Modular vibrating mesh aerosol-generating device

Abstract

The invention relates to an aerosol-generating device comprising a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion. The aerosolization module is releasably connectable to the main body and the mouthpiece. The invention also relates to a method of generating an inhalable aerosol with such aerosol- generating device.

Description

[0001] MODULAR VIBRATING MESH AEROSOL-GENERATING DEVICE

[0002] The present invention relates to an aerosol-generating device comprising a main body, an aerosolization module and a mouthpiece.

[0003] Aerosol-generating devices using vibrating mesh modules are often also referred to as vibrating mesh (VM) nebulizers. Such vibrating mesh nebulizers are used for the generation of a respirable aerosol that can be used for instance for treating respiratory diseases.

[0004] Vibrating mesh nebulizers use mesh deformation or vibration to push a liquid through a mesh. In a typical vibrating mesh nebulizer, a piezo element, which is in contact with a mesh, is used to produce vibrations of the mesh. The mesh is adjacent and in direct contact with a liquid drug-containing substrate. Holes in the mesh may have a conical structure, with the largest cross-section of the cone in contact with the liquid substrate. The mesh deformation generates a pressure field in the liquid, thus pumping and loading the holes with liquid. The liquid volume displaced through the holes breaks up into droplets, and are ejected into a mouthpiece chamber. The droplets mix with the air and directly form an aerosol in the mouthpiece chamber. During inhalation, ambient air crosses the mouthpiece chamber to transport the aerosol to the user.

[0005] Various techniques are known to flavorize a generated aerosol in order to enhance the user experience. For example, flavorants may be provided directly to the aerosol-forming substrate. However, adding flavor to a solid or a liquid substrate may be complex and may require specific equipment such as to prevent inadvertent release. In particular, the flavor material needs to be compatible with the aerosol-generating device and in particular with the used aerosol-forming substrate.

[0006] It would be desirable to provide a VM aerosol generating device, which allows for more flexibility and convenience for the user. It would further be desirable to provide a VM aerosol generating device, which facilitates handling and maintenance of the aerosol generating device.

[0007] According to an embodiment of the invention there is provided an aerosol-generating device which may comprise a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion. The aerosolization module may be releasably connectable to the main body and the mouthpiece.

[0008] According to an embodiment of the invention there is provided an aerosol-generating device comprising a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion. The aerosolization module is releasably connectable to the main body and the mouthpiece. The mouthpiece, the aerosolization module and the main body may each be separate modules, which may be configured to be replaceable. Configuring the modules as separate replaceable modules may be advantageous in economic respect. In case of malfunction, only the defective module may need to be replaced, while the other modules can be continued to be used.

[0009] The aerosol-generating device may be a portable device. The aerosol-generating device may be provided with suitable sensorial or flavour enhancing features. In particular, the mouthpiece may be provided with suitable sensorial or flavour enhancing features.

[0010] The mouthpiece may comprise a substrate opening for releasing liquid aerosol-forming substrate from the liquid storage portion of the mouthpiece.

[0011] The substrate opening may be provided with a sealing element. The sealing element may assist in retaining the stored liquid aerosol-forming substrate in the liquid storage portion. The sealing element may be a sealing foil. The sealing foil may be provided to cover the substrate opening. Before use, a user may have to remove the sealing foil from the substrate opening.

[0012] In addition, or alternatively to the sealing foil, the substrate opening may comprise a valve. The valve may also assist in retaining the stored liquid aerosol-forming substrate in the liquid storage portion. In particular, the valve may assist in retaining the stored liquid aerosolforming substrate in the liquid storage portion after the sealing foil has been removed.

[0013] The valve may be selected from the group including but not limited to diaphragm valves, slit valves, poppet valves, duckbill valves, flap valves, check valves, piston valves and pinch valves.

[0014] The mouthpiece may comprise an air inlet, an airflow channel, an aerosol forming chamber and an aerosol outlet. The mouthpiece may be configured to define a continuous airflow passage from the air inlet, via the airflow channel and the aerosol forming chamber and towards the aerosol outlet. Upon inhalation by a user, air is sucked into the mouthpiece via the air inlet.

[0015] The air inlet may be provided at a distal end of the mouthpiece. The air inlet may be configured to be in fluid contact to a corresponding air passage of the main body and / or the aerosolization module. When the mouthpiece is assembled to the aerosolization module, the air inlet of the mouthpiece may be connected to a corresponding air outlet of the aerosolization module. Thus, upon connecting the mouthpiece to the aerosolization module a continuous air passage is obtained.

[0016] The airflow channel of the mouthpiece may be configured to fluidly connect the air inlet of the mouthpiece with the aerosol forming chamber. The airflow channel of the mouthpiece may be configured to introduce the air in a tangential direction into the aerosol forming chamber. Introducing the air in a tangential direction may lead to a cyclonic airflow within the aerosol forming chamber. Such cyclonic airflow may enhance aerosol formation in the aerosol forming chamber.

[0017] The aerosol-forming chamber may have a generally cylindrical form. The aerosolforming chamber may have a generally cylindrical form and may have circular or elliptical cross-section. Providing the aerosol-forming chamber with a cylindrical form with circular or elliptical cross-section may enhance the cyclonic airflow effect as obtained by the tangentially introduced airflow.

[0018] Within the aerosol-forming chamber the airflow is mixed with vaporized aerosol-forming substrate to form an inhalable aerosol. The aerosol-forming chamber may comprise an opening through which vaporized aerosol-forming substrate is introduced into the aerosolforming chamber. This opening is also referred to as vapour opening. The vapour opening may be configured to be in fluid communication with the aerosolization module. In the assembled state, the vapour opening may be located adjacent the aerosolization unit of the aerosolization module. The cross section of the vapour opening may correspond to the cross-section of the aerosol-forming chamber. In other words, the vapour opening may extend across the complete bottom of the aerosol-forming chamber.

[0019] Aerosol formed in the aerosol-forming chamber is carried towards the mouthpiece outlet and may be inhaled by a user taking a puff at the mouthpiece outlet.

[0020] Each of the openings at the mouthpiece, in particular the vapour opening, the substrate opening and the air inlet, may comprise a seal element. Each of the seal elements may extend around one of the respective openings. The seal elements may be formed from polymeric material. The seal elements may be configured to engage with corresponding surfaces of the removable aerosolization module. Upon assembly of the mouthpiece and the aerosolization module the seal elements assist in sealing the corresponding fluid passages.

[0021] By way of example, the seal elements may be formed from materials such as neoprene rubber, natural rubber, silicone rubber, nitrile rubber, ethylene propylene diene monomer (EPDM) rubber, styrene-butadiene rubber; silicone rubber is preferred due to its biocompatibility. The hardness and Young’s modulus may also be influenced by any processing steps undertaken on the material used for sealing member; for example, the addition of one or more additives to the material selected for the sealing member.

[0022] A flavor plug may be provided within the airflow passage of the mouthpiece. The flavor plug may be provided at the air inlet of the airflow passage of the mouthpiece. By providing a flavor plug within the airflow passage of the mouthpiece handling of the device may be facilitated. In particular, such construction may avoid the need for further manipulations by the user to include and activate the flavor plug. The flavor plug may be configured to comprise a porous material. The flavour plug may be disposed in such way in the airflow passage of the mouthpiece that air that is guided along the airflow passage of the mouthpiece needs to pass through the porous material of the flavor plug. In this way the user does not need to come into contact with the flavor plug. When the mouthpiece is discarded, the flavor plug is automatically also disposed of.

[0023] The flavor plug may comprise a housing with at least one aperture and with a connection portion for connecting the flavor plug to the aerosol-generating device. A flavor substrate may be arranged within the housing.

[0024] The flavor plug may comprise at least two apertures. The flavor plug may be shaped such as to define an air flow channel through the plug. The flavor plug may be configured such that upon connection of the flavor plug to the aerosol-generating device at least a part of the airflow path of the aerosol-generating device is directed through the flavor plug.

[0025] The flavor plug may comprise a porous material adjacent to a breakable capsule comprising a flavoured material. The flavor plug may comprise a porous material surrounding a breakable capsule comprising a flavoured material. The breakable capsule may comprise a liquid or gel flavor compound surrounded by a membrane. Upon rupture of the capsule, the flavour compound may be dispersed throughout the porous material of the flavour plug. The dispersed flavour compound is released to the airflow guided through the flavour plug during a user experience.

[0026] The aerosolization module may define an airflow passage that is configured to establish an air channel between an outside air inlet of the main body and the air inlet of the mouthpiece. The airflow passage of the aerosolization module may extend between an aerosolization module air inlet and an aerosolization module air outlet. In a particular simple configuration, the air flow passage extends along a linear path from the aerosolization module air inlet to the aerosolization module air outlet. The cross section of the aerosolization module air outlet may correspond to the cross section of the mouthpiece air inlet. In this way a continuous and homogenous air flow passage is defined.

[0027] The aerosolization module may comprise an aerosolization unit. The aerosolization unit may be a mesh aerosolization unit. The aerosolization unit may be a vibrating mesh aerosolization unit.

[0028] The aerosolization unit may comprise electrical connections. The electrical connections may provide an electrical connection to the main body. The aerosolization unit may comprise a vibratable transducer.

[0029] As used herein, the term “vibratable transducer” is used to refer to a device configured to convert energy from an initial form into a different form, where the different form comprises or consists of a vibratory output. The aerosolization unit may comprise a piezo-electric actuator. The aerosolization unit may comprise a vibrating element. The vibrating element may be one of a vibrating mesh, a vibrating membrane, or a vibrating plate.

[0030] Piezo-electric actuators are preferred because they are an energy-efficient and lightweight means of providing a vibratory output from an electric input. Piezo-electric actuators possess a high energy conversion efficiency from electric to mechanical power. Further, piezoelectric actuators are available in a wide variety of materials and shapes. For a piezo-electric actuator, inputting an electrical driving signal to the piezo-electric actuator results in a mechanical output in the form of a vibration. The vibratory output from the transducer induces vibration of the vibrating membrane. So, the use of a piezo-electric actuator in or as the transducer provides an energy-efficient means of inducing vibration of the membrane. However, as an alternative to the use of piezo-electric actuators, actuator(s) including one or more of electromagnetic elements, magnetostrictive elements, or electrostrictive elements may also be employed in the vibratable transducer.

[0031] The aerosolization unit may comprise a vibratable transducer holder configured to hold the vibratable transducer. The aerosolization unit may comprise the vibrating element. The vibratable transducer may be operably coupled to the vibrating membrane so as to, in use, vibrate the vibrating membrane in a substantially axial direction.

[0032] The vibratable transducer holder may be overmoulded around the vibratable transducer. The vibratable transducer may be integrated in the vibratable transducer holder. The vibratable transducer holder may comprise a flexible material. The flexible material of the vibratable transducer holder may have a hardness ranging from 5 Shore A to 120 Shore A, preferably from between 20 Shore A to 40 Shore A. The vibratable transducer holder may comprise rubber materials. By providing the vibratable transducer holder made of rubber material, the vibrating element may be kept in place without significantly damping the vibration of the vibrating element. By providing the vibratable transducer holder made of rubber material, sealing between the aerosolization unit and the mouthpiece may be provided. By providing the vibratable transducer holder made of rubber material, axial tolerances of the components of the aerosol-generating system may be compensated.

[0033] As used herein, the reference to “Shore A” is to the Shore A hardness scale. The Shore A hardness value of a sample of material is determined by the extent of penetration of a foot of a durometer into the sample.

[0034] The vibratable transducer holder may be axisymmetric. By providing the vibrating transducer holder axisymmetric, no orientation during assembly is required. The vibratable transducer holder may be washer shaped. The vibratable transducer holder may have a thickness of between 1 millimeter to 10 millimeters, preferably between 2 millimeters to 5 millimeters, and more preferably about 3 millimeters.

[0035] The vibratable transducer may be washer shaped. The vibratable transducer may comprise the vibrating element.

[0036] The vibrating element may be disposed on a vibrating plane and when the aerosolgenerating system is assembled, the vibrating plane may be not perpendicular to the longitudinal axis of the aerosol-generating system. The vibrating plane may be parallel to or includes the longitudinal axis of the aerosol-generating system. The vibrating plane may not be horizontal with respect to the aerosol-generating system. The vibrating plane may be vertical with respect to the aerosol-generating system.

[0037] The aerosolization unit may be a heated aerosolization unit. The aerosolization unit may be an electrically or inductively heated aerosolization unit. The aerosolization unit may be an electrically or inductively heated mesh heater aerosolization unit.

[0038] The aerosolization module may be configured to release the vaporized aerosol-forming substrate into the aerosol forming chamber of the mouthpiece, when the aerosolization module is connected to the mouthpiece. Thus, the aerosolization module may be configured such that the release side of the aerosolization unit coincides with vapour opening of the aerosol-forming chamber of the mouthpiece.

[0039] The aerosolization module may further comprise a liquid channel. The liquid channel of the aerosolization module may extend between a liquid inlet of the aerosolization module and the aerosolization unit of the aerosolization module. In the assembled state, the liquid inlet of the aerosolization module may be in fluid communication with the substrate opening of the mouthpiece. The liquid channel may be configured to transport liquid aerosol-forming substrate from the liquid storage portion of the mouthpiece to the aerosolization unit of the aerosolization module.

[0040] The liquid channel may be configured to transport the liquid aerosol-forming substrate via capillary forces. The dimensions of the liquid channel may be configured such that the liquid aerosol-forming is transported along the channel via capillary force, only. The dimensions required to establish capillary transport depend on the properties of the liquid aerosol-forming substrate used. The flow through the liquid channel may also be promoted by gravitation.

[0041] Alternatively, or additionally, the liquid channel may comprise a wicking element that extends along the liquid channel. The wicking element may comprise a spongy fibrous or otherwise porous material. The liquid substrate may be transported by capillary action of the wicking element.

[0042] The wicking element may have a cylindrical shape. The wicking element may be cylindrical. The wicking element may comprise or consists of a porous material. The wicking element may comprise or consists of at least one of natural fibers, synthetic polymeric fibers, polyethylene or polypropylene fibers, porous ceramic material, cellulose fibers.

[0043] The liquid aerosol-forming substrate may be conveyed from the liquid storage portion towards the aerosolization unit of the aerosolization module. If the aerosolization unit comprises a mesh aerosolization unit, the liquid aerosol-forming substrate may be conveyed from the liquid storage portion towards the pumping side of the mesh of the aerosolization unit of the aerosolization module.

[0044] The wicking element may extend up to the vibrating mesh. The last portion of the wicking element should be compliant enough such that the vibrational movement of the mesh is not damped. Ideally a small gap is maintained between the wicking element and the vibrating mesh in order to avoid dampening of the vibration. When the aerosol-generating system is assembled, there may be a gap between the fluid permeable element and the vibrating element. By providing a gap between the fluid permeable element and the vibrating element when the aerosol-generating system is assembled, the gap may be filled with liquid aerosolforming substrate by capillary forces. The gap may be larger than 0 millimeter and smaller than 0.5 millimeter. The gap may be of between 0.01 millimeter to 0.5 millimeter, preferably between 0.02 millimeter to 0.2 millimeter, more preferably about 0.1 millimeter.

[0045] Upon activation of the mesh aerosolization unit, the liquid aerosol-forming substrate is displaced through the holes of the mesh. The liquid aerosol-forming substrate is released from the release side of the mesh and is ejected into the aerosol-forming chamber of the mouthpiece. As described above, the aerosolized liquid substrate mixes with the air and forms an aerosol in the aerosol-forming chamber of the mouthpiece. This aerosol may be inhaled by a user taking a puff at the outlet end of the mouthpiece.

[0046] In embodiments in which the substrate opening of the mouthpiece comprises a valve, the liquid inlet of the liquid channel of the aerosolization module may comprise a valve opening element. The valve opening element may be configured to open the valve of the substrate opening of the mouthpiece upon connection of the mouthpiece and the aerosolization module. The opening element may be configured to automatically open the valve of the substrate opening of the mouthpiece upon connection of the mouthpiece to the aerosolization module. The valve opening element may be provided in the form of a protruding tube-shaped element. The valve opening element may be provided in the form of a piercing element. The use of an opening element may further enhance usability of the aerosol-generating device. Upon connection of the mouthpiece to the aerosolization module the liquid substrate is released to the liquid channel and is transported towards the aerosolization unit of the aerosolization module. Thus, this configuration shortens the required time from assembly of the device until the device is ready for aerosol generation. The valve opening feature may also be constituted by a rigid wicking material that triggers the opening of the valve. The rigid wicking material may be pin-shaped, or may have a more complex geometry.

[0047] The opening element may also be manually operated by the user. Manual operation may allow the user to have more control over the functionality of the aerosol-generating device. Manual operation may also be advantageous in situations in which it is desired to keep the liquid storage portion of the device sealed while the device is in the assembled state. Such situations may include situations in which it is anticipated that the device may not be used over an extended time period. Such situations may include sleeping times of the user, extended travelling time or other planned periods of non-usage of the aerosol-generating device.

[0048] The aerosolization module may comprise an activation element, which is configured to activate a flavor plug of the mouthpiece. The activation element may be configured to automatically activate the flavor plug of the mouthpiece upon connection of the mouthpiece to the aerosolization module. In particular, if the flavor plug comprises a rupturable capsule, the activation element may be configured as a capsule breaking feature. The activation element may be configured as a passive activation element. A passive activation element, does not require additionally activated components. A passive activation element may perform automatic activation of the flavor plug upon connection of the mouthpiece to the aerosolization module.

[0049] The activation element may be provided at the air outlet of the aerosolization module. The aerosolization module may be configured such that the position of the activation element coincides with the position of the air inlet and, thus, with the position of the flavor plug of the mouthpiece.

[0050] The activation element may be configured as a protruding element, which may be configured to have sharp tip, suitable to rupture the rupturable capsule of the flavor plug. The size and shape of the activation element may be configured such that it is suitable to activate the flavor plug. In cases where rupturing of the flavor capsule requires only application of a slight pressure, the activation element may also be configured as a blunt protruding component. Such component may be sufficient to generate a slight pressure for rupturing the flavor capsule upon connection of the mouthpiece and the aerosolization module.

[0051] Since the aerosolization unit of the aerosolization module may require electrical power for its operation, the aerosolization unit may comprise electrical contacts, which allow to establish an electric connection upon connection of the aerosolization module to the main body of the aerosol-generating device.

[0052] The main body of the aerosol-generating device may be configured for continuous use. The main body of the aerosol-generating device may comprise a power supply and a controller. The controller may be configured to control all electric components of the aerosol-generating device. The controller may be configured to provide electrical power from the power supply to all electric components of the aerosol-generating device. The main body may comprise any further electronic or mechanical components required for operation of the aerosol-generating device.

[0053] The main body may comprise an air flow passage that is configured to fluidly connect an outside air inlet of the main body with an air outlet of the main body. The air outlet in turn may be configured to connect to the air inlet of the airflow passage of the aerosolization module, when the main body and the aerosolization module are connected to each other.

[0054] The airflow passage in the main body may be connected to a puff sensor. The puff sensor may be connected to the controller and may detect a change in pressure when a user takes a puff at the aerosol-generating device. Upon detection of a puff, the controller may activate the aerosolization unit of the aerosolization module.

[0055] The main body may be continuously used by the user. The components of the main body may not come into contact with the aerosol-forming substrate or with the generated aerosol. As such, the main body may require rather little maintenance. The aerosolization module and the mouthpiece may be changed regularly. The mouthpiece may be configured as a consumable, which has to be replaced, once the liquid storage portion is depleted. Alternatively, the liquid storage portion of the mouthpiece may be configured to be refillable. In this way the mouthpiece may also be used for extended periods of time. However, since the mouthpiece comes into contact with the generated aerosol, and since the flavor plug of the mouthpiece may not be refillable, a regular replacement of the mouthpiece may be advisable.

[0056] The aerosolization module may also be regularly replaced. The aerosolization module may be configured to be replaced each time when the mouthpiece is exchanged. However, since the aerosolization module in normal use does not come into contact with the generated aerosol, usage time of the aerosolization module may be longer than the usage time of the mouthpiece. The controller may be configured to indicate to the user, when it is necessary to replace the mouthpiece and / or the aerosolization module.

[0057] The components of the aerosol-generating device may be connected with each other by suitable connection means. The main body and the mouthpiece may be connectable to the aerosolization module by a releasable connection mechanism. Such releasable connection mechanisms may include one or more of a snap fit connection, a form-fit connection, and a bayonet connection. Such releasable connection mechanisms may include magnetic connection elements. The main body, the mouthpiece and the aerosolization module may be configured to comprise corresponding connection elements. The present invention also relates to a method of generating an inhalable aerosol with an aerosol-generating device as described herein. The aerosol-generating device may comprise a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion. The aerosolization module may be releasably connectable to the main body and the mouthpiece.

[0058] The modular design of the aerosol-generating device may allow to generate aerosol in a repeatable and consistent way. Thus, usability and user experience may be enhanced. All functionalities of the aerosol-generating device are carried out by the individual modules of the device. A user is only required to assemble the various modules. Extended cleaning, servicing or maintenance of the device may not be required. Thus, the device and method as described above may allow for an easy and convenient user experience.

[0059] As used herein, the term ‘aerosol-forming substrate’ may relate to a substrate capable of releasing volatile compounds that can form an aerosol or a vapor. The term ‘aerosol-forming substrate’ may also relate to a substrate capable to be mechanically nebulized. The aerosolforming substrate may be in gel form or may be in liquid form. The terms ‘aerosol’ and ‘vapor’ are used synonymously. The aerosol-forming substrate may be liquid.

[0060] As used herein, the term ‘liquid’ refers to a substance provided in liquid form and encompasses substances provided in the form of a gel.

[0061] The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosolforming substrate may be a nicotine salt matrix.

[0062] The aerosol-forming substrate may comprise plant-based material. The aerosolforming substrate may comprise tobacco.

[0063] As used herein, the term ‘proximal’ refers to a user-end, or mouthpiece-end of the aerosol-generating system or a part or portion thereof, and the term ‘distal’ refers to the end opposite to the proximal end. As used herein the term ‘lateral’ refers to a direction orthogonal to the longitudinal axis of the aerosol-generating system.

[0064] The power supply may require recharging and may have a capacity that enables to store enough energy for one or more user experiences, for example, the power supply may have sufficient capacity to continuously generate aerosol for a period of around six minutes or for a period of a multiple of six minutes. In another example, the power supply may have sufficient capacity to provide a predetermined number of puffs. The aerosol-generating system may comprise a charging port for recharging the power supply.

[0065] The power supply may be a direct current (DC) power supply. In one embodiment, the power supply is a DC power supply having a DC supply voltage in the range of 2.5 Volts to 4.5 Volts and a DC supply current in the range of 1 Amp to 10 Amps (corresponding to a DC power supply in the range of 2.5 Watts to 45 Watts). The main body may advantageously comprise a direct current to alternating current (DC / AC) inverter for converting a DC current supplied by the DC power supply to an alternating current. The DC / AC converter may comprise a Class-D, Class-C or Class-E power amplifier. The AC power output of the DC / AC converter is supplied to the induction coil.

[0066] The control electronics may be configured to control a supply of power from the power supply to the atomizer module so as to, in use, activate the vibratable transducer.

[0067] The control electronics may include one or more controller modules and / or processors configured for use in generating an input driving signal for the vibratable transducer, as well as any computer-readable medium storing instructions for use in the generating of the input driving signal. The computer-readable medium may contain instructions for use in the generating of the input driving signal by the controller modules and / or processors. The computer-readable medium may preferably be a non-transitory computer-readable medium.

[0068] Preferably, the power source is rechargeable. By way of example, the power source may comprise a lithium-ion battery.

[0069] The main body may comprise a main body housing. The mouthpiece may comprise a mouthpiece housing. The aerosolization module may comprise an aerosolization module housing. At least one of the main body housing, mouthpiece housing, aerosolization module housing may be formed from materials such as rigid plastic material (such as but not limited to polypropylene, high-density polyethylene (HDPE), polyethylene terephthalate (PET), polyetheretherketone (PEEK), or polysulfone (PSU)) or a metallic material (such as but not limited to aluminium)).

[0070] The main body housing may be elongate. The main housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably, the material is light and non-brittle. The main body housing may include a user interface to activate the aerosol-generating system, for example a button to initiate heating of the aerosol-generating system or a display to indicate a state of the aerosol-generating device or of the aerosol-forming substrate.

[0071] Below, there 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 another example, embodiment, or aspect described herein.

[0072] Example 1 : An aerosol-generating device comprising: a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion, wherein the aerosolization module is releasably connectable to the main body and the mouthpiece.

[0073] Example 2: The aerosol-generating device according to example 1, wherein the mouthpiece comprises a substrate opening for releasing liquid aerosol-forming substrate from the liquid storage portion of the mouthpiece to the aerosolization module.

[0074] Example 3: The aerosol-generating device according to any one of the preceding examples, wherein the substrate opening comprises a valve.

[0075] Example 4: The aerosol-generating device according to any one of the preceding examples, wherein the mouthpiece comprises an air inlet, an airflow channel, an aerosol forming chamber and an aerosol outlet.

[0076] Example 5: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol forming chamber comprises an opening which is in fluid communication with the aerosolization module.

[0077] Example 6: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol forming chamber is configured to receive outside air from the airflow channel of the mouthpiece and vaporized aerosol-forming substrate from the aerosolization module.

[0078] Example 7: The aerosol-generating device according to any one of the preceding examples, wherein in the aerosol-forming chamber outside air of the airflow channel is mixed with the vaporized aerosol-forming substrate to form an inhalable aerosol.

[0079] Example 8: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol-forming chamber has a cylindrical form.

[0080] Example 9: The aerosol-generating device according to any one of the preceding examples, wherein the air flow channel is configured to introduce the outside air into the aerosol-forming chamber in a tangentially direction of the aerosol forming chamber.

[0081] Example 10: The aerosol-generating device according to any one of the preceding examples, wherein a flavor plug is provided within the airflow passage of the mouthpiece.

[0082] Example 11: The aerosol-generating device according to any one of the preceding examples, wherein the flavor plug is provided at the air inlet of the airflow passage of the mouthpiece.

[0083] Example 12: The aerosol-generating device according to any one of the preceding examples, wherein the flavor plug comprises a porous material.

[0084] Example 13: The aerosol-generating device according to any one of the preceding examples, wherein the flavor plug comprises a breakable capsule, comprising a flavoured material. Example 14: The aerosol-generating device according to any one of the preceding examples, wherein breakable capsule comprises a liquid or gel flavor compound surrounded by a membrane.

[0085] Example 15: The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module defines an air flow passage that is configured to establish an air channel between an outside air inlet of the main body and the air inlet of the mouthpiece.

[0086] Example 16: The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module comprises an aerosolization unit, preferably a vibrating mesh aerosolization unit.

[0087] Example 17: The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module is configured, in the assembled state, to release the vaporized aerosol-forming substrate into the aerosol forming chamber of the mouthpiece.

[0088] Example 18: The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module comprises a liquid channel in fluid communication with the substrate opening of the mouthpiece.

[0089] Example 19: The aerosol-generating device according to any one of the preceding examples, wherein the liquid channel is configured to transport liquid aerosol-forming substrate from the liquid storage portion of the mouthpiece to the aerosolization unit of the aerosolization module.

[0090] Example 20: The aerosol-generating device according to any one of the preceding examples, wherein the liquid channel is configured to transport the liquid aerosol-forming substrate via capillary forces.

[0091] Example 21 : The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module comprises an opening element, which is configured to open the valve of the substrate opening of the mouthpiece.

[0092] Example 22: The aerosol-generating device according to any one of the preceding examples, wherein the opening element is manually operated by the user.

[0093] Example 23: The aerosol-generating device according to any one of the preceding examples, wherein the opening element is configured to automatically open the valve of the substrate opening of the mouthpiece upon connection of the mouthpiece to the aerosolization module.

[0094] Example 24: The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module defines an air flow passage that is configured to fluidly connect an outside air inlet of the main body with the air inlet of the mouthpiece. Example 25: The aerosol-generating device according to any one of the preceding examples, wherein the aerosolization module comprises an activation element, which is configured to activate the flavor plug of the mouthpiece.

[0095] Example 26: The aerosol-generating device according to any one of the preceding examples, wherein the activation element is configured to automatically activate the flavor plug of the mouthpiece upon connection of the mouthpiece to the aerosolization module.

[0096] Example 27: The aerosol-generating device according to any one of the preceding examples, wherein the main body comprises an air flow passage that is configured to fluidly connect an outside air inlet of the main body with an air inlet of the airflow passage of the aerosolization module.

[0097] Example 28: The aerosol-generating device according to any one of the preceding examples, wherein the main body comprises a power supply and a controller.

[0098] Example 29: The aerosol-generating device according to any one of the preceding examples, wherein the main body and the mouthpiece are connectable to the aerosolization module by a releasable connection mechanism, such as a snap fit connection.

[0099] Example 30: A method of generating an inhalable aerosol with an aerosol-generating device according to any one of the preceding examples, wherein the aerosol-generating device comprises a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion, wherein the aerosolization module is releasably connectable to the main body and the mouthpiece.

[0100] Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

[0101] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0102] Fig. 1 shows a modular aerosol-generating device;

[0103] Fig. 2 shows cross-sections of the mouthpiece of the modular device;

[0104] Fig. 3 shows perspective views of the mouthpiece of the modular device;

[0105] Fig. 4 shows the airflow path in the mouthpiece of the modular device;

[0106] Fig. 5 shows perspective views of the aerosolization module;

[0107] Fig. 6 shows the liquid flow path in the aerosolization module;

[0108] Fig. 7 shows an exploded view of the modular aerosol-generating device;

[0109] Fig. 8 shows a device with a flavor plug; and

[0110] Fig. 9 shows a mouthpiece with a sealing foil. Fig. 1 shows the modular design of an aerosol-generating device 10 of the present invention. The device comprises essentially three modules, namely a main body 12, an aerosolization module 14, and a mouthpiece 16 with an integrated liquid storage portion 18. The aerosolization module 14 is releasably connectable to the main body 12 and the mouthpiece 16.

[0111] Fig. 2 shows cross-sectional views of the mouthpiece 16. In the inner volume of the mouthpiece 16 a liquid storage portion 18 is defined. The liquid storage portion 18 serves for storing liquid aerosol-forming substrate 20. There is provided a substrate opening 22 for releasing the stored liquid aerosol-forming substrate 20 from the liquid storage portion 18 of the mouthpiece 16. At the substrate opening there is provided a valve 24 by which release of the liquid aerosol-forming substrate 20 from the liquid storage portion 18 may be controlled. The valve 24 is normally closed. Upon connection with the aerosolization module 14, the valve 24 is opened to allow release of the liquid aerosol-forming substrate 20. This mechanism is explained in more detail below.

[0112] The mouthpiece 16 also defines a continuous airflow passage from an air inlet 26, via an airflow channel 28 and via an aerosol forming chamber 30 towards an aerosol outlet 32.

[0113] The air inlet 26 is provided at a distal end 34 of the mouthpiece 16. As described below, the air inlet 26 is configured to be in fluid contact to a corresponding air passage of the aerosolization module 14 and the main body 12. The airflow channel 28 of the mouthpiece 16 extends between the air inlet 26 and the aerosol forming chamber 30. In the depicted embodiment, the aerosol-forming chamber 30 is configured with a cylindrical shape and a circular cross-section. The airflow channel 28 extends in a generally horizontal direction and is configured to introduce the air in a tangential direction into the cylindrical aerosol forming chamber 30. By introducing the air in a tangential direction, a cyclonic airflow within the aerosol forming chamber 30 is obtained.

[0114] Within the aerosol-forming chamber 30 the airflow is mixed with vaporized aerosolforming substrate 20 to form an inhalable aerosol. For this purpose, the bottom of the aerosol forming chamber 30 is open and defines a vapour opening 36. As depicted in Fig. 4, in the assembled state, the vapour opening 36 is placed on top of the release side of an aerosolization unit 40 of the aerosolization module 14. Thus, vaporized aerosol-forming substrate 20 is released into the aerosol-forming chamber 30. The aerosol-forming substrate 20 is mixed with the cyclonic airflow and forms an aerosol in the aerosol forming chamber 30.

[0115] The aerosol formed in the aerosol-forming chamber 30 is carried towards the mouthpiece outlet 32 an may be inhaled by a user taking a puff at the mouthpiece outlet 32. As depicted in the three-dimensional views of Fig. 3, the mouthpiece 16 in total comprises three openings (substrate opening 22, air inlet 26, vapour opening 36), which are provided at the distal end 34 of the mouthpiece 16.

[0116] Seal elements 38 are provided around each of the openings at the distal end 34 of the mouthpiece 16. All seal elements 38 are formed from polymeric material. The seal elements 38 are configured to engage with corresponding surfaces of the aerosolization module 14. Upon assembly of the mouthpiece 16 and the aerosolization module 14 the seal elements 38 help to avoid release or spillage of air and liquid substrate 20 from the connection portions of the corresponding fluid passages.

[0117] Fig. 4 shows details of the airflow through the mouthpiece 16 in the assembled state. Outside air is provided to the air inlet 26 of the mouthpiece 16 from corresponding air flow passages 52, 79 of the aerosolization module 14 and of the main body 12. The air is then guided in a generally horizontal direction towards the aerosol-forming chamber 30. The air is introduced into the cylindrical aerosol-forming chamber 30 in a tangential direction (indicated by the tangential arrows in the right-hand side view of Fig. 4). The tangential introduction of the airflow leads to a cyclonic airflow in the aerosol forming chamber 30. In the aerosol-forming chamber 30 the airflow entrains vaporized substrate, which is released from the aerosolization unit 40 into the aerosol forming chamber 30. The resulting aerosol is inhaled by a user from the mouthpiece outlet 32 (indicated by the straight vertical arrows in the right-hand side view of Fig. 4).

[0118] In Fig. 4 the connection portions for establishing a releasable connection between the mouthpiece 16 and the aerosolization module 14 are depicted. The mouthpiece 16 comprises elastic snapping elements 84 that engage with corresponding connection elements 86 of the aerosolization module 14.

[0119] The three-dimensional views of Fig. 5 show details of the aerosolization module 14. In the upper view of Fig. 5 the proximal end 42 of the aerosolization module 14 can be seen. The structures provided at the proximal end 42 of the aerosolization module 14 are configured to co-operate with the above described three openings at the distal end of the mouthpiece 16. The aerosolization unit 40 is provided in the form of a vibrating mesh. The vibrating mesh is a composite overmoulded component comprising a mesh and piezoelectric actuators (not shown). Electric contacts 46 are provided for providing electric power and for controlling operation of the vibrating mesh. The size and the position of the vibrating mesh corresponds to the size and the position of the vapour opening 36 of the mouthpiece 16. Upon connection with the mouthpiece 16, the seal elements 38 provided around the vapour opening 36 lie against the surface area surrounding the vibrating mesh. The aerosolization module 14 further comprises an outlet end 50 of the aerosolization module air passage 52 and a liquid inlet 54 comprising a valve opening structure 56. In the assembled state the outlet end 50 of the air passage 52 connects with the mouthpiece air inlet 26. In the same way, the liquid inlet of the aerosolization module connects with the substrate opening 22 of the mouthpiece 16. The protruding valve opening feature 56, engages with and opens the valve 24 at the liquid substrate opening 22 of the mouthpiece 16. In this way, fluid connections for the airflow and of the flow of the liquid substrate 20 between the mouthpiece 16 and the aerosolization module 14 is established upon connection of these modules.

[0120] The distal end 44 of the aerosolization module 14 depicted in the lower view of Fig. 5 is to be connected to the proximal end of the main body 12 of the aerosol-generating device 10. The distal end 44 of the aerosolization module 14 comprises the air inlet 58 of the airflow passage 52 and electric contacts 60. Around the air inlet 58 again a seal element 62 is provided. The electric contacts 60 are configured to contact with corresponding electric contacts 80 (shown in Fig. 7) of the main body 12, in order to connect with the controller and the power supply. The housing of the aerosolization module 14 comprises snap fit connection portions 64 to engage with corresponding portions 82 of the main body 12.

[0121] Fig. 6 illustrates the liquid flow within the aerosolization module 14. The aerosolization module 14 comprises a liquid channel 70 extending from the liquid inlet 54 of the aerosolization module 14 to the supply side 72 of the aerosolization unit 40 of the aerosolization module 14. In the assembled state, as depicted in Fig. 6, the protruding valve opening feature 56 of the liquid inlet 54 engages with and opens the valve 24 of the substrate opening 22 of the mouthpiece 16. The valve opening feature 56 is a protruding tube-shaped element that, in the assembled state, extends through the valve 24 and allows liquid aerosol-forming substrate 20 to enter into the liquid inlet 54.

[0122] The liquid aerosol-forming substrate 20 is released from the liquid storage portion 18 of the mouthpiece 16 into the liquid inlet 54 of the liquid passageway of the aerosolization module 14. The liquid aerosol-forming substrate 20 is transported along the liquid channel 70 to the supply side 72 of the aerosolization unit 40. The liquid channel 70 comprises a porous material which transports the liquid aerosol-forming substrate 20 via capillary forces towards the aerosolization unit 40. In this case the aerosolization unit 40 is provided in the form of a vibrating mesh. The mesh deformation during vibration generates a pressure field in the liquid substrate 20, thus pumping and loading the holes of the membrane with liquid. Upon vibration of the mesh, the liquid volume is displaced through the holes, breaks up into droplets, and is ejected into the aerosol forming chamber 30 where the substrate is mixed with the airflow to form an aerosol. Fig. 7 shows an exploded view of the modular aerosol-generating device 10. As can be seen therefrom the proximal end 76 of the main body 12 comprises an air outlet 78 and electrical connections 80 that are to engage with the corresponding connections of the distal end 44 of the aerosolization module 14. The main body 12 further comprises a power supply and a controller (not shown).

[0123] The air outlet 78 of the main body 12 connects to an air flow passage of the main body 12, which in turn is configured to fluidly connect to an outside air inlet. Outside air can thus be delivered to the internal air passages of the aerosol-generating device 10. The airflow passage in the main body 12 is connected to a puff sensor (not shown). The puff sensor is connected to the controller. Upon detection of a puff, the controller activates the vibrating mesh of the aerosolization module 14.

[0124] Fig. 7 further shows the coinciding positions of the air flow outlets 78,50 of the main body 12 and the aerosolization module 14. Further, the snap fit connections 64, 82, 84, 86 can be seen, which are pairwise provided at corresponding positions between the mouthpiece 16 and the aerosolization module 14, as well as between the aerosolization module 14 and the main body 12. The snap fit connections 64, 82, 84, 86 allow for a releasable connection of the mouthpiece 16 and the aerosolization module 14 and for a releasable connection of the aerosolization module 14 and the main body 12.

[0125] Fig. 8 shows a further embodiment of the aerosol-generating device in which a flavor plug 90 is provided in the air flow passage of the mouthpiece 16. In more detail, the flavor plug 90 is provided at the air inlet 26 of the airflow passage of the mouthpiece 16. The flavor plug 90 is provided in the form of a rupturable capsule 92 that is embedded in a porous material 94. The porous material 94 lies flush with the distal end of the mouthpiece 16. The porous material 94 extends over the full cross-section of the air inlet 26 of the mouthpiece 16.

[0126] In this embodiment the aerosolization module 14 comprises an activation element 96, which is configured to activate the flavor plug 90 of the mouthpiece 16. The activation element 96 is configured as a protruding element with lateral air openings 98. Upon connection of the mouthpiece 16 and the aerosolization module 14, the protruding portion of the activation element 96 presses against and breaks open the capsule 92 of the flavor plug 90. The flavoured components of the capsule 92 are dispersed throughput the porous material 94 of the flavor plug 90 and are continuously released during use of the aerosol-generating device 10.

[0127] The lower view of Fig. 8 shows a cross-section of the assembled aerosol-generating device 10 comprising a flavour plug 90. The dotted arrows show details of the airflow passage through the device 10. The air flows from the main body outlet 78 via the airflow passage 52 in the aerosolization module 14 towards the mouthpiece 16. The airflow leaves the aerosolization module 14 through the lateral air openings 98 in the activation element 96 and is guided through the porous material 94 of the flavour plug 90. The flavorized air is then further guided along the air channel 28 to be introduced tangentially into the aerosol-forming chamber 30. Fig. 9 shows perspective views of the mouthpiece 16. The mouthpiece 16 may be used as consumable, which is to be replaced after the liquid storage portion 18 is depleted. The user may replace the depleted mouthpiece 16, by a fresh and filled mouthpiece 16. In order to avoid spillage or leakage during transport, one or more of the openings at the distal end 34 of the mouthpiece 16 may be covered by a sealing foil 100. In the depicted embodiment the sealing foil 100 is configured to cover the liquid release opening 22 and the air inlet 26 of the mouthpiece 16. Before installing a fresh mouthpiece 16, a user pulls the sealing foil 100 from the distal end 34 of the mouthpiece 16.

Claims

CLAIMS1. An aerosol-generating device comprising: a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion, wherein the aerosolization module is releasably connectable to the main body and the mouthpiece.

2. The aerosol-generating device according to claim 1 , wherein the mouthpiece comprises a substrate opening for releasing liquid aerosol-forming substrate from the liquid storage portion of the mouthpiece to the aerosolization module.

3. The aerosol-generating device according to any one of the preceding claims, wherein the mouthpiece comprises an air inlet, an airflow channel, an aerosol forming chamber and an aerosol outlet.

4. The aerosol-generating device according to claim 3, wherein the aerosol forming chamber comprises an opening which is in fluid communication with the aerosolization module.

5. The aerosol-generating device according to any one of the preceding claims, wherein a flavor plug is provided within the airflow passage of the mouthpiece.

6. The aerosol-generating device according to any one of the preceding claims, wherein the aerosolization module defines an air flow passage that is configured to establish an air channel between an outside air inlet of the main body and the air inlet of the mouthpiece.

7. The aerosol-generating device according to any one of the preceding claims, wherein the aerosolization module comprises an aerosolization unit, preferably a vibrating mesh aerosolization unit.

8. The aerosol-generating device according to any one of the preceding claims, wherein the aerosolization module is configured, in the assembled state, to release the vaporized aerosol-forming substrate into the aerosol forming chamber of the mouthpiece.

9. The aerosol-generating device according to any one of claims 2 to 8, wherein the aerosolization module comprises a liquid channel in fluid communication with the substrate opening of the mouthpiece.

10. The aerosol-generating device according to any one of the preceding claims, wherein the aerosolization module comprises an opening element, which is configured to open a valve of the substrate opening of the mouthpiece.

11. The aerosol-generating device according to claim 10, wherein the opening element is configured to automatically open the valve of the substrate opening of the mouthpiece upon connection of the mouthpiece to the aerosolization module.

12. The aerosol-generating device according to any one of claims 3 to 11 , wherein the aerosolization module defines an air flow passage that is configured to fluidly connect an outside air inlet of the main body with the air inlet of the mouthpiece.

13. The aerosol-generating device according to any one of claims 5 to 12, wherein the aerosolization module comprises an activation element, which is configured to activate the flavor plug of the mouthpiece.

14. The aerosol-generating device according to any one of the preceding claims, wherein the main body comprises an air flow passage that is configured to fluidly connect an outside air inlet of the main body with an air inlet of the airflow passage of the aerosolization module.

15. A method of generating an inhalable aerosol with an aerosol-generating device according to any one of the preceding claims, wherein the aerosol-generating device comprises a main body, an aerosolization module, and a mouthpiece with an integrated liquid storage portion, wherein the aerosolization module is releasably connectable to the main body and the mouthpiece.

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