Aerosol-generating device with a module

Abstract

An aerosol-generating device (100), comprising: a housing (20); an air inlet (17), an air outlet (18), and an airflow passage extending within the housing from the air inlet (17) to the air outlet (18), a module (50) within the housing, an electronic component (80) within the module, and wherein the electronic component is in fluid communication with the air flow passage through the module (50).

Description

[0001] AEROSOL-GENERATING DEVICE WITH A MODULE

[0002] The present specification relates to an aerosol-generating device for heating an aerosol-forming substrate to generate an aerosol. Particularly, but not exclusively, the invention relates to an aerosol-generating device comprising a protective module within the aerosol-generating device. The module ensures the protection of certain sensitive components of the aerosol-generating device.

[0003] In a number of handheld aerosol-generating devices, electronic components such as an electronic pressure sensor and Printed Circuit Boards (PCB) may be used to detect when or how a user is using the aerosol-generating device. For example, the electronic pressure sensor may be configured to detect a “puff action” when the user begins puffing on the aerosolgenerating device. During a puff action, air from the environment external to the aerosolgenerating device flows into the aerosol-generating device. This influx of air temporarily increases the internal pressure of the aerosol-generating device. The increase in the internal pressure is detected by the pressure sensor as a “puff action”. When the electronic pressure sensor detects a puff action, it usually sends a signal to a controller on a PCB which then controls or activates other components of the aerosol-generating device, such as the heating element which heats the aerosol-forming substrate to form an aerosol.

[0004] The temporary influx of air into the aerosol-generating device during a “puff action” may also include the influx of other components from the external environment into the aerosol-generating device. It is generally undesirable for such components from the external environment to seep into the internal environment of the aerosol-generating device. This may adversely affect the aerosol-generating device such as causing damage to the electronic components of the aerosol-generating device. It would therefore be desirable to provide an aerosol-generating device which does not or is less likely to suffer from such problems.

[0005] According to a first aspect of the invention, there is provided an aerosol-generating device comprising: a housing; an air inlet, an air outlet, and an airflow passage extending within the housing from the air inlet to the air outlet, a module within the housing, an electronic component within the module, and wherein the electronic component is in fluid communication with the air flow passage through the module.

[0006] With an aerosol-generating device of the type of the first aspect of the invention, there may be various reasons for arranging the electronic component to be in fluid communication with the air flow passage. For example, the electronic component may be configured to perform one or more functions in response to air passing from the air inlet into the airflow passage. For example, the electronic component may be a pressure sensor. In such circumstances, the electronic component may be configured to detect a “puff action” when the user begins puffing on the aerosol-generating device. During a puff action, air from the environment external to the aerosol-generating device flows into the aerosol-generating device through the air inlet and into the air flow passage. The influx of air through the air inlets temporarily increases the internal pressure of the air flow passage. As the electronic component is in fluid communication with the air flow passage, the increase in pressure is detected by the pressure sensor as a “puff action”. When this occurs, the sensor is efficiently sends a signal to a controller on a PCB which then controls or activates other components of the aerosol-generating device, such as the heating element which heats the aerosol-forming substrate to form an aerosol. This mechanism is efficient and effective; however, the present inventors have appreciated that this could lead to problems in the performance of the electronic component.

[0007] The temporary influx of air into the aerosol-generating device, through the air inlets, during a “puff action” may also include the influx of moisture and other particulate matter into the aerosol-generating device. It is generally undesirable for moisture and other particulate matter from the external environment to seep into the internal environment of the aerosolgenerating device such as the air flow passage. Since the air flow passage is in fluid communication with the electronic component, the influx of moisture and other particulate matter into the aerosol-generating device during a puff action may interfere with the electronic component and even cause damage to the electronic component.

[0008] By providing an electronic component within a module, such that the electronic is in fluid communication with the airflow passage through the module, such adverse effects can be avoided or mitigated. In particular, the module can provide a means for preventing moisture and other particulate matter seeping onto the aerosol-generating device through the air inlets, from coming into contact with the electronic component. The construction of the device of the first aspect may therefore, in some embodiments, be able to provide the electronic component with protection from water and / or debris ingress and also provide mechanical support and protection for the electronic component.

[0009] As used herein the term “electronic component” may refer to any component of the aerosol-generating device which operates by means of an electrical current.

[0010] As used herein, the term “sensor” may refer to any suitable sensing means for sensing one or more signals indicative of one or more properties of the surrounding environment. As used herein, “sensor” can refer to various sensors including but not limited to pressure sensors, gas sensors, humidity sensors, temperature sensors, airflow sensors, carbon dioxide sensors, oxygen sensors, and so forth.

[0011] As used herein, the term “sensor” may refer to any suitable sensing means for sensing one or more signals indicative of a change in pressure.

[0012] As used herein the term “pressure sensor” may also refer to any suitable sensing means for sensing one or more signals indicative of a change in pressure. As used herein, the term “first surface of the pressure sensor” relates to a component of the pressure sensor, for instance, a deformable membrane suitable for sensing one or more signals indicative of a change in pressure.

[0013] As used herein, the term “air inlet” refers to an opening in the housing of the aerosolgenerating device that allows air from the external environment to flow into the aerosolgenerating device during a puff action.

[0014] As used herein, the term “air outlet” refers to an opening in the housing of the aerosolgenerating device which allows aerosol to flow out of the aerosol-generating device during a puff action.

[0015] As used herein, the term “air release outlet” refers to an opening in the housing of the aerosol-generating device that allows air to be released from within the aerosol-generating device to the external environment.

[0016] As used herein, the term “elastomer” refers to a material with elastic properties.

[0017] As used herein, the term “hydrophobic elastomer” refers to a material with elastic properties that also repels water. Such materials do not absorb water. Examples of elastomers used herein may include but are not limited to Silicone Rubber and Polytetrafluoroethylene (PTFE) Elastomers.

[0018] As used herein, an “engaging member” refers to a part or component of the device disclosed herein, that interacts with another part (such as an engaging element) to perform the function of connecting.

[0019] As used herein, an “engaging element” refers to a part or component of the device disclosed herein, that interacts with another part (such as an engaging member) to perform the function of connecting.

[0020] As used herein, the term “rigid material” refers to materials that do not easily bend, flex or deform under force.

[0021] The aerosol-generating device may comprise a plurality of components within the housing, the plurality of components may include the electronic component.

[0022] The electronic component may be any electronic component configured to perform one or more functions in response to air passing from the air inlet into the airflow passage. For example, the electronic component may be a component configured to detect a change in conditions within the aerosol-generating device as a result of air passing from the air inlet into the airflow passage. The electronic component may include a pressure sensor, wherein the pressure sensor may be a puff sensor. Advantageously, the pressure sensor may detect a puff action when there is an influx of air from the external environment, through the air inlet which results in a change in the internal pressure within the aerosol-generating device.

[0023] The electronic component may be within the module, wherein the module is configured to house and protect at least the pressure sensor of the aerosol-generating device. The module may be configured to restrict the ingress of one or both of moisture and particulate matter from the air inlet to the electronic component. The module may be configured to provide mechanical protection and ingress protection to the electronic component housed within the module of the aerosol-generating device. Advantageously, providing the electronic component within the module of the aerosol-generating device, protects the electronic components from moisture and other particulate matter glowing into the aerosol-generating device during a puff action. The module is also configured to prevent mechanical deformation of the electronic component.

[0024] The module may abut the air inlet, and wherein the electronic component is in fluid communication with the air flow passage through the module.

[0025] The module may abut the air inlet, such that the air outlet is in fluid communication with the air inlet through the module.

[0026] The air inlet may be one of a plurality of air inlets, and wherein the airflow passage extends within the housing from the plurality of air inlets to the air outlet.

[0027] The portion of the airflow path extending from the air inlet to the electronic component may follow a convoluted path. The portion of the airflow path extending from the air inlet to the electronic component may comprise at least one turn of at least 60 degrees, more preferably at least two turns of at least 60 degrees. The portion of the airflow path extending from the air inlet to the electronic component may comprise at least two opposing turns, more preferably at least three opposing turns. The portion of the airflow path extending from the air inlet to the electronic component may comprise at least one turn of at least 90 degrees, more preferably at least two turn of at least 90 degrees. The portion of the airflow path extending from the air inlet to the electronic component may comprise at least one turn of at least 145 degrees, more preferably at least two turn of at least 145 degrees. Arranging for this portion of the airflow path to follow such paths can advantageously help to restrict the ingress of one or both of moisture and particulate matter from the air inlet to the electronic component.

[0028] The housing may comprise a mouthpiece for delivering aerosol to a user. The mouthpiece may comprise the air outlet. The air outlet may be in fluid communication with the mouthpiece.

[0029] The housing may comprise a housing wall, wherein the housing wall further comprises an external surface and an internal surface, and wherein the external surface of the housing wall forms the external surface of the housing and wherein the internal surface of the housing wall forms the internal surface of the housing.

[0030] The internal surface of the housing wall may define an internal volume of the housing.

[0031] The air inlet may extend through the housing from the external surface of the housing wall to the internal surface of the housing wall. According to a first embodiment of the present invention, the module may be an enclosure configured to house and protect the electronic component within the module.

[0032] The module may comprise a sealing edge configured to engage with an internal surface of the wall of the housing to create a tightfitting interference fit.

[0033] The sealing edge may engage with the portion of the wall of the housing wherein the air inlet is located. This advantageously ensures an air-tight seal around the air-inlets such that all air flowing into the aerosol-generating device flows through the module.

[0034] The module may comprise a chamber extending within the module. The chamber may comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet. Advantageously, moisture and other particulate matter can collect within the chamber, and thus be prevented from progressing further towards the electronic component.

[0035] The chamber may be a first chamber.

[0036] The sealing edge may define the first chamber extending within the module.

[0037] The chamber may comprise a concave internal curvature between the air inlet and the chamber outlet. The chamber may comprise a turn of at least 30 degrees between the air inlet and the chamber outlet. Preferably the chamber may comprise a turn of at least 40 degrees, preferably at least 60 degrees, more preferably at least 80 degrees, even more preferably at least 90 degrees, between the air inlet and the chamber outlet. The chamber may comprise a turn of no more than 100 degrees between the air inlet and the chamber outlet. Advantageously, this can help the chamber to resist the flow of water and dust particles into the chamber outlet through the air inlet. Due to the concave internal curvature of the chamber, water and dust particles would face a higher resistance to their flow through the chamber, because they would have to flow against gravity towards the chamber outlet.

[0038] The chamber outlet may be arranged orthogonal to the air inlet. This can help to reduce the likelihood of any liquid that enters the chamber through the air inlet progressing beyond the chamber and through the outlet during normal use of the aerosol-generating device. The chamber outlet may be positioned above the air inlet when the aerosol-generating device is in an upright position. By way of example, the aerosol-generating device may be in an upright position when a base of the aerosol-generating device sits on a flat surface.

[0039] The chamber outlet may comprise a tapered lip that promotes the flow of liquid into the first passage of the module. This advantageously promotes the flow of any liquid collected proximate the chamber outlet to flow into the first chamber where the liquid can then leave the aerosol-generating device through the air inlets. A portion of the module including the sealing edge and the chamber, may be made of a hydrophobic elastomer. This may advantageously repel water particles from flowing through the chamber outlet.

[0040] The module may comprise a second chamber extending within the module, wherein the electronic component may be housed within the second chamber of the module.

[0041] The second chamber may comprise a chamber inlet. The second chamber may be in fluid communication with the air flow passage through the chamber inlet.

[0042] The average diameter of the chamber outlet may be greater than the average diameter of the chamber inlet. Advantageously, when the average diameter of the chamber outlet is greater than the average diameter of the chamber inlet, it reduces the risk of water retention in the first chamber.

[0043] The chamber inlet may comprise an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second chamber. This advantageously prevents liquid collected proximate the chamber inlet from flowing into the second chamber, where the electronic component is present.

[0044] The module may comprise a first passage, at a first end the chamber outlet, and wherein the chamber outlet is in fluid communication with the airflow passage through the first passage.

[0045] The average diameter of the chamber outlet may be greater than the average diameter of the first passage. Advantageously, when the average diameter of the chamber outlet is greater than the average diameter of the first passage, it reduces the risk of water retention along the first passage and advantageously allows any water present therein to freely flow- out from this space. Advantageously, this also reduces the risk of the airflow passage being blocked by water and dust particles.

[0046] The module may comprise a second passage at a first end of the chamber inlet, wherein the electronic component is in fluid communication with the air flow passage through the second passage.

[0047] The portion of the module comprising the second chamber may be made of a rigid material configured to resist mechanical deformation. Advantageously, this protects the electronic component from mechanical load.

[0048] The module may further comprise a top portion, wherein the top portion comprises a plurality of openings, the plurality of openings including a first opening at a first end of the first passage, and a second opening at a first end of the second passage.

[0049] The top portion of the module may be in the form of a cap.

[0050] The first passage may be delimited by the chamber outlet and the first opening of the top portion of the module. The second passage may be delimited by the cavity inlet and the second opening of the top portion of the module.

[0051] The second opening may comprise an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second passage of the module. This advantageously prevents liquid collected at the cap from flowing into the portion of the module where the electronic component is present.

[0052] The first opening may comprise a tapered lip that promotes the flow of liquid into the first passage of the module. This advantageously promotes the flow of any liquid collected at the top portion to flow into the chamber through the first passage where the liquid can then leave the aerosol-generating device through the air inlets.

[0053] Advantageously, the height of the top portion may be adjusted such that the overall length of the module may be adjusted to the pre-configured length of the housing. Moreover, the top portion also provides for an easier assembly process of the module.

[0054] According to a second embodiment of the present invention, the module may be a split-enclosure comprising a first portion and a second portion, wherein the first portion of the module and the second portion of the module together are configured to house and protect the electronic component within the module. Proving the module as a split-enclosure may advantageously improve the manufacturing of the aerosol-generating device.

[0055] The first portion of the module may comprise a sealing edge configured to engage with an internal surface of the wall of the housing to create a tightfitting interference fit.

[0056] The sealing edge may engage with the portion of the wall of the housing wherein the air inlet is located. This advantageously ensures an air-tight seal around the air-inlets such that all air flowing into the aerosol-generating device flows through the module.

[0057] The first portion of the module may comprise a chamber extending within the module, and wherein the chamber comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet. Advantageously, moisture and other particulate matter can collect within the chamber, and thus be prevented from progressing further towards the electronic component.

[0058] The sealing edge may define the chamber extending within the first portion of the module. The chamber may comprise a concave internal curvature between the air inlet and the chamber outlet. The chamber may comprise a turn of at least 30 degrees between the air inlet and the chamber outlet. Preferably the chamber may comprise a turn of at least 40 degrees, preferably at least 60 degrees, more preferably at least 80 degrees, even more preferably at least 90 degrees, between the air inlet and the chamber outlet. The chamber may comprise a turn of no more than 100 degrees between the air inlet and the chamber outlet. Advantageously, this can help the chamber to resist the flow of water and dust particles into the chamber outlet through the air inlet. Due to the concave internal curvature of the chamber, water and dust particles would face a higher resistance to their flow through the chamber, because they would have to flow against gravity towards the chamber outlet.

[0059] The chamber outlet may be arranged orthogonal to the air inlet. This can help to reduce the likelihood of any liquid that enters the chamber through the air inlet progressing beyond the chamber and through the outlet during normal use of the aerosol-generating device. The chamber outlet may be positioned above the air inlet when the aerosol-generating device is in an upright position. By way of example, the aerosol-generating device may be in an upright position when a base of the aerosol-generating device sits on a flat surface.

[0060] The first portion of the module including the sealing edge and the chamber, may be made of a hydrophobic elastomer. This may advantageously repel water particles from flowing through the chamber outlet.

[0061] The module may comprise a cavity extending within the second portion of the module and wherein the electronic component is within the cavity of the second portion of the module.

[0062] The cavity may comprise a cavity inlet. The cavity may be in fluid communication with the air flow passage through the cavity inlet.

[0063] The second portion of the module may comprise a first opening, overlying the chamber outlet, and wherein the chamber outlet is in fluid communication with the airflow passage through the first opening.

[0064] The average diameter of the chamber outlet may be greater than the average diameter of the first opening of the second portion of the module. Advantageously, when the average diameter of the chamber outlet is greater than the average diameter of the first opening of the second portion of the module, this may prevent any misalignment of the chamber outlet and the first opening during the device assembly process. Therefore, the risk that the chamber outlet would block the first opening in the second portion of the module is minimised. Additionally, when the average diameter of the chamber outlet is greater than the average diameter of the first opening of the second portion of the module, this reduces the risk of water retention along the first opening and advantageously allows any water present therein to freely flow-out from this space.

[0065] The second portion of the module may comprise a second opening, and wherein the electronic component is in fluid communication with the air flow passage through the second opening.

[0066] The second portion of the module may comprise an engaging member that is configured to engage with a corresponding engaging element of the first portion of the module.

[0067] The second portion of the module may be made of a rigid material, wherein the second portion of the module is configured to resist mechanical deformation, such that the second portion of the module protects the electronic component from mechanical load. The module may further comprises a cap that is configured to engage with a first end of the module.

[0068] The cap may comprise a plurality of openings, the plurality of openings including a first opening configured to overlie the chamber outlet of the first portion of the module, and a second opening configured to overlie the first opening of the second portion of the module.

[0069] The second opening of the cap may comprise an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the first opening of the second portion of the module. This advantageously prevents liquid collected at the cap from flowing into the module where the electronic component is present.

[0070] The first opening of the cap may comprise a tapered lip that promotes the flow of liquid back into the chamber of the first portion of the module. This advantageously allows any liquid collected at the cap to exit the aerosol-generating device through the chamber in the first portion of the module.

[0071] Advantageously, the height of the cap may be adjusted such that the overall length of the module may be adjusted to the pre-configured length of the housing. Moreover, the cap also provides for an easier assembly process of the module.

[0072] According to a third embodiment of the present invention, the module may comprise a sealing edge around the air inlet, and wherein the sealing edge defines a chamber extending within the module. The sealing edge may advantageously seal the air inlets from the rest of the aerosol-generating device, such that all air flowing into the aerosol-generating device flows through the module. Advantageously, moisture and other particulate matter can collect within the chamber.

[0073] The module may be made of an elastomer, preferably a hydrophobic elastomer. This may advantageously repel water flowing into the aerosol-generating device. Examples of elastomers used herein may include but are not limited to Silicone Rubber and Polytetrafluoroethylene (PTFE) Elastomers.

[0074] Alternatively, the module may be made of plastic materials with the ability to bend elastically. Such materials may include but are not limited to blends between polymers such as polycarbonate (PC) and acrylonitrile butadiene styrene (ABS).

[0075] The chamber may comprise a chamber outlet, and wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet.

[0076] The chamber may comprises a concave internal curvature between the air inlet and the chamber outlet, such that the chamber resists the flow of water and dust particles into the chamber outlet through the air inlet.

[0077] The module may further comprises a bracket that encloses the electronic component within the module. The bracket may comprise a bracket inlet wherein the electronic component is in fluid communication with the airflow passage through the bracket inlet.

[0078] The bracket may be made of rigid material, such that the bracket is designed to resist mechanical deformation of the module.

[0079] The module may further comprise a cap that is configured to engage with a first end of the module, and wherein the cap comprises a plurality of openings, the plurality of openings including a first opening configured to overlie the chamber outlet, and a second opening configured to overlie the bracket inlet.

[0080] The cap may be configured such that the second opening of the cap comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the bracket inlet. This advantageously prevents liquid collected at the cap from flowing into the module where the electronic component is present.

[0081] The cap may be configured such that the first opening of the cap comprises a tapered lip that promotes the flow of liquid back into the chamber through the chamber outlet. This advantageously allows any liquid collected at the cap to exit the aerosol-generating device through the chamber in the first portion of the module.

[0082] The housing may comprise a bracket configured to engage with the cap of the module.

[0083] The device may comprise a heating element, and wherein the heating element may be positioned with the bracket. The bracket may be in fluid communication with the first air flow passage.

[0084] The invention is defined in the claims. However, 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.

[0085] Example 1 : An aerosol-generating device, comprising: a housing; an air inlet, an air outlet, and an airflow passage extending within the housing from the air inlet to the air outlet, a module within the housing, an electronic component within the module, and wherein the electronic component is in fluid communication with the air flow passage through the module.

[0086] Example 2: The aerosol-generating device according to any preceding Example, comprising a plurality of components within the housing, the plurality of components including the electronic component.

[0087] Example 3: The aerosol-generating device according to any preceding Example wherein the electronic component includes a pressure sensor, and wherein the pressure sensor is a puff sensor. Example 4: The aerosol-generating device according to any preceding Example, wherein the electronic component is within the module, and wherein the module is configured to house and protect at least the pressure sensor of the aerosol-generating device.

[0088] Example 5: The aerosol-generating device according to Example 4, wherein the module is configured to provide mechanical protection and ingress protection to the electronic component housed within the module of the aerosol-generating device.

[0089] Example 6: The aerosol-generating device according to any preceding Example, wherein the module abuts the air inlet, and wherein the electronic component is in fluid communication with the air flow passage through the module.

[0090] Example 7: The aerosol-generating system according to Example 6, wherein the module abuts the air inlet, such that the air outlet is in fluid communication with the air inlet through the module.

[0091] Example 8: The aerosol-generating device according to any preceding Example wherein the air inlet is a first air inlet, and the aerosol-generating device further comprises one or more second air inlets in a plurality of air inlets

[0092] Example 9: The aerosol-generating device according to any preceding Example, wherein the housing comprises a mouthpiece for delivering aerosol to a user.

[0093] Example 10: The aerosol-generating device according to Example 9, wherein the mouthpiece comprises the air outlet.

[0094] Example 11 : The aerosol-generating device according to Example 10, wherein the air outlet is in fluid communication with the mouthpiece.

[0095] Example 12: The aerosol-generating device according to any preceding Example, wherein the housing comprises a housing wall, wherein the housing wall further comprises an external surface and an internal surface, and wherein the external surface of the housing wall forms the external surface of the housing and wherein the internal surface of the housing wall forms the internal surface of the housing.

[0096] Example 13: The aerosol-generating device according to Example 12, wherein the internal surface of the housing wall defines an internal volume of the housing.

[0097] Example 14: The aerosol-generating device according to any of Examples 12 to 13, wherein the air inlet extends through the housing from the external surface of the housing wall to the internal surface of the housing wall.

[0098] Example 15: The aerosol-generating device according to any preceding Example wherein the module is a split-enclosure comprising a first portion and a second portion, wherein the first portion of the module and the second portion of the module together are configured to house and protect the electronic component within the module. Example 16: The aerosol-generating device according to Example 15, wherein the first portion of the module comprises a sealing edge configured to engage with an internal surface of the wall of the housing to create a tightfitting interference fit.

[0099] Example 17: The aerosol-generating device according to Example 16, wherein the sealing edge engages with the portion of the wall of the housing wherein the air inlet is located.

[0100] Example 18: The aerosol-generating device according to Example 17, wherein the sealing edge defines a chamber extending within the module, and wherein the chamber comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet.

[0101] Example 19: The aerosol-generating device according to Example 18, wherein the chamber comprises a concave internal curvature between the air inlet and the chamber outlet, and wherein the chamber resists the flow of water and dust particles into the chamber outlet through the air inlet.

[0102] Example 20: The aerosol-generating device according to any of Examples 15 to 19, wherein the first portion of the module including the sealing edge and the chamber, is made of a hydrophobic elastomer.

[0103] Example 21 : The aerosol-generating device according to any of Examples 16 to 20, wherein the second portion of the module comprises a cavity and wherein the electronic component is within the cavity of the second portion of the module.

[0104] Example 22: The aerosol-generating device according to Example 21 , wherein the second portion of the module comprises a first opening, overlying the chamber outlet, and wherein the chamber outlet is in fluid communication with the airflow passage through the first opening.

[0105] Example 23: The aerosol-generating device according to Example 22, wherein the average diameter of the chamber outlet is greater than the average diameter of the first opening of the second portion of the module.

[0106] Example 24: The aerosol-generating device according to Example 23, wherein the second portion of the module comprises a second opening, and wherein the electronic component is in fluid communication with the air flow passage through the second opening.

[0107] Example 25: The aerosol-generating device according to any of Examples 15 to 25, wherein the second portion of the module comprises an engaging member that is configured to engage with a corresponding engaging element of the first portion of the module.

[0108] Example 26: The aerosol-generating device according to any of Examples 16 to 25, wherein the second portion of the module is made of a rigid material, wherein the second portion of the module is configured to resist mechanical deformation, such that the second portion of the module protects the electronic component from mechanical load. Example 27: The aerosol-generating device according to any of Examples 22 to 26, wherein the module further comprises a cap that is configured to engage with a first end of the module, and wherein the cap comprises a plurality of openings, the plurality of openings including a first opening configured to overlie the chamber outlet of the first portion of the module, and a second opening configured to overlie the first opening of the second portion of the module.

[0109] Example 28: The aerosol-generating device according to Example 27, wherein at least the second opening of the cap comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the first opening of the second portion of the module.

[0110] Example 29: The aerosol-generating device according to Example 28 wherein the first opening of the cap comprises a tapered lip that promotes the flow of liquid back into the chamber of the first portion of the module.

[0111] Example 30: The aerosol-generating device according to any of Examples 1 to 15, wherein the module is an enclosure configured to house and protect the electronic component within the module.

[0112] Example 31 : The aerosol-generating device according to Examples 31 , wherein the module comprises a chamber extending within the module.

[0113] Example 32: The aerosol-generating device according to Example 31 , wherein the chamber comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet, and wherein the chamber is a first chamber.

[0114] Example 33: The aerosol-generating device according to Examples 31 or 32, wherein the module comprises a sealing edge that defines the chamber extending within the module.

[0115] Example 34: The aerosol-generating device according to Example 33 wherein the sealing edge configured to engage with an internal surface of the wall of the housing to create a tightfitting interference fit.

[0116] Example 35: The aerosol-generating device according to Example 32 or 33, wherein the sealing edge is configured to engage with the portion of the wall of the housing wherein the air inlet is located.

[0117] Example 36: The aerosol-generating device according to any of Examples 32 to 35, wherein the chamber comprises a concave internal curvature between the air inlet and the chamber outlet.

[0118] Example 37: The aerosol-generating device according to any of Examples 32 to 36, wherein the chamber comprises a turn of at least 30 degrees between the air inlet and the chamber outlet, preferably at least 40 degrees, preferably at least 60 degrees, more preferably at least 80 degrees, even more preferably at least 90 degrees, between the air inlet and the chamber outlet.

[0119] Example 38: The aerosol-generating device according to Example 37, wherein the chamber comprises a turn of less than or equal to 100 degrees between the air inlet and the chamber outlet.

[0120] Example 39: The aerosol-generating device according to Examples 32 to 38, wherein the chamber outlet is arranged orthogonal to the air inlet.

[0121] Example 40: The aerosol-generating device according to any of Examples 32 to 39, wherein the chamber outlet is positioned above the air inlet when the aerosol-generating device is in an upright position.

[0122] Example 41 : The aerosol-generating device according to any of Examples 32 to 40, wherein the chamber outlet comprises a tapered lip that promotes the flow of liquid into the first passage of the module.

[0123] Examples 42: The aerosol-generating device according to any of Examples 30 to 41 , wherein a portion of the module including the sealing edge and the chamber, is made of a hydrophobic elastomer.

[0124] Example 43: The aerosol-generating device according to any of Examples 32 to 42, wherein the module comprises a second chamber extending within the module, wherein the electronic component is housed within the second chamber of the module.

[0125] Example 44: The aerosol-generating device according to Example 43, wherein the second chamber comprises a chamber inlet, and wherein the second chamber is in fluid communication with the air flow passage through the chamber inlet.

[0126] Example 45: The aerosol-generating device according to Example 44, wherein the average diameter of the chamber outlet is greater than the average diameter of the chamber inlet.

[0127] Example 46: The aerosol-generating device according to Example 44 or 45, wherein the chamber inlet comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second chamber.

[0128] Example 47: The aerosol-generating device according to Example 32 to 46, wherein the module comprises a first passage, overlying the chamber outlet, and wherein the chamber outlet is in fluid communication with the airflow passage through the first passage.

[0129] Example 48: The aerosol-generating device according to Example 47, wherein the average diameter of the chamber outlet is greater than the average diameter of the first passage.

[0130] Example 49: The aerosol-generating device according to Examples 47 or 48, wherein the module comprises a second passage, wherein the electronic component is in fluid communication with the air flow passage through the second passage. Example 50: The aerosol-generating device according to Example 49, wherein the portion of the module comprising the second chamber is made of a rigid material configured to resist mechanical deformation.

[0131] Example 51 : The aerosol-generating device according to any of Example 47 to 50, wherein the module further comprises a top portion, wherein the top portion comprises a plurality of openings, the plurality of openings including a first opening at a first end of the the first passage, and a second opening at a second end of the second passage.

[0132] Example 52: The aerosol-generating device according to Example 51 , wherein the top portion of the module is in the form of a cap.

[0133] Example 53: The aerosol-generating device according to Example 51 or 52, wherein the first passage is delimited by the chamber outlet and the first opening of the top portion of the module.

[0134] Example 54: The aerosol-generating device according to any of Examples 51 to 53, wherein the second passage is delimited by the chamber inlet and the second opening of the top portion of the module.

[0135] Example 55: The aerosol-generating device according to any of Examples 51 to 54, wherein the second opening comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second passage of the module.

[0136] Example 56: The aerosol-generating device according to any of Examples 51 to 55, wherein the first opening comprises a tapered lip that promotes the flow of liquid into the first passage of the module.

[0137] Example 57: The aerosol-generating device according to any of Examples 15 to 56 wherein the module further comprises a bracket that encloses the electronic component within the module.

[0138] Example 58: The aerosol-generating device according to Example 57, wherein the bracket comprises a bracket inlet wherein the electronic component is in fluid communication with the airflow passage through the bracket inlet.

[0139] Example 59: The aerosol-generating device according to Example 57 or 58, wherein the bracket is made of rigid material, such that the bracket is designed to resist mechanical deformation of the module. Example 60: The aerosol-generating device according to any of Examples 57 to 60 wherein the device comprises a heating element, and wherein the heating element is positioned with the bracket.

[0140] Example 61 : The aerosol-generating device according to any of Examples 57 to 60, wherein the bracket is in fluid communication with the first air flow passage. Example 62: The aerosol-generating device according to any of Examples 57 to 61 when dependent on any of Examples 27 to 29, wherein the bracket is configured to engage the cap of the module.

[0141] Example 63: The aerosol-generating device according to any of Examples 57 to 62 when dependent on any of Examples 51 to 56, wherein the bracket is configured to engage the top portion of the module.

[0142] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0143] Figure 1 is a schematic view of an aerosol-generating device according to a first embodiment of the present invention;

[0144] Figure 2 is an exploded view of the aerosol-generating device of Figure 1 ;

[0145] Figure 3 is a perspective view of a first portion of a module of the aerosol-generating device of Figure 1 ;

[0146] Figure 4 is a perspective view of a second portion of the module, of the aerosolgenerating device of Figure 1 ;

[0147] Figure 5 is a perspective view of a cap of the module, of the aerosol-generating device of Figure 1 ;

[0148] Figure 6 is a perspective view of the module of the aerosol-generating device of Figure 1 , showing the first portion of the module, the second portion of the module, and the cap of the module attached together;

[0149] Figure 7 is a cross-sectional view of the module of Figure 6;

[0150] Figure 8 is a cross-sectional view of the module of Figures 6, showing the air flow path within the module;

[0151] Figure 9 is a perspective view of a bracket of the aerosol-generating device of Figure 1 ;

[0152] Figure 10 is a cross-sectional view of the of the module of Figure 6, with the bracket of Figure 9 attached;

[0153] Figure 11 is the cross-sectional view of the module of Figure 10, showing the air flow path through the module and through the bracket; and

[0154] Figure 12 is a schematic view of the aerosol-generating device according to a second embodiment of the invention.

[0155] Figure 1 shows an aerosol-generating device 100 according to a first embodiment of the invention comprising a mouthpiece 10 for use with the aerosol-generating device. The mouthpiece 10 comprises a liquid reservoir or liquid storage portion 12 containing a liquidaerosol forming substrate for use with the aerosol-generating device 100. The liquid reservoir 12 is configured to deliver liquid aerosol-forming substrate to a heating element 15. As the user puffs on the mouthpiece 10, an air supply is drawn into the aerosol-generating device 100 through the air inlet 17. The air supply at an ambient temperature condenses the vapour created by the heating element 15 to form a stream of generated aerosol. The mouthpiece 10 comprises an air outlet 18 and as the user puffs on the mouthpiece 10, the stream of generated aerosol may exit the device through the air outlet 18. As such, the aerosol-generating device 100 comprises a first air flow passage extending between the air inlets 17 and the air outlet 18, wherein, the first airflow passage is configured to deliver generated aerosol to the user.

[0156] The aerosol-generating device 100 comprises a housing 20. The housing comprises a housing wall 21 which further comprises an external surface 212 and an internal surface 211. The external surface 212 of the housing wall forms the external surface of the housing 20. The internal surface 211 of the housing wall forms the internal surface of the housing 20. The internal surface of the housing wall also defines an internal volume of the housing. The air inlet 17 extend through the housing wall 20 from the external surface 212 of the housing wall to the internal surface 211 of the housing wall.

[0157] The aerosol-generating device 100 of Figure 1 also comprises a module 50 disposed within the internal volume of the housing. The module 50 comprises a first portion 60 and a second portion 40 which are configured to form a split enclosure that is designed to house and protect one or more electronic components 80 within the aerosol-generating device. The first portion of the module 60 has a sealing edge 62, which creates an air-tight seal around the air inlet 17. This can help to ensure that the air inlet 17 is in fluid communication through the airflow passage only through the first portion 60 of the module. As such, the sealing edge 62 may help to reduce the ingress of undesirable matter, such as moisture and particulate matter, into certain areas of the internal volume of the housing. For example, the sealing edge may help to reduce the likelihood of undesirable matter reaching an area of the internal volume of the housing containing the electronic component.

[0158] The housing 20 also comprises a housing component 24 configured to engage the internal surface 211 of the housing wall 21 , at a second end of the housing 20, to create a tight-fitting interference fit. The housing component 24 comprises peripheral perforations 26, 27 at the second end of the housing component 24.

[0159] As shown in Figure 1 , the engagement between the housing component 24 and the housing wall 21 , is configured such that an interstice 22 is present. The interstice 22 is configured to form an air release outlet for the aerosol-generating device. The air release outlet is able to provide an internal air flow pathway that ensures a synchronised pressure between the external environment and the internal environment of the aerosol-generating device when the aerosol-generating device is not being used.

[0160] Figure 2 is an exploded view of the aerosol-generating device 100 shown in Figure 1. The aerosol-generating device comprises a housing 20 which is connected to a mouthpiece 10. The mouthpiece 10 is located at the proximal end of the aerosol-generating device 100 and is configured for the user to puff on. The mouthpiece 10 defines the air outlet 18 and a portion of the airflow passage leading up to it. The mouthpiece 10 also comprises a liquid reservoir (not shown) that is configured to hold a liquid aerosol-forming substrate. The liquid reservoir is in fluid communication with a heating element 15. The heating element 15 is configured to vaporise liquid aerosol-forming substrate received from the liquid reservoir. The heating element 15 receives electrical power from a power supply unit. The power supply unit comprises a battery 19 wherein the battery 19 is electrically connected to the electronic component of the aerosol-generating device 100. The electronic component comprises the control circuitry 80 which is configured to control the power supply to the heating element 15 when the user is performing a puff action. The heating element 15 is a resistive heater in the form of a rolled mesh that surrounds a portion of the airflow passage. The allows for a large surface area of the heating element 15 to be exposed to airflow within the airflow passage.

[0161] The aerosol-generating device further comprises a flavour ring 11 configured to indicate the flavour of the vapour generated by the aerosol-generating device. The flavour ring is coloured to indicate a specific flavour, for example, a green flavour ring may indicate that the aerosol-generating device 10 comprises an aerosol-forming substrate that produces a mint flavour. The second housing component 24 that is configured to connect to the housing 20 through an interference fit is also shown. The first portion of the module 60 and the second portion of the module 40, is configured to form a split enclosure designed to house and protect the control circuitry 80. The module also comprises a puff sensor cap 461 made of silicone that is configured to provide additional protection for the puff sensor. The first 60 and second 40 portions of the module 50 comprise a plurality of openings that ensure that the puff sensor is in fluid communication with the air flow passage. A puff sensor 81 is configured to detect a “puff action” by sensing a change in pressure. The puff sensor 81 is configured to be positioned within a chamber 46 of the second portion of the module 40.

[0162] During a “puff action”, the change in pressure is caused when the user is puffing through the mouthpiece 10 of the aerosol-generating device 100. When this happens, air from the external environment flows into the housing 20 of the aerosol generating device through the air inlets 17. Simultaneously, air is also configured to flow into the module 50 that is in fluid communication with the puff sensor 81 . The change in pressure detected by the puff sensor 81 “triggers” the control circuitry 80 to record a puff action. When the control circuitry 80 does this, other components of the device 100 such as the heating element are activated or otherwise controlled.

[0163] During a puff action, the temporary influx of air into the aerosol-generating device 100, through the air inlet 17, during may also include the influx of moisture and other particulate matter into the aerosol-generating device which may interfere with the control circuitry 80 and puff sensor 81. This may lead to one or both of these components becoming damaged or failing to perform satisfactorily.. To mitigate such problems, the control circuitry 80 and the puff sensor 81 are provided within the housing in the module 40 as shown in Figures 2 to 11. This arrangement embodies a range of features which (individually and collectively) help to reduce the likelihood of undesirable external contaminants reaching these components, whilst still ensuring a fluid communication with the airflow passage remains available. This range of features is described in further detail below with reference to Figures 2 to 11.

[0164] The puff sensor 81 is electrically connected to the control circuitry 80. The control circuitry 80 is electrically connected to the battery 19. During a puff action, when a user puffs on the device, the puff sensor 81 sends a signal to the control circuitry 80 which records a puff action. The control circuitry 80 then sends power from the battery 19 to the heating element 15 to increase a temperature of the heating element.

[0165] Figure 3 shows a perspective view of the of the first portion 60 of the module. The first portion 60 of the module comprises the sealing edge 62 in form of a continuous protrusion that extends across the external surface of the first portion of the module. The sealing edge is configured to engage with the internal surface 211 of the wall of the housing 20 to create a tight-fitting interference fit. The sealing edge specifically engages with the wall of the housing 20 wherein the air inlets 20 are present. This effectively seals the air inlets from the rest of the aerosol-generating device such that all air flowing into the aerosol-generating device is configured to flow through the first portion of the module. The sealing edge of the first portion 60 of the module may be made of silicone due to its elastic and hydrophobic properties, however, any other suitable material may also be used. In some preferred embodiments, the entirety of the first portion of the module is made from silicone or another elastic material.

[0166] The use of an elastic material is preferred, because the elastic material can be compressed against the internal surface 211 of the housing, and thus create a good sealing between the sealing edge and the air inlet 17. The sealing edge also defines chamber 63 which leads to a chamber outlet 64. The chamber 63 is designed to have a surface having a concave internal curvature which promotes the flow of liquid away from the chamber outlet 64 and towards the air inlet. Accordingly, any liquid that flows into the aerosol-generating device through the air inlet 17, during a puff action may collect within the chamber 63 of the first portion 60 of the module. The concave internal curvature of the chamber 63, naturally promotes the flow of any collected liquid within the chamber, out of the aerosol-generating device through the air inlet 17. At the same time, the concave internal curvature of the chamber 63 naturally opposes the flow of liquid through the chamber outlet, therefore, reducing the chances of any liquid from the environment external to the aerosol-generating device from migrating further into the aerosol-generating device. Additionally, the hydrophobic properties of the material forming the first component of the module may further enhance the removal of any water / liquid form the chamber 63. The chamber outlet 64 is also arranged orthogonal to the air inlet 17. This can help to reduce the likelihood of any liquid that enters the chamber through the air inlet 17 progressing beyond the chamber and through the outlet 64 during normal use of the aerosol-generating device.

[0167] Figure 4 shows a perspective view of the second portion 40 of the module. The second portion 40 of the module hosts the control circuitry 80 and the puff sensor 81. The second portion of the module comprises an inner chamber 46 which is designed to specifically house the puff sensor. During the assembly of the module, the control circuity and the puff sensor is positioned within the second portion of the module such that, the puff sensor cap 461 is placed over the puff sensor 81 , and the puff sensor, including the puff sensor cap are pushed into the inner chamber 46 of the second portion 40 of the module. The second portion of the module is made of rigid material that is designed to provide mechanical support for the electronic components housed within the module 50 of the aerosol-generating device. As such when an external force is applied to the housing 20 of the device 100, for instance, if a user accidentally squeezes the aerosol-generating device 100 during use, the second portion of the module resists deformation and protects the electronic components from any mechanical deformation that may result in the damage of said electronic components.

[0168] The second portion 40 of the module comprises engaging members 45 that are configured to engage with corresponding engaging element 65 of the first portion 60 of the module to create a tight enclosure for the electronic components within the module 50. The second portion of the module also comprises cap engaging members 43 that are configured to engage with corresponding cap engaging element 33 of the cap 30.

[0169] The second portion 40 of the module comprises a first opening 44 that is sized and positioned to overlie the chamber outlet 64 when the first portion 60 engages with the second portion 40. The chamber outlet 64 is in fluid communication with the air flow passage through the first opening 44. As illustrated by Figures 2 and 3, the chamber outlet 64 is configured such that the average diameter of the chamber outlet is greater than the diameter of the first opening 44. This helps to minimises the risk of misalignment of the opening during the assembly process and also minimises the risk of the chamber outlet 64 blocking the opening 44. Furthermore, as the chamber outlet 64 is larger than the first opening 44, water retention can be prevented along the opening 44 as the water is allowed to flow freely into the chamber 63 and out of the aerosol-generating device.

[0170] The second portion 40 of the module further comprises a second opening 47 that is in fluid communication with the inner chamber 46. As such, air flowing through the air inlet 17, and consequently through the first air flow passage is configured to flow into the inner chamber 46 through the second opening 47. Therefore, the puff sensor present within the inner chamber 46 can detect a puff action as air flows into the inner chamber 46 through the opening 47. The second portion 40 of the module also comprises a third opening 48 for the passage of wires to the control circuitry.

[0171] Figure 5 shows a perspective view of a cap 30 that is configured to form part of the air flow path of the air flow passage. The cap comprises the cap engaging element 33 that is configured to engage with the engaging member 43 of the second portion 40 of the module. The cap comprises a first cap opening 34 (not shown) that is configured to overlie the first opening 44 of the second portion of the module 40. The cap also comprises a second cap opening 31 configured to overlie the second opening 47 of the second portion 40 of the module. The cap further comprises a third cap opening 32 configured to overlie the third opening 48 of the second portion 40, for the passage of wires to the control circuitry.

[0172] Figure 6 shows a perspective view of the first portion of the first portion 60 and second portion 40 of the module assembled together. The cap 30 is also shown attached to the second portion 40 of the module. Figure 7 is a cross-sectional view of the components of Figure 6. The first cap opening 34 is in fluid communication with the air inlet 17 and the chamber outlet 64 through the first opening 44 of the second portion 40. The first cap opening 34 is configured to have a tapered lip which promotes the flow of any water retention at the cap, into the chamber 63, through the opening 44. Therefore, any water / liquid retention in the cap is directed to the first cap opening 34 such that it can flow through the opening 44 and chamber outlet 64, into the chamber 64 and out of the device 100, through the air inlet 17.

[0173] The second cap opening is positioned to overlie the second opening 47 of the second portion 40. The inner chamber 46 is in fluid communication with the airflow passage through the second cap opening 31 and the opening 47 of the second portion 40. The second cap opening 31 comprises an elevated lip that is configured to create a barrier that prevents liquid at the cap from flowing into the second opening 47 of the second portion 40 of the module. Therefore, any water / liquid retention in the cap is prevented from flowing into the inner chamber 46. The third cap opening 32 and the third opening 48 of the second portion allow for the passage of wires to the control circuitry 80.

[0174] Figure 8 is the same cross-sectional view of figure 7, showing the air flow path to the puff sensor 81 for the aerosol-generating device to detect a puff action. As described in more detail below, the air flow path to the puff sensor 81 follows a convoluted path wherein the configuration of the module forces the air flow to repeatedly shift direction. Air flowing into the aerosol-generating device through the air inlet 17 flows into the chamber 63 of the first portion of the module 60. The air flowing through the air inlet 17 follows the convex profile of the chamber 63 and changes direction compared to the direction of the air flowing through the chamber inlet, turning approximately 90 degrees as it flows towards the chamber outlet 64. The air then flows through the chamber outlet 64 and through the first opening 44 of the second portion 40 of the module. The air flow pathway between the chamber outlet 64 and the first opening 44 of the second portion 40 of the module is a relatively constricted airflow pathway compared to the airflow pathway through the chamber 63 of the first portion 40 of the module. The air flowing through the first opening 44 of the second portion 40 of the module then flows through the first cap opening 34 and then changes direction again, turning approximately 90 degrees while flowing towards the second cap opening 31. The air flow then subsequently changes direction by approximately 90 degrees and flows through the second opening 47 of the second portion 40, into the chamber, where the puff sensor 81 is present. The air flow pathway between the second cap opening 31 and the second opening 47 of the second portion 40 of the module is a relatively constricted airflow pathway compared to the airflow pathway through the first cap opening 34 and the second cap opening 31 . Air flowing into the chamber 46 leads to a change in pressure within the chamber 46, which is then detected by the puff sensor 81 , and “triggers” the control circuitry 80 to record a puff action. When the control circuitry 80 does this, other components of the device 100 such as the heating element are activated or otherwise controlled.

[0175] In certain embodiments (not shown) the portion of the module shown in Figure 6 is a single portion. That is, according to certain embodiments of the present invention, the portion of the module shown in Figure 6 is not made of multiple components. In such embodiments (not shown) the module comprises a chamber extending within the module. The chamber may comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet. A sealing edge may define the chamber extending within the module. The chamber outlet may comprise a tapered lip that promotes the flow of liquid into the first passage of the module.

[0176] The module may comprise a second chamber extending within the module, wherein the electronic component may be housed within the second chamber of the module. The second chamber may comprise a chamber inlet. The second chamber may be in fluid communication with the air flow passage through the chamber inlet. The chamber inlet may comprise an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second chamber.

[0177] Figure 9 is a perspective view of a bracket 13 that forms part of the air flow passage and provides an air flow path to the heating element 15, that is within the bracket 13.

[0178] Figure 10 is a cross-sectional view of the bracket 13 attached to the module and the cap. As shown in Figure 10, the first portion 60 and second portion 40 of the module 50 are attached together, and the cap 30 is also attached to the second portion 40 of the module. The bracket 13 is attached over the cap 30 and the air flow path within the bracket 30 is in fluid communication with the first and section cap opening 34 and 31 respectively. The heating element 15, in the form of a mesh heater, is also shown in the middle of the bracket 13. Figure 11 is the same cross-sectional view of figure 10, showing the air flow path through the bracket 13 and to the mesh heater 15. Air flowing into the aerosol-generating device through the air inlet 17 flows into the chamber 63 of the first portion of the module 60. The air then flows through the chamber outlet 64 and through the first opening 44 of the second portion 40 of the module. The air then flows through the first cap opening 34 and then into the second cap opening 31. The air then flows into the chamber, where the puff sensor 81 is present, through the second opening 47 of the second portion 40. Simultaneously, the air flows into the bracket 13 and then follows a convoluted path along the edges of the bracket 13 before flowing into a chamber of the bracket where the heating element is present.

[0179] Air flowing into the chamber 46 leads to a change in pressure within the chamber 46, which is then detected by the puff sensor 81 , and “triggers” the control circuitry 80 to record a puff action. When the control circuitry 80 does this, other components of the device 100 such as the heating element are activated or otherwise controlled. The heating element 15 is in fluid communication with a liquid reservoir (not shown) that is configured to hold a liquid aerosolforming substrate. When the heating element is activated, it vaporises the liquid aerosolforming substrate received from the liquid reservoir.

[0180] Figure 12 shows an aerosol-generating device 1000 according to a second embodiment of the invention comprising a mouthpiece 101 for use with the aerosol-generating device. The mouthpiece 101 comprises a liquid reservoir 121 containing a liquid-aerosol forming substrate for use with the aerosol-generating device 1000. The liquid reservoir 121 is configured to deliver liquid aerosol-forming substrate to the heating element 151.

[0181] The aerosol-generating device 1000 comprises a housing 201. The air inlet 171 extend through the housing 201 from the external surface of the housing wall to the internal surface of the housing wall.

[0182] The module 601 of the aerosol-generating device 1000 is also shown in Figure 1. The module is designed to house and protect the electronic components 801 within the aerosolgenerating device. The sealing edge 621 of the module creates an air-tight seal around the air inlet which ensures that the air inlet is in fluid communication through the airflow passage through the module 601. As such, the module 601 can ensure that no components from the external environment, such as moisture and particulate matter can seep into the aerosolgenerating device, especially the electronic components, through the air inlets. The electronic components are positioned within a bracket 401 of the of the module 601.

[0183] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

Claims1. An aerosol-generating device, comprising: a housing; an air inlet, an air outlet, and an airflow passage extending within the housing from the air inlet to the air outlet, a module within the housing, an electronic component within the module, and wherein the electronic component is in fluid communication with the air flow passage through the module.

2. The aerosol-generating device according to any preceding claim, comprising a plurality of components within the housing, the plurality of components including the electronic component.

3. The aerosol-generating device according to any preceding claim wherein the electronic component includes a pressure sensor, and wherein the pressure sensor is a puff sensor.

4. The aerosol-generating device according to any preceding claim, wherein the electronic component is within the module, and wherein the module is configured to house and protect at least the pressure sensor of the aerosol-generating device.

5. The aerosol-generating device according to claim 4, wherein the module is configured to provide mechanical protection and ingress protection to the electronic component housed within the module of the aerosol-generating device.

6. The aerosol-generating device according to any preceding claim, wherein the module abuts the air inlet, and wherein the electronic component is in fluid communication with the air flow passage through the module.

7. The aerosol-generating system according to claim 6, wherein the module abuts the air inlet, such that the air outlet is in fluid communication with the air inlet through the module.

258. The aerosol-generating device according to any preceding claim wherein the air inlet is a first air inlet, and the aerosol-generating device further comprises one or more second air inlets in a plurality of air inlets9. The aerosol-generating device according to any preceding claim, wherein the housing comprises a mouthpiece for delivering aerosol to a user.

10. The aerosol-generating device according to claim 9, wherein the mouthpiece comprises the air outlet.

11. The aerosol-generating device according to claim 10, wherein the air outlet is in fluid communication with the mouthpiece.

12. The aerosol-generating device according to any preceding claim, wherein the housing comprises a housing wall, wherein the housing wall further comprises an external surface and an internal surface, and wherein the external surface of the housing wall forms the external surface of the housing and wherein the internal surface of the housing wall forms the internal surface of the housing.

13. The aerosol-generating device according to claim 12, wherein the internal surface of the housing wall defines an internal volume of the housing.

14. The aerosol-generating device according to any of claims 12 to 13, wherein the air inlet extends through the housing from the external surface of the housing wall to the internal surface of the housing wall.

15. The aerosol-generating device according to any preceding claim wherein the module is a split-enclosure comprising a first portion and a second portion, wherein the first portion of the module and the second portion of the module together are configured to house and protect the electronic component within the module.

16. The aerosol-generating device according to claim 15, wherein the first portion of the module comprises a sealing edge configured to engage with an internal surface of the wall of the housing to create a tightfitting interference fit.

17. The aerosol-generating device according to claim 16, wherein the sealing edge engages with the portion of the wall of the housing wherein the air inlet is located.

18. The aerosol-generating device according to claim 17, wherein the sealing edge defines a chamber extending within the module, and wherein the chamber comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet.

19. The aerosol-generating device according to claim 18, wherein the chamber comprises a concave internal curvature between the air inlet and the chamber outlet, and wherein the chamber resists the flow of water and dust particles into the chamber outlet through the air inlet.

20. The aerosol-generating device according to any of claims 15 to 19, wherein the first portion of the module including the sealing edge and the chamber, is made of a hydrophobic elastomer.

21. The aerosol-generating device according to any of claims 16 to 20, wherein the second portion of the module comprises a cavity and wherein the electronic component is within the cavity of the second portion of the module.

22. The aerosol-generating device according to claim 21, wherein the second portion of the module comprises a first opening, overlying the chamber outlet, and wherein the chamber outlet is in fluid communication with the airflow passage through the first opening.

23. The aerosol-generating device according to claim 22, wherein the average diameter of the chamber outlet is greater than the average diameter of the first opening of the second portion of the module.

24. The aerosol-generating device according to claim 23, wherein the second portion of the module comprises a second opening, and wherein the electronic component is in fluid communication with the air flow passage through the second opening.

25. The aerosol-generating device according to any of claims 15 to 25, wherein the second portion of the module comprises an engaging member that is configured to engage with a corresponding engaging element of the first portion of the module.

26. The aerosol-generating device according to any of claims 16 to 25, wherein the second portion of the module is made of a rigid material, wherein the second portion of themodule is configured to resist mechanical deformation, such that the second portion of the module protects the electronic component from mechanical load.

27. The aerosol-generating device according to any of claims 22 to 26, wherein the module further comprises a cap that is configured to engage with a first end of the module, and wherein the cap comprises a plurality of openings, the plurality of openings including a first opening configured to overlie the chamber outlet of the first portion of the module, and a second opening configured to overlie the first opening of the second portion of the module.

28. The aerosol-generating device according to claim 27, wherein at least the second opening of the cap comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the first opening of the second portion of the module.

29. The aerosol-generating device according to claim 28 wherein the first opening of the cap comprises a tapered lip that promotes the flow of liquid back into the chamber of the first portion of the module.

30. The aerosol-generating device according to any of claims 1 to 15, wherein the module is an enclosure configured to house and protect the electronic component within the module.

31. The aerosol-generating device according to claims 30, wherein the module comprises a chamber extending within the module.

32. The aerosol-generating device according to claim 31 , wherein the chamber comprises a chamber outlet, wherein the air inlet is in fluid communication with the airflow passage though the chamber outlet, and wherein the chamber is a first chamber.

33. The aerosol-generating device according to claims 31 or 32, wherein the module comprises a sealing edge that defines the chamber extending within the module.

34. The aerosol-generating device according to claim 33 wherein the sealing edge is configured to engage with an internal surface of the wall of the housing to create a tightfitting interference fit.

35. The aerosol-generating device according to claim 32 to 34, wherein the sealing edge is configured to engage with the portion of the wall of the housing wherein the air inlet is located.

36. The aerosol-generating device according to any of claims 32 to 35, wherein the chamber comprises a concave internal curvature between the air inlet and the chamber outlet.

37. The aerosol-generating device according to any of claims 32 to 36, wherein the chamber comprises a turn of at least 30 degrees between the air inlet and the chamber outlet, preferably at least 40 degrees, preferably at least 60 degrees, more preferably at least 80 degrees, even more preferably at least 90 degrees, between the air inlet and the chamber outlet.

38. The aerosol-generating device according to claim 37, wherein the chamber comprises a turn of less than or equal to 100 degrees between the air inlet and the chamber outlet.

39. The aerosol-generating device according to claims 32 to 38, wherein the chamber outlet is arranged orthogonal to the air inlet.

40. The aerosol-generating device according to any of claims 32 to 39, wherein the chamber outlet is positioned above the air inlet when the aerosol-generating device is in an upright position.

41. The aerosol-generating device according to any of claims 32 to 40, wherein the chamber outlet comprises a tapered lip that promotes the flow of liquid into the first passage of the module.

42. The aerosol-generating device according to any of claims 30 to 41 , wherein a portion of the module including the sealing edge and the chamber, is made of a hydrophobic elastomer.

43. The aerosol-generating device according to any of claims 32 to 42, wherein the module comprises a second chamber extending within the module, wherein the electronic component is housed within the second chamber of the module.

44. The aerosol-generating device according to claim 43, wherein the second chamber comprises a chamber inlet, and wherein the second chamber is in fluid communication with the air flow passage through the chamber inlet.

45. The aerosol-generating device according to claim 44, wherein the average diameter of the chamber outlet is greater than the average diameter of the chamber inlet.

46. The aerosol-generating device according to claim 44 or 45, wherein the chamber inlet comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second chamber.

47. The aerosol-generating device according to claim 32 to 46, wherein the module comprises a first passage, overlying the chamber outlet, and wherein the chamber outlet is in fluid communication with the airflow passage through the first passage.

48. The aerosol-generating device according to claim 47, wherein the average diameter of the chamber outlet is greater than the average diameter of the first passage.

49. The aerosol-generating device according to claims 47 or 48, wherein the module comprises a second passage, wherein the electronic component is in fluid communication with the air flow passage through the second passage.

50. The aerosol-generating device according to claim 49, wherein the portion of the module comprising the second chamber is made of a rigid material configured to resist mechanical deformation.

51. The aerosol-generating device according to any of claim 47 to 50, wherein the module further comprises a top portion, wherein the top portion comprises a plurality of openings, the plurality of openings including a first opening at a first end of the first passage, and a second opening at a first opening of the second passage.

52. The aerosol-generating device according to claim 51 , wherein the top portion of the module is in the form of a cap.

53. The aerosol-generating device according to claim 51 or 52, wherein the first passage is delimited by the chamber outlet and the first opening of the top portion of the module.

54. The aerosol-generating device according to any of claims 51 to 53, wherein the second passage is delimited by the chamber inlet and the second opening of the top portion of the module.

55. The aerosol-generating device according to any of claims 51 to 54, wherein the second opening comprises an elevated lip, wherein the elevated lip is configured to create a barrier that prevents liquid from flowing into the second passage of the module.

56. The aerosol-generating device according to any of claims 51 to 55, wherein the first opening comprises a tapered lip that promotes the flow of liquid into the first passage of the module.

57. The aerosol-generating device according to any of claims 15 to 56 wherein the module further comprises a bracket that encloses the electronic component within the module.

58. The aerosol-generating device according to claim 57, wherein the bracket comprises a bracket inlet wherein the electronic component is in fluid communication with the airflow passage through the bracket inlet.

59. The aerosol-generating device according to claim 57 or 58, wherein the bracket is made of rigid material, such that the bracket is designed to resist mechanical deformation of the module.

60. The aerosol-generating device according to any of claims 57 to 60 claim wherein the device comprises a heating element, and wherein the heating element is positioned with the bracket.

61. The aerosol-generating device according to any of claims 57 to 60, wherein the bracket is in fluid communication with the first air flow passage.

62. The aerosol-generating device according to any of claims 57 to 61 when dependent on any of claims 27 to 29, wherein the bracket is configured to engage the cap of the module.

63. The aerosol-generating device according to any of claims 57 to 62 when dependent on any of claims 51 to 56, wherein the bracket is configured to engage the top portion of the module.

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