquid absorber 52. The liquid absorber 52 is arranged in the insert 30. The liquid absorber 52 is comprised in the insert 30. The insert 30 comprises the leakage trap 48.

[0109] In some examples, at least a portion of the inner surface of the cartridge housing 26 has a Polytetrafluoroethylene (PTFE) or ceramic coating. The vapour outlet channel 24 may have a PTFE or ceramic coating. The vapour outlet channel 24 has an inner surface and an outer surface. The inner surface and / or the outer surface may have a PTFE or ceramic coating. The PTFE or ceramic coating prevents oxidation caused by the vapour generating liquid, for instance, if the cartridge housing 26 and / or vapour outlet channel 24 are formed of aluminium.

[0110] In operation of the vapour generating system 100, vapour generating liquid is conveyed from the liquid store 14 to the porous liquid transfer element 18. The vapour generating liquid is held and transferred by the porous liquid transfer element 18 (by capillary action) and is heated by heat thermally transferred to the vapour generation area 19 from the heater 22 through the thermal interface material 20. The heat from the heater 22 is transferred through the thermal interface material 20 to vapour generating liquid held and transferred by the porous liquid transfer element 18, resulting in the generation of a vapour. The vapour escapes from the porous liquid transfer element 18 into the vaporisation chamber 16, and then flows from the vaporisation chamber 16 along the vapour outlet channel 24 where it cools and condenses to form an aerosol that is inhaled by a user of the vapour generating device 10, for instance, through the mouthpiece 72.

[0111] The vaporisation of the vapour generating liquid is facilitated by the addition of air flowing from the surrounding environment through the air inlet 38 or air inlets 38. Air flows into the vaporisation chamber 16 via an airflow path defined by the airflow channels 86 provided by the castellations 34 comprised in the porous liquid transfer element 18. Air then flows from the vaporisation chamber 16 along the vapour outlet channel 24, for instance, to the mouthpiece 72 of the device. Vapour generated is entrained in the air as it flows into the vaporisation chamber 16 and along the vapour outlet channel 24 to the mouthpiece 72.

[0112] The flow of air and / or vapour through the removeable cartridge 10, i.e., through the vaporisation chamber 16, along the vapour outlet channel 24, and out of the mouthpiece 72 of the vapour generating device 12, is aided by negative pressure created by a user drawing air through the mouthpiece 72.

[0113] After the vapour generating liquid in the liquid store 14 of the removeable cartridge 10 has been depleted, the removeable cartridge 10 can be disconnected from the vapour generating device 12 and a replacement removeable cartridge 10 can then be connected in its place, to allow further use of the vapour generating device 12.

[0114] In some examples, the removeable cartridge 10 may be re-filled with vapour generating liquid so that the removeable cartridge 10 can be re-used.

[0115] After a first use or after multiple uses a removeable cartridge 10 may be at end of life. To facilitate recycling or disposal of such removeable cartridges 10, in examples of the disclosure the cartridge housing 26 comprises a frangible line 46 defining a first housing portion 42 and a second housing portion 44. The frangible line 46 is arranged to facilitate separation of the first and second housing portions 42, 44 for separate recycling or disposal. Removable cartridges 10 according to examples of the disclosures can readily be recycled by separation of the first and second housing portions 42, 44 at the frangible line 46. The first and second housing portions 42, 44 can therefore be recycled or disposed of separately.

[0116] The frangible line 46 is a line of weakness in the cartridge housing 26. Accordingly, the cartridge housing 26 can be readily or easily cut or broken along the frangible line 46. The frangible line 46 is a cutting line.

[0117] A typical recycling and / or disposal procedure is illustrated in Figure 16. In Figure 16A, a cutting, breaking, or any other separation action is performed along the frangible line 46. The separation action can comprise twisting, bending, squeezing, etc. It can be done manually by a user or using an appropriate separation tool or machine. Accordingly, a user can separate the first and second housing portions 42, 44 by breaking the cartridge housing 26 at the frangible line 46. In Figure 16B, the first and second housing portions 42, 44 are separated. According to different embodiments, the frangible line 46 can be formed by a continuous groove or a series of separated grooves or embossments. Alternatively or additionally, the frangible line 46 can be formed by perforations.

[0118] In some embodiments, the frangible line 46 extends according to the whole perimeter of the cartridge housing 26. In some other embodiments, the frangible line 46 extends only on one or several sides of the cartridge housing 26. For example, the frangible line 46 can extend only on one wide side of the cartridge housing 26 or on opposite wide sides of the cartridge housing 26.

[0119] Another recycling and / or disposal procedure is illustrated in Figures 17A to 17D. In some examples, the recycling and / or disposal procedure is a method which comprises locating the removeable cartridge 10 in an adapter 114 comprising a first adapter part 116 and a second adapter part 118. The adapter 114 is therefore atwo-part adapter 114. The first adapter part 116 receives the first housing portion 42 and the second adapter part 118 receives the second housing portion 44. The method further comprises rotating the first adapter part 116 and / or the second adapter part 118 about a rotation line 122 causing the cartridge housing 26 to break along the frangible line 46 and the first and second housing portions 42, 44 to separate. The adapter 114 is therefore used to facilitate breaking of the cartridge housing 26 at the frangible line 46 to separate the first and second housing portions 42, 44. Figures 17A and 17B, illustrate the positioning, indicated by arrows A, of a depleted or spent removeable cartridge 10 (at end of life) inside the two-part adapter 114 by user action or an automated process. The two-part adapter 114 comprises the first adapter part 116 and the second adapter part 118. The first adapter part 116 is configured to receive the first housing portion 42. The second adapter part 118 is configured to receive the second housing portion 44. In the illustrated example, the second adapter part 118 comprises handle portions 120. The handle portions 120 facilitate rotation of the second adapter part 118 relative to the first adapter part 116 by improving grip and / or increasing mechanical advantage. In other examples, the first adapter part 116 and / or second adapter part 118 may comprise the handle portion 120. The first adapter part 116 and / or second adapter part 118 may comprise a pair of handle portions 120. The pair of handle portions 120 may extend radially in opposite directions from the first adapter part 116 or may extend radially in opposite directions from the second adapter part 118. In the illustrated example, a pair of handle portions 120 extend radially in opposite directions from the second adapter part 118.

[0120] In Figure 17C, the second adapter part 118 has been rotated relative to the first adapter part 116 in a direction B about a rotation line 122 in a direction B causing the first housing portion 42 to separate from the second housing portion 44 at the frangible line 46 (i.e., the cartridge housing 26 has been cut or broken at the frangible line 46). Rotation can be omni directional. In some examples, the first adapter part 114 and / or second adapter part 116 are rotatable about the rotation line 122.

[0121] As best shown in Figure 17B, the rotation line 122 between the first and second adapter parts 116, 118 is aligned in use with the frangible line 46 between the first and second housing portions 42, 44.

[0122] In Figure 17D, the first and second adapter parts 116, 118 have been separated in a direction C and the respective separated first and second housing portions 42, 44 can be isolated for disposal or recycling.

[0123] In some examples, for instance the illustrated example, the first adapter part 116 is held or fixed and the second adapter part 118 is rotated, e.g., by hand (which may be facilitated by handle portions 120). Accordingly, the method may comprise rotating the second adapter part 118 relative to the first adapter part 116, wherein the first adapter part 116 remains stationary. 11

[0124] Alternatively, the second adapter part 118 may be held or fixed and the first adapter part 116 rotated, e.g., by hand. Accordingly, the method may comprises rotating the first adapter part 116 relative to the second adapter part 118, wherein the second adapter 118 part remains stationary.

[0125] Alternatively, the method may comprise simultaneously rotating both the first and second adapter parts 116, 118 in opposite directions.

[0126] In some examples, the separated first housing portion 42, which may exclusively comprise aluminium, is recycled and the separated second housing portion 44, which may comprise plastics and other materials, is disposed of or recycled separately.

[0127] The cartridge housing 26 is easily cut or broken at the frangible line 46, which defines a line of weakness. The process described above can be automated in a recycling centre.

[0128] The two-part adapter 114 may be made of aluminium or plastics.

[0129] Preferably, the longitudinal extension of the first adapter part 116 is greater than the one of the second adapter part 118. For example, the first adapter part 116 can extend longitudinally according to at least 50%, preferably 60%, more preferably 70%, more preferably 80% and advantageously 90% of the overall longitudinal length of the adapter 114. Accordingly, the second adapter part 118 can extend longitudinally according to at most 50%, preferably 40%, more preferably 30%, more preferably 20% and advantageously 10% of the overall longitudinal length of the adapter 114.

[0130] The first housing portion 42 may be formed of aluminium. The second housing portion 44 may be formed of aluminium. The first housing portion 42 may be formed exclusively of aluminium. The second housing portion 44 may be formed exclusively of aluminium.

[0131] Preferably, the longitudinal extension of the first housing portion 42 is greater than the one of the second housing portion 44. For example, the first housing portion 42 can extend longitudinally according to at least 50%, preferably 60%, more preferably 70%, more preferably 80% and advantageously 90% of the longitudinal length of the cartridge housing 26. Accordingly, the second housing portion 44 can extend longitudinally according to at most 50%, preferably 40%, more preferably 30%, more preferably 20% and advantageously 10% of the longitudinal length of the cartridge housing 26.

[0132] The first housing portion 42 may have a height of from 12.40mm to 37.20mm. Preferably, the first housing portion 42 may have a height of 24.80mm.

[0133] The second housing portion 44 may have a height of from 1.05mm to 3.15mm. Preferably, the second housing portion 44 may have a height of 2.1mm.

[0134] A groove defining the frangible line 46 may have a height of 0.2mm.

[0135] In the illustrated example, the cartridge housing 26 comprises a capping end portion 58. The capping end portion 58 closes the second housing portion 44. The capping end portion 58 may be formed of aluminium. The capping end portion 58 may be formed exclusively of aluminium. The capping end portion 58 may be an aluminium cap. In some examples, the capping end portion 58 has a wall thickness of from 0.1 mm to 0.15 mm. As best shown in Figure 15, the capping end portion 58 comprises an opening 63 through which the heater 22 of the device 10 can engage with the thermal interface material 20.

[0136] In the illustrated example, the liquid store 14 and the vapour outlet channel 24 are associated with the first housing portion 42. The vaporisation assembly 15 is associated with the second housing portion 44. The insert 30 is associated with the second housing portion 44. Accordingly, non-metallic, e.g., plastic components can be provided only in the second housing portion 44, and this can be disposed of or recycled separately from the first housing portion 42 which can comprise only metal components, e.g., aluminium components.

[0137] In the illustrated example, the vapour outlet channel 24 is connected to the first housing portion 42. The vapour outlet channel 24 may be ultrasonically welded to the first housing portion 42. Accordingly, the vapour outlet channel 24 and the cartridge housing 26 may be connected by ultrasonic welding. In some examples, a sealant may be applied at the interface between the vapour outlet channel 24 and the first housing portion 42. The sealant may be a food grade sealant. The sealant prevents potential leakage in case of ultrasonic welding imperfections. With reference to Figure 10 in particular, which shows a magnification of the vapour outlet 61 of the vapour outlet channel 24, in some examples the vapour outlet channel 24 has a contact face 96 connecting to the first housing portion 42. The contact face 96 comprises grooves 98. In the illustrated example, the contact face 96 comprises two grooves 98. The grooves 98 have a triangular cross section. The grooves 98 provide an improved weld.

[0138] Referring to Figure 11 in particular, in the illustrated example the cartridge housing 26 comprises hard stops 35 for locating the insert 30. The cartridge housing 26 also comprises hard stops 59 for locating the capping end portion 58. The hard stops 59 provide a dent which prevents the capping end portion 58 from moving.

[0139] Referring to Figure 12 in particular, in the illustrated example the insert 30 comprises a pair of seals 43 which engage with the inner surface of the cartridge housing 26. The seals 43 may be high temperature silicone seals. The seals 43 are provided in grooves 51, which are best shown in Figures 13 and 14.

[0140] In the illustrated example, as best shown in Figure 12, the porous liquid transfer element 18 comprises a first seal 45 which engages with an inner surface of the opening 49 in the insert 30. The porous liquid transfer element 18 comprises a second seal 47 which engages with an outer surface of the vapour outlet channel 24. The first and second seal 45, 47 may be a high temperature silicone seal.

[0141] Examples of the disclosure provide a method of manufacturing a removeable cartridge 10 as described above. The method comprises deep drawing and / or stretch drawing a first sheet material to form a cartridge housing 26. The cartridge housing 26 provides the liquid store 14.

[0142] Accordingly, in the illustrated example the cartridge housing 26 is formed by a process of deep drawing and / or stretch drawing. The cartridge housing 26 may be formed from a sheet of aluminium by a process of deep drawing and / or stretch drawing. The sheet of material may have a thickness of 0.3 mm.

[0143] The method further comprises forming a frangible line 46 in the cartridge housing 26. The frangible line 46 defines the first housing portion 42 and the second housing portion 44. Figure 18 illustrates stages of an example method of forming the cartridge housing 26 from an aluminium sheet by deep drawing. In Figure 18 A, a deep drawing tool 102 is acting on the aluminium sheet 104 in a direction Y. The stages of the method are ordered according to arrow X, i.e., 18A to 18E. As the deep drawing tool 102 acts on the aluminium sheet 104, the aluminium sheet 104 gradually elongates as shown in Figure 18B, 18C and 18D to form a body (i.e., shell) of the cartridge housing 26. In Figure 18D, the frangible line 46 has been formed in the cartridge housing 26 of a removeable cartridge 10 as described in more detail below with reference to Figures 19A to 19C and 20A and 20B.

[0144] In Figure 18E, the opening 65 has been provided in the cartridge housing 26, along with air inlets 38, hard stops 35 (although not visible in Figure 18E) and hard stops 59.

[0145] Figures 19A to 19C and 20A and 20B illustrate an example method of forming the frangible line 46 in the cartridge housing 26.

[0146] In some examples, a tool 106 is used to form the frangible line 46 in the cartridge housing 26. The tool 106 comprises a rotatable blade 108. The method comprises receiving the removeable cartridge 10 in a rotatable cartridge holder 110. The method further comprises urging the rotatable blade 108 against the cartridge housing 26. The method further comprises rotating the removeable cartridge 10 by the rotatable cartridge holder 110 to cause the rotatable blade 108 to form the frangible line 46 in the cartridge housing 26 by a cutting action.

[0147] In Figure 19A, the rotatable cartridge holder 110 is about to engage a removeable cartridge 10 in a direction indicated by arrow A. The tool 106 is positioned such that the rotatable blade 108, which in this example is spring-loaded, is contacting the cartridge housing 26 at the required position of the frangible line 46. The tool 106 has a fixed position.

[0148] In Figure 19B, the rotatable cartridge holder 110 has engaged with the removeable cartridge 10, i.e., the removeable cartridge 10 is received in the rotatable cartridge holder 110, and the spring-loaded rotatable blade 108 is being urged against the cartridge housing 26 by spring 112. The rotatable cartridge holder 110 has engaged with an upper portion of the removeable cartridge 10. In Figure 19C, the removeable cartridge 10 has been rotated (arrow C) by 90 degrees relative to the tool 106 by the rotatable cartridge holder 110 and a portion of the frangible line 46 has been formed by a cutting action of the spring-loaded rotatable blade 108. The spring has extended applying a constant pressure on the rotatable blade 108 as it rotates, the rotation of the rotatable blade 108 being caused by the rotation of the removeable cartridge 10. The removeable cartridge 10 has been rotated about its vertical axis. Rotation can be omni directional. The direction of extension and compression of the spring 112 is indicated by arrow B.

[0149] In Figure 20A, a groove defining the frangible line 46 has been cut by the rotatable blade 108. The spring 112 is in an extended condition to urge the rotatable blade 108 against the wider side of the cartridge housing 26. In Figure 20B, the spring 112 is in a compressed condition to urge the rotatable blade 108 against the narrower side of the cartridge housing 26. A pivot 114 allows the rotatable blade 108 to rotate minimizing wear on the rotatable blade 108. The rotatable blade 108 may be stainless steel.

[0150] The method further comprises deep drawing and / or stretch drawing a second sheet material to form the vapour outlet channel 24. Accordingly, in the illustrated example the vapour outlet channel 24 is formed by a process of deep drawing and / or stretch drawing. The vapour outlet channel 24 may be formed from a sheet of aluminium by a process of deep drawing and / or stretch drawing. This process may be the same or similar to that described in relation to Figure 17.

[0151] Accordingly, the method comprises providing first and second sheets of material. The first and second sheets of material may be aluminium sheets.

[0152] The method further comprises connecting the vapour outlet channel 24 to the cartridge housing 26 and filling the liquid store 14 with a vapour generating liquid.

[0153] The method further comprises providing the vaporisation assembly 15. The vaporisation assembly 15 comprises the vapour generation area 19 and the thermal interface material 20. As described above, the vapour generation area 19 comprises the vaporisation chamber 16 and the porous liquid transfer element 18. The method further comprises applying the capping end portion 58 to the cartridge housing 26 to encase the liquid store 14, the vapour outlet channel 24 and the vaporisation assembly 15.

[0154] In some examples, a method of assembling the removeable cartridge 10 comprises the following sequence of steps:

[0155] Step 1 is to ultrasonically weld the vapour outlet channel 24 into the cartridge housing 26. The vapour outlet channel 24 and the cartridge housing 26 are formed as described above by a process of deep drawing and / or stretch drawing respective sheets of material.

[0156] Step 2 is to rotate the cartridge housing 26 upside down and fill the liquid store 14 with vapour generating liquid.

[0157] Step 3 is to insert the porous liquid transfer element 18 into the opening 49 of the insert 30. In this example the thermal interface material 20 has been over-moulded into the non-metallic body 31 of the insert 30.

[0158] Step 4 is to insert the insert 30 comprising seals 43 into the cartridge housing 26 up to the hard stops 35, which locate the insert 30.

[0159] Step 5 is to insert the liquid absorber 52 into the insert 30.

[0160] Step 6 is to close the cartridge housing 26 with the capping end portion 58. In the illustrated example, the cartridge housing 26 is punched to provide a stop 59 to prevent movement of the capping end portion 58. The stop 59 is best shown in Figure 11. A sealant may be applied around capping end portion 58.

[0161] The figures also illustrate a method of manufacturing a vapour generating device 12 according to examples of the disclosure. The figures also illustrate a method of providing a system 100 according to examples of the disclosure.

[0162] There is thus described a removeable cartridge 10, a vapour generating device 12, a system 100 and methods according to examples of the disclosure with a number of advantages as detailed above. Furthermore, to increase the sustainability of the removeable cartridge 10, i.e., the pod, most of its component parts can be made from aluminium as described above. Accordingly, such components parts can readily be separated and recycled. Aluminium component parts can readily be recycled, particularly when separated from other non-metallic components of the removeable cartridge 10. In the illustrated example, the heater 22 is part of the vapour generating device 12 which reduces the complexity of the removeable cartridge 10 and therefore its cost. In other (nonillustrated) examples, the heater 22 may be part of the removeable cartridge 10 rather than the vapour generating device 12. In other words, the removeable cartridge 10 may include a heater 22, for example instead of the thermal interface material 20 described above. In such examples, the heater 22 (which may, e.g., be a resistive heating element or an inductively heatable susceptor) is, thus, part of the vaporisation assembly 15 and may be associated with the second housing portion 44.

[0163] In some examples, where the removeable cartridge 10 comprises aluminium component parts, for instance, the cartridge housing 26 and vapour outlet channel 24 being formed of aluminium, around 85 % of the aluminium in the removeable cartridge is available for recycling.

[0164] The removeable cartridge 10 according to examples of the disclosure comprises only a limited number of components. For example, in some examples as discussed above, the removeable cartridge 10 does not have a heater 22 which is instead provided by the vapour generating device 12. This arrangement may further simplify the recycling process, reduce cost of manufacture, improve sustainability, and reduce environmental impact.

[0165] The removeable cartridge 10 is suitable for mass production, for example, by being manufactured by a deep drawing and / or stretch process and by minimizing the number of components. Furthermore, the assembly operations are reduced to a minimum which speeds up the manufacturing.

[0166] Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to those embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0167] Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context. Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

Claims

Claims1. A removeable cartridge (10) for a vapour generating device (12), wherein the removeable cartridge (10) comprises: a liquid store (14) for holding a vapour generating liquid; a vaporisation assembly (15) comprising: a vapour generation area (19), the vapour generation area (19) comprising a vaporisation chamber (16) and a porous liquid transfer element (18) associated with the vaporisation chamber (16), wherein the porous liquid transfer element (18) is configured to hold and transfer vapour generating liquid from the liquid store (14); the removeable cartridge (10) further comprising: a vapour outlet channel (24) fluidly connected to the vaporisation chamber (16); and a cartridge housing (26), wherein the cartridge housing (26) comprises a frangible line (46) defining a first housing portion (42) and a second housing portion (44), wherein the frangible line (46) is arranged to facilitate separation of the first and second housing portions (42, 44).

2. A removeable cartridge according to claim 1, wherein the removeable cartridge (10) comprises an insert (30) having a non-metallic body (31), wherein the vapour generation area (19) is nested in the insert (30).

3. A removeable cartridge according to claim 1 or claim 2, wherein the removeable cartridge (20) comprises an airflow channel (36), wherein the airflow channel (36) comprises an air inlet (38) through which ambient air can flow into the airflow channel (36) and an air outlet (40) through which ambient air can flow out of the airflow channel (36) into the vaporisation chamber (16) to facilitate vaporisation of vapour generating liquid.

4. A removeable cartridge according to claim 3, wherein the removeable cartridge (10) has a cartridge axis Y, wherein the airflow channel (36) extends perpendicular to the cartridge axis Y.

5. A removeable cartridge according to claim 3 or claim 4, wherein the removeable cartridge (10) comprises a leakage trap (48) associated with the airflow channel (36), wherein the leakage trap (48) comprises:a liquid drain (50) in the airflow channel (36) through which liquid can drain from the airflow channel (36); and a liquid absorber (52), wherein the liquid absorber (52) is arranged to absorb liquid drained through the liquid drain (50) from the airflow channel (36).

6. A removeable cartridge according to any of the preceding claims, wherein the liquid store (14) and the vapour outlet channel (24) are associated with the first housing portion (42), and the vaporisation assembly (15) is associated with the second housing portion (44).

7. A removeable cartridge according to any of the preceding claims, wherein the vaporisation assembly (15) further comprises a heater (22).

8. A removeable cartridge according to any of the preceding claims, wherein the removeable cartridge (10) has a substantially cuboidal shape.

9. A removeable cartridge according to any of the preceding claims, wherein the cartridge housing (26) and the vapour outlet channel (24) are formed of aluminium.

10. A removeable cartridge (10) for a vapour generating device (12), wherein the removeable cartridge (10) comprises: a liquid store (14) for holding a vapour generating liquid; a vaporisation assembly (15), the vaporisation assembly (15) comprising: a vapour generation area (19), the vapour generation area (19) comprising a vaporisation chamber (16) and a porous liquid transfer element (18) associated with the vaporisation chamber (16), wherein the porous liquid transfer element (18) is configured to hold and transfer vapour generating liquid from the liquid store (14); and a thermal interface material (20) arranged to thermally couple, in use, the vapour generation area (19) and a heater (22) comprised in the vapour generating device (12); the removeable cartridge (10) further comprising: a vapour outlet channel (24) fluidly connected to the vaporisation chamber (16); and a cartridge housing (26), wherein the cartridge housing (26) comprises a frangible line (46) defining a first housing portion (42) and a second housing portion (44), wherein the frangible line (46) is arranged to facilitate separation of the first and second housing portions (42, 44).

11. A removeable cartridge according to claim 10, wherein the removeable cartridge (10) comprises an insert (30) having a non-metallic body (31), wherein the vapour generation area (19) is nested in the insert (30).

12. A removeable cartridge according to claim 10 or claim 11, wherein the vapour generation area (19) comprises a base (32), the base (32) being provided by the thermal interface material (20).

13. A removeable cartridge according to any of claims 10 to 12, wherein the thermal interface material (20) contacts the porous liquid transfer element (18) associated with the vaporisation chamber (16).

14. A removeable cartridge according to claim 13, wherein the porous liquid transfer element (18) comprises castellations (34), wherein the thermal interface material (20) contacts the castellations (34).

15. A removeable cartridge according to any of claims 10 to 14, wherein the removeable cartridge (20) comprises an airflow channel (36), wherein the airflow channel (36) comprises an air inlet (38) through which ambient air can flow into the airflow channel (36) and an air outlet (40) through which ambient air can flow out of the airflow channel (36) into the vaporisation chamber (16) to facilitate vaporisation of vapour generating liquid.

16. A removeable cartridge according to claim 15, wherein the removeable cartridge (10) has a cartridge axis Y, wherein the airflow channel (36) extends perpendicular to the cartridge axis Y.

17. A removeable cartridge according to claim 15 or claim 16, wherein the removeable cartridge (10) comprises a leakage trap (48) associated with the airflow channel (36), wherein the leakage trap (48) comprises: a liquid drain (50) in the airflow channel (36) through which liquid can drain from the airflow channel (36); and a liquid absorber (52), wherein the liquid absorber (52) is arranged to absorb liquid drained through the liquid drain (50) from the airflow channel (36).

18. A removeable cartridge according to any of claims 10 to 17, wherein the liquid store (14) and the vapour outlet channel (24) are associated with the first housing portion (42), and the vaporisation assembly (15) is associated with the second housing portion (44).

19. A removeable cartridge according to any of claims 10 to 18, wherein the removeable cartridge (10) has a substantially cuboidal shape.

20. A removeable cartridge according to any of claims 10 to 19, wherein the cartridge housing (26) and the vapour outlet channel (24) are formed of aluminium.

21. A vapour generating system (100), the vapour generating system (100) comprising: a vapour generating device (12) and a removable cartridge (10), wherein the removable cartridge (10) comprises: a liquid store (14) for holding a vapour generating liquid; a vaporisation assembly (15), the vaporisation assembly (15) comprising: a vapour generation area (19), the vapour generation area (19) comprising a vaporisation chamber (16) and a porous liquid transfer element (18) associated with the vaporisation chamber (16), wherein the porous liquid transfer element (18) is configured to hold and transfer vapour generating liquid from the liquid store (14); and a thermal interface material (20); the removeable cartridge further comprising: a vapour outlet channel (24) fluidly connected to the vaporisation chamber (16); and a cartridge housing (26), wherein the cartridge housing (26) comprises a frangible line (46) defining a first housing portion (42) and a second housing portion (44), wherein the frangible line (46) is arranged to facilitate separation of the first and second housing portions (42, 44), wherein the vapour generating device (12) comprises: a device housing (54) defining a chamber (56) configured to operably receive the removeable cartridge (10); and a heater (22), wherein the heater (22) contacts the thermal interface material (20) of the removeable cartridge (10) when the removeable cartridge (10) is operablyreceived in the chamber (56) to thermally couple the heater (22) and the vapour generation area (19).

22. A vapour generating system according to claim 21, wherein the vapour generating device (12) comprises: a force generating mechanism (90), the force generating mechanism (90) being configured to cause the heater (22) of the vapour generating device (12) and the thermal interface material (20) of the removable cartridge (10) to be forced together when the removeable cartridge (10) is operably received in the chamber (56).

23. A method of manufacturing a removeable cartridge (10) for a vapour generating device (12), the method comprising: deep drawing and / or stretch drawing a first sheet material to form a cartridge housing (26), the cartridge housing (26) providing a liquid store (14); forming a frangible line (46) in the cartridge housing (26), the frangible line (46) defining a first housing portion (42) and a second housing portion (44); deep drawing and / or stretch drawing a second sheet material to form a vapour outlet channel (24); connecting the vapour outlet channel (24) to the cartridge housing (26); filling the liquid store (14) with a vapour generating liquid; providing a vaporisation assembly (15), the vaporisation assembly (15) comprising: a vapour generation area (19), the vapour generation area (19) comprising a vaporisation chamber (16) and a porous liquid transfer element (18) associated with the vaporisation chamber (16), wherein the porous liquid transfer element (18) is configured to hold and transfer vapour generating liquid from the liquid store (14); and a thermal interface material (20) arranged to thermally couple, in use, the vapour generation area (19) and a heater (22) comprised in the vapour generating device (12); the method further comprising: applying a capping end portion (58) to the cartridge housing (26) to encase the liquid store (14), the vapour outlet channel (24) and the vaporisation assembly (15).

24. A method of recycling a removeable cartridge according to any of claim 10 to 20, wherein the method comprises:locating the removeable cartridge (10) in an adapter (114) comprising a first adapter part (116) and a second adapter part (118), wherein the first adapter part (116) receives the first housing portion (42), and the second adapter part (118) receives the second housing portion (44); and rotating the first adapter part (116) and / or the second adapter part (118) about a rotation line (112) causing the cartridge housing (26) to break along the frangible line (46) and the first and second housing portions (42, 44) to separate.

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