Note: Descriptions are shown in the official language in which they were submitted.
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AEROSOL GENERATION DEVICE
TECHNICAL FIELD
The following disclosure relates to devices for generating an aerosol which is
inhaled by a user, such as electronic cigarettes. In particular, the
disclosure
relates to aerosol generation devices where the aerosol is generated by
heating
an aerosol substrate.
BACKGROUND
Aerosol generation devices consume an aerosol substrate in order to generate
an
aerosol. A user of the device must replace the aerosol substrate periodically
in
order to generate more of the aerosol.
Additionally, aerosol generation devices often include a mouthpiece through
which
the user may inhale the generated aerosol. The mouthpiece must be kept clean
to maintain hygiene.
It is desirable to make it easy for the user to use the device. The simplest
way to
achieve this is to make the entire device disposable, such that the user
replaces
the aerosol substrate and provides a clean mouthpiece, by replacing the entire
device. Alternatively, the consumable aerosol substrate can be packaged in a
container configured to interface with the device, such that the user can
replace
the container without having to directly handle the aerosol substrate.
Additionally,
the mouthpiece may be provided as a part of the container.
However, it is also desirable to reduce the environmental impact of the
aerosol
generation device. This goal can conflict with making the device easy to use,
because some types of container are not environmentally friendly, and an
entirely
disposable aerosol generation device may also not be environmentally friendly.
Accordingly, it is desirable to provide an aerosol generation device which
supports
easy and clean replacement of an aerosol substrate while reducing
environmental
impact.
SUMMARY
According to a first aspect, the present disclosure provides an aerosol
generation
device comprising: a power supply module comprising an electrical power
supply;
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a substrate module comprising a container for an aerosol substrate; and a
heater
module configured to detachably engage with the power supply module, the
heater module comprising: a mouthpiece; a heating element configured to
receive
power from the electrical power supply and heat the aerosol substrate to
generate
an aerosol; and a receiving means configured to detachably engage with the
substrate module and bring the heating element and the aerosol substrate
together for generating the aerosol, wherein: the container of the substrate
module
is sealed prior to engaging with the heater module, and the heater module is
configured to break the sealing of the container upon or after engaging with
the
substrate module, the heater module is adapted to partly enclose the substrate
module when engaged therewith, and the power supply module is adapted to
partly enclose the heater module when engaged therewith.
By providing a three-module device, the power supply module, substrate module
and heater module can be individually replaced only as often as necessary.
Furthermore, each module can be made of entirely different materials and
manufactured separately before being assembled into the device. The assembly
of modules to form the complete aerosol generation device can be performed by
the end user and/or performed as an additional industrial manufacturing stage.
Optionally, the aerosol substrate is a liquid or gel.
Liquid or gel substrates are particularly difficult for a user to handle
directly, and
the benefits of providing a container for the substrate are greater than for a
solid
substrate.
Optionally, the substrate module comprises a fluid transfer element configured
to
transfer liquid from the container to the heating element.
Providing a fluid transfer element configured to operate with the heater
module
makes handling a liquid substrate easier and more reliable to increase aerosol
generation and decrease wastage of the substrate.
Optionally, the receiving means comprises a closure component arranged to open
for receiving the substrate module and to close for aerosol generation.
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By providing a closure component, the substrate module can be entirely
contained
within the receiving means during aerosol generation, meaning that the
conditions
for aerosol generation can be more precisely controlled, and the quality of
generated aerosol can be improved.
Optionally, the receiving means is a clam-shell container or a container
comprising
a housing closed by a closing door.
A clam-shell container or housing-and-door container configuration each
provide
a specific closure component that is simple to operate and robust.
Optionally, the sealing of the container comprises a first layer that is not
soluble in
the aerosol substrate and a second layer that is soluble in the aerosol
substrate.
With this configuration, a breach of the first layer becomes self-reinforcing
as the
second layer is exposed to the substrate, and dissolves to weaken the overall
sealing.
Optionally, the soluble layer comprises a polysaccharide, starch or protein-
based
material or biodegradable polyvinylalcohol (PVA) film.
Optionally, the sealing of the container comprises a foil seal layer
comprising a
moisture barrier. This has the effect of improving hygiene and reducing
moisture
exchange between the substrate module and an environment.
Optionally, the container and/or sealing of the container comprises a polymer
film
comprising a gas barrier and/or moisture barrier layer or coating and at least
one
support layer.
Optionally, the gas and/or moisture barrier layer is EVOH, PVOH, SiOx, or
natural
wax or combinations thereof.
Optionally, the support layer comprises: paper, polylactic acid (PLA),
poly(glycolic
acid) (PGA), bio-PET, PBAT, polymer(s) of cellulose-derived or starch-derived
biodegradable polymers (BPs), chitosan or microbially synthesized polyesters.
Optionally, the receiving means comprises a piercing element configured to
pierce
or cut the sealing of the container. This has the effect of making the device
simpler
and easier to operate, because a user does not need to manually open the
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container upon providing a fresh substrate module for the aerosol generation
device, and the container is opened under controlled conditions that are less
likely
to waste the aerosol substrate or create a mess due to a leak.
Optionally, the sealing of the container is configured to break upon melting,
burning or decomposing upon heating by the heating element and the heating
element is configured to melt, burn or decompose the sealing of the container.
This makes the device simpler and easier to operate, because a user does not
need to manually open the container upon providing a fresh substrate module
for
the aerosol generation device, and the container is opened under controlled
conditions that are less likely to waste the aerosol substrate or create a
mess due
to a leak.
Optionally, the heater module is configured to open the sealing of the
container
upon commencing aerosol generation. This has the advantage of not opening the
substrate module until the user wishes to perform aerosol generation, allowing
the
user to store a substrate module in the device without any risk of a leak and,
in
the general case where multiple different aerosol substrates can be used in
the
device, allowing the user to change their mind about which aerosol substrate
should be used by swapping the substrate module even after the substrate
module has engaged with the receiving means.
Optionally, the substrate module is biodegradable or compostable (according to
EN1342 Standard). This reduces the environmental impact of the device,
particularly because the part of the device that is expected to be replaced
most
frequently has reduced environmental impact.
Optionally, the container and/or the sealing of the container comprise a
polysaccharide, starch or protein-based material, paper, polylactic acid
(PLA),
poly(glycolic acid) (PGA), bio-PET, PBAT, polymer(s) of cellulose-derived or
starch-derived biodegradable polymers (BPs), chitosan or microbially
synthesized
polyesters.
Optionally, the heating element is detachable from the heater module. This
improves the adaptability of the device such that parts can be replaced only
as
frequently as necessary. For example, some users may wish to improve hygiene
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by replacing the mouthpiece with the heater module more often than they
replace
the heating element. On the other hand, in some embodiments, the mouthpiece
can be cleaned or covered to remain hygienic for longer, and the heating
element
may have a shorter lifetime than the rest of the heater module. Additionally
or
5 alternatively, the heating element may be detached for the
purpose of cleaning to
extend its lifetime.
Optionally, the electrical power supply is detachable from the power supply
module. This has the advantage that the device may be used continuously by
swapping the electrical power supply. For example, rechargeable batteries
could
be swapped into the aerosol generation device such that one battery can be
used
in the device while another is being recharged. Furthermore, this feature
eliminates the need for a recharging port in rechargeable aerosol generation
device embodiments.
According to a second aspect, the present disclosure provides a heater module
for an aerosol generation device, wherein the aerosol generation device
comprises: a power supply module comprising an electrical power supply,
wherein the power supply module is adapted to partly enclose the heater module
when engaged therewith; and a substrate module comprising a container for an
aerosol substrate, the heater module being configured to detachably engage
with
the power supply module, the heater module comprising: a mouthpiece; a heating
element configured to receive power from the electrical power supply and heat
the
aerosol substrate to generate an aerosol; and a receiving means configured to
detachably engage with the substrate module and bring the heating element and
the aerosol substrate together for generating the aerosol, wherein: the
container
of the substrate module is sealed prior to engaging with the heater module,
and
the heater module is configured to break the sealing of the container upon or
after
engaging with the substrate module, and the heater module is adapted to partly
enclose the substrate module when engaged therewith.
According to a third aspect, the present disclosure provides a substrate
module
for an aerosol generation device, wherein the aerosol generation device
comprises: a power supply module comprising an electrical power supply; and a
heater module configured to detachably engage with the power supply module,
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the heater module comprising: a mouthpiece; and a heating element configured
to receive power from the electrical power supply and heat an aerosol
substrate
to generate an aerosol; wherein the power supply module is adapted to partly
enclose the heater module when engaged therewith, the substrate module
comprising a container for the aerosol substrate, wherein: the substrate
module is
configured to detachably engage with a receiving means of the substrate
module,
the receiving means being configured to bring the heating element and the
aerosol
substrate together for generating the aerosol, the container of the substrate
module is sealed prior to engaging with the heater module, and the sealing of
the
container is adapted to break upon the substrate module engaging with the
heater
module, and the heater module is adapted to partly enclose the substrate
module
when engaged therewith.
According to a fourth aspect, the present disclosure provides a package
comprising: a plurality of substrate modules according to the third aspect;
and a
cardboard support.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic block diagram of an aerosol generation device;
Figs. 2A, 2B and 2C are schematic block diagrams of modules of the aerosol
generation device in a disassembled state;
Fig. 3 is a schematic block diagram of a first example of a heater module
receiving
a substrate module;
Fig. 4 is a schematic block diagram of a second example of a heater module;
Fig. 5 is a schematic block diagram of a third example of a heater module
receiving
a substrate module;
Fig. 6 is a schematic block diagram of a fourth example of a heater module
receiving a substrate module;
Fig. 7 is a schematic block diagram of a fifth example of a heater module
receiving
a substrate module;
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Figs. 8A to 8D are schematic block diagrams of a sixth example of a heater
module
receiving a substrate module;
Fig. 9 is a schematic block diagram of a package of replaceable modules for an
aerosol generation device.
DETAILED DESCRIPTION
Fig. 1 is a schematic block diagram of an aerosol generation device 1. The
aerosol generation device is modular and can be assembled and disassembled in
use.
Specifically, the aerosol generation device 1 comprises a power supply module
11, a substrate module 12 and a heater module 13.
Figs. 2A, 2B and 20 are schematic block diagrams illustrating disassembled
modules of the aerosol generation device 1.
As shown in Fig. 2A, the power supply module 11 comprises an electrical power
supply 111. The electrical power supply 111 may be any means of electrical
power
storage, such as a battery. The electrical power supply 111 is preferably
rechargeable. The power supply module 11 may additionally have a charging port
for charging the electrical power supply 111.
Optionally, the power supply module 11 may additionally comprise control
circuitry
112 to control delivery of power from the electrical power supply 111 to the
heater
module 13. The control circuitry 112 may, for example, comprise a user input
such
as a button or switch to activate the heater module, and may also comprise a
timing circuit for controlling a cycle of aerosol generation. The control
circuitry may
comprise sensing means for controlling aerosol generating conditions such as a
pressure or flow rate sensor.
As further shown in Fig. 2A, the power supply module 11 comprises a heater
module engaging element 113 for engaging with and partially enclosing the
heater
module 13. This may for example take the form of a recess with a screw thread
or one or more flexible clips or magnets that are adapted to engage with
corresponding features of the heater module 13. Additionally, the heater
module
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engaging element 113 comprises electrical contacts for supplying power to the
heater module 13.
In some embodiments, the electrical power supply 111 is detachable from the
power supply module 11. For example, the electrical power supply 111 may be a
rechargeable or disposable battery, and may be one of a plurality of
electrical
power supplies 111 that can be swapped into the aerosol generation device 1
and
charged outside the device 1.
The power supply module 11 may be further configured to separate, providing an
electrical power supply 111, a control circuitry 112 and a casing including
the
heater module engaging element 113, such that each element of the power supply
module 11 can be individually replaced only as required. Allowing disassembly
of
modules of the device also improves recyclability, by improving the ease of
separating parts comprising different materials.
As shown in Fig. 2B, the substrate module 12 comprises a container for an
aerosol
substrate 121.
The aerosol substrate 121 may be a liquid or gel aerosol substrate, for
example
comprising an aerosolisation agent and a flavourant. In particular, the
aerosol
substrate 121 may comprise nicotine, and may be used to generate a nicotine-
containing aerosol as in reduced-risk smoking applications. The formulations
of the
aerosol substrate usually comprise, in addition to nicotine, further
components
such as solvents, thickening agents, stabilizing agents, flavoring and/or
taste
regulators. Alternatively, the aerosol substrate 121 may be a solid or semi-
solid
aerosol substrate such as a tobacco product. This may be tobacco in dried or
cured form, in some cases with additional ingredients for flavouring or
producing
a smoother or otherwise more pleasurable experience. In some examples, the
substrate such as tobacco may be treated with a vaporising agent. The
vaporising
agent may improve the generation of vapour from the substrate. The vaporising
agent may include, for example, a polyol such as glycerol, or a glycol such as
propylene glycol. The substrate may be provided as a solid or paste type
material
in shredded, pelletised, powdered, granulated, strip or sheet form, optionally
a
combination of these.
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In some cases, the aerosol substrate may contain no tobacco, or even no
nicotine,
but instead may contain naturally or artificially derived ingredients for
flavouring,
volatilisation, improving smoothness, and/or providing other pleasurable
effects.
The container may take the form of a soft bag or capsule, or may have a rigid
form. The container is sealed prior to the substrate module 12 being assembled
into the aerosol generation device 1, and a sealing 122 of the container is
broken
upon or after assembly of the aerosol generation device 1. The sealing 122 may
form the whole of, or only one or more specific parts of, the container. The
sealing
122 may be broken by any suitable means including piercing, cutting, bursting,
heating, burning, melting, or decomposing. For instance, the sealing may
comprise a weakened area such as a reduced thickness or a weaker seam.
The container and/or sealing 122 preferably comprises a foil layer (such as
aluminium foil) to improve hygiene and preserve freshness prior to the sealing
122
being broken.
The container and/or sealing may additionally or alternatively comprise a
polymer
layer to increase the strength of the sealing without increasing a required
foil
thickness. The polymer layer may be chosen to have a relatively low melting or
decomposing temperature, so that the sealing 122 can be relatively easily
broken
by a deliberate thermal effect (e.g. heating, burning, melting, decomposing)
that
can be supplied by the heater module 13 but is unlikely to be experienced
during
storage.
In embodiments that combine a foil layer and a polymer layer, a thickness of
the
foil layer may be made sufficiently thin so that the foil layer preserves
freshness
prior to use of the substrate module 12 but, after the polymer layer is
broken, the
foil layer is not strong enough to maintain the integrity of the sealing 122
on its
own. This means that the foil layer may be broken, for example, using a
mechanical force such tearing, breaking or piercing or using a thermal effect
that
is not actually hot enough to melt the material from which the foil layer is
made
(e.g. aluminium).
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In an embodiment, the container may be substantially impervious to moisture
and/or gas, for example to protect an aerosol substrate that contains
hygroscopic
or oxygen-sensitive components that may deteriorate during storage or reduce
shelf life.
5 The container and/or sealing may comprise a polymer film
comprising a gas
barrier and/or moisture barrier layer or coating. The gas barrier and/or
moisture
barrier layer or coating may, for example, be EVOH, PVOH, SiOx, natural wax.
The container and/or sealing layer may further comprise at least one support
layer.
The support layer or layers may be polymer or cellulose or a combination
thereof.
10 The polymer may be biodegradable or compostable (According to EN1342
Standard).
The polymer may be derived from renewable resources such as polylactic acid
(PLA), poly(glycolic acid) (PGA). In an example, the container and/or sealing
may
be paper, PLA or PGA coated with natural wax or a laminate of paper, PLA or
PGA
and natural wax.
The support layer may also be formed of biodegradable or compostable
polymer(s) derived from non-renewable resources can be: bio-PET (Ethylene
polyterephthalate), PBAT (Polybutylene adipate terephthalate).
The support layer may also be formed of biodegradable or compostable
polymer(s) of cellulose-derived or starch-derived biodegradable polymers
(BPS),
chitosan or microbially synthesized
polyesters such as PH B
(polyhydroxybutyrate), P3HB, PHV or PHBV. Where the aerosol substrate 121 is
a liquid or gel, the container and/or sealing 122 may additionally or
alternatively
comprise a layer that is soluble in the substrate, but is either not in
contact with
the substrate prior to breaking the seal, or is only soluble when the
substrate has
been heated above room temperature. For example, the soluble layer may
comprise a polysaccharide, starch or protein-based material or biodegradable
polyvinylalcohol (PVA) film.
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The materials for the substrate module 12 are preferably chosen such that the
substrate module 12 is biodegradable or compostable, at least after the
aerosol
substrate 121 has been consumed. In one embodiment, this is achieved by
providing the aerosol substrate in a container that is entirely made from a
biodegradable or compostable sealing layer 122. The container and/or sealing
layer may, for example, comprise a polysaccharide, starch or protein-based
material.
As shown in Fig. 20, the heater module 13 comprises a mouthpiece 131, a
heating
element 132 and a receiving means 133.
The mouthpiece 131 is configured for a user to draw aerosol from the aerosol
generation device 1.
The heating element 132 is configured to receive power from the electrical
power
supply 111 (when the aerosol generation device 1 is assembled) and to heat the
aerosol substrate 121 to generate an aerosol.
As used herein, the term "aerosol" shall mean a system of particles dispersed
in
the air or in a gas, such as mist, fog, or smoke. Accordingly the term
"aerosolise"
(or "aerosolize") means to make into an aerosol and/or to disperse as an
aerosol.
For the avoidance of doubt, aerosol is used to consistently describe mists or
droplets comprising atomised, volatilised or vaporised particles. Aerosol also
includes mists or droplets comprising any combination of atomised, volatilised
or
vaporised particles.
The heating element 132 may be any suitable heater, producing heat via
electrical
resistance or via a chemical reaction that can be controlled electrically. For
example, the heating element 132 may comprise a resistive wire or mesh.
Alternatively, combustion of a fuel in the heating element may be electrically
controlled by controlling ignition and controlling the supply of fuel to a
combustion
point, similar to the mechanism of a conventional lighter.
In embodiments where the aerosol substrate 121 is heated inside the substrate
module 12, the heating element 132 may be arranged on a surface of the
receiving
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means 133 or embedded in the heater module 13 close to a surface of the
receiving means 133. In other embodiments, the aerosol substrate 121 is
transferred out of the substrate module 12 (as in examples below), and the
heating
element 132 may be located wherever is appropriate for generating the aerosol.
The receiving means 133 is configured to detachably engage with the substrate
module 12 and to bring the heating element 132 and the aerosol substrate 121
together for generating the aerosol. The receiving means 133 of Fig. 2C is
also
configured to at least partly enclose the substrate module 12 in order to
improve
the change of the substrate module 12 correctly engaging when inserted by a
user, and in order to at least partly fix a position of the substrate module
12 during
aerosol generation. More specifically, in some embodiments, the receiving
means
133 comprises a recess in a surface of the heater module 13.
As further shown in Fig. 2C, in some embodiments, the receiving means 133
comprises a closure component 1331 arranged to open for receiving the
substrate
module 12 and to close for aerosol generation. The closure component may take
the form of a simple hinged door as shown in Fig. 20, a clam-shell
configuration
where the door has a recess for receiving part of the substrate module 12, or
may
take other forms such as a sliding door on a rail, or a separate lid that is
detachable
from the heater module 13 or attached by a flexible connection.
The closure component is, in some embodiments, configured to seal a recess of
the receiving means 133 such that the aerosol substrate 121 is contained in
the
receiving means 133 even if it leaks from the substrate module 12.
In other embodiments, the heater module engaging element 113 may also serve
as an alternative to a closure component 1331. More specifically, as shown in
Fig. 1, the heater module engaging element 113 can be configured to at least
partly enclose the substrate module 12 within the receiving means 133 of the
heater module 13. In such embodiments, the closure component 1331 may be
omitted.
When the aerosol generation device 1 is assembled as shown in Fig. 1, the
heater
module 13 engages with the substrate module 12 and with the power supply
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module 11 to form a complete aerosol generation device 1 that has a supply of
aerosol substrate 121 and of electrical power 111 to be used with the heating
element 132 to generate the aerosol.
Fig. 3 is a schematic block diagram of a first example of a heater module 13
receiving a substrate module 12.
In this example, the heater module 13 additionally comprises an air flow inlet
134
and an air flow outlet 135 arranged to allow a user to inhale air with aerosol
via
the mouthpiece 131. The power supply module 11 may comprise a hole
corresponding to the air flow inlet, or may otherwise be shaped to leave a gap
for
the air flow inlet.
The inlet and outlet 134, 135 are connected via respective channels to the
receiving means 133 where they each end with a respective piercing elements
1332 configured to pierce the sealing 122 of the substrate module 12 upon the
heater module 13 engaging with the substrate module 12. The piercing elements
may simply be protruding ends of the channels that are sharp enough to break
the
sealing 122 when a user pushes the substrate module 12 into the receiving
means
133 or when the closure component 1331 is moved to a closed position.
The configuration of Fig. 3 is suitable when the aerosol substrate 121 is a
porous
solid or semi-solid substrate. When the aerosol generation device 1 is
assembled
and the user inhales at the mouthpiece 131, air flows in through the inlet
134,
through the substrate 121 and out through the outlet 135. The heating element
132 may be activated to transmit heat through the broken sealing 122 and to
heat
the aerosol substrate 121 to generate the aerosol. Thus, as the air flows
through
the substrate 121, the aerosol is added to the air flow and provided to the
user.
Fig. 4 is a schematic block diagram of a second example of a heater module.
In the second example, a closure component 1331 takes the form of a clam-shell
in which two parts of the receiving means 133 are hinged together so that the
substrate module 12 can be received entirely within the heater module 13. In
this
particular example, the two parts are hinged near the mouthpiece but the two
parts
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could be hinged elsewhere, for example at a bottom end of the heater module or
along a longitudinal side in the axial direction of the module.
Similarly to Fig. 3, piercing elements 1332 are again arranged at the ends of
channels connected to an air flow inlet and outlet, and the air flow inlet and
outlet
are configured to direct air through the aerosol substrate 121 (when the
substrate
module 12 is inserted).
Additionally, each part of the clam-shell comprises a heating element 132.
More
generally, any number of heating elements 132 can be included in embodiments,
with different configurations, to improve efficiency of generating the
aerosol.
Fig. 5 is a schematic block diagram of a third example of a heater module
receiving
a substrate module.
In the third example, the heater module 13 comprises an aerosol generation
chamber 136 that is separate from the substrate module 12, and comprises a
fluid
transfer element configured to transfer a fluid or gel aerosol substrate 121
from
the substrate module 12 to the aerosol generation chamber 136.
The fluid transfer element 137 may for example be a capillary tube. An end of
the
fluid transfer element 137 extends into the receiving means and comprises a
piercing element arranged to pierce the sealing 122 of a substrate module 12.
Another end of the fluid transfer element 137 extends up to or into the
aerosol
generation chamber 136.
In the third example, the heating element 132 is arranged near the fluid
transfer
element 137. For example, the heating element 132 may be arranged in a loop
or coil around the fluid transfer element 137 or a resistive circuit printed
on the
element 137. The heating element 132 may be located between the receiving
means 133 and the aerosol generation chamber 136, or may be located in the
aerosol generation chamber 136 (as shown in Fig. 5).
The fluid transfer element 137 may be formed from a material with high thermal
conductivity in order to improve heat transfer from the heating element 132 to
the
aerosol substrate 121 as it passes through the fluid transfer element 137. For
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example, the fluid transfer element 137 may be formed from a metal. The fluid
transfer element may also be made of ceramic.
In some embodiments, the fluid transfer element 137 may comprise a pump (not
shown).
5 With the configuration of Fig. 5, the aerosol substrate 121 is
aerosolised as it
leaves the fluid transfer element 137 and enters the aerosol generation
chamber
136. As air flows through the aerosol generation chamber 136, this carries the
aerosol to the mouthpiece 131.Fig. 6 is a schematic block diagram of a fourth
example of a heater module 13 receiving a substrate module 12.
10 The fourth example is largely similar to the third example,
except the fluid transfer
element 137 does not have a piercing element 1332. Instead, the heating
element
132 is configured to activate to supply heat towards the substrate module 12
and
to provide a thermal effect (such as heating, burning, melting or decomposing)
to
break the sealing 122. The aerosol substrate 121 is then transferred through
the
15 fluid transfer element either through capillary action or
through pumping.
As with the configurations of Figs. 2C and 4, a closure component 1331 may be
configured to close around the substrate module 12. The closure component 1331
may advantageously press the sealing 122 against the end of the fluid transfer
element 137 to improve heat transfer efficiency for breaking the sealing 122
and
to reduce the chance of the aerosol substrate 121 leaking between the
substrate
module 12 and the receiving means 133.
This configuration, which lacks a piercing element 1332, has the advantage
that
the sealing 122 is not broken until the heating element 132 is activated at
the time
of aerosol generation, and therefore the substrate module 12 can be stored in
the
assembled aerosol generation device 1 without any risk that a liquid or gel
aerosol
substrate 121 leaks through the broken sealing 122.
Fig. 7 is a schematic block diagram of a fifth example of a heater module
receiving
a substrate module.
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The fifth example is largely similar to the fourth example, except the fluid
transfer
element 123 forms part of the substrate module 12 rather than the heater
module
13.
Instead of the fluid transfer element, in this example, the heater module 13
has a
gap 138 connecting the receiving means 133 to the aerosol generation chamber
136. The gap 138 is sized to receive the fluid transfer element 123, so that
the
fluid transfer element 123 extends past the heating element 132 and up to or
into
the aerosol generation chamber 136.
As with the fourth example, the sealing 122 is broken by a thermal effect
caused
by the heating element 132.
Figs. 8A to 8D are schematic block diagrams of a sixth example of a heater
module
receiving a substrate module.
The sixth example is largely similar to the third example, except the fluid
transfer
element 137 is replaced with a moveable fluid transfer element 1371 configured
to break the sealing 122 after the heater module 13 engages with the substrate
module 12.
Figs. 8A and 80 show a state of the moveable fluid transfer element 1371 prior
to
breaking the sealing 122, with Fig. 80 being a magnified view focussing on the
moveable fluid transfer element 1371.
In Figs. 8A and 80, the moveable fluid transfer element 1371 is in a retracted
position in a gap 138, extending into the aerosol generation chamber 136, and
not
protruding from a surface of the receiving means 133.
The heating element 132 is arranged in the aerosol generation chamber 136
(preferably as a loop around the moveable fluid transfer element 1371), and an
actuator 139 is arranged between the aerosol generation chamber 136 and the
receiving means 133. The actuator 139 is configured to move the moveable fluid
transfer element 1371. The actuator 139 may be any suitable actuator. For
example, the actuator may comprise a grip engaged with the moveable fluid
transfer element 1371, a spring configured to bias the grip towards the
retracted
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position, and an electromagnet configured to bias the grip towards an extended
position when activated.
In Figs. 8B and 8D, the moveable fluid transfer element 1371 is in the
extended
position in the gap 138, extending out of the surface of the receiving means
133
and breaking the sealing 122 of the substrate module 12. An other end of the
moveable fluid transfer element 1371 is still adjacent to the heating element
132.
Thus, in the extended position, the aerosol substrate 121 can be drawn out of
the
substrate module 12 and the aerosol can be generated.
The sixth example of a heater module 13 may be configured to only move the
moveable fluid transfer element 1371 into the extended position when the user
is
ready for aerosol generation. This means that the sealing 122 is not broken
prior
to commencing aerosol generation, and the risk of a leak is reduced when the
substrate module 12 is stored assembled in the device 1.
The aerosol generation device 1 may be distributed in various forms. In some
embodiments, the aerosol generation device 1 may be distributed as a fully
formed device having a power supply module 11, a substrate module 12 and a
heater module 13. The device 1 may also be distributed as a kit comprising a
power supply module 11, one or more substrate modules 12 and one or more
heater modules 13.
In many embodiments, the substrate module 12 will be replaced more frequently
than the heater module 13 or the power supply module 11, and the substrate
module 12 may be distributed as a package of one or more substrate modules 12.
Fig. 9 is a schematic block diagram of a package 2 of replaceable modules for
an
aerosol generation device.
As shown in Fig. 9, a plurality of substrate modules 12 may be distributed in
a
form where they are attached to a cardboard support 21. The cardboard support
21 may, for example, be an open cardboard sheet, a pair of open cardboard
sheets between which the substrate modules are arranged, or a cardboard
enclosure surrounding the substrate modules 12. Each substrate module 12 may
be attached to the cardboard support 21 using a dot of glue. Using a cardboard
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support has the advantage that, if the substrate modules 12 are biodegradable
as
described above, then the whole package is biodegradable.
Furthermore, if the number of substrate modules 12 which can be used with a
heater module 13 while maintaining hygiene of the mouthpiece 131 is known,
then
the substrate module 12 and heater module 13 can be distributed accordingly in
a package with multiple substrate modules 12 per heater module 13. The number
of substrate modules 12 per heater module 13 may typically be in the range of
six
to twenty. Each of the substrate modules 12 and the heater module 13 may be
wrapped, for example in a foil pack such as flow wrap, for hygiene and to
protect
the module before use. In the example shown in Fig. 9, the heater module 13 is
recommended to be replaced after every six substrate modules 12 have been
used, and the package 2 comprises one heater module 13 and six substrate
modules 12 mounted on or enclosed in a cardboard support 21.
In some embodiments, it is also advantageous to allow replacing the mouthpiece
131 separately from the heating element 132, with either being replaced more
frequently than the other. In order to accommodate this, the heating element
132
may be detachable from the heater module 13. For example, the heating element
132 may be fixed by press fitting to the heater module 13.
In one example shown in Fig. 10, the heater module 13 comprises a cradle 1321
adapted to receive the heating element 132 via the receiving means 133. More
specifically, when the closure component 1331 is in an open position, and no
portion 2 of aerosol generating substrate is present, the receiving means 133
may
provide access to the cradle 1321 for inserting the heating element 132. The
heating element 132 may for example be a disposable resistive element adapted
to engage with electrical contacts in the cradle 1321, and the cradle may
consist
of supports for two opposite ends of the heating element, each support having
an
electrical contact.
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