AEROSOL DELIVERY DEVICE

FIELD OF THE DISCLOSURE

The present disclosure relates to an aerosol delivery device, and, more particularly but not exclusively, to an aerosol delivery device in which a turbulence inducing element is configured to turn flow towards a circumferential direction.

The present disclosure also relates to an aerosol delivery device, and, more particularly but not exclusively, to an aerosol delivery device for a smoking substitute system.

The present disclosure also relates to an aerosol delivery device, and, more particularly but not exclusively, to an aerosol delivery device having an air-flow directing member in an airflow path.

The present disclosure also relates to a smoking substitute device and a system including the device, and, more particularly but not exclusively, to a smoking substitute device for delivering an aerosol to a user.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances is generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute devices in order to avoid the smoking of tobacco.

Such smoking substitute devices can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute devices, which may also be known as electronic nicotine delivery systems, may comprise electronic systems that permit a user to simulate the act of smoking by producing an aerosol, also referred to as a “vapor”, which is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavorings without, or with fewer of, the odor and health risks associated with traditional smoking.

In general, smoking substitute devices are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and tobacco products.

The popularity and use of smoking substitute devices has grown rapidly in the past few years. Some smoking substitute devices are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute devices do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form).

There are a number of different categories of smoking substitute devices, each utilizing a different smoking substitute approach. A smoking substitute approach corresponds to the manner in which the substitute system operates for a user.

One approach for a smoking substitute device is the so-called “vaping” approach, in which a vaporizable liquid, typically referred to (and referred to herein) as “e-liquid”, is heated by a heating device to produce an aerosol vapor which is inhaled by a user. An e-liquid typically includes a base liquid as well as nicotine and/or flavorings. The resulting vapor therefore typically contains nicotine and/or flavorings. The base liquid may include propylene glycol and/or vegetable glycerin.

A typical vaping smoking substitute device includes a mouthpiece, a power source (typically a battery), a tank or liquid reservoir for containing e-liquid, as well as a heating device. In use, electrical energy is supplied from the power source to the heating device, which heats the e-liquid to produce an aerosol (or “vapor”) which is inhaled by a user through the mouthpiece.

Vaping smoking substitute devices can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute devices which typically have a heater and a sealed tank and heating element which is pre-filled with e liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute devices include a main body which includes the power source, wherein the main body is configured to be physically and electrically coupled to a consumable including the tank and the heating element. In this way, when the tank of a consumable has been emptied, that consumable is disposed of. The main body can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute devices are completely disposable, and intended for one-use only.

There are also “open system” vaping smoking substitute devices which typically have a tank that is configured to be refilled by a user, so the device can be used multiple times.

An example vaping smoking substitute device is the myblu™ e-cigarette. The myblu™ e cigarette is a closed system device which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid, as well as a vaporizer, which for this device is a heating filament coiled around a portion of a wick. The wick is partially immersed in the e-liquid and conveys e-liquid from the tank to the heating filament. The device is activated when a microprocessor on board the main body detects a user inhaling through the mouthpiece. When the device is activated, electrical energy is supplied from the power source to the vaporizer, which heats e-liquid from the tank to produce a vapor which is inhaled by a user through the mouthpiece.

Another example vaping smoking substitute device is the blu PROT™ e-cigarette. The blu PROT™ e cigarette is an open system device which includes a main body, a (refillable) tank, and a mouthpiece. The main body and tank are physically and electrically coupled together by screwing one to the other. The mouthpiece and refillable tank are physically coupled together by screwing one into the other, and detaching the mouthpiece from the refillable tank allows the tank to be refilled with e-liquid. The device is activated by a button on the main body. When the device is activated, electrical energy is supplied from the power source to a vaporizer, which heats e-liquid from the tank to produce a vapor which is inhaled by a user through the mouthpiece.

Another approach for a smoking substitute device is the so-called “heat not burn” (“HNB”) approach in which tobacco (rather than e-liquid) is heated or warmed to release vapor. The tobacco may be leaf tobacco or reconstituted tobacco. The vapor may contain nicotine and/or flavorings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e., does not undergo combustion.

A typical HNB smoking substitute device may include a main body and a consumable. The consumable may include the tobacco material. The main body and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating device that is typically located in the main body, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapor. A vapor may be formed from a carrier in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerin) and additionally volatile compounds released from the tobacco. The released vapor may be entrained in the airflow drawn through the tobacco.

As the vapor passes through the smoking substitute device (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapor cools and condenses to form an aerosol (also referred to as a vapor) for inhalation by the user. The aerosol will normally contain the volatile compounds.

In HNB smoking substitute devices, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odor and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

An example of the HNB approach is the IQOS® smoking substitute device from Philip Morris Ltd. The IQOS® smoking substitute device uses a consumable, including reconstituted tobacco located in a wrapper. The consumable includes a holder incorporating a mouthpiece. The consumable may be inserted into a main body that includes a heating device. The heating device has a thermally conductive heating knife which penetrates the reconstituted tobacco of the consumable, when the consumable is inserted into the heating device. Activation of the heating device heats the heating element (in this case a heating knife), which, in turn, heats the tobacco in the consumable. The heating of the tobacco causes it to release nicotine vapor and flavorings which may be drawn through the mouthpiece by the user through inhalation.

A second example of the HNB approach is the device known as “Glo”® from British American Tobacco p.l.c. Glo® comprises a relatively thin consumable. The consumable includes leaf tobacco which is heated by a heating device located in a main body. When the consumable is placed in the main body, the tobacco is surrounded by a heating element of the heating device. Activation of the heating device heats the heating element, which, in turn, heats the tobacco in the consumable. The heating of the tobacco causes it to release nicotine vapor and flavorings which may be drawn through the consumable by the user through inhalation. The tobacco, when heated by the heating device, is configured to produce vapor when heated rather than when burned (as in a smoking apparatus, e.g., a cigarette). The tobacco may contain high levels of aerosol formers (carrier), such as vegetable glycerin (“VG”) or propylene glycol (“PG”).

In prior art smoking substitute devices, some of the un-vaporized e-liquid passes through the wick and to the mouthpiece. This can result in un-vaporized e-liquid passing into the user's mouth, which may be unpleasant for the user. Further leakage occurs due to leakage paths present between the components of the consumable. Additionally, it is desirable to provide consumables which are easier and cheaper to manufacture.

In other prior art smoking substitute devices, airflow through the system can be turbulent and can experience significant pressure drops. This can result in a user needing to provide a significant inhalation force to receive a suitable quantity of aerosol from the system.

The present disclosure has been devised in light of the above considerations.

SUMMARY OF THE DISCLOSURE

First Mode: An Aerosol Delivery Device in which a Turbulence Inducing Element is Configured to Turn Flow Towards a Circumferential Direction

At its most general, a first mode of the present disclosure relates to an aerosol delivery device in which a turbulence inducing element is configured to turn flow towards a circumferential direction.

According to a first aspect of the first mode of the present disclosure, there is provided an aerosol delivery device comprising: a flow passage configured to provide fluid communication between a vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising an aerosol vapor formed from liquid vaporized by the vaporizer in use; and a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to turn the flow towards a circumferential direction.

Turning the flow induces turbulence in the flow, which causes removal of large drops of liquid from the flow, thereby reducing leakage of liquid into the user's mouth. Turning towards the circumferential direction has been found to be particularly beneficial, because it allows the aerosol flow passage to occupy less volume in the device than if the flow is turned towards an alternative direction.

According to a second aspect of the first mode of the present disclosure, there is provided an aerosol delivery device comprising: a vaporizer configured to form an aerosol vapor from e-liquid; a flow passage configured to provide fluid communication between the vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising the aerosol vapor in use; a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to induce turbulence in the flow; and a vaporizer chamber containing the vaporizer and the turbulence inducing element, wherein the turbulence inducing element is at least 1 mm downstream of the vaporizer.

Optionally, the turbulence inducing element is configured to turn the flow towards a circumferential direction.

Optionally, the turbulence inducing element of the first or second aspect of the first mode is further configured to turn the flow towards a radial direction.

Advantageously, the turbulence inducing element of the first or second aspect of the first mode comprises a baffle across the flow passage, the baffle forming a first flow obstacle to turn the flow towards the radial direction.

Conveniently, the turbulence inducing element of the first or second aspect of the first mode comprises first and second inlets downstream of the baffle configured to effect branching of the flow.

Optionally, the turbulence inducing element of the first or second aspect of the first mode comprises an upstand, and the flow passage comprises an outlet tube, wherein the outlet tube and the upstand are configured to together form a second flow obstacle to turn the flow towards the circumferential direction.

Advantageously, the second flow obstacle is configured to effect additional branching of the flow.

Conveniently, the turbulence inducing element of the first or second aspect of the first mode comprises an outlet tube, the turbulence inducing element further configured to turn the flow such that the flow is in a substantially axial direction at the outlet tube.

Optionally, the turbulence inducing element of the first or second aspect of the first mode comprises a protrusion forming a third flow obstacle to turn the flow towards the axial direction.

Advantageously, the aerosol delivery device of the first or second aspect of the first mode further comprises a reservoir for storing a liquid, the reservoir in fluid communication with the vaporizer to pass e-liquid to the vaporizer for vaporization.

Conveniently, the reservoir stores the liquid.

Optionally, the liquid is an e-liquid.

Advantageously, the liquid comprises nicotine.

Conveniently, the aerosol delivery device of the first or second aspect of the first mode further comprises a mouthpiece, the mouthpiece comprising the mouthpiece aperture.

Optionally, the aerosol delivery device of the first aspect of the first mode further comprises the vaporizer.

Advantageously, the aerosol delivery device of the first aspect of the first mode further comprises a vaporizer chamber.

Conveniently, the vaporizer chamber containing the vaporizer, wherein the turbulence inducing element of the first or second aspect of the first mode is at least partially located in the vaporizer chamber.

Optionally, the turbulence inducing element of the first aspect of the first mode is located at least 1 mm downstream of the vaporizer.

The turbulence inducing element of the first or second aspect of the first mode may be at least 2 mm downstream of the vaporizer, such as at least 2.5 mm downstream of the vaporizer.

Optionally, the turbulence inducing element of the first or second aspect of the first mode is at most 5 mm downstream of the vaporizer such as at most 4 mm (e.g., substantially 3 mm) downstream of the vaporizer.

Optionally, the aerosol delivery device of the first or second aspect of the first mode is a consumable for a smoking substitute device.

Advantageously, the aerosol delivery device of the first or second aspect of the first mode is a smoking substitute device.

The disclosure includes the combination of the aspects and preferred features of the first mode described except where such a combination is clearly impermissible or expressly avoided.

Second Mode: An Aerosol Delivery Device with an Airflow Path Around an Airflow-Directing Member

At its most general, a second mode of the present disclosure relates to an aerosol delivery device in which an airflow path around an airflow-directing member (baffle) within a vaporizing chamber has a reduced cross-sectional area to match a minimum upstream cross-sectional area of the airflow path in the vaporizing chamber.

In a first aspect of the second mode, there is provided an aerosol delivery device having a chamber airflow path through a vaporizing chamber housing a vaporizer, the chamber airflow path extending through at least one aperture defined by an upstream edge of a transverse baffle mounted downstream from the vaporizer, wherein the chamber airflow path through the at least one aperture has a transverse cross-sectional area that is substantially equal or less than a minimum transverse cross-sectional area of the chamber airflow path downstream from the at least one aperture.

The inclusion of a baffle downstream from the vaporizer may help to reduce (or prevent) un-vaporized liquid from the vaporizer passing to the user. The un-vaporized liquid may collect on an upstream surface of the baffle facing the vaporizer, whilst vapor is able to pass through the aperture(s) defined by the upstream edge of the baffle. Reducing the size of the aperture so that it has an equal or smaller transverse cross-sectional area (perpendicular to the chamber airflow path) than the chamber airflow path downstream of the aperture(s), effectively reduces the surface area of a downstream end wall of the chamber that is exposed to the air flow in the chamber airflow path through the aperture. In this way, it is possible to reduce or eliminate the chance of un-vaporized liquid depositing on this chamber end wall and thus being carried into the airflow downstream of the aperture(s).

The terms “transversely” and “transverse” are used herein in relation to the cross-sectional area of the airflow path to describe a direction that is substantially perpendicular to the airflow path. The terms “transversely” and “transverse” are used herein in relation to components of the device to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The device has a device airflow path extending from at least one inlet of the device to an outlet of the device with the vaporizing chamber interposed between the inlet(s) and the outlet. The term “upstream” is used to define a direction towards the inlet(s) of the device. The term “downstream” is used to define a direction towards the outlet of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the second mode of the present disclosure.

In some embodiments, the chamber airflow path has a portion extending from the aperture to a downstream edge of the transverse baffle wherein the chamber airflow path at the downstream edge of the transverse baffle has a transverse cross-sectional area that is substantially equal or less than a minimum transverse cross-sectional area of the chamber airflow path downstream from the downstream edge of the transverse baffle.

In some embodiments, the portion of the chamber airflow path extending from the aperture to the downstream edge of the transverse baffle has a constant transverse cross-sectional area.

The chamber airflow path is partly defined by one or more walls of the vaporizing chamber. For example, the at least one aperture may be defined by the upstream edge of the baffle and the opposing sidewall of the chamber.

Where there is a constant transverse cross-sectional area between the aperture and the downstream edge of the baffle, the transverse width of the aperture (i.e., the transverse spacing between the upstream edge of the baffle and the sidewall of the chamber) equals the transverse spacing between the downstream edge of the baffle and the sidewall of the vaporizing chamber.

In some embodiments, the transverse width of the aperture(s) (i.e., the transverse spacing between the upstream edge of the baffle and the sidewall of the chamber) equals (or is less than) the longitudinal spacing between the downstream edge of the baffle and the end wall of the vaporizing chamber.

In some embodiments, the device comprises a passage extending longitudinally from the vaporizing chamber to the outlet of the device. In these embodiments, the chamber airflow path extends to a passage opening which may be provided in a downstream end wall of the vaporizing chamber.

The aperture (and the upstream/downstream edges of the baffle) may be offset transversely (i.e., laterally) from the longitudinal axis of the passage (e.g., may be radially outwards of the passage opening).

In some embodiments, the transverse width of the downstream end wall of the vaporizing chamber between the passage opening and the sidewall of the vaporizing chamber (measured between the radially outermost limit of the passage opening and the proximal sidewall) is less than the length of the chamber airflow path between the upstream edge and the downstream edge of the baffle.

In some embodiments, the chamber airflow path, between the vaporizer and the passage, may comprise at least one deflection. For example, a first portion of the chamber airflow path may extend in a generally longitudinal direction from the vaporizer to the aperture and/or the downstream edge of the baffle. A second portion of the airflow path between the first portion and the passage, may extend generally radially (laterally), e.g., generally parallel to a planar upper surface of the baffle, such that there may be a deflection between the first and second portions.

The device airflow path may comprise a third portion in the passage extending in a generally longitudinal direction. Thus, the device airflow path may deflect between the lateral direction (of the second portion) to a longitudinal direction (of the third portion) at or proximate to the passage opening.

The baffle may have two laterally opposed upstream edges that at least partly define two laterally opposed apertures (e.g., between the upstream edges and opposed sidewalls of the chamber). In this way, the chamber airflow path may be bifurcated as it passes downstream of the vaporizer. In these embodiments, it is preferable that the transverse cross-sectional area of the chamber airflow path in both branches of the bifurcated flow is as described above.

Accordingly, both branches of the bifurcated chamber airflow path may have a transverse cross-sectional area that is substantially equal or less than a minimum transverse cross-sectional area of the chamber airflow path downstream from the apertures.

In some embodiments, both branches of the bifurcated chamber airflow path have an equal transverse cross-sectional area downstream from the apertures.

The baffle may be configured (i.e., shaped and positioned) such that there is no direct longitudinal line of sight between the vaporizer and the passage. A transverse width of the baffle may be substantially the same or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially the same or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than 30% of a corresponding transverse width of the chamber, or may, e.g., be greater than 40%, or 50%.

The passage opening (i.e., the opening from the vaporizing chamber into the passage) may have a transverse cross-sectional area of more than 5 mm2. The passage opening may have a transverse cross-sectional area of no more than 10 mm2. The passage opening may have an internal diameter of more than 2.5 mm. The passage opening may have an internal diameter of no more than 4 mm. The transverse cross-sectional area of the or each aperture may be less than the cross-sectional area of the passage opening.

There may be an inlet substantially transversely aligned with the baffle (i.e., both may be aligned along a shared longitudinal axis). The inlet may be substantially transversely aligned with the passage opening (e.g., the inlet may be aligned on the longitudinal axis). The inlet, baffle and passage opening may be aligned along the longitudinal axis.

The vaporizing chamber may comprise opposing parallel sidewalls that are substantially parallel to the longitudinal axis, and a downstream (e.g., end) wall extending transversely between the sidewalls. The passage opening may be formed in the downstream wall of the chamber.

The device may comprise a tank (reservoir) for containing the vaporizable liquid (e.g., an e-liquid) with the vaporizer being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The passage may extend longitudinally within the tank and a passage wall may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall. The ribs may extend for the full length of the passage wall. The ribs may project (e.g., radially outwardly) into the tank.

The device may comprise an insert defining the device inlet(s). The insert may be inserted into an open end of the tank so as to seal against the tank housing. The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the chamber between wall(s) (e.g., sidewalls) of the chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the wall(s) of the chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the or each aperture at least partly defined by the baffle (e.g., defined between the upstream edges and wall(s) of the chamber). In this respect, the chamber airflow path may pass around, through or proximal the wick and through the aperture(s). The upstream edge(s) (and downstream edge(s) of the baffle) may extend across the chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber airflow path. This vapor may subsequently cool to form an aerosol in the vaporizing chamber.

The device may be in the form of a consumable. The consumable may be configured for engagement with a main body (i.e., so as to form a smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g., power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g., e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is snap engagement between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with a main body. In this way, one end of the device (i.e., the inlet end) may be coupled with the main body, whilst an opposing end (i.e., the outlet end) of the consumable may define a mouthpiece.

The main body or the consumable may comprise a power source or be connectable to a power source. The power source may be electrically connected (or connectable) to the heater. The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to a heater of the consumable. The electrical interface may also be used to identify the consumable from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable is connected to the main body.

The main body may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The consumable or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The consumable or main body may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e., puff) sensor may be provided that is configured to detect a puff (i.e., inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the main body.

In an alternative embodiment the device may be a non-consumable device in which an aerosol former (e.g., e-liquid) of the system may be replenished by re-filling the tank of the device (rather than replacing the consumable). In this embodiment, the consumable described above may instead be a non-consumable component that is integral with the main body. Thus, the device may comprise the features of the main body described above. In this embodiment, the only consumable portion may be e-liquid contained in the tank of the device. Access to the tank (for re-filling of the e-liquid) may be provided via, e.g., an opening to the tank that is sealable with a closure (e.g., a cap).

The device may be a smoking substitute device (e.g., an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g., an e-cigarette consumable).

In a second aspect of the second mode there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect of the second mode, the consumable being engageable with the main body such that vaporizer of the consumable is connected to the power source of the main body.

The consumable may be an e-cigarette consumable. The main body may be as described above with respect to the first aspect of the second mode. The main body may, for example, be an e-cigarette device for supplying power to the consumable.

The disclosure includes the combination of the aspects and preferred features of the second mode described except where such a combination is clearly impermissible or expressly avoided.

Third Mode: An Aerosol Delivery Device with an Airflow-Directing Member Having a Sloped Surface

At its most general, a third mode of the present disclosure relates to an aerosol delivery device in which an airflow-directing member (i.e., a baffle) having a sloped surface is provided in an airflow path through the device.

In a first aspect of the third mode there is provided an aerosol delivery device comprising: a vaporizer mounted within a vaporizing chamber for vaporizing a vaporizable liquid; a passage extending along a longitudinal axis from the vaporizing chamber to an outlet of the device; an airflow path extending from an inlet of the device, through the vaporizing chamber and passage, to the outlet; and a baffle interposed between the vaporizer and the passage and comprising a sloped surface for directing airflow within the airflow path towards the passage.

The inclusion of a baffle interposed between the vaporizer and passage may help to reduce (or prevent) un-vaporized liquid from the vaporizer passing into the passage. The un-vaporized liquid may collect on an upstream surface of the baffle facing the vaporizer, whilst vapor is able to flow around the baffle (over the sloped surface) into the passage.

To maximize the protection (from liquid) provided by the baffle, it is desirable to maximize the cross-sectional size of the baffle (i.e., its coverage across the chamber). However, this results in a reduction in the cross-sectional area of the airflow path between the baffle and, e.g., walls of the chamber as it passes from the vaporizer to the passage. This reduction in cross-sectional area results in an increase in the velocity of an airflow along the airflow path, which in turn can result in a higher propensity for un-vaporized liquid (e.g., that is collected on the baffle) to be carried by the airflow into the passage.

In the present disclosure, this reduction in cross-sectional area of the portion of the airflow path (at least partly defined by the baffle) is (at least partly) mitigated by the provision of the sloped surface. The sloped surface provides a larger airflow path (between the baffle and, e.g., walls of the chamber) whilst maintaining the cross-sectional area of an upstream (vaporizer-facing) surface of the baffle. The larger cross-sectional area reduces velocity of an airflow along the airflow path so as to reduce the tendency for un-vaporized liquid to be carried from the vaporizing chamber to the passage.

The term “upstream” is used to define a direction towards the inlet of the device. The term “downstream” is used to define a direction towards the outlet of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the third mode of the present disclosure.

The sloped surface at least partly defines a portion of the airflow path. The sloped surface extends obliquely from an upstream transverse edge of the baffle towards the longitudinal axis of the passage. The sloped surface is for directing airflow within the airflow path towards the passage, e.g., towards an opening from the vaporizing chamber to the passage, e.g., towards the longitudinal axis of the passage.

The terms “transversely” and “transverse” are used herein to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The sloped surface may be in the form of a chamfered or beveled surface of the baffle. In this respect, the sloped surface may extend from the upstream transverse edge to a downstream transverse edge that is closer to the longitudinal axis than the upstream transverse edge. The sloped surface may be substantially planar, or may be arcuate (i.e., curved). An included angle between the sloped surface and an upstream (i.e., vaporizer-facing) surface of the baffle may be acute. An upstream surface of the baffle (e.g., connected to the sloped surface) may be substantially planar.

In some embodiments a portion of the airflow path at least partly defined by the sloped surface of the baffle may further be at least partly defined by one or more walls of the vaporizing chamber. The sloped surface of the baffle may be (e.g., radially) inwards of the wall(s) of the vaporizing chamber.

The upstream edge of the baffle may at least partly define an aperture through which the airflow path passes. The aperture may be at least partly defined by the wall(s) of the vaporizing chamber. That is, the aperture may be defined between the upstream edge and the wall(s) of the vaporizing chamber. The aperture may be offset transversely (i.e., laterally) from the longitudinal axis of the passage (e.g., may be radially outwards with respect to the passage).

In some embodiments, the airflow path between the vaporizer and the passage, may comprise at least one deflection. For example, a first portion of the airflow path may extend in a generally longitudinal direction from the vaporizer to the aperture. A second portion of the airflow path between the first portion and the passage, may extend generally obliquely (both laterally and longitudinally) and generally parallel to the sloped surface, such that there may be a deflection between the first and second portions. The airflow path may comprise a third portion in the passage extending in a generally longitudinal direction. Thus, the airflow path may deflect from the oblique direction (of the second portion) to a longitudinal direction (of the third portion) at or proximate to an opening to the passage.

The baffle may comprise two sloped surfaces (i.e., each being as described above), the two sloped surfaces being transversely opposed. The two sloped surfaces may have equal and opposite slopes. Where the baffle comprises two sloped surfaces, the baffle may comprise two corresponding upstream edges that at least partly define two corresponding apertures (e.g., between the upstream edges and corresponding wall(s) of the chamber). In this way, the airflow path may be bifurcated so as to comprise two respective branches, each extending through a respective aperture (and between the sloped surfaces and the vaporizing chamber wall(s)).

The baffle extends across (e.g., transversely across) the vaporizing chamber and may be configured (i.e., shaped and positioned) such that there is no direct longitudinal line of sight between the vaporizer and the passage (i.e., an opening to the passage). A transverse width of the baffle may be substantially equal to or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially equal to or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than 30% of a corresponding transverse width of the chamber, or may, e.g., be greater than 40%, or 50% of the transverse width of the chamber.

The device may comprise an inlet substantially transversely aligned with the baffle (i.e., both may be aligned along a common longitudinal axis). The inlet may be substantially transversely aligned with the passage opening (e.g., the inlet may be aligned on the longitudinal axis). The inlet, baffle and passage opening may be aligned along the longitudinal axis.

The vaporizing chamber may comprise opposing parallel side walls that are substantially parallel to the longitudinal axis, and a downstream (e.g., end) wall extending transversely between the side walls. The passage opening may be formed in the downstream wall of the chamber.

The tank may be defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not. The passage may extend longitudinally within the tank and a passage wall may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall. The ribs may extend for the full length of the passage wall. The ribs may project (e.g., radially outwardly) into the tank.

The device may comprise an insert defining the inlet(s). The insert may be inserted into an open end of the tank so as to seal against the tank housing. The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the chamber between wall(s) (e.g., side walls) of the chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the wall(s) of the chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the or each aperture at least partly defined by the baffle (e.g., defined between the upstream edges and wall(s) of the chamber). In this respect, the airflow path may pass around, through or proximate the wick and through the aperture(s). The upstream edge(s) of the baffle may extend across the chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber portion of the airflow path. This vapor may subsequently cool to form an aerosol in the vaporizing chamber.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess or cavity of the main body, such that there is snap engagement between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with the main body. In this way, one end of the device (i.e., the inlet end) may be coupled with the main body, whilst an opposing end (i.e., the outlet end) of the consumable may define a mouthpiece.

The main body may comprise a power source or be connectable to a power source. The power source may be electrically connected (or connectable) to the heater. The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery.

The main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The main body may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e., puff) sensor may be provided (as part of the main body and/or consumable) that is configured to detect a puff (i.e., inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the main body.

The device may be a smoking substitute device (e.g., an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g., an e-cigarette consumable).

In a second aspect of the third mode there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect of the third mode, the consumable being engageable with the main body such that vaporizer of the consumable is connected to the power source of the main body.

The consumable may be an e-cigarette consumable. The main body may be as described above with respect to the first aspect. The main body may, for example, be an e-cigarette device for supplying power to the consumable.

The disclosure includes the combination of the aspects and preferred features of the third mode described except where such a combination is clearly impermissible or expressly avoided.

Fourth Mode: An Aerosol Delivery Device in which an Airflow Path Through a Vaporizing Chamber is a Single, Deflected Path

At its most general, a fourth mode of the present disclosure relates to an aerosol delivery device in which an airflow path through a vaporizing chamber is a single, deflected path through a lateral aperture on a transverse baffle.

In a first aspect of the fourth mode, there is provided an aerosol delivery device having a chamber airflow path through a vaporizing chamber housing a vaporizer, the chamber airflow path being a unitary, deflected path extending through a single lateral aperture on a transverse baffle mounted within the vaporizing chamber downstream of the vaporizer.

The inclusion of a baffle downstream of the vaporizer may help to reduce (or prevent) un-vaporized liquid from the vaporizer passing to the user during smoking of the device. The un-vaporized liquid may collect on an upstream surface of the baffle facing the vaporizer, whilst vapor is able to through the aperture in the baffle towards the user.

Known devices have two laterally opposed apertures on the baffle so that vapor can flow in a bifurcated path through the vaporizing chamber. It has been found that the provision of two lateral apertures can result in collection of liquid within one of the apertures during storage on the device on its side (whilst not being vaped). With two holes, liquid can flow into one (under gravity) whilst air within the device is equalized through the other hole. The collected liquid is then inhaled by the user during commencement of vaping. By providing a baffle having only a single lateral aperture, liquid flow into the aperture during storage (and therefore subsequent liquid inhalation) is reduced as air equalization is only possible through the same, single aperture.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the fourth mode of the present disclosure.

In some embodiments, the aperture is defined by a transverse edge of the baffle. For example, the aperture may be defined by an upstream edge of a transverse baffle mounted downstream from the vaporizer.

The chamber airflow path is partly defined by one or more walls of the vaporizing chamber. For example, the aperture may be defined by the upstream edge of the baffle and a sidewall of the vaporizing chamber facing the upstream edge of the baffle.

The baffle may depend laterally from a sidewall of the vaporizing chamber, i.e., the baffle may extend laterally from the sidewall of the vaporizing chamber that does not define the aperture. Thus, the vaporizing chamber may comprise a first sidewall which (along with the baffle) defines the aperture (and chamber airflow path) and a laterally opposing second sidewall from which the baffle depends.

In some embodiments, the chamber airflow path has a portion extending from the aperture to a downstream edge of the transverse baffle. In some embodiments, the portion of the chamber airflow path extending from the aperture to the downstream edge of the transverse baffle has a constant transverse cross-sectional area. Where there is a constant transverse cross-sectional area between the aperture and the downstream edge of the baffle, the transverse width of the aperture (i.e., the transverse spacing between the upstream edge of the baffle and the first sidewall of the vaporizing chamber) equals the transverse spacing between the downstream edge of the baffle and the first sidewall of the vaporizing chamber.

The aperture (and the upstream/downstream edges of the baffle) is/are offset transversely (i.e., laterally) from the longitudinal axis of the passage (e.g., may be radially outwards of the passage opening).

In some embodiments, the chamber airflow path may comprise at least one deflection. The chamber airflow path may comprise a single, undivided chamber airflow path having at least one lateral deflection (e.g., two lateral deflections) between a generally longitudinal portion and a generally radial portion. The chamber airflow path may further comprise at least one axial deflection (e.g., two axial deflections) between a generally radial portion and generally longitudinal portion.

For example, a first portion of the chamber airflow path may extend in a generally longitudinal direction to the vaporizer (e.g., from the inlet(s)) and may be aligned with the axial center of the device. A second portion of the chamber airflow path may then extend generally radially from the vaporizer to the aperture. Thus, there is a first lateral deflection in the chamber airflow path as it passes from the vaporizer to the aperture.

A third portion of the chamber airflow path from the aperture (i.e., the upstream edge of the baffle) to the downstream edge of the baffle may be generally longitudinal and is laterally offset from the axial center of the device. Thus, there is a first axial deflection between the second and third portions of the chamber air flow path.

A fourth portion of the chamber airflow path between the third portion and the passage, may extend generally radially (laterally), e.g., generally parallel to a planar upper surface of the baffle, such that there is a second lateral deflection between the third and fourth portions of the chamber airflow path.

The chamber airflow path may then comprise a second axial deflection from the lateral direction (of the fourth portion) to a longitudinal direction as it leaves the vaporizing chamber at the passage opening.

The baffle may be configured (i.e., shaped and positioned) such that there is no direct longitudinal line of sight between the vaporizer and the passage. A transverse width of the baffle may be substantially the same or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially the same or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than 30% of a corresponding transverse width of the vaporizing chamber, or may, e.g., be greater than 40%, or 50%.

The passage opening (i.e., the opening from the vaporizing chamber into the passage) may have a transverse cross-sectional area of more than 5 mm2. The passage opening may have a transverse cross-sectional area of no more than 10 mm2. The passage opening may have an internal diameter of more than 2.5 mm. The passage opening may have an internal diameter of no more than 4 mm. The transverse cross-sectional area of the aperture may be less than the cross-sectional area of the passage opening.

The vaporizing chamber may comprise opposing first and second parallel sidewalls that are substantially parallel to the longitudinal axis, and a downstream (e.g., end) wall extending transversely between the sidewalls. The passage opening may be formed in the downstream end wall of the vaporizing chamber.

The device may comprise an insert defining the device inlet(s). The insert may be inserted into an open end of the tank so as to seal against the tank housing (e.g., an inside surface of the tank housing). The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the vaporizing chamber between wall(s) (e.g., between the first and second sidewalls) of the vaporizing chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the sidewalls of the vaporizing chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the aperture at least partly defined by the baffle (e.g., defined between the upstream edge and first sidewall of the vaporizing chamber). In this respect, the chamber airflow path may pass around, through or proximal the wick and through the aperture. The upstream edge (and downstream edge of the baffle) may extend across the vaporizing chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The device may be a smoking substitute device (e.g., an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g., an e-cigarette consumable).

In a second aspect of the fourth mode there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect of the fourth mode, the consumable being engageable with the main body such that vaporizer of the consumable is connected to the power source of the main body.

The disclosure includes the combination of the aspects and preferred features of the fourth mode described except where such a combination is clearly impermissible or expressly avoided.

Fifth Mode: An Aerosol Delivery Device with an Airflow Path Circumventing a Vaporizer

At its most general, a fifth mode of the present disclosure relates to an aerosol delivery device in which an airflow path through the aerosol delivery device circumvents a vaporizer.

According to a first aspect of the fifth mode, there is provided an aerosol delivery device for a smoking substitute system, the aerosol delivery device comprising a device airflow path extending from at least one inlet of the device to an outlet of the device, and a vaporizer for vaporizing a vaporizable liquid, wherein the device airflow path circumvents the vaporizer.

In this way, the device airflow path does not pass through the vaporizer. Therefore, the possibility of un-vaporized liquid from the vaporizer being entrained in the airflow, and thus through the outlet of the device and into the mouth of a user, is reduced or eliminated.

The terms “transversely” and “transverse” are used herein in relation to components of the device to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The device has an upper end comprising the outlet and a lower end comprising the at least one inlet. The device has a longitudinal axis which extends between the upper and lower ends. The term “downstream” used herein is intended to refer to a longitudinal direction of the device towards the outlet. The term “upstream” used herein is intended to refer to a longitudinal direction of the device away from the outlet.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the fifth mode of the present disclosure.

The device airflow path may comprise at least one inlet airflow path extending within a respective inlet channel from the at least one inlet to a respective channel opening downstream of the vaporizer such that the chamber airflow path circumvents the vaporizer.

The vaporizer may be disposed within a vaporizing chamber. In these embodiments, the device airflow path comprises at least one inlet airflow path extending from the at least one inlet within a respective inlet channel to the vaporizing chamber, and at least one chamber airflow path extending from the channel through the chamber. As the airflow passes through the vaporizing chamber, vaporized liquid in the vaporizing chamber (which has been vaporized by the vaporizer) may be entrained in the airflow within the chamber airflow path for delivery to the outlet of the device, and therefore to the user.

The or each inlet may be provided on the lowermost surface of the device, e.g., on the lowermost surface of a base portion of the device provided at the lower end of the device.

The or each inlet channel (and the or each inlet airflow path) may extend (e.g., in a generally longitudinal direction) through the base portion of the aerosol delivery device. The or each inlet channel may extend from the respective inlet of the device to a respective inlet channel opening within the vaporizing chamber. Thus, the/each inlet airflow path extends from the respective inlet of the device, through the base portion and through the inlet channel opening into the vaporizing chamber.

In some embodiments, the or each inlet channel opening (and the or each inlet on the lowermost surface of the device/base portion) is offset from the central longitudinal axis of the aerosol delivery device, e.g., off-set in the front to rear direction of the device (which is perpendicular to both the transverse and longitudinal direction).

Where there are two inlet airflow paths, the inlet channel openings (and each inlet on the lowermost surface of the device) may be spaced from each other in the front to rear direction of the device. They may be equally spaced from the central longitudinal axis of the aerosol delivery device on either side of the central longitudinal axis in a front to rear direction. They may be (transversely) aligned with each other in the front to rear direction of the device.

The/each inlet channel opening may be offset from the vaporizer within the vaporizing chamber in the front to rear direction of the device. The/each inlet channel opening may be offset from the vaporizer within the vaporizing chamber in the longitudinal direction of the device. The opening of the/each inlet channel in the vaporizing chamber may be axially downstream of the vaporizer (i.e., closer to the outlet of the device).

In this way, airflow in the inlet airflow path may enter the vaporizing chamber downstream of the vaporizer, which may further help to reduce the amount of un-vaporized liquid entrained in the chamber airflow path towards the outlet of the device.

The vaporizer may be transversely elongated, e.g., it may comprise a transversely elongated wick and a heating element. The vaporizer may be positioned so that it overlies the axial center of the base portion (e.g., it extends transversely to intersect the longitudinal axis of the device).

The opening(s) of the or each inlet channel may be elongated in the transverse direction such that it/they extend substantially parallel to the vaporizer (i.e., the wick of the vaporizer). Accordingly, the or each inlet channel may have a transversely elongated (e.g., substantially rectangular) transverse cross-sectional profile. The cross-sectional profile/area of the inlet channel may be substantially uniform between the respective inlet and channel opening. In this way, the airflow within the inlet channel is substantially laminar.

The lowermost (upstream) surface of the base portion may have a generally rectangular profile with opposing transverse edges spaced by opposing front and rear edges (where the front to rear direction of the device extends perpendicular to both the longitudinal and transverse directions).

The or each inlet on the lowermost surface of the base portion may be elongated in the transverse direction such that it/they extend parallel to the front and rear edges of the lowermost surface of the base portion.

The aerosol delivery device may comprise a tank (reservoir) for containing the vaporizable liquid (e.g., an e-liquid) with the vaporizer being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The base portion may be a base insert defining the inlet(s). The base insert may be inserted into an open lower end of the tank so as to seal against an inside surface of the tank housing. The base insert may comprise an inner, longitudinally-extending sleeve that defines wall(s) of the vaporizing chamber. The base insert may be configured to support the vaporizer within the vaporizing chamber. The base insert may define the inlet channels. The base insert may be formed of silicone.

The vaporizing chamber may comprise opposing parallel side walls that are substantially parallel to the longitudinal axis of the device and are spaced by front and rear walls of the chamber, and a downstream wall extending transversely between the side walls (and front to rear between the front and rear walls). The walls of the vaporizing chamber (e.g., the front and rear walls) may have at least one step formed therein, such that a portion of each (front/rear) wall is substantially perpendicular to the longitudinal axis of the device. The step(s) may be provided downstream of the vaporizer within the vaporizing chamber. The opening of the/each inlet channel may be formed in the step(s) of the wall(s) of the vaporizing chamber (i.e., the opening of the/each inlet channel may be formed in the step portion of the wall perpendicular to the longitudinal axis of the device).

The aerosol delivery device may comprise a passage extending to the outlet of the device, e.g., at a mouthpiece of the aerosol delivery device. The passage may extend from a passage opening in the vaporizing chamber to the outlet. In this respect, a user may draw fluid (e.g., air) from the inlet, through the inlet channel(s) and through the vaporizing chamber into the passage opening and through the passage by inhaling at the outlet (i.e., using the mouthpiece).

The passage may comprise passage walls extending within the tank such that the tank may surround the passage. The passage opening may be formed in the downstream wall of the vaporizing chamber. The inner sleeve of the base insert may seal against the passage walls.

The wick may comprise a porous material. The wick may be elongate and extend transversely across the vaporizing chamber between wall(s) (e.g., side walls) of the vaporizing chamber. The wick may also comprise one or more portions in contact with liquid stored in the tank. For example, opposing transverse ends of the wick may protrude into the tank and a central portion (between the ends) may extend across the vaporizing chamber. Thus, fluid may be drawn (e.g., by capillary action) along the wick, from the reservoir to the central portion of the wick.

The filament may be wound about the central portion of the wick. In operation, the power source may supply electricity to (i.e., apply a voltage across) the filament so as to heat the filament. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the device airflow path. This vapor may subsequently cool to form an aerosol in the passage.

The aerosol delivery device may be in the form of a consumable.

In a second aspect of the fifth mode, there is provided a smoking substitute system comprising: the aerosol delivery device of the first aspect of the fifth mode; and a main body comprising a power source, wherein the power source supplies power to the vaporizer.

The consumable may be configured for engagement with the main body (i.e., so as to form a closed smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g., power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g., vaporizable e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is an interference fit (e.g., snap engagement) between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the aerosol delivery device may comprise one or more engagement portions for engaging with a main body. In this way, the lower end of the aerosol delivery device (e.g., the base portion) may be coupled with the main body, whilst the upper end of the aerosol delivery device may define a mouthpiece of the smoking substitute system.

The power source may be electrically connected (or connectable) to the vaporizer of the aerosol delivery device when engaged with the main body. The power source may be a battery (e.g., a rechargeable battery). A connector in the form of, e.g., a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. A pair of contact pins may comprise the electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Specifically, downstream ends of the contact pins may provide the electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to the heating element of the consumable. The electrical interface may also be used to identify the aerosol delivery device from a list of known types. For example, the consumable may have a certain concentration of nicotine and the electrical interface may be used to identify this. The electrical interface may additionally or alternatively be used to identify when a consumable is connected to the main body.

The main body may comprise an interface, which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of a consumable engaged with the main body. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The aerosol delivery device or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the vaporizer of the aerosol delivery device (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The main body or aerosol delivery device may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

A puff sensor (i.e., airflow sensor) may be provided that is configured to detect a puff (i.e., inhalation from a user). The puff sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. That is, the controller may control power supply to the heater of the consumable in response to a puff detection by the sensor. The control may be in the form of activation of the vaporizer in response to a detected puff. That is, the aerosol delivery device may be configured to be activated when a puff is detected by the puff sensor. The puff sensor may form part of the consumable or the main body.

The disclosure includes the combination of the aspects and preferred features of the fifth mode described except where such a combination is clearly impermissible or expressly avoided.

Sixth Mode: A Smoking Substitute Device Having an Air Inlet

At its most general, a sixth mode of the present disclosure relates to a smoking substitute device having an air inlet arranged to provide a substantially linear/direct airflow path to a vaporizer for use with the device.

In a first aspect of the sixth mode there is provided a smoking substitute device comprising: a body accommodating a power source; one or more side walls projecting longitudinally from an end surface of the body, such that the end surface and the one or more side walls define a cavity for receipt of a vaporizable liquid reservoir and a vaporizer to vaporize the vaporizable liquid; and an air inlet aperture formed in the one or more side walls, the aperture arranged so as to direct air that is external to the device into the cavity in a substantially transverse direction across the end surface.

The provision of an air inlet that directs air transversely across the end surface provides a direct airflow path to the vaporizer. By providing a direct airflow path, as opposed to an airflow path that involves multiple turns/deflections, the pressure drop along the airflow path may be reduced. Similarly, turbulence in the air flow, which can be caused by turns/deflections in the airflow path, may be reduced by providing a more direct airflow. This may result in a reduction in the suction required by a user to draw air into the device and through the vaporizer.

The terms “transversely” and “transverse” are used herein to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the sixth mode of the present disclosure.

The end surface of the body (i.e., defining a base of the cavity) extends substantially transversely between the side wall(s). The aperture may be positioned so as to be proximate the end surface. For example, the aperture may be spaced from the end surface by a longitudinal distance that is less than 6 mm. The aperture the aperture may be spaced from the end surface by a longitudinal distance that is less than 4 mm, or less than 2 mm. An edge of the aperture may be longitudinally aligned with the end surface (i.e., there may be no longitudinal spacing between the aperture and the end surface).

The aperture may be circular, and may have a diameter of less than, e.g., 2 mm. The aperture may alternatively be in the form of a slot. The slot may extend longitudinally or may be perpendicular to the longitudinal axis. The aperture (or slot) may have a cross-sectional area that is less than 10 mm²or less than 8 mm², or, e.g., less than 5 mm².

The one or more side walls may comprise opposing front and rear walls (or wall portions) and opposing lateral walls (or wall portions) extending between the front and rear walls. The distance between the lateral walls may be greater than the distance between the front and rear walls. The distance between the lateral walls may be, e.g., greater than twice the distance between the front and rear walls.

The aperture may be formed in any one of the front, rear, or lateral walls. The device may comprise two opposing apertures (i.e., each being as described above). For example, each of the lateral walls may comprise an aperture, or each of the front and rear walls may comprise an aperture.

The device may form part of an open smoking substitute system or a closed smoking substitute system. Where the device forms part of a closed smoking substitute system, the device may be configured for engagement (i.e., physical and electrical engagement) with a smoking substitute consumable. In such embodiments, a consumable may be received in the cavity. In that respect the side wall(s) may comprise an engagement portion for engaging a consumable. The engagement portion may be in the form of, e.g., an inwardly extending detent or protrusion for engaging with a recess, lip, aperture, edge, etc. of a consumable.

The device may comprise an electrical interface for electrically interfacing with a consumable received in the cavity. The electrical interface may be electrically connected to the power source, so as to provide power from the power source to the consumable when interfaced therewith. The electrical interface may comprise two (e.g., transversely spaced) electrical contacts projecting longitudinally into the cavity from the end surface of the body (i.e., from the base of the cavity). The electrical contact(s) may project from or through a central portion of the end surface.

In a second aspect of the sixth mode there is disclosed a smoking substitute system comprising: a device according to the first aspect of the sixth mode; a tank for storing vaporizable liquid; a vaporizer for vaporizing the vaporizable liquid, the vaporizer mounted in a vaporizing chamber; and an airflow path extending substantially transversely from the air inlet aperture to an inlet of the vaporizing chamber.

It should be appreciated that the term “substantially transverse” does not require the airflow path to extend exactly transversely. For example, the airflow path may be inclined by a small angle from a transverse axis (e.g., less than 25 degrees, or, e.g., less than 15 degrees, or, e.g., less than 5 degrees). Similarly, a small portion of the airflow path may not be transverse (e.g., less than 10% of the length of the airflow path, or, e.g., less than 5% of the length of the airflow path). In some embodiments, the airflow path may extend transversely (e.g., precisely transversely).

The air flow path may extend between the vaporizer (and/or the vaporizer chamber) and the end surface of the device. The air flow path may extend between the tank and the end surface of the device.

The air inlet aperture may be substantially longitudinally aligned (i.e., share a common transverse reference plane) with the vaporizing chamber, vaporizer and/or the vaporizing chamber inlet, when the consumable is received in the cavity. The aperture may be substantially longitudinally aligned with an upstream end of the consumable when the consumable is received in the cavity.

The vaporizing chamber inlet may be oriented so as to be parallel to a transverse reference plane (i.e., so as to be perpendicular to the air inlet aperture). The vaporizing chamber inlet may, for example, be formed in an upstream (e.g., lower transverse) wall of the vaporizing chamber. In such embodiments, airflow from the transverse airflow path may be redirected at the inlet to a longitudinal direction. Only a single redirection (i.e., turn/deflection) of the airflow may be required between the air inlet aperture and the vaporizer). The term “upstream” is used to define a direction away from the outlet of the device. The term “downstream” is used to define a direction towards the outlet of the device.

In other embodiments, the vaporizing chamber inlet may be oriented so as to be parallel to a longitudinal reference plane (i.e., so as to be parallel to the air inlet aperture). In such embodiments, the vaporizing chamber inlet may, for example, be formed in a lateral wall (extending longitudinally between upstream and downstream walls) of the vaporizing chamber.

The vaporizing chamber may comprise a single (e.g., centrally located inlet), or a plurality of (e.g., two) inlets. Where the vaporizing chamber comprises a plurality of inlets, the airflow path may extend to all of the vaporizing chamber inlets (e.g., the airflow path may comprise branches or may comprise a plenum space).

The system may comprise a passage that extends from the vaporizing chamber to an outlet of the device. An opening to the passage may be formed in a downstream transverse wall of the chamber.

A baffle may be interposed between the vaporizer and the passage. The baffle may extend generally transversely in the vaporizing chamber and may be arranged such that un-vaporized liquid collects on an upstream (e.g., planar) surface of the baffle. The baffle may be aligned with the passage opening (from the vaporizing chamber).

The outlet may form part of a mouthpiece of the device. The mouthpiece may be integrally formed with the passage (i.e., the one or more walls of the passage). The mouthpiece may define an outer surface of the device that is received in a user's mouth in use.

The vaporizer is in fluid communication with the tank so as to be in fluid communication with vaporizable liquid (e.g., e-liquid) in the tank. The e-liquid may, for example, may comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. The tank housing may be integrally formed with the mouthpiece and/or the passage. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The passage may extend longitudinally within the tank and the one or more passage walls may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall(s) may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall(s). The ribs may extend for the full length of the passage wall(s). The ribs may project (e.g., radially outwardly) into the tank.

The system may comprise an insert, which may define the vaporizing chamber inlet. The insert may be inserted into an open end of the tank so as to seal against the tank housing. The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall(s)). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to the power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber portion of the airflow path. This vapor may subsequently cool to form an aerosol in the passage or vaporizing chamber.

As is discussed above with respect to the first aspect of the sixth mode, the system may be an open smoking substitute system or a closed smoking substitute system. Where the system is an open smoking substitute system the tank may be refillable, and the tank and vaporizer may be permanently mounted in the cavity defined by the side walls.

On the other hand, when the system is a closed smoking substitute system, the system may comprise a consumable. The consumable may include the tank, vaporizing chamber (and vaporizer) and, e.g., the passage. The consumable may be configured for engagement with the device (i.e., so as to form the smoking substitute system). For example, the consumable may comprise disposable components of the system, whilst the device may comprise non-disposable or non-consumable components (e.g., the power supply, a controller, a sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the vaporizable liquid may be replenished by replacing a used consumable with an unused consumable.

As is discussed above with respect to the first aspect of the sixth mode, the device and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partly received in the cavity defined by the side wall(s) of the device, such that there is snap engagement between the device and the consumable. Alternatively, the device and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with the device. In this way, one end of the consumable (i.e., an upstream end comprising the vaporizing chamber inlet) may be coupled with the device, whilst an opposing end (i.e., an outlet end) of the consumable may define the mouthpiece.

The airflow path (extending substantially transversely from the air inlet aperture) may extend between the consumable and the device when the consumable is received in the cavity. That is, the airflow path may extend between (and be defined by) the upstream (inlet) end (e.g., defined by the insert) of the consumable and the end surface of the body.

The end surface and/or the upstream end (e.g., underside) of the consumable may comprise guide portions that at least partly define the airflow path so as to guide airflow from the air inlet to the vaporizing chamber inlet. The end surface and/or upstream end of the consumable may comprise a channel for directing air across the end surface. The device or the consumable may comprise spacer portions for spacing the upstream end (and/or inlet) of the consumable from the end surface of the body when the consumable is received in the cavity. The spacer portion may, e.g., be a lip or seat (e.g., extending inwardly from the one or more side walls) on which the consumable is supported above the end surface.

The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery. The consumable may comprise an electrical interface for interfacing with the electrical interface of the device. The electrical interface of the consumable may include one or more electrical contacts. Thus, when the device is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to the heater of the consumable. The electrical interface (of the device and/or consumable) may also be used to identify the consumable from a list of known types. The electrical interface (of the device and/or consumable) may additionally or alternatively be used to identify when the consumable is connected to the device.

The device may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This (information) interface may be able to identify a characteristic (e.g., a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the information interface.

The device may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The device may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

The device may be an e-cigarette device and the consumable may be an e-cigarette consumable.

The disclosure includes the combination of the aspects and preferred features of the sixth mode described except where such a combination is clearly impermissible or expressly avoided.

SUMMARY OF THE FIGURES

So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1A is a side view of a smoking substitute device of the first mode.

FIG. 1B is a side view of main body of the smoking substitute device of the first mode.

FIG. 1B is a side view of consumable of the smoking substitute device of the first mode.

FIG. 2A is a schematic drawing of the main body of the first mode.

FIG. 2B is a schematic drawing of the consumable of the first mode.

FIG. 3 is a cross-sectional view of the consumable of the first mode.

FIG. 4 is a cross-sectional view of a manufacturing assembly of the first mode.

FIG. 5A is a cross-sectional view of a portion of a second consumable of the first mode.

FIG. 5B is a bottom view of the portion of the second consumable of the first mode.

FIG. 6A is a vertical sectional view of a portion of a third consumable of the first mode.

FIG. 6B is a horizontal sectional view of a portion of the third consumable of the first mode.

FIG. 7A is a front schematic view of a smoking substitute system of the second mode.

FIG. 7B is a front schematic view of a main body of the system of the second mode.

FIG. 7C is a front schematic view of a consumable of the system of the second mode.

FIG. 8A is a schematic of the components of the main body of the second mode.

FIG. 8B is a schematic of the components of the consumable of the second mode.

FIG. 9A is a section view of the consumable of the second mode.

FIG. 9B is a detailed section view of a vaporizing chamber of the consumable of the second mode.

FIG. 10 is a section view of a manufacturing assembly for manufacturing the consumable of the second mode.

FIG. 11A is a front schematic view of a smoking substitute system of the third mode.

FIG. 11B is a front schematic view of a main body of the system of the third mode.

FIG. 11C is a front schematic view of a consumable of the system of the third mode.

FIG. 12A is a schematic of the components of the main body of the third mode.

FIG. 12B is a schematic of the components of the consumable of the third mode.

FIG. 13A is a section view of the consumable of the third mode.

FIG. 13B is a detailed section view of a vaporizing chamber of the consumable of the third mode.

FIG. 14 is a section view of a manufacturing assembly for manufacturing the consumable of the third mode.

FIG. 15A is a front schematic view of a smoking substitute system of the fourth mode.

FIG. 15B is a front schematic view of a main body of the system of the fourth mode.

FIG. 15C is a front schematic view of a consumable of the system of the fourth mode.

FIG. 16A is a schematic of the components of the main body of the fourth mode.

FIG. 16B is a schematic of the components of the consumable of the fourth mode.

FIG. 17A is a section view of the consumable of the fourth mode.

FIG. 17B and FIG. 17C are detailed section views of a vaporizing chamber of the consumable of the fourth mode.

FIG. 18 is a section view of a manufacturing assembly for manufacturing the consumable of the fourth mode.

FIG. 19A is a front schematic view of a smoking substitute system of the fifth mode.

FIG. 19B is a front schematic view of a main body of the system of the fifth mode.

FIG. 19C is a front schematic view of a consumable of the system of the fifth mode.

FIG. 20A is a schematic of the components of the main body of the fifth mode.

FIG. 20B is a schematic of the components of the consumable of the fifth mode.

FIG. 21 is a section view of the consumable of the fifth mode.

FIG. 22A is a perspective view of a base insert of the consumable of the fifth mode.

FIG. 22B is an alternative perspective view of the base insert of FIG. 22A.

FIG. 22C is a section view of the base insert of FIG. 22A.

FIG. 23A is a front schematic view of a smoking substitute system of the sixth mode.

FIG. 23B is a front schematic view of a device of the system of the sixth mode.

FIG. 23C is a front schematic view of a consumable of the system of the sixth mode.

FIG. 24A is a schematic of the components of the device of the sixth mode.

FIG. 24B is a schematic of the components of the consumable of the sixth mode.

FIG. 25A is a schematic section view of the device of the sixth mode.

FIG. 25B is a section view of the consumable engaged with the device of the sixth mode.

FIG. 26 is a section view of a manufacturing assembly for manufacturing the consumable of the sixth mode.

DETAILED DESCRIPTION OF THE FIGURES

First Mode: An Aerosol Delivery Device in which a Turbulence Inducing Element is Configured to Turn Flow Towards a Circumferential Direction

Aspects and embodiments of the first mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 1A shows an aerosol delivery device, which is a smoking substitute device 110. In this example, the smoking substitute device 110 includes a main body 120 and a consumable 150. The consumable 150 may alternatively be referred to as a “pod”. The consumable may also be referred to as a cartridge or cartomizer. In other examples, the term “aerosol delivery device” may apply to the consumable 150 alone rather than the smoking substitute device 110.

In this example, the smoking substitute device 110 is a closed system vaping device, wherein the consumable 150 includes a liquid reservoir or sealed tank 156 and is intended for one-use only.

FIG. 1A shows the smoking substitute device 110 with the main body 120 physically coupled to the consumable 150.

FIG. 1B shows the main body 120 of the smoking substitute device 110 without the consumable 150.

FIG. 1C shows the consumable 150 of the smoking substitute device 110 without the main body 120.

The main body 120 and the consumable 150 are configured to be physically coupled together, in this example by pushing the consumable 150 into an aperture in a top end 122 of the main body 120, such that there is an interference fit between the main body 120 and the consumable 150. In other examples, the main body 120 and the consumable could be physically coupled together by screwing one onto the other, or through a bayonet fitting, for example. An optional light 126, e.g., an LED, located behind a small translucent cover, is located a bottom end 124 of the main body 120. The optional light 126 may be configured to illuminate when the smoking substitute device 110 is activated.

The consumable 150 includes a mouthpiece (not shown in FIG. 1A-1C) at a top end 152 of the consumable 150, as well as one or more air inlets (not shown) so that air can be drawn into the smoking substitute device 110 when a user inhales through the mouthpiece. At a bottom end 154 of the consumable 150, there is located a tank 156 that contains e-liquid. The tank 156 may be a translucent body, for example.

The tank 156 preferably includes a window 158, so that the amount of e-liquid in the tank 156 can be visually assessed. The main body 120 includes a slot 128 so that the window 158 of the consumable 150 can be seen whilst the rest of the tank 156 is obscured from view when the consumable 150 is inserted into the aperture in the top end 122 of the main body 120.

The tank 156 may be referred to as a “clearomizer” if it includes a window 158, or a “cartomizer” if it does not.

The consumable 150 may identify itself to the main body 120, via an electrical interface, RFID chip, or barcode.

FIG. 2A is a schematic drawing of the main body 120 of the smoking substitute device 110.

FIG. 2B is a schematic drawing of the consumable 150 of the smoking substitute device 110.

As shown in FIG. 2A, the main body 120 includes a power source 118, a control unit 130, a memory 132, a wireless interface 134, an electrical interface 136, and, optionally, one or more additional components 138.

The power source 118 is preferably a battery, more preferably a rechargeable battery.

The control unit 130 may include a microprocessor, for example.

The memory 132 is preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the control unit 130 to perform certain tasks or steps of a method.

The wireless interface 134 is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 134 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 134 may also be configured to communicate wirelessly with a remote server.

The electrical interface 136 of the main body 120 may include one or more electrical contacts. The electrical interface 136 may be located in, and preferably at the bottom of, the aperture in the top end 122 of the main body 120. When the main body 120 is physically coupled to the consumable 150, the electrical interface 136 may be configured to pass electrical power from the power source 118 to (e.g., a heating device of) the consumable 150 when the smoking substitute device 110 is activated, e.g., via the electrical interface 160 of the consumable 150 (discussed below). The electrical interface may be configured to receive power from a charging station, when the main body 120 is not physically coupled to the consumable 150 and is instead coupled to the charging station. The electrical interface 136 may also be used to identify the consumable 150 from a list of known consumables. For example, the consumable may be a particular flavor and/or have a certain concentration of nicotine. This can be identified to the control unit 130 of the main body 120 when the consumable is connected to the main body. Additionally, or alternatively, there may be a separate communication interface provided in the main body 120 and a corresponding communication interface in the consumable 150 such that, when connected, the consumable can identify itself to the main body 120.

The additional components 138 of the main body 120 may comprise the optional light 126 discussed above.

The additional components 138 of the main body 120 may, if the power source 118 is a rechargeable battery, comprise a charging port configured to receive power from the charging station. This may be located at the bottom end 124 of the main body 120. Alternatively, the electrical interface 136 discussed above is configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 138 of the main body 120 may, if the power source 118 is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 138 of the main body 120 may include an airflow sensor for detecting airflow in the smoking substitute device 110, e.g., caused by a user inhaling through a mouthpiece 166 (discussed below) of the smoking substitute device 110. The smoking substitute device 110 may be configured to be activated when airflow is detected by the airflow sensor. This optional sensor could alternatively be included in the consumable 150 (though this is less preferred where the consumable 150 is intended to be disposed of after use, as in this example). The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 138 of the main body 120 may include an actuator, e.g., a button. The smoking substitute device 110 may be configured to be activated when the actuator is actuated. This provides an alternative to the airflow sensor noted, as a mechanism for activating the smoking substitute device 110.

As shown in FIG. 2B, the consumable 150 includes the tank 156, an electrical interface 160, a heating device 162, one or more air inlets 164, a mouthpiece 166, and, optionally, one or more additional components 168. The consumable 150 includes a heater chamber 170, which contains the heating device 162.

The electrical interface 160 of the consumable 150 may include one or more electrical contacts. The electrical interface 136 of the main body 120 and an electrical interface 160 of the consumable 150 are preferably configured to contact each other and thereby electrically couple the main body 120 to the consumable 150 when the bottom end 154 of the consumable 150 is inserted into the top end 122 of the main body 120 (as shown in FIG. 1A) to physically coupled the consumable 150 to the main body 120. In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 in the main body 120 to the heating device 162 in the consumable 150.

The heating device 162 is preferably configured to heat e-liquid contained in the tank 156, e.g., using electrical energy supplied from the power source 118, in order to vaporize the e-liquid. In one example, the heating device 162 includes a heating filament and a wick, wherein a first portion of the wick extends into the tank 156 in order to draw e-liquid out from the tank 156, and wherein the heating filament coils around a second portion of the wick located outside the tank 156. In this example, the heating filament is configured to heat up e-liquid drawn out of the tank 156 by the wick to produce an aerosol vapor.

The one or more air inlets 164 are preferably configured to allow air to be drawn into the smoking substitute device 110, when a user inhales through the mouthpiece 166. When the consumable 150 is physically coupled to the main body 120, the air inlet 164 receives air which flows from the top end 122 of the main body 120, between the main body 120 and the bottom end 154 of the consumable 150.

In use, a user activates the smoking substitute device 110, e.g., through actuating an actuator included in the main body 120 or by inhaling through the mouthpiece 166 as described above. Upon activation, the control unit 130 may supply electrical energy from the power source 118 to the heating device 162 (via electrical interfaces 136, 160), which may cause the heating device 162 to heat e-liquid drawn from the tank 156 to produce a vapor which is inhaled by a user through the mouthpiece 166.

As an example of one of the one or more additional components 168, an interface for obtaining an identifier of the consumable may be provided. As discussed above, this interface may be, for example, an RFID reader, a barcode or QR code reader, or an electronic interface which is able to identify the consumable to the main body. The consumable may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body.

Of course, a skilled reader would readily appreciate that the smoking substitute device 110 shown in FIG. 1 and FIG. 2 shows just one example implementation of a smoking substitute device, and that other forms of smoking substitute device could be used.

As another example, an entirely disposable (one use) smoking substitute device could be used as the smoking substitute device.

FIG. 3 shows a cross-sectional view of a consumable 150. The consumable comprises a tank 156 for storing e-liquid, a mouthpiece 166 and an outlet tube 306, which in this example is a chimney or tube. The tank 156 surrounds the outlet tube 306, with the outlet tube extending through a central portion of the tank 156. The outlet tube 306 has a substantially circular cross-section.

The tank 156 is provided by an outer casing of the consumable 150. The outer casing of the consumable 150 comprises a tank wall 304. The tank wall 304 extends completely around the outlet tube 306 to define the tank 156 in the form of an annulus between the outlet tube 306 and the tank wall 304. The tank wall 304 extends from the bottom of the consumable up to the mouthpiece 166. Where the tank wall 304 meets the mouthpiece 166, the mouthpiece 166 has a larger outer width than the tank 156, which means that there is a lip 168 around the bottom of the mouthpiece 166.

The tank wall 304 tapers, which means that it has a thickness which decreases. The thickness of the tank wall 304 decreases along a first demolding direction, as defined below with respect to FIG. 4. The first demolding direction is a downward direction in FIG. 3, which is a direction away from the mouthpiece 166. This means that, aside from a small number of indents (for example, to provide physical connection between the consumable 150 and the main body 120), the thickness of the tank wall 304 generally decreases with increasing distance along the first demolding direction.

The thickness of the tank wall 304 decreases due to internal surfaces of the tank wall 304 being angled to the first demolding direction at a first tank draft angle. Additionally, the thickness of the tank wall 304 decreases due to external surfaces of the tank wall 304 being angled to the first demolding direction at a second tank draft angle.

The first tank draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

The second tank draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

The first tank draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

The second tank draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

It will be appreciated that the first tank draft angle and the second tank draft angle need not be the same as each other, and may be selected independently according to the above draft angles. In fact, one of the first tank draft angle and the second tank draft angle may be substantially 0 degrees, while the other may vary as described above.

Similarly, the outlet tube 306 comprises an outlet wall 307. The outlet wall 307 extends fully around the circular cross-section of the outlet tube 306 to provide the outlet tube 306. The outlet wall 307 tapers, which means that it has a thickness which decreases. The thickness of the outlet wall 307 decreases along the first demolding direction, as defined below with respect to FIG. 4. As before, the first demolding direction is a downward direction in FIG. 3, which is a direction away from the mouthpiece 166. This means that the thickness of the outlet wall 307 generally decreases along the first demolding direction. The thickness of the outlet wall 307 decreases due to an inner surface of the outlet wall 307 being angled to the first demolding direction at a first outlet draft angle. Additionally, the thickness of the outlet wall 307 decreases due to an external surface of the outlet wall 307 being angled to the first demolding direction at a second outlet draft angle.

The first outlet draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

The second outlet draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0, preferably at least 3.5.

The first outlet draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

The second outlet draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

It will be appreciated that the first outlet draft angle and the second outlet draft angle need not be the same as each other, and may be selected independently according to the above draft angles. In fact, one of the first outlet draft angle and the second outlet draft angle may be substantially 0 degrees, while the other may vary as described above.

Similarly, the outlet draft angles and tank draft angles may be selected independently from each other according to the above draft angles.

The outlet tube 306 has an internal width (i.e., a width/diameter of a passage through the outlet tube 306) which generally decreases in a downstream direction (i.e., downstream with respect to the fluid flow when a user inhales, which is an upward direction in FIG. 3). The downstream direction is a direction towards the mouthpiece 166 and, in this example, is an opposite direction to the first demolding direction. This decrease in width occurs due to the second outlet draft angle described above.

A difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.10 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.12 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.14 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.16 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.18 mm.

The difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.30 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.28 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.26 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.24 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.22 mm.

More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is substantially 0.20 mm. The outlet tube 306 is substantially 30 mm long. In other examples, the outlet tube 306 may have a length less than 30 mm.

The airway has an internal width less than 5.0 mm at an upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.5 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.2 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.8 mm at the upstream end of the outlet tube 306.

The airway has an internal width greater than 2.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.5 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.2 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.4 mm at the upstream end of the outlet tube 306.

More specifically, the airway has an internal width of substantially 3.6 mm at the upstream end of the outlet tube 306.

The airway has an internal width less than 4.8 mm at a downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.3 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.0 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.6 mm at the downstream end of the outlet tube 306.

The airway has an internal width greater than 1.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.3 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.0 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.2 mm at the downstream end of the outlet tube 306.

More specifically, the airway has an internal width of substantially 3.4 mm at a downstream end of the outlet tube 306.

The mouthpiece 166 comprises a mouthpiece aperture 314. The outlet tube 306 fluidly connects the heating device 162 to the mouthpiece 166, and, more specifically, the outlet tube 306 fluidly connects the heating device 162 to the mouthpiece aperture 314.

The mouthpiece aperture 314 has a radially inwardly directed inner surface 316. The inner surface 316 of the mouthpiece aperture 314 joins an outer surface 318 of the mouthpiece 166 (i.e., a surface which the user inserts into their mouth in use) at an outer edge 320 of the mouthpiece aperture 314. The outer edge 320 surrounds the mouthpiece aperture 314.

At the outer edge 320, the angle between the inner surface 316 of the mouthpiece aperture 314 and the outer surface 318 of the mouthpiece 166 (i.e., the “mouthpiece angle”) is less than 90 degrees. In the present example, this is due to the outer edge 320 being rounded to define a substantially smooth curve. For the purposes of this disclosure, the rounded portion is considered to be part of the inner surface 316. In this case, where the outer edge 320 is rounded, the mouthpiece angle is substantially 0 degrees. The smooth curve extends between the outer surface 318 and a lower portion of the inner surface 316, the lower portion extending in a substantially downward direction in FIG. 3 (i.e., normal to the outer surface 318 at the outer edge 320 and parallel to the direction of fluid flow in the outlet tube 306).

In the present example, the curve followed by the rounded portion is substantially an arc of a circle. The radius of the rounded portion is preferably less than 1.0 mm. More specifically, the radius of the rounded portion is less than 0.8. More specifically, the radius of the rounded portion is less than 0.6 mm.

The radius of the rounded portion is greater than 0.2 mm. More specifically, the radius of the rounded portion is greater than 0.4 mm.

However, in other examples, the radius of the rounded portion is less than 0.4 mm, and may be less than 0.2 mm. However, the rounded portion need not follow such a curve, and could be any substantially smooth curve.

In other examples, the outer edge 320 is not rounded, and is instead chamfered or beveled, such that the inner surface 316 comprises an angled portion, which extends at constant angle from the outer edge 320. Such a portion may extend the full depth of the mouthpiece aperture 314 (i.e., up to an inner edge 322, where the mouthpiece aperture 314 meets an inner surface of the mouthpiece 166), or may extend only part of the depth of the mouthpiece aperture 314, up to a lower portion extending in the substantially downward direction as described above.

The mouthpiece angle is preferably less than 75 degrees, preferably less than 60 degrees, preferably less than 45 degrees, preferably less than 30 degrees, preferably less than 15 degrees, preferably substantially 0 degrees.

In other examples, the inner surface 316 may comprise a combination of rounded portions and angled portions, and may include several angled portions angled at different angles.

Within the tank 156 there is a heating device 162, which in this example is a coil and wick assembly. The heating device 162 comprises an outer shell with one or more apertures. These apertures are filled with a wick material, so that e-liquid may only ingress the heating device 162 from the tank 156 via capillary action. The wick material passes through or proximal to a coil, which is connected to one or more electrical contacts.

The consumable 150 further comprises a tank seal 308, which seals a bottom portion of the tank 156 beneath the heating device 162. The tank seal 308 is connected to the heating device 162, and the tank seal 308 comprises an air inlet 164, such that air flow is permitted from outside the tank through the air inlet 164 to the heating device 162.

The tank 156, the outlet tube 306 and the mouthpiece 166 are integrally formed with each other. The tank 156, the outlet tube 306 and the mouthpiece 166 make up a single component formed from a continuous piece of material. The tank 156, the outlet tube 306 and the mouthpiece 166 are formed in an injection molding process as described below with respect to FIG. 4. The tank 156, the outlet tube 306 and the mouthpiece 166 are made of a thermoplastic material. More specifically, the tank 156, the outlet tube 306 and the mouthpiece 166 are made of polypropylene.

The outlet tube 306 comprises a filter 310 located within the outlet tube 306. The filter 310 is tubular with an annular cross-section, and an outer surface of the filter 310 is in contact with an inner surface of the outlet tube 306. The outlet tube 306 comprises a void 312, and the filter 310 does not extend into the void 312. The void 312 is a portion of the outlet tube 306 in which no filter is present.

The void 312 comprises a downstream void portion 313 downstream of the filter 310. The downstream portion is located above the filter 310 and below the mouthpiece aperture 314 in FIG. 3. In other examples, the filter 310 extends to the mouthpiece aperture 314. The void 312 further comprises an upstream void portion 315 upstream of the filter 310. The void 312 occupies preferably at least 5% of a total length of the outlet tube 306, preferably at least 10% of the total length of the outlet tube 306, preferably at least 15% of the total length of the outlet tube 306, preferably at least 20% of the total length of the outlet tube 306, preferably at least 25% of the total length of the outlet tube 306.

The void 312 occupies preferably not more than 30% of a total length of the outlet tube 306, preferably not more than 25% of the total length of the outlet tube 306, preferably not more than 20% of the total length of the outlet tube 306, preferably not more than 15% of the total length of the outlet tube 306, preferably not more than 10% of the total length of the outlet tube 306. In this example, the filter 310 has a length of substantially 25 mm.

The outlet tube 306 comprises a retainer (not shown) which retains the filter 310 in position in the outlet tube 306. The retainer comprises a rib, which extends inwardly from an inner surface of the outlet tube to retain the filter in position in the outlet tube by an interference fit.

The filter 310 is made from a fabric, which may be cotton or another fiber. The filter may be formed of a mesh. The filter permits flow of vaporized e-liquid through the filter 310, but prevents flow of un-vaporized e-liquid through the filter 310. This reduces leakage of un-vaporized e-liquid into the user's mouth. The filter 310 may be a gas-permeable and liquid-impermeable membrane.

In use, when the consumable 150 is connected to the main body 120, the user inserts the mouthpiece 166 into their mouth. The user inhales through the mouthpiece aperture 314, which draws air through the air inlet 164 and into the heating device 162.

At the same time, an electrical current is provided to the one or more contacts, which causes heating of the coil, and consequent vaporization of the e-liquid within the wick material. The air flow passes through the coil and wick assembly, drawing with it vaporized e-liquid to form the aerosol vapor. The aerosol vapor flows up the outlet tube 306, before exiting the consumable 150 via mouthpiece aperture 314. The e-liquid only enters the coil and wick assembly via the one or more apertures and then, only via the wick.

As the aerosol vapor flows through the outlet tube 306, it passes the filter 310, which filters un-vaporized e-liquid out of the aerosol vapor. The void 312 provides a portion of the outlet tube 306 for condensation settling. The void 312 provides an unobstructed portion of the inner surface of the outlet tube 306 at which un-vaporized e-liquid which remains in the aerosol vapor downstream of the filter 310 can condense and flow down the inner surface of the outlet tube 306 into the filter 310. This further reduces leakage of un-vaporized e-liquid into the user's mouth.

FIG. 4 shows a drawing of a manufacturing assembly 400 which is used to manufacture the consumable 150. The manufacturing assembly 400 comprises a first mold 402 and a second mold 404.

The first mold 402 has a shape which complements that of a first end (a lower end in FIG. 3) of the integrally formed tank 156, mouthpiece 166 and outlet tube 306. The first mold 402 therefore has a shape which matches the inner surfaces of the tank 156, and the inner and outer surfaces of the outlet tube 306.

The second mold 404 has a shape which complements that of a second end (an upper end in FIG. 4) of the integrally formed tank 156, mouthpiece 166 and outlet tube 306. The second mold 404 therefore has a shape which matches the outer surface 318 of the mouthpiece 166 and the inner surface 316 of the mouthpiece aperture 314.

When the first mold 402 and the second mold 404 are brought together, they define a closed cavity which has the shape of the tank 156, the mouthpiece 166 and the outlet tube 306.

To manufacture the tank 156, the mouthpiece 166 and the outlet tube 306, heated material is injected into the cavity between the first mold 402 and the second mold 404. At this point, the first mold 402 and the second mold 404 meet at a boundary between external surfaces of the mouthpiece 166 and the tank 156.

The material is subsequently cooled, and the first mold 402 and the second mold 404 are separated, with the first mold 402 travelling in the first demolding direction 406 (i.e., away from the second mold 404) and the second mold 404 travelling in a second demolding direction 408 (i.e., away from the first mold 402 and opposite to the first demolding direction 406). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The filter 310 is then inserted into the outlet tube 306, and the heating device 162, tank seal 308 and any additional components are inserted into the tank 156. The filter 310 is pushed into the outlet tube 306 through the upstream end of the outlet tube 306. Since the filter 310 is shorter than the outlet tube 306, the outlet tube 306 comprises the void 312.

In some examples (particularly where the void comprises the downstream void portion 313), the filter 310 is pushed into the outlet tube 306 using an insertion tool (not shown), with the insertion tool sized so that the filter 310 is inserted such that the filter 310 does not extend to the downstream end of the outlet tube 306, thereby providing the downstream void portion 313. In other examples, the filter 310 is pushed fully up to the mouthpiece aperture 314, with the filter 310 abutting against the mouthpiece aperture 314, which is narrower than the outlet tube 306.

Referring to FIG. 5A and FIG. 5B, there is shown a portion of a second consumable 500. For clarity, the heating device 162, the tank seal 308 and the filter 310 are omitted from FIG. 5A and FIG. 5B. However, the portion of the second consumable 250 is for use with the heating device 162, tank seal 308, filter 310 and any additional components described above.

The second consumable 500 comprises all of the features of the consumable 150 as described above. Many of the reference numerals relating to those features are omitted from FIG. 5A and FIG. 5B for clarity. However, like reference numerals are used in FIG. 5A and FIG. 5B where features referred to previously are referred to again.

In addition to the features which are common with the consumable 150, the second consumable 500 comprises a support 502. The support 502 comprises a first rib 504 and a second rib 506.

Each of the first and second ribs 504, 506 extends in a radially outward direction (with respect to the central axis of the outlet tube) from an external surface of the outlet wall 307 to an inner surface of the tank wall 304. More specifically, each of the first and second ribs 504, 506 extends to the inner surface of the tank wall 304 at a downstream end of the second consumable 500, where the tank wall 304 is also a wall of the mouthpiece 166.

Each of the first and second ribs 504, 506 also extends from an external surface of a wall of the mouthpiece aperture 314. Since the external surface of the wall of the mouthpiece aperture 314 is continuous with the external surface of the outlet wall 307, each of the first and second ribs 504, 506 connects to the external surfaces of the wall of the mouthpiece aperture and the outlet tube up to the downstream end of the second consumable 500.

As best illustrated in FIG. 5B, the first and second ribs 504, 506 are substantially equally spaced around the outlet tube 306. More specifically, the first and second ribs 504, 506 are spaced from each other by 180 degrees around the central axis of the outlet tube 306. The first and second ribs 504, 506 are substantially aligned with a horizontal (as shown in FIG. 5B) line of symmetry of the outlet tube, and extend along a line equidistant between front and rear portions of the second consumable 500.

The support 502 is formed of the same material as the outlet tube 306 and the tank 156. The support 502 is integrally formed with the tank 156 and the outlet tube 306.

The second consumable 500 operates in the same way as the consumable 150, with the support 502 providing structural support to maintain the outlet tube 306 in alignment with the heating device in use.

The second consumable 500 is manufactured through the same process as that described in FIG. 4, with the manufacturing assembly 400 modified so that the closed cavity formed when the first and second molds 402, 404 are brought together further defines the shape of the support 502. The support 502 provides structural support to the outlet tube 306 during demolding and subsequent assembly of the second consumable 500.

Referring to FIG. 6A and FIG. 6B, there is shown a portion of a third consumable 600. The third consumable 600 comprises all of the features of the second consumable 500 as described above. Many of the reference numerals relating to those features are omitted from FIG. 6A and FIG. 6B for clarity. However, like reference numerals are used in FIG. 6A and FIG. 6B where features referred to previously are referred to again. The third consumable 600 functions in generally the same manner as the second consumable 500, and only the differences are described here.

In addition to the features which are common with the second consumable 500, the third consumable 600 comprises turbulence inducing element 602. The turbulence inducing element 602 is partially located in an end portion of the outlet tube 306. The turbulence inducing element 602 is partially located in the heater chamber 170. The turbulence inducing element 602 is formed from silicone. The turbulence inducing element 602 is held in position by a friction fit with the end portion of the outlet tube 306.

The turbulence inducing element 602 is at least 1 mm downstream of the heating device 162 (i.e., the “vaporizer”). It has been found that positioning the turbulence inducing element 602 at least this distance downstream of the heating device 162 permits the aerosol to fully form before the turbulence inducing element 602 is reached. This means that the turbulence induced by the turbulence inducing element 602 is more effective in breaking up any large droplets formed in the aerosol, which reduces leakage of liquid to the user's mouth.

More specifically, the turbulence inducing element is at least 1.5 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at least 2 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at least 2.5 mm downstream of the vaporizer.

The turbulence inducing element is at most 5 mm downstream of the vaporizer. It has been found that positioning the turbulence inducing element 602 beyond this distance from the vaporizer has little effect on the leakage to the user's mouth. It is therefore desirable to have the turbulence inducing element at most this distance from the vaporizer to provide a more compact consumable. More specifically, the turbulence inducing element is at most 5 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at most 4 mm downstream of the vaporizer. More specifically, the turbulence inducing element is substantially 3 mm downstream of the vaporizer.

The turbulence inducing element 602 comprises a baffle 604. The baffle 604 provides a substantially planar surface positioned normal to a longitudinal axis of the third consumable 600 in a flow path from the heating device 162 to the outlet tube 306. The baffle 604 is a first flow obstacle. The baffle 604 is provided by an in-use lowermost surface of the turbulence inducing element 602.

The turbulence inducing element 602 comprises first and second inlets 606, 608 downstream of the baffle 604. The first and second inlets 606, 608 are in side portions of the turbulence inducing element 602. The first and second inlets 606, 608 are formed by apertures between the baffle 604 and the end portion of the outlet tube 306. The first and second inlets 606, 608 are substantially diametrically opposed. In other examples only one inlet is provided.

The turbulence inducing element 602 comprises first and second upstands 610, 612. Each of the first and second upstands 610, 612 is provided downstream of a respective one of the first and second inlets 606, 608. The first and second upstands 610, 612 extend in a direction substantially normal to the plane of the baffle 604 in a substantially axial direction. The first and second upstands 610, 612 provide substantially circumferential surfaces (i.e., surfaces which extend in a circumferential direction). The circumferential directions are normal to the longitudinal axis of the third consumable 600. The circumferential directions are parallel to the circumference of the outlet tube 306. Each upstand 610, 612 is a second flow obstacle. The first and second upstands 610, 612 are substantially diametrically opposed with respect to the outlet tube 306. The first and second upstands contact the internal surface of the outlet tube 306 to provide the friction fit between the turbulence inducing element 602 and the outlet tube 306.

The turbulence inducing element 602 comprises a protrusion 614. The protrusion 614 extends across a diameter of the outlet tube 306. The protrusion 614 extends along a direction substantially normal to a diameter extending between the first and second upstands 610, 612. The protrusion 614 protrudes parallel to the longitudinal axis of the third consumable 600 to contact the outlet tube 306. The protrusion 614 is a third flow obstacle. The protrusion is of substantially uniform height (measured along the axial direction).

In use, the aerosol vapor flows through the heater chamber 170 and contacts the turbulence inducing element 60. The position of the baffle 604 means that the flow of aerosol contacts the baffle 604 and is turned towards a radial direction. More specifically, the flow branches (i.e., splits into two flow streams) at the baffle 604, with the flow streams turned towards substantially opposite radially outward directions. The radial directions are normal to the longitudinal axis of the third consumable 600. The radial directions are parallel to radii of the outlet tube 306.

The effect of turning towards the radial direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. In the present example, the flow is turned such that it flows in a substantially radial direction, but, in other examples, this is not the case.

As such, after the flow branches at the baffle 604 to form two flow streams, each flow stream flows through a respective one of the first and second inlets 606, 608. Since the first and second inlets 606, 608 are in side portions of the turbulence inducing element 602, the flow turns from radially outward to radially inward to flow through the first and second inlets 606, 608.

In the present example, substantially all of the flow passes through turbulence inducing element 602, and substantially all of the flow is turned by the turbulence inducing element 602 as described.

The first and second upstands 610, 612 cooperate with the end portion of the outlet tube 306 to turn the flow streams towards circumferential directions. The substantially radially inward flow streams contact the circumferential surface of the upstands 610, 612, causing the flow streams to turn towards the circumferential direction. More specifically, each of the flow streams branches again, with each stream splitting into two further flow streams turned towards circumferential directions.

The effect of turning towards the circumferential direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. However, in the present example, the flow is turned such that it is in a substantially radial direction.

The protrusion 614 is therefore configured to turn the flow towards the axial direction within the outlet tube 306, where the flow streams recombine to flow through the outlet tube 306 as before.

The effect of turning towards the axial direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. However, in the present example, the flow is turned such that it flows substantially parallel to a circumferential direction.

Second Mode: An Aerosol Delivery Device with an Airflow Path Around an Airflow-Directing Member

Aspects and embodiments of the second mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 7A shows a first embodiment of a smoking substitute system 100b. In this example, the smoking substitute system 100b includes a main body 102b and an aerosol delivery device in the form of a consumable 104b. The consumable 104b may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100b is a closed system vaping system, wherein the consumable 104b includes a sealed tank 106b and is intended for single-use only. The consumable 104b is removably engageable with the main body 102b (i.e., for removal and replacement). FIG. 7A shows the smoking substitute system 100b with the main body 102b physically coupled to the consumable 104b, FIG. 7B shows the main body 102b of the smoking substitute system 100b without the consumable 104b, and FIG. 7C shows the consumable 104b of the smoking substitute system 100b without the main body 102b.

The main body 102b and the consumable 104b are configured to be physically coupled together by pushing the consumable 104b into a cavity at an upper end 108b of the main body 102b, such that there is an interference fit between the main body 102b and the consumable 104b. In other examples, the main body 102b and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104b includes a mouthpiece (not shown in FIG. 7A, 1B or 1C) at an upper end 109b of the consumable 104b, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104b when a user inhales through the mouthpiece. The tank 106b containing e-liquid is located at the lower end 111b of the consumable 104b.

The tank 106b includes a window 112b, which allows the amount of e-liquid in the tank 106b to be visually assessed. The main body 102b includes a slot 114b so that the window 112b of the consumable 104b can be seen whilst the rest of the tank 106b is obscured from view when the consumable 104b is inserted into the cavity at the upper end 108b of the main body 102b.

The lower end 110b of the main body 102b also includes a light 116b (e.g., an LED) located behind a small translucent cover. The light 116b may be configured to illuminate when the smoking substitute system 100b is activated. Whilst not shown, the consumable 104b may identify itself to the main body 102b, via an electrical interface, RFID chip, or barcode.

FIG. 8A and FIG. 8B are schematic drawings of the main body 102b and consumable 104b. As is apparent from FIG. 8A, the main body 102b includes a power source 118b, a controller 120b, a memory 122b, a wireless interface 124b, an electrical interface 126b, and, optionally, one or more additional components 128b.

The power source 118b is preferably a battery, more preferably a rechargeable battery. The controller 120b may include a microprocessor, for example. The memory 122b preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120b to perform certain tasks or steps of a method.

The wireless interface 124b is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124b could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124b may also be configured to communicate wirelessly with a remote server.

The electrical interface 126b of the main body 102b may include one or more electrical contacts. The electrical interface 126b may be located in a base of the aperture in the upper end 108b of the main body 102b. When the main body 102b is physically coupled to the consumable 104b, the electrical interface 126b is configured to transfer electrical power from the power source 118b to the consumable 104b (i.e., upon activation of the smoking substitute system 100b).

The electrical interface 126b may be configured to receive power from a charging station when the main body 102b is not physically coupled to the consumable 104b and is instead coupled to the charging station. The electrical interface 126b may also be used to identify the consumable 104b from a list of known consumables. For example, the consumable 104b may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126b). This can be indicated to the controller 120b of the main body 102b when the consumable 104b is connected to the main body 102b. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102b and a corresponding communication interface in the consumable 104b such that, when connected, the consumable 104b can identify itself to the main body 102b.

The additional components 128b of the main body 102b may comprise the light 116b discussed above.

The additional components 128b of the main body 102b may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118b is a rechargeable battery). This may be located at the lower end 110b of the main body 102b. Alternatively, the electrical interface 126b discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128b of the main body 102b may, if the power source 118b is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128b of the main body 102b may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100b, e.g., caused by a user inhaling through a mouthpiece 136b of the consumable 104b. The smoking substitute system 100b may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104b. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128b of the main body 102b may include a user input, e.g., a button. The smoking substitute system 100b may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100b.

As shown in FIG. 8B, the consumable 104b includes the tank 106b, an electrical interface 130b, a vaporizer 132b, one or more air inlets 134b, a mouthpiece 136b, and one or more additional components 138b.

The electrical interface 130b of the consumable 104b may include one or more electrical contacts. The electrical interface 126b of the main body 102b and an electrical interface 130b of the consumable 104b are configured to contact each other and thereby electrically couple the main body 102b to the consumable 104b when the lower end 111b of the consumable 104b is inserted into the upper end of the main body 102b (as shown in FIG. 7A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118b in the main body 102b to the vaporizer 132b in the consumable 104b.

The vaporizer 132b is configured to heat and vaporize e-liquid contained in the tank 106b using electrical energy supplied from the power source 118b. As will be described further below, the vaporizer 132b includes a heating filament and a wick. The wick draws e-liquid from the tank 106b and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134b are preferably configured to allow air to be drawn into the smoking substitute system 100b, when a user inhales through the mouthpiece 136b. When the consumable 104b is physically coupled to the main body 102b, the air inlets 134b receive air, which flows to the air inlets 134b along a gap between the main body 102b and the lower end 111b of the consumable 104b.

In operation, a user activates the smoking substitute system 100b, e.g., through interaction with a user input forming part of the main body 102b or by inhaling through the mouthpiece 136b as described above. Upon activation, the controller 120b may supply electrical energy from the power source 118b to the vaporizer 132b (via electrical interfaces 126b, 130b), which may cause the vaporizer 132b to heat e-liquid drawn from the tank 106b to produce a vapor which is inhaled by a user through the mouthpiece 136b.

An example of one of the one or more additional components 138b of the consumable 104b is an interface for obtaining an identifier of the consumable 104b. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104b may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102b.

It should be appreciated that the smoking substitute system 100b shown in FIG. 7A to FIG. 8B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 9A is a section view of the consumable 104b described above. The consumable 104b comprises a tank 106b for storing e-liquid, a mouthpiece 136b and a passage 140b extending along a longitudinal axis of the consumable 104b. In the illustrated embodiment the passage 140b is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106b surrounds the passage 140b, such that the passage 140b extends centrally through the tank 106b.

A tank housing 142b of the tank 106b defines an outer casing of the consumable 104b, whilst a passage wall 144b defines the passage 140b. The tank housing 142b extends from the lower end 111b of the consumable 104b to the mouthpiece 136b at the upper end 109b of the consumable 104b. At the junction between the mouthpiece 136b and the tank housing 142b, the mouthpiece 136b is wider than the tank housing 142b, so as to define a lip 146b that overhangs the tank housing 142b. This lip 146b acts as a stop feature when the consumable 104b is inserted into the main body 102b (i.e., by contact with an upper edge of the main body 102b).

The tank 106b, the passage 140b and the mouthpiece 136b are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 10, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142b tapers, such that the thickness of the tank housing 142b decreases in a first demolding direction (as will be discussed further with respect to FIG. 10). In FIG. 9A the first demolding direction is in a downward direction away from the mouthpiece 136b. This means that, aside from a small number of indents (which provide physical connection between the consumable 104b and the main body 102b), the thickness of the tank housing 142b decreases with increasing distance away from the mouthpiece 136b. In particular, the tank housing 142b tapers in this way, because internal and external surfaces of the tank housing 142b are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142b and passage wall 144b as a single (i.e., unitary) component.

Like the tank housing 142b, the passage wall 144b is also tapered such that the thickness of the passage wall 144b decreases along the first demolding direction. Again, the thickness of the passage wall 144b decreases due to internal and external surfaces of the passage wall 144b being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144b, the passage 140b has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 9A). For example, the passage 140b has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140b (e.g., approximately 3.6 mm). On the other hand, the passage 140b has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140b (e.g., approximately 3.4 mm).

The mouthpiece 136b comprises a mouthpiece aperture 148b defining an outlet of the passage 140b. The mouthpiece aperture 148b has a radially inwardly directed inner surface 150b, which joins an outer surface 152b of the mouthpiece 136b (i.e., a surface which contacts a user's lips in use) at an outer edge 154b of the mouthpiece aperture 148b. At this outer edge 154b, the included angle between the inner surface 150b of the mouthpiece aperture 148b and the outer surface 152b of the mouthpiece 136b (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154b being rounded. This outer edge 154b may otherwise be chamfered or beveled.

The vaporizer 132b is located in a vaporizing chamber 156b of the consumable 104b. This is best shown in FIG. 9B, which provides a detailed view of the vaporizing chamber 156b. The vaporizing chamber 156b is downstream of the air inlet 134b of the consumable 104b and is fluidly connected to the mouthpiece aperture 148b (i.e., outlet) by the passage 140b. In particular, the passage 140b extends between the mouthpiece aperture 148b and a passage opening 158b from the chamber 156b. This passage opening 158b is formed in a downstream (i.e., upper) wall 160b of the chamber 156b.

The vaporizer 132b comprises a porous wick 162b and a heater filament 164b coiled around the porous wick 162b. As is apparent from FIG. 9A and FIG. 9B, the porous wick 162b extends transversely across the chamber 156b between sidewalls 166b of the chamber 156b which form part of an inner sleeve 168b of an insert 170b that defines the lower end 111b of the consumable 104b that connects with the main body 102b. The insert 170b is inserted into an open lower end of the tank 106b so as to seal against the tank housing 142b.

In this way, the inner sleeve 168b projects into the tank 106b and seals with the passage 140b (around the passage wall 144b) so as to separate the chamber 156b from the e-liquid in the tank 106b. Ends of the porous wick 162b project through apertures in the inner sleeve 168b and into the tank 106b so as to be in contact with the e-liquid in the tank 106b. In this way, e-liquid is transported along the porous wick 162b (e.g., by capillary action) to a central portion of the porous wick 162b. The transported e-liquid is heated by the heater filament 164b (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing in the vaporizing chamber 156b. This vaporized liquid may cool to form an aerosol in the passage 140b, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156b. This may be undesirable for a user. To reduce or avoid this, the consumable 104b comprises a baffle 172b, which is shown in more detail in FIG. 9B. The baffle 172b extends across the chamber 156b so as to be interposed between the vaporizer 132b and the passage opening 158b. In this way, un-vaporized liquid from the porous wick 162b may collect on an upstream (i.e., lower) planar surface 174b of the baffle 172b rather than entering the passage opening 158b. The baffle 172b also causes airflow from the vaporizer 132b to the passage opening 158b to be redirected around the baffle 172b. The baffle 172b comprises two opposing upstream edges 176b around which the airflow is redirected. These upstream edges 176b and the sidewalls 166b of the chamber 156b define two respective apertures 178b spaced either side of the baffle 172b. The baffle further comprises two downstream edges 179b.

The chamber air flow path, i.e., the airflow through the vaporizing chamber 156b from proximal the vaporizer 132b to the passage opening 158b extends is bifurcated and has two branches extending through the apertures 178b in a generally longitudinal direction between the upstream edges 176b and the downstream edges 179b. The transverse cross-sectional area of the chamber air flow path as it passes between the upstream and downstream edges 176b, 179b is constant within each branch and equal between the two branches. Furthermore, the transverse cross-sectional area of the chamber airflow path between the upstream and downstream edges 176b, 179b in each branch is equal to the minimum (smallest) cross-sectional area of the chamber airflow path downstream of the downstream edges 179b, i.e., between the downstream edges 179b and the passage opening 158b. In fact, the chamber airflow path between the apertures 178b and the passage opening 158b is constant. The chamber airflow path will deflect radially towards the passage opening 158b at the downstream edges 179b.

Although not clear from FIG. 9B, the transverse width of the apertures 178b equals the longitudinal spacing between the downstream edges 179b of the baffle 172b and the end wall 160b of the vaporizing chamber 156b. Furthermore, the transverse width of the end wall 160b of the vaporizing chamber 156b between the passage opening 158b and the sidewall 166b of the vaporizing chamber 156b (measured between the radially outermost limit of the passage opening 158b and the proximal sidewall 166b) is less than the length of the chamber airflow path between the upstream edges 176b and the downstream edges 179b of the baffle 172b.

Upon inhalation by a user at the mouthpiece aperture 148b, air flows along the bifurcated chamber airflow path around the porous wick 162b, through the apertures 178b and into the passage 140b via the passage opening 158b.

FIG. 10 shows a drawing of a manufacturing assembly 282b which is used to manufacture the consumable 104b. The manufacturing assembly 282b comprises a first mold 284b and a second mold 286b.

The first mold 284b has a shape which complements that of a first end of the integrally formed tank housing 142b and mouthpiece 136b. The first mold 284b therefore has a shape which matches the inner surfaces defining the tank 106b.

The second mold 286b has a shape which complements that of a second end of the integrally formed tank housing 142b and mouthpiece 136b. The second mold 286b has a shape which matches the outer surface of the mouthpiece 136b and the inner surface of the mouthpiece aperture 148b.

When the first mold 284b and the second mold 286b are brought together, they define a closed cavity which has the shape of the tank housing 142b, the mouthpiece 136b and the passage walls 144b.

To manufacture these components, heated material is injected into the cavity between the first mold 284b and the second mold 286b. At this point, the first mold 284b and the second mold 286b meet at a boundary between external surfaces of the mouthpiece 136b and the tank housing 142b.

The material is subsequently cooled, and the first mold 284b and the second mold 286b are separated, with the first mold 284b travelling in the first demolding direction 288b (i.e., away from the second mold 286b) and the second mold 286b travelling in a second demolding direction 290b (i.e., away from the first mold 284b and opposite to the first demolding direction 288b). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The insert 170b and any additional components are subsequently inserted into the tank 106b.

Third Mode: An Aerosol Delivery Device with an Airflow-Directing Member Having a Sloped Surface

Aspects and embodiments of the third mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 11A shows a first embodiment of a smoking substitute system 100c. In this example, the smoking substitute system 100c includes a main body 102c and an aerosol delivery device in the form of a consumable 104c. The consumable 104c may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100c is a closed system vaping system, wherein the consumable 104c includes a sealed tank 106c and is intended for single-use only. The consumable 104c is removably engageable with the main body 102c (i.e., for removal and replacement). FIG. 11A shows the smoking substitute system 100c with the main body 102c physically coupled to the consumable 104c, FIG. 11B shows the main body 102c of the smoking substitute system 100c without the consumable 104c, and FIG. 11C shows the consumable 104c of the smoking substitute system 100c without the main body 102c.

The main body 102c and the consumable 104c are configured to be physically coupled together by pushing the consumable 104c into a cavity at an upper end 108c of the main body 102c, such that there is an interference fit between the main body 102c and the consumable 104c. In other examples, the main body 102c and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104c includes a mouthpiece (not shown in FIG. 11A, 1B or 1C) at an upper end 109c of the consumable 104c, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104c when a user inhales through the mouthpiece. The tank 106c containing e-liquid is located at the lower end 111c of the consumable 104c.

The tank 106c includes a window 112c, which allows the amount of e-liquid in the tank 106c to be visually assessed. The main body 102c includes a slot 114c so that the window 112c of the consumable 104c can be seen whilst the rest of the tank 106c is obscured from view when the consumable 104c is inserted into the cavity at the upper end 108c of the main body 102c.

The lower end 110c of the main body 102c also includes a light 116c (e.g., an LED) located behind a small translucent cover. The light 116c may be configured to illuminate when the smoking substitute system 100c is activated. Whilst not shown, the consumable 104c may identify itself to the main body 102c, via an electrical interface, RFID chip, or barcode.

FIG. 12A and FIG. 12B are schematic drawings of the main body 102c and consumable 104c. As is apparent from FIG. 12A, the main body 102c includes a power source 118c, a controller 120c, a memory 122c, a wireless interface 124c, an electrical interface 126c, and, optionally, one or more additional components 128c.

The power source 118c is preferably a battery, more preferably a rechargeable battery. The controller 120c may include a microprocessor, for example. The memory 122c preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120c to perform certain tasks or steps of a method.

The wireless interface 124c is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124c could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124c may also be configured to communicate wirelessly with a remote server.

The electrical interface 126c of the main body 102c may include one or more electrical contacts. The electrical interface 126c may be located in a base of the aperture in the upper end 108c of the main body 102c. When the main body 102c is physically coupled to the consumable 104c, the electrical interface 126c is configured to transfer electrical power from the power source 118c to the consumable 104c (i.e., upon activation of the smoking substitute system 100c).

The electrical interface 126c may be configured to receive power from a charging station when the main body 102c is not physically coupled to the consumable 104c and is instead coupled to the charging station. The electrical interface 126c may also be used to identify the consumable 104c from a list of known consumables. For example, the consumable 104c may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126c). This can be indicated to the controller 120c of the main body 102c when the consumable 104c is connected to the main body 102c. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102c and a corresponding communication interface in the consumable 104c such that, when connected, the consumable 104c can identify itself to the main body 102c.

The additional components 128c of the main body 102c may comprise the light 116c discussed above.

The additional components 128c of the main body 102c may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118c is a rechargeable battery). This may be located at the lower end 110c of the main body 102c. Alternatively, the electrical interface 126c discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128c of the main body 102c may, if the power source 118c is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128c of the main body 102c may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100c, e.g., caused by a user inhaling through a mouthpiece 136c of the consumable 104c. The smoking substitute system 100c may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104c. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128c of the main body 102c may include a user input, e.g., a button. The smoking substitute system 100c may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100c.

As shown in FIG. 12B, the consumable 104c includes the tank 106c, an electrical interface 130c, a vaporizer 132c, one or more air inlets 134c, a mouthpiece 136c, and one or more additional components 138c.

The electrical interface 130c of the consumable 104c may include one or more electrical contacts. The electrical interface 126c of the main body 102c and an electrical interface 130c of the consumable 104c are configured to contact each other and thereby electrically couple the main body 102c to the consumable 104c when the lower end 111c of the consumable 104c is inserted into the upper end 108c of the main body 102c (as shown in FIG. 11A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118c in the main body 102c to the vaporizer 132c in the consumable 104c.

The vaporizer 132c is configured to heat and vaporize e-liquid contained in the tank 106c using electrical energy supplied from the power source 118c. As will be described further below, the vaporizer 132c includes a heating filament and a wick. The wick draws e-liquid from the tank 106c and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134c are preferably configured to allow air to be drawn into the smoking substitute system 100c, when a user inhales through the mouthpiece 136c. When the consumable 104c is physically coupled to the main body 102c, the air inlets 134c receive air, which flows to the air inlets 134c along a gap between the main body 102c and the lower end 111c of the consumable 104c.

In operation, a user activates the smoking substitute system 100c, e.g., through interaction with a user input forming part of the main body 102c or by inhaling through the mouthpiece 136c as described above. Upon activation, the controller 120c may supply electrical energy from the power source 118c to the vaporizer 132c (via electrical interfaces 126c, 130c), which may cause the vaporizer 132c to heat e-liquid drawn from the tank 106c to produce a vapor which is inhaled by a user through the mouthpiece 136c.

An example of one of the one or more additional components 138c of the consumable 104c is an interface for obtaining an identifier of the consumable 104c. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104c may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102c.

It should be appreciated that the smoking substitute system 100c shown in FIG. 11A to FIG. 12B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 13A is a section view of the consumable 104c described above. The consumable 104c comprises a tank 106c for storing e-liquid, a mouthpiece 136c and a passage 140c extending along a longitudinal axis of the consumable 104c. In the illustrated embodiment the passage 140c is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106c surrounds the passage 140c, such that the passage 140c extends centrally through the tank 106c.

A tank housing 142c of the tank 106c defines an outer casing of the consumable 104c, whilst a passage wall 144c defines the passage 140c. The tank housing 142c extends from the lower end 111c of the consumable 104c to the mouthpiece 136c at the upper end 109c of the consumable 104c. At the junction between the mouthpiece 136c and the tank housing 142c, the mouthpiece 136c is wider than the tank housing 142c, so as to define a lip 146c that overhangs the tank housing 142c. This lip 146c acts as a stop feature when the consumable 104c is inserted into the main body 102c (i.e., by contact with an upper edge of the main body 102c).

The tank 106c, the passage 140c and the mouthpiece 136c are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 14, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142c tapers, such that the thickness of the tank housing 142c decreases in a first demolding direction (as will be discussed further with respect to FIG. 14). In FIG. 13A the first demolding direction is in a downward direction away from the mouthpiece 136c. This means that, aside from a small number of indents (which provide physical connection between the consumable 104c and the main body 102c), the thickness of the tank housing 142c decreases with increasing distance away from the mouthpiece 136c. In particular, the tank housing 142c tapers in this way, because internal and external surfaces of the tank housing 142c are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142c and passage wall 144c as a single (i.e., unitary) component.

Like the tank housing 142c, the passage wall 144c is also tapered such that the thickness of the passage wall 144c decreases along the first demolding direction. Again, the thickness of the passage wall 144c decreases due to internal and external surfaces of the passage wall 144c being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144c, the passage 140c has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 13A). For example, the passage 140c has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140c (e.g., approximately 3.6 mm). On the other hand, the passage 140c has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140c (e.g., approximately 3.4 mm).

The mouthpiece 136c comprises a mouthpiece aperture 148c defining an outlet of the passage 140c. The mouthpiece aperture 148c has a radially inwardly directed inner surface 150c, which joins an outer surface 152c of the mouthpiece 136c (i.e., a surface which contacts a user's lips in use) at an outer edge 154c of the mouthpiece aperture 148c. At this outer edge 154c, the included angle between the inner surface 150c of the mouthpiece aperture 148c and the outer surface 152c of the mouthpiece 136c (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154c being rounded. This outer edge 154c may otherwise be chamfered or beveled.

The vaporizer 132c is located in a vaporizing chamber 156c of the consumable 104c. This is best shown in FIG. 13B, which provides a detailed view of the vaporizing chamber 156c. The vaporizing chamber 156c is downstream of the air inlet 134c of the consumable 104c and is fluidly connected to the mouthpiece aperture 148c (i.e., outlet) by the passage 140c. In particular, the passage 140c extends between the mouthpiece aperture 148c and a passage opening 158c from the chamber 156c. This passage opening 158c is formed in a downstream (i.e., upper) wall 160c of the chamber 156c.

The vaporizer 132c comprises a porous wick 162c and a heater filament 164c coiled around the porous wick 162c. As is apparent from FIG. 13A and FIG. 13B, the porous wick 162c extends transversely across the chamber 156c between sidewalls 166c of the chamber 156c which form part of an inner sleeve 168c of an insert 170c that defines the lower end 111c of the consumable 104c that connects with the main body 102c. The insert 170c is inserted into an open lower end of the tank 106c so as to seal against the tank housing 142c.

In this way, the inner sleeve 168c projects into the tank 106c and seals with the passage 140c (around the passage wall 144c) so as to separate the chamber 156c from the e-liquid in the tank 106c. Ends of the porous wick 162c project through apertures in the inner sleeve 168c and into the tank 106c so as to be in contact with the e-liquid in the tank 106c. In this way, e-liquid is transported along the porous wick 162c (e.g., by capillary action) to a central portion of the porous wick 162c that is exposed to airflow through the chamber 156c. The transported e-liquid is heated by the heater filament 164c (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing past the porous wick 162c. This vaporized liquid may cool to form an aerosol in the passage 140c, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156c. This may be undesirable for a user. To reduce or avoid this, the consumable 104c comprises a baffle 172c, which is shown in more detail in FIG. 13B. The baffle 172c extends transversely across the chamber 156c so as to be interposed between the vaporizer 132c and the passage opening 158c. In this way, un-vaporized liquid from the porous wick 162c may collect on an upstream (i.e., lower) planar surface 174c of the baffle 172c rather than entering the passage opening 158c. The baffle 172c also causes airflow from the vaporizer 132c to the passage opening 158c to be redirected around the baffle 172c. The baffle 172c comprises two opposing transverse edges 176c around which the airflow is redirected. These transverse edges 176c and the sidewalls 166c of the chamber 156c define two respective apertures 178c spaced either side of the baffle 172c. Upon inhalation by a user at the mouthpiece aperture 148c, air flows along a bifurcated airflow path around the porous wick 162c, through the apertures 178c and into the passage 140c via the passage opening 158c.

In order to reduce the velocity of the air flowing around the baffle 172c, the baffle 172c comprises two sloped surfaces 180c, which are disposed at a downstream side of the baffle 172c. Each sloped surface 180c slopes inwardly (towards the longitudinal axis and the passage opening 158c) from a respective transverse edge 176c. The sloped surfaces 180c are connected by a downstream (i.e., upper) planar surface 182c of the baffle 172c such that the baffle 172c has a generally trapezoidal cross-section (i.e., taken along a longitudinally oriented plane as shown in FIG. 13B).

The presence of the sloped surfaces 180c provides an increased gap between the baffle 172c and the sidewalls 166c when compared to a similar baffle having perpendicular (i.e., non-sloped) edge surfaces. This increased gap lowers the velocity of the air, which results in reduced propensity for the air to carry un-vaporized liquid (e.g., that has collected on the upstream surface of the baffle 172c) into the passage 140c. As such, a larger baffle 172c may be used (so as to provide greater protection to the passage opening 158c). In the illustrated embodiment, the baffle 172c has a transverse width that is substantially the same as an inner diameter of the passage 140c.

FIG. 14 shows a drawing of a manufacturing assembly 282c which is used to manufacture the consumable 104c. The manufacturing assembly 282c comprises a first mold 284c and a second mold 286c.

The first mold 284c has a shape which complements that of a first end of the integrally formed tank housing 142c and mouthpiece 136c. The first mold 284c therefore has a shape which matches the inner surfaces defining the tank 106c.

The second mold 286c has a shape which complements that of a second end of the integrally formed tank housing 142c and mouthpiece 136c. The second mold 286c has a shape which matches the outer surface of the mouthpiece 136c and the inner surface of the mouthpiece aperture 148c.

When the first mold 284c and the second mold 286c are brought together, they define a closed cavity which has the shape of the tank housing 142c, the mouthpiece 136c and the passage walls 144c.

To manufacture these components, heated material is injected into the cavity between the first mold 284c and the second mold 286c. At this point, the first mold 284c and the second mold 286c meet at a boundary between external surfaces of the mouthpiece 136c and the tank housing 142c.

The material is subsequently cooled, and the first mold 284c and the second mold 286c are separated, with the first mold 284c travelling in the first demolding direction 288c (i.e., away from the second mold 286c) and the second mold 286c travelling in a second demolding direction 290c (i.e., away from the first mold 284c and opposite to the first demolding direction 288c). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The insert 170c and any additional components are subsequently inserted into the tank 106c.

Fourth Mode: An Aerosol Delivery Device in which an Airflow Path Through a Vaporizing Chamber is a Single, Deflected Path

Aspects and embodiments of the fourth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 15A shows a first embodiment of a smoking substitute system 100d. In this example, the smoking substitute system 100d includes a main body 102d and an aerosol delivery device in the form of a consumable 104d. The consumable 104d may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100d is a closed system vaping system, wherein the consumable 104d includes a sealed tank 106d and is intended for single-use only. The consumable 104d is removably engageable with the main body 102d (i.e., for removal and replacement). FIG. 15A shows the smoking substitute system 100d with the main body 102d physically coupled to the consumable 104d, FIG. 15B shows the main body 102d of the smoking substitute system 100d without the consumable 104d, and FIG. 15C shows the consumable 104d of the smoking substitute system 100d without the main body 102d.

The main body 102d and the consumable 104d are configured to be physically coupled together by pushing the consumable 104d into a cavity at an upper end 108d of the main body 102d, such that there is an interference fit between the main body 102d and the consumable 104d. In other examples, the main body 102d and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104d includes a mouthpiece (not shown in FIG. 15A, 1B or 1C) at an upper end 109d of the consumable 104d, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104d when a user inhales through the mouthpiece. The tank 106d containing e-liquid is located at the lower end 111d of the consumable 104d.

The tank 106d includes a window 112d, which allows the amount of e-liquid in the tank 106d to be visually assessed. The main body 102d includes a slot 114d so that the window 112d of the consumable 104d can be seen whilst the rest of the tank 106d is obscured from view when the consumable 104d is inserted into the cavity at the upper end 108d of the main body 102d.

The lower end 110d of the main body also includes a light 116d (e.g., an LED) located behind a small translucent cover. The light 116d may be configured to illuminate when the smoking substitute system 100d is activated. Whilst not shown, the consumable 104d may identify itself to the main body 102d, via an electrical interface, RFID chip, or barcode.

FIG. 16A and FIG. 16B are schematic drawings of the main body 102d and consumable 104d. As is apparent from FIG. 16A, the main body 102d includes a power source 118d, a controller 120d, a memory 122d, a wireless interface 124d, an electrical interface 126d, and, optionally, one or more additional components 128d.

The power source 118d is preferably a battery, more preferably a rechargeable battery. The controller 120d may include a microprocessor, for example. The memory 122d preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120d to perform certain tasks or steps of a method.

The wireless interface 124d is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124d could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124d may also be configured to communicate wirelessly with a remote server.

The electrical interface 126d of the main body 102d may include one or more electrical contacts. The electrical interface 126d may be located in a base of the aperture in the upper end 108d of the main body 102d. When the main body 102d is physically coupled to the consumable 104d, the electrical interface 126d is configured to transfer electrical power from the power source 118d to the consumable 104d (i.e., upon activation of the smoking substitute system 100d).

The electrical interface 126d may be configured to receive power from a charging station when the main body 102d is not physically coupled to the consumable 104d and is instead coupled to the charging station. The electrical interface 126d may also be used to identify the consumable 104d from a list of known consumables. For example, the consumable 104d may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126d). This can be indicated to the controller 120d of the main body 102d when the consumable 104d is connected to the main body 102d. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102d and a corresponding communication interface in the consumable 104d such that, when connected, the consumable 104d can identify itself to the main body 102d.

The additional components 128d of the main body 102d may comprise the light 116d discussed above.

The additional components 128d of the main body 102d may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118d is a rechargeable battery). This may be located at the lower end 110d of the main body 102d. Alternatively, the electrical interface 126d discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128d of the main body 102d may, if the power source 118d is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128d of the main body 102d may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100d, e.g., caused by a user inhaling through a mouthpiece 136d of the consumable 104d. The smoking substitute system 100d may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104d. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128d of the main body 102d may include a user input, e.g., a button. The smoking substitute system 100d may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100d.

As shown in FIG. 16B, the consumable 104d includes the tank 106d, an electrical interface 130d, a vaporizer 132d, one or more air inlets 134d, a mouthpiece 136d, and one or more additional components 138d.

The electrical interface 130d of the consumable 104d may include one or more electrical contacts. The electrical interface 126d of the main body 102d and an electrical interface 130d of the consumable 104d are configured to contact each other and thereby electrically couple the main body 102d to the consumable 104d when the lower end 111d of the consumable 104d is inserted into the upper end 108d of the main body 102d (as shown in FIG. 15A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118d in the main body 102d to the vaporizer 132d in the consumable 104d.

The vaporizer 132d is configured to heat and vaporize e-liquid contained in the tank 106d using electrical energy supplied from the power source 118d. As will be described further below, the vaporizer 132d includes a heating filament and a wick. The wick draws e-liquid from the tank 106d and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134d are preferably configured to allow air to be drawn into the smoking substitute system 100d, when a user inhales through the mouthpiece 136d. When the consumable 104d is physically coupled to the main body 102d, the air inlets 134d receive air, which flows to the air inlets 134d along a gap between the main body 102d and the lower end 110d of the consumable 104d.

In operation, a user activates the smoking substitute system 100d, e.g., through interaction with a user input forming part of the main body 102d or by inhaling through the mouthpiece 136d as described above. Upon activation, the controller 120d may supply electrical energy from the power source 118d to the vaporizer 132d (via electrical interfaces 126d, 130d), which may cause the vaporizer 132d to heat e-liquid drawn from the tank 106d to produce a vapor which is inhaled by a user through the mouthpiece 136d.

An example of one of the one or more additional components 138d of the consumable 104d is an interface for obtaining an identifier of the consumable 104d. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104d may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102d.

It should be appreciated that the smoking substitute system 100d shown in FIG. 15A to FIG. 16B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 17A is a section view of the consumable 104d described above. The consumable 104d comprises a tank 106d for storing e-liquid, a mouthpiece 136d and a passage 140d extending along a longitudinal axis of the consumable 104d. In the illustrated embodiment the passage 140d is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106d surrounds the passage 140d, such that the passage 140d extends centrally through the tank 106d.

A tank housing 142d of the tank 106d defines an outer casing of the consumable 104d, whilst a passage wall 144d defines the passage 140d. The tank housing 142d extends from the lower end 111d of the consumable 104d to the mouthpiece 136d at the upper end 109d of the consumable 104d. At the junction between the mouthpiece 136d and the tank housing 142d, the mouthpiece 136d is wider than the tank housing 142d, so as to define a lip 146d that overhangs the tank housing 142d. This lip 146d acts as a stop feature when the consumable 104d is inserted into the main body 102d (i.e., by contact with an upper edge of the main body 102d).

The tank 106d, the passage 140d and the mouthpiece 136d are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 18, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142d tapers, such that the thickness of the tank housing 142d decreases in a first demolding direction (as will be discussed further with respect to FIG. 18). In FIG. 17A the first demolding direction is in a downward direction away from the mouthpiece 136d. This means that, aside from a small number of indents (which provide physical connection between the consumable 104d and the main body 102d), the thickness of the tank housing 142d decreases with increasing distance away from the mouthpiece 136d. In particular, the tank housing 142d tapers in this way, because internal and external surfaces of the tank housing 142d are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142d and passage wall 144d as a single (i.e., unitary) component.

Like the tank housing 142d, the passage wall 144d is also tapered such that the thickness of the passage wall 144d decreases along the first demolding direction. Again, the thickness of the passage wall 144d decreases due to internal and external surfaces of the passage wall 144d being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144d, the passage 140d has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 17A). For example, the passage 140d has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140d (e.g., approximately 3.6 mm). On the other hand, the passage 140d has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140d (e.g., approximately 3.4 mm).

The mouthpiece 136d comprises a mouthpiece aperture 148d defining an outlet of the passage 140d. The mouthpiece aperture 148d has a radially inwardly directed inner surface 150d, which joins an outer surface 152d of the mouthpiece 136d (i.e., a surface which contacts a user's lips in use) at an outer edge 154d of the mouthpiece aperture 148d. At this outer edge 154d, the included angle between the inner surface 150d of the mouthpiece aperture 148d and the outer surface 152d of the mouthpiece 136d (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154d being rounded. This outer edge 154d may otherwise be chamfered or beveled.

The vaporizer 132d is located in a vaporizing chamber 156d of the consumable 104d. This is best shown in FIG. 17B, which provides a detailed view of the vaporizing chamber 156d. The vaporizing chamber 156d is downstream of the air inlet 134d of the consumable 104d and is fluidly connected to the mouthpiece aperture 148d (i.e., outlet) by the passage 140d. In particular, the passage 140d extends between the mouthpiece aperture 148d and a passage opening 158d from the vaporizing chamber 156d. This passage opening 158d is formed in a downstream (i.e., upper) wall 160d of the vaporizing chamber 156d.

The vaporizer 132d comprises a porous wick 162d and a heater filament 164d coiled around the porous wick 162d. As is apparent from FIG. 17A and FIG. 17B, the porous wick 162d extends transversely across the vaporizing chamber 156d between sidewalls 166ad, 166b of the vaporizing chamber 156d which form part of an inner sleeve 168d of a silicone insert 170d that defines the lower end 111d of the consumable 104d that connects with the main body 102d. The insert 170d is inserted into an open lower end of the tank 106d so as to seal against the internal surface of the tank housing 142d.

In this way, the inner sleeve 168d projects into the tank 106d and seals with the passage 140d (around the passage wall 144d) so as to separate the vaporizing chamber 156d from the e-liquid in the tank 106d. Ends of the porous wick 162d project through apertures in the inner sleeve 168d and into the tank 106d so as to be in contact with the e-liquid in the tank 106d. In this way, e-liquid is transported along the porous wick 162d (e.g., by capillary action) to a central portion of the porous wick 162d. The transported e-liquid is heated by the heater filament 164d (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing in the vaporizing chamber 156d. This vaporized liquid may cool to form an aerosol in the passage 140d, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the vaporizing chamber 156d. This may be undesirable for a user. To reduce or avoid this, the consumable 104d comprises a baffle 172d, which is shown in more detail in FIG. 17B. The baffle 172d extends across the vaporizing chamber 156d so as to be interposed between the vaporizer 132d and the passage opening 158d. In this way, un-vaporized liquid from the porous wick 162d may collect on an upstream (i.e., lower) planar surface 174d of the baffle 172d rather than entering the passage opening 158d. The baffle 172d also causes the chamber airflow path from the vaporizer 132d to the passage opening 158d to be redirected around the baffle 172d.

The baffle 172d depends from and is integral with a (second) side wall 166b of the vaporizing chamber 156d, i.e., the baffle 172d is integral with the silicone insert 170d. The baffle 172d comprises an upstream edge 176d around which the airflow is redirected. This upstream edge 176d and the (first) sidewall 166a of the vaporizing chamber 156d define a single aperture 178d at a lateral edge of the baffle 172d. The aperture 178d is laterally offset from the longitudinal axis of the passage opening 158d. The baffle 172d further comprises a downstream edge 179d.

As shown in FIG. 17C, first portion 182d of the chamber airflow path extends in a generally longitudinal direction to the vaporizer 132d from the air inlet 134d and is aligned with the axial center of the device (i.e., aligned with the longitudinal axis of the passage 140d). A second portion 183d of the chamber airflow path then extends generally radially from the vaporizer 132d to the aperture 178d. Thus, there is a first lateral deflection in the chamber airflow path as it passes from the vaporizer 132d to the aperture 178d.

A third portion 184d of the chamber airflow path from the aperture 178d (i.e., the upstream edge 176d of the baffle 179d) to the downstream edge 179d of the baffle 172d is generally longitudinal and is laterally offset from the axial center of the device. Thus, there is a first axial deflection between the second and third portions 183d, 184d of the chamber air flow path. The transverse cross-sectional area of the third portion 184d of the chamber air flow path as it passes between the upstream and downstream edges 176d, 179d is substantially constant.

A fourth portion 185d of the chamber airflow path between the third portion 184d and the passage 140d extends generally radially (laterally) parallel to a planar upper surface of the baffle 172d, such that there is a second lateral deflection between the third and fourth portions 184d, 185d of the chamber airflow path.

Upon inhalation by a user at the mouthpiece aperture 148d, air flows along the single, unified chamber airflow path around the porous wick 162d, through the aperture 178d and into the passage 140d via the passage opening 158d.

FIG. 18 shows a drawing of a manufacturing assembly 282d which is used to manufacture the consumable 104d. The manufacturing assembly 282d comprises a first mold 284d and a second mold 286d.

The first mold 284d has a shape which complements that of a first end of the integrally formed tank housing 142d and mouthpiece 136d. The first mold 284d therefore has a shape which matches the inner surfaces defining the tank 106d.

The second mold 286d has a shape which complements that of a second end of the integrally formed tank housing 142d and mouthpiece 136d. The second mold 286d has a shape which matches the outer surface of the mouthpiece 136d and the inner surface of the mouthpiece aperture 148d.

When the first mold 284d and the second mold 286d are brought together, they define a closed cavity which has the shape of the tank housing 142d, the mouthpiece 136d and the passage walls 144d.

To manufacture these components, heated material is injected into the cavity between the first mold 284d and the second mold 286d. At this point, the first mold 284d and the second mold 286d meet at a boundary between external surfaces of the mouthpiece 136d and the tank housing 142d.

The material is subsequently cooled, and the first mold 284d and the second mold 286d are separated, with the first mold 284d travelling in the first demolding direction 288d (i.e., away from the second mold 286d) and the second mold 286d travelling in a second demolding direction 290d (i.e., away from the first mold 284d and opposite to the first demolding direction 288d). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The insert 170d and any additional components are subsequently inserted into the tank 106d.

Fifth Mode: An Aerosol Delivery Device with an Airflow Path Circumventing a Vaporizer

Aspects and embodiments of the fifth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 19A shows a first embodiment of a smoking substitute system 100e. In this example, the smoking substitute system 100e includes a main body 102e and an aerosol delivery device in the form of a consumable 104e. The consumable 104e may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100e is a closed system vaping system, wherein the consumable 104e includes a sealed tank 106e and is intended for single-use only. The consumable 104e is removably engageable with the main body 102e (i.e., for removal and replacement). FIG. 19A shows the smoking substitute system 100e with the main body 102e physically coupled to the consumable 104e, FIG. 19B shows the main body 102e of the smoking substitute system 100e without the consumable 104e, and FIG. 19C shows the consumable 104e of the smoking substitute system 100e without the main body 102e.

The main body 102e and the consumable 104e are configured to be physically coupled together by pushing the consumable 104e into a cavity at an upper end 108e of the main body 102e, such that there is an interference fit between the main body 102e and the consumable 104e. In other examples, the main body 102e and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104e includes a mouthpiece (not shown in FIG. 19A, 18 or 1C) at an upper end 109e of the consumable 104e, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104e when a user inhales through the mouthpiece. The tank 106e containing e-liquid is located at the lower end 111e of the consumable 104e.

The tank 106e includes a window 112e, which allows the amount of e-liquid in the tank 106e to be visually assessed. The main body 102e includes a slot 114e so that the window 112e of the consumable 104e can be seen whilst the rest of the tank 106e is obscured from view when the consumable 104e is inserted into the cavity at the upper end 108e of the main body 102e.

The lower end 111e of the main body 102e also includes a light 116e (e.g., an LED) located behind a small translucent cover. The light 116e may be configured to illuminate when the smoking substitute system 100e is activated. While not shown, the consumable 104e may identify itself to the main body 102e, via an electrical interface, RFID chip, or barcode.

FIG. 20A and FIG. 20B are schematic drawings of the main body 102e and consumable 104e. As is apparent from FIG. 20A, the main body 102e includes a power source 118e, a controller 120e, a memory 122e, a wireless interface 124e, an electrical interface 126e, and, optionally, one or more additional components 128e.

The power source 118e is preferably a battery, more preferably a rechargeable battery. The controller 120e may include a microprocessor, for example. The memory 122e preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120e to perform certain tasks or steps of a method.

The wireless interface 124e is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124e could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124e may also be configured to communicate wirelessly with a remote server.

The electrical interface 126e may be located in a base of the aperture in the upper end 108e of the main body 102e. When the main body 102e is physically coupled to the consumable 104e, the electrical interface 126e is configured to transfer electrical power from the power source 118e to the consumable 104e (i.e., upon activation of the smoking substitute system 100e).

The electrical interface 126e may be configured to receive power from a charging station when the main body 102e is not physically coupled to the consumable 104e and is instead coupled to the charging station. The electrical interface 126e may also be used to identify the consumable 104e from a list of known consumables. For example, the consumable 104e may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126e). This can be indicated to the controller 120e of the main body 102e when the consumable 104e is connected to the main body 102e. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102e and a corresponding communication interface in the consumable 104e such that, when connected, the consumable 104e can identify itself to the main body 102e.

The additional components 128e of the main body 102e may comprise the light 116e discussed above.

The additional components 128e of the main body 102e may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118e is a rechargeable battery). This may be located at the lower end 110e of the main body 102e. Alternatively, the electrical interface 126e discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128e of the main body 102e may, if the power source 118e is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128e of the main body 102e may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100e, e.g., caused by a user inhaling through a mouthpiece 136e of the consumable 104e. The smoking substitute system 100e may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104e. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128e of the main body 102e may include a user input, e.g., a button. The smoking substitute system 100e may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100e.

As shown in FIG. 20B, the consumable 104e includes the tank 106e, an electrical interface 130e, a vaporizer 132e, one or more air inlets 134e, a mouthpiece 136e, and one or more additional components 138e.

The electrical interface 126e of the main body 102e and an electrical interface 130e of the consumable 104e are configured to contact each other and thereby electrically couple the main body 102e to the consumable 104e when the lower end 110e of the consumable 104e is inserted into the upper end of the main body 102e (as shown in FIG. 19A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118e in the main body 102e to the vaporizer 132e in the consumable 104e.

The vaporizer 132e is configured to heat and vaporize e-liquid contained in the tank 106e using electrical energy supplied from the power source 118e. As will be described further below, the vaporizer 132e includes a heating filament and a wick. The wick draws e-liquid from the tank 106e and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134e are preferably configured to allow air to be drawn into the smoking substitute system 100e, when a user inhales through the mouthpiece 136e. When the consumable 104e is physically coupled to the main body 102e, the air inlets 134e receive air, which flows to the air inlets 134e along a gap between the main body 102e and the lower end 110e of the consumable 104e.

In operation, a user activates the smoking substitute system 100e, e.g., through interaction with a user input forming part of the main body 102e or by inhaling through the mouthpiece 136e as described above. Upon activation, the controller 120e may supply electrical energy from the power source 118e to the vaporizer 132e (via electrical interfaces 126e, 130e), which may cause the vaporizer 132e to heat e-liquid drawn from the tank 106e to produce a vapor which is inhaled by a user through the mouthpiece 136e.

An example of one of the one or more additional components 138e of the consumable 104e is an interface for obtaining an identifier of the consumable 104e. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104e may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102e.

It should be appreciated that the smoking substitute system 100e shown in FIG. 19A to FIG. 20B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 21 is a section view of the consumable 104e described above. The consumable 104e comprises a tank 106e for storing e-liquid, a mouthpiece 136e and a passage 140e extending along a longitudinal axis of the consumable 104e. In the illustrated embodiment the passage 140e is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106e surrounds the passage 140e, such that the passage 140e extends centrally through the tank 106e.

A tank housing 142e of the tank 106e defines an outer casing of the consumable 104e, whilst a passage wall 144e defines the passage 140e. The tank housing 142e extends from the lower end 111e of the consumable 104e to the mouthpiece 136e at the upper end 109e of the consumable 104e. At the junction between the mouthpiece 136e and the tank housing 142e, the mouthpiece 136e is wider than the tank housing 142e, so as to define a lip 146e that overhangs the tank housing 142e. This lip 146e acts as a stop feature when the consumable 104e is inserted into the main body 102e (i.e., by contact with an upper edge of the main body 102e).

The tank 106e, the passage 140e and the mouthpiece 136e are integrally formed with each other so as to form a single unitary component. This component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142e tapers, such that the thickness of the tank housing 142e decreases in a downward direction away from the mouthpiece 136e. This means that, aside from a small number of indents (which provide physical connection between the consumable 104e and the main body 102e), the thickness of the tank housing 142e decreases with increasing distance away from the mouthpiece 136e. In particular, the tank housing 142e tapers in this way, because internal and external surfaces of the tank housing 142e are angled with respect to the downward direction away from the mouthpiece 136e. This tapering assists in forming the tank housing 142e and passage wall 144e as a single (i.e., unitary) component.

The mouthpiece 136e comprises a mouthpiece aperture 148e defining an outlet of the passage 140e.

The vaporizer 132e is located in a vaporizing chamber 156e of the consumable 104e. The vaporizing chamber 156e is downstream of the air inlets 134e (discussed later with references to FIG. 22A-FIG. 22C) of the consumable 104e and is fluidly connected to the mouthpiece aperture 148e (i.e., outlet) by the passage 140e. In particular, the passage 140e extends between the mouthpiece aperture 148e and an opening 158e from the chamber 156e. This opening 158e is formed in a downstream (i.e., upper) wall 160e of the chamber 156e.

The lower end 111e (i.e., base) of the consumable 104e that connects with the main body 102e is defined by a base insert 170e. The base insert 170e is inserted into an open lower end of the tank 106e so as to seal against an internal surface of the tank housing 142e.

The vaporizer 132e comprises a porous wick 162e and a heater filament 164e (not shown in FIG. 21, but described in more detail below in relation to FIG. 22A to FIG. 22C) coiled around the porous wick 162e. The porous wick 162e extends transversely across the chamber 156e between sidewalls of the chamber 156e which form part of an inner sleeve 168e of the base insert 170e.

The inner sleeve 168e projects into the tank 106e and seals with the passage 140e (around the passage wall 144e) so as to separate the chamber 156e from the e-liquid in the tank 106e. Transverse ends of the porous wick 162e project into the tank 106e so as to be in contact with the e-liquid in the tank 106e. In this way, e-liquid is transported along the porous wick 162e (e.g., by capillary action) to a central portion of the porous wick 162e that is exposed to airflow through the chamber 156e. The transported e-liquid is heated by the heater filament 164e (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing within the vaporizing chamber 156e. This vaporized liquid may cool to form an aerosol in the passage 140e, which may then be inhaled by a user.

FIG. 22A illustrates the base insert 170e of the consumable 104e. FIG. 22A also illustrates the coiled heater filament 164e but does not show the porous wick 162e. A pair of contact pins 200e having a circular cross section in the longitudinal direction are embedded in the base portion 170e. As is more clearly shown in FIG. 22C, the contact pins 200e extend through the base portion 170e in a direction substantially parallel to the longitudinal axis of the consumable 104e.

An upper (downstream) face 202e of each of the pair of contact pins 200e is electrically connected to respective ends of the heater filament 164e. The upper face 202e of each of the pair of contact pins 200e is also physically connected to respective ends of the heater filament 164e. The upper faces 202e of the contact pins 200e may be connected to the heater filament 164e by crimping, welding or compressing.

As shown in FIG. 22B, a lower (upstream) face 204e of each of the contact pins 200e comprises the electrical interface 130e for interfacing with the corresponding electrical interface 126e on the main body 102e. Thus, when the consumable 104e is engaged with the main body 102e, the lower faces 204e of the contact pins 200e contact corresponding electrical contacts on the main body 102e. As the main body electrical contacts are electrically connected to the power source 118e, power can be supplied by the main body 102e, via the contact pins 200e, to the heater filament 164e in order to heat the heater filament 164e.

The contact pins 200e are aligned with each other in a transverse direction perpendicular to the longitudinal direction of the device. The contact pins 200e are also transversely aligned parallel to the transversely extending porous wick 162e.

Furthermore, as shown more clearly in FIG. 22C, the connection between the upper face 202e of each contact pin 200e and the heater filament 164e is located upstream of the heater filament 164e and porous wick 162e.

As shown in FIG. 22C, the heater filament 164e and the porous wick 162e are positioned to overlie the axial center of the base insert 170e. Accordingly, the heater filament 164e and porous wick 162e are centrally positioned in the consumable 104e in the transverse plane relative to the longitudinal axis of the consumable 104e, such that the central longitudinal axis 210e of the consumable 104e intersects the heater filament 164e and porous wick 162e.

Each contact pin 200e is spaced in the transverse direction from the central longitudinal axis 210e of the consumable 104e. Specifically, each contact pin 200e is spaced from the central longitudinal axis 210e of the consumable 104e by a same distance on either side of the central longitudinal axis 210e.

Each of the contact pins 200e is substantially cylindrical. However, as shown in FIG. 22A-FIG. 22C, each contact pin 200e tapers towards the upper face 202e, which is connected to the heater filament 164e.

The contact pins 200e may be formed from a metal/metal alloy with high electrical conductivity. The contact pins 200e may be formed from one or more of silver, copper, gold, platinum, palladium, tungsten, nickel, graphite, molybdenum, for example.

As previously mentioned, the heater filament 164e and porous wick 162e are positioned within a vaporizing chamber 156e. As shown in FIG. 22A-FIG. 22C, a pair of inlet channels 220e extend through the base insert 170e into the vaporizing chamber 156e. The inlet channels extend in a generally longitudinal direction of the device. They allow air to flow through the base insert 170e from air inlets 134e at the lowermost surface 111e of the consumable 104e (i.e., lowermost surface of the base portion 170e), through openings 224e into the vaporizing chamber 156e. Thus, by drawing on the mouthpiece 136e, a user may draw air through the air inlets 134e, the inlet channels 220e, the vaporizing chamber 156e, the passage 140e, and out through the outlet defined by the mouthpiece aperture 148e in the mouthpiece 136e.

In FIG. 22A-FIG. 22C, the two openings 224e of the inlet channels 220e are transversely offset from the central longitudinal axis 210e of the consumable 104e on either side of the central longitudinal axis 210e in the front to back direction. The two openings 224e of the inlet channels 220e are equally spaced from the central longitudinal axis 210e of the aerosol delivery device on either side of the central longitudinal axis 210e. They are aligned with each other in the front to rear direction.

The openings 224e of the inlet channels 220e are formed in perpendicular stepped portions 230e in the front and rear walls of the vaporizing chamber 156e. The stepped portions 230e in the front and rear walls, and therefore the openings 224e of the inlet channels 220e, are axially downstream of the heater filament 164e and the porous wick 162e.

The openings 224e of the inlet channels 220e are elongated in the transverse direction such that they extend substantially parallel to the transversely-extending porous wick 162e. The air inlets 134e at the lowermost surface 111e of the base portion 170e are also elongated in the transverse direction such that they extend substantially parallel to the transverse axis aligning the lower faces 204e of the contact pins 200e on the lowermost surface of the base portion.

Sixth Mode: A Smoking Substitute Device Having an Air Inlet

Aspects and embodiments of the sixth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 23A shows a first embodiment of a smoking substitute system 100f. In this example, the smoking substitute system 100f includes a device 102f and a consumable 104f. The consumable 104f may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the device may be integral with the consumable. In such (open) systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100f is a closed system vaping system, wherein the consumable 104f includes a sealed tank 106f and is intended for single-use only. The consumable 104f is removably engageable with the device 102f (i.e., for removal and replacement). FIG. 23A shows the smoking substitute system 100f with the device 102f physically coupled to the consumable 104f, FIG. 23B shows the device 102f of the smoking substitute system 100f without the consumable 104f, and FIG. 23C shows the consumable 104f of the smoking substitute system 100f without the device 102f.

The device 102f and the consumable 104f are configured to be physically coupled together by pushing the consumable 104f into a cavity (not shown in FIG. 23A-FIG. 23C) at an upper end 108f of the device 102f, such that there is an interference fit between the device 102f and the consumable 104f. In other examples, the device 102f and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104f includes a mouthpiece (not shown in FIG. 23A-1C) at an upper end 109f of the consumable 104f, and one or more air inlets (again, not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104f when a user inhales through the mouthpiece. The tank 106f containing e-liquid is located at the lower end 111f of the consumable 104f.

The tank 106f includes a window 112f, which allows the amount of e-liquid in the tank 106f to be visually assessed. The device 102f includes a slot 114f so that the window 112f of the consumable 104f can be seen whilst the rest of the tank 106f is obscured from view when the consumable 104f is inserted into the cavity at the upper end 108f of the device 102f.

The lower end 110f of the device 102f also includes a light 116f (e.g., an LED) located behind a small translucent cover. The light 116f may be configured to illuminate when the smoking substitute system 100f is activated. Whilst not shown, the consumable 104f may identify itself to the device 102f, via an electrical interface, RFID chip, or barcode.

FIG. 24A and FIG. 24B are schematic drawings of the device 102f and consumable 104f. As is apparent from FIG. 24A, the device 102f includes a power source 118f, a controller 120f, a memory 122f, a wireless interface 124f, an electrical interface 126f, and, optionally, one or more additional components 128f.

The power source 118f is preferably a battery, more preferably a rechargeable battery. The controller 120f may include a microprocessor, for example. The memory 122f preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120f to perform certain tasks or steps of a method.

The wireless interface 124f is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124f could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124f may also be configured to communicate wirelessly with a remote server.

The electrical interface 126f of the device 102f may include one or more electrical contacts. The electrical interface 126f may be located at a base of the cavity in the upper end 108f of the device 102f. When the device 102f is physically coupled to the consumable 104f, the electrical interface 126f is configured to transfer electrical power from the power source 118f to the consumable 104f (i.e., upon activation of the smoking substitute system 100f).

The electrical interface 126f may be configured to receive power from a charging station when the device 102f is not physically coupled to the consumable 104f and is instead coupled to the charging station. The electrical interface 126f may also be used to identify the consumable 104f from a list of known consumables. For example, the consumable 104f may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126f). This can be indicated to the controller 120f of the device 102f when the consumable 104f is connected to the device 102f. Additionally, or alternatively, there may be a separate communication interface provided in the device 102f and a corresponding communication interface in the consumable 104f such that, when connected, the consumable 104f can identify itself to the device 102f.

The additional components 128f of the device 102f may comprise the light 116f discussed above.

The additional components 128f of the device 102f may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118f is a rechargeable battery). This may be located at the lower end 110f of the device 102f. Alternatively, the electrical interface 126f discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128f of the device 102f may, if the power source 118f is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128f of the device 102f may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the substitute system 100f, e.g., caused by a user inhaling through a mouthpiece 136f of the consumable 104f. The smoking substitute system 100f may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104f. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128f of the device 102f may include a user input, e.g., a button. The smoking substitute system 100f may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100f.

As shown in FIG. 24B, the consumable 104f includes the tank 106f, an electrical interface 130f, a vaporizer 132f, one or more air inlets 134f, a mouthpiece 136f, and one or more additional components 138f.

The electrical interface 130f of the consumable 104f may include one or more electrical contacts. The electrical interface 126f of the device 102f and an electrical interface 130f of the consumable 104f are configured to contact each other and thereby electrically couple the device 102f to the consumable 104f when the lower end 111f of the consumable 104f is inserted into the cavity at the upper end of the device 102f (as shown in FIG. 23A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118f of the device 102f to the vaporizer 132f of the consumable 104f.

The vaporizer 132f is configured to heat and vaporize e-liquid contained in the tank 106f using electrical energy supplied from the power source 118f. As will be described further below, the vaporizer 132f includes a heating filament and a wick. The wick draws e-liquid from the tank 106f and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlet(s) 134f are preferably configured to allow air to be drawn into the consumable 104f, when a user inhales through the mouthpiece 136f. As will be discussed further below, when the consumable 104f is physically coupled to the device 102f air flows along an airflow path between the device 102f and the lower end 111f of the consumable 104f to the air inlet(s) of the consumable 104f.

In operation, a user activates the smoking substitute system 100f, e.g., through interaction with a user input forming part of the device 102f or by inhaling through the mouthpiece 136f as described above. Upon activation, the controller 120f may supply electrical energy from the power source 118f to the vaporizer 132f (via electrical interfaces 126f, 130f), which may cause the vaporizer 132f to heat e-liquid drawn from the tank 106f to produce a vapor which is inhaled by a user through the mouthpiece 136f.

An example of one of the one or more additional components 138f of the consumable 104f is an interface for obtaining an identifier of the consumable 104f. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104f may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the device 102f.

It should be appreciated that the smoking substitute system 100f shown in FIG. 23A to FIG. 24B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 25A is a schematic section view of an upper end of the device 102f. The device 102f comprises a body 174f accommodating the power source 118f, and side walls 176f. The side walls 176f extend (upwardly) from an end surface 184f of the body 174f in a longitudinal direction so as to define a cavity 178f for receipt of the consumable 104f. In order to facilitate engagement with the consumable 104f, two of the side walls 176f include two inwardly extending projections 180f. These projections 180f engage with recesses of the consumable 104f when received in the cavity 178f, so as to help retain the consumable 104f in the cavity 178f. When engaged in this manner (as shown in FIG. 25B), the consumable 104f interfaces with the electrical interface 130f (in the form of electrical contacts) of the device 102f such that power is supplied to the consumable 104f from the power source 118f of the device 102f.

Each of the side walls 176f comprises an air inlet aperture 182f formed therein. Each air inlet aperture 182f is formed in its respective side wall 176f at a (longitudinal) position that is adjacent the end surface 184f of the cavity 178f. That is, a lower edge of each aperture 182f is aligned with the end surface 184f of the cavity 178f. As will be discussed further below with response to FIG. 25B, this positioning of the apertures 182f allows air (i.e., that is external to the device 102f) to be directed into the cavity 178f in a substantially transverse direction and between body 174f (i.e., the end surface 184f) and the consumable 104f.

FIG. 25B is a section view of the device 102f engaged with the consumable 104f. The consumable 104f comprises a tank 106f for storing e-liquid, a mouthpiece 136f and a passage 140f extending along a longitudinal axis of the consumable 104f. In the illustrated embodiment the passage 140f is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106f surrounds the passage 140f, such that the passage 140f extends centrally through the tank 106f.

A tank housing 142f of the tank 106f defines an outer casing of the consumable 104f, whilst a passage wall 144f defines the passage 140f. The tank housing 142f extends from the lower end 111f of the consumable 104f to the mouthpiece 136f at the upper end 109f of the consumable 104f. At the junction between the mouthpiece 136f and the tank housing 142f, the mouthpiece 136f is wider than the tank housing 142f, so as to define a lip 146f that overhangs the tank housing 142f. This lip 146f acts as a stop feature when the consumable 104f is inserted into the device 102f (i.e., by contact with an upper end of the side walls 176f of the device 102f).

The tank 106f, the passage 140f and the mouthpiece 136f are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 26, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142f tapers, such that the thickness of the tank housing 142f decreases in a first demolding direction (as will be discussed further with respect to FIG. 26). In FIG. 25A the first demolding direction is in a downward direction away from the mouthpiece 136f. This means that, aside from a small number of indents (which provide physical connection between the consumable 104f and the device 102f), the thickness of the tank housing 142f decreases with increasing distance away from the mouthpiece 136f. In particular, the tank housing 142f tapers in this way, because internal and external surfaces of the tank housing 142f are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142f and passage wall 144f as a single (i.e., unitary) component.

Like the tank housing 142f, the passage wall 144f is also tapered such that the thickness of the passage wall 144f decreases along the first demolding direction. Again, the thickness of the passage wall 144f decreases due to internal and external surfaces of the passage wall 144f being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144f, the passage 140f has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 25B). For example, the passage 140f has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140f (e.g., approximately 3.6 mm). On the other hand, the passage 140f has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140f (e.g., approximately 3.4 mm).

The mouthpiece 136f comprises a mouthpiece aperture 148f defining an outlet of the passage 140f. The mouthpiece aperture 148f has a radially inwardly directed inner surface 150f, which joins an outer surface 152f of the mouthpiece 136f (i.e., a surface which contacts a user's lips in use) at an outer edge 154f of the mouthpiece aperture 148f. At this outer edge 154f, the included angle between the inner surface 150f of the mouthpiece aperture 148f and the outer surface 152f of the mouthpiece 136f (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154f being rounded. This outer edge 154f may otherwise be chamfered or beveled.

The vaporizer 132f is located in a vaporizing chamber 156f of the consumable 104f. The vaporizing chamber 156f is fluidly connected to the mouthpiece aperture 148f (i.e., outlet) by the passage 140f. In particular, the passage 140f extends between the mouthpiece aperture 148f and a passage opening 158f from the chamber 156f. This passage opening 158f is formed in a downstream (i.e., upper) wall 160f of the chamber 156f.

The air inlet 134f of the consumable 104f (as discussed above) is an air inlet 134f to the vaporizing chamber. This air inlet 134f is fluidly connected to each of the air inlet apertures 182f via respective airflow paths that extend transversely across the end surface 184f of the body 174f. In particular, these airflow paths are defined between the body 174f (i.e., the end surface 184f) and the consumable 104f (i.e., the insert 170f). That is, when the consumable 104f is received in the cavity 178f, a gap is maintained between the insert 170f and the end surface 184f. This gap is aligned with the air inlet apertures 182f to permit transverse airflow therethrough. Whilst not shown, the end surface 184f or the consumable 104f may comprise guide surfaces (e.g., ribs) that project therefrom so as to at least partly define the airflow path (e.g., to define the transverse path that the airflow takes).

The vaporizer 132f comprises a porous wick 162f and a heater filament 164f coiled around the porous wick 162f. The porous wick 162f extends transversely across the chamber 156f between sidewalls 166f of the chamber 156f which form part of an inner sleeve 168f of an insert 170f that defines the lower end 111f of the consumable 104f (i.e., that connects with the device 102f). The insert 170f is inserted into an open lower end of the tank 106f so as to seal against the tank housing 142f.

In this way, the inner sleeve 168f projects into the tank 106f and seals with the passage 140f (around the passage wall 144f) so as to separate the chamber 156f from the e-liquid in the tank 106f. Ends of the porous wick 162f project through apertures in the inner sleeve 168f and into the tank 106f so as to be in contact with the e-liquid in the tank 106f. In this way, e-liquid is transported along the porous wick 162f (e.g., by capillary action) to a central portion of the porous wick 162f that is exposed to airflow through the chamber 156f. The transported e-liquid is heated by the heater filament 164f (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing past the porous wick 162f. This vaporized liquid may cool to form an aerosol in the passage 140f, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156f. This may be undesirable for a user. To reduce this, the consumable 104f comprises a baffle 172f. The baffle 172f extends across the chamber 156f so as to be interposed between the vaporizer 132f and the passage opening 158f. In this way, un-vaporized liquid from the porous wick 162f may collect on an upstream (i.e., lower) planar surface of the baffle 172f rather than entering the passage opening 158f.

FIG. 26 shows a drawing of a manufacturing assembly 286f which is used to manufacture the consumable 104f described above. The manufacturing assembly 286f comprises a first mold 288f and a second mold 290f.

The first mold 288f has a shape which complements that of a first end of the integrally formed tank housing 142f and mouthpiece 136f. The first mold 288f therefore has a shape which matches the inner surfaces defining the tank 106f.

The second mold 290f has a shape which complements that of a second end of the integrally formed tank housing 142f and mouthpiece 136f. The second mold 290f has a shape which matches the outer surface of the mouthpiece 136f and the inner surface of the mouthpiece aperture 148f.

When the first mold 288f and the second mold 290f are brought together, they define a closed cavity which has the shape of the tank housing 142f, the mouthpiece 136f and the passage walls 144f.

To manufacture these components, heated material is injected into the cavity between the first mold 288f and the second mold 290f. At this point, the first mold 288f and the second mold 290f meet at a boundary between external surfaces of the mouthpiece 136f and the tank housing 142f.

The material is subsequently cooled, and the first mold 288f and the second mold 290f are separated, with the first mold 288f travelling in a first demolding direction 292f (i.e., away from the second mold 290f) and the second mold 290f travelling in a second demolding direction 294f (i.e., away from the first mold 288f and opposite to the first demolding direction 292f). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

Subsequently, the insert 170f (e.g., including the vaporizer) and any additional components are inserted into the tank 106f to form the consumable 104f.

CONCLUSION

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the disclosure in diverse forms thereof.

While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the disclosure that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

Number	Date	Country	Kind
19166271.7	Mar 2019	EP	regional
19166276.6	Mar 2019	EP	regional
19166284.0	Mar 2019	EP	regional
19166304.6	Mar 2019	EP	regional
19166313.7	Mar 2019	EP	regional
19166315.2	Mar 2019	EP	regional
19166318.6	Mar 2019	EP	regional

	Number	Date	Country
Parent	PCT/EP20/56071	Mar 2020	US
Child	17486209		US
Parent	PCT/EP20/56078	Mar 2020	US
Child	PCT/EP20/56071		US
Parent	PCT/EP20/56081	Mar 2020	US
Child	PCT/EP20/56078		US
Parent	PCT/EP20/56085	Mar 2020	US
Child	PCT/EP20/56081		US
Parent	PCT/EP20/56095	Mar 2020	US
Child	PCT/EP20/56085		US
Parent	PCT/EP20/56098	Mar 2020	US
Child	PCT/EP20/56095		US

AEROSOL DELIVERY DEVICE

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Abstract

Description

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Priority Claims (7)

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE STATEMENT

Continuations (6)