SMOKING SUBSTITUTE SYSTEM

FIELD OF THE INVENTION

The present invention relates to smoking substitute systems, a consumable containing a solid additive, and liquid aerosol-forming substrate for use with said consumable and methods for manufacture thereof.

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 are 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 “vapour”, which is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour 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. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute devices as desirable lifestyle accessories. 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 utilising a different smoking substitute approach.

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

A typical vaping smoking substitute device includes a mouthpiece, a power source (typically a battery), a tank 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 “vapour”) 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 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, the main body can be reused by connecting it to a new 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 heating device, which for this device is a heating filament coiled around a portion of a wick which is partially immersed in the e-liquid. 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 heating device, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.

Another example vaping smoking substitute device is the blu PRO™ e-cigarette. The blu PRO™ 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 heating device, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.

A host of e-liquid formulations are commercially available for use in vaping smoking substitute devices. The formulations are typically based on vegetable glycerine or propylene glycol in combination with various flavourings. E-liquids may optionally contain nicotine.

Generally, e-liquids do not contain solid material as this can interfere with the capillary action of the wick and cause problems with clogging. There have been prior proposals for enabling a consumer to infuse base liquid with solid material in order to customise the flavour of the e-liquid. However, the intention is that solid material is removed prior to supplying the e-liquid to a device for vapourization.

There have also been prior proposals for smoking substitute devices that include a cartridge to accommodate a liquid composition that contains solid material. However, the devices are required to include filtering mechanisms to prevent the solid material interfering with transfer of liquid from the cartridge. For example, WO2017/001351 provides a cartridge for an aerosol-generating system having a liquid storage container containing a liquid aerosol-forming substrate that includes at least one flavour object, such as flakes of solid tobacco material having an average thickness between about 30 μm and 120 μm. A filter is arranged between the outlet of the cartridge and a portion of the liquid storage container including the flavour object.

US2018/0297048A also proposes a cartridge for an aerosol-generating system, the cartridge including a liquid storage container containing a first liquid composition and a plurality of capsules, each encapsulating a second liquid composition. The capsules include a frangible shell. Once the capsules have been burst the two liquid compositions mix to form the composition to be aerosolised by an aerosol-generating device. A capsule retainer is provided to prevent any capsule shells from exiting the cartridge.

The present inventors have observed that when utilizing liquid aerosol-forming substrate (vapourisable liquids) which contain a solid suspension, for example flavourings or tobacco, the solids may block the vapourization means, usually by blocking a wick that forms part of the vapourization means. Thus, clogging of the solids can occur around the wick and reduce, or entirely cut off, the wick from the remaining liquid aerosol-forming substrate. Solid materials in the consumable may also be burnt by contact with the vapourization means (e.g. by contact with the coil that is used as a heater) which creates an unpleasant experience for a user. Proposals of the present invention, and their subsidiary aspects, seek to address these problems.

SUMMARY

The proposals set out below have been devised in light of the above considerations. The inventors have identified five alternative solutions (namely the first through to fifth proposals) with the intention of addressing the problem of blocking of the flow of liquid aerosol-forming substrate through a consumable to the vapourization means by solid additive.

First Proposal

According to a first aspect of a first proposal of the invention there is provided a consumable for a smoking substitute device which contains a liquid aerosol-forming substrate, wherein the liquid aerosol-forming substrate comprises a solid additive, characterised in that the solid additive is provided in the form of one or more bodies that are sized to prevent the solid additive blocking the flow of liquid through the consumable.

Typically the consumable comprises a vapourization means which includes a wick, and a tank containing the liquid aerosol-forming substrate which contains a solid additive.

In the present invention, blocking of the flow of liquid aerosol-forming substrate through the consumable to the vapourization means by the solid additive is prevented. Also, blocking of the vapourization means by displaced solids may be prevented.

The present invention may also facilitate the addition of components (materials) to a liquid aerosol-forming liquid (vapourisable liquid) in a carefully controlled manner (as a solid additive) as opposed to adding a powder or granular material to the tank of a consumable in a less controlled manner. The dosing of materials may be more carefully controlled by the use of a solid additive. In some instances the solid additive may remove materials from the liquid aerosol-forming substrate, for example, the solid additive may include a catalyst that removes components from the liquid aerosol-forming substrate.

In the present invention, problems mentioned above are overcome by the use of a solid additive in the form of bodies that are sized to prevent the blocking of the flow of liquid through the consumable. The obstruction of flow of liquid through the consumable is in most cases caused by the blocking of the wick that is located within the tank of a consumable; the blocking of the wick being caused by a build-up of solid material (usually in the form of powder) on the surface of the wick. The powder normally forms a layer on the surface of the wick such that the vapourisable liquid is prevented from passing into the main body of the wick.

In the present invention the use of larger bodies means that a layer of solid material cannot form on the surface of the wick; thus blocking of the wick is prevented. Typically, a consumable does not require a filter for restraining the solid additive to avoid clogging of the wick.

It is preferable that the width, the length and the height of the solid bodies, are each greater than the distance between the walls of the heater assembly and the walls of the tank. The width, length and height are references to the x, y and z axes of the bodies concerned.

The solid additive preferably comprises one or more bodies that have a width, a length and a height which are each greater than 2 mm, in size. It is preferable that the width, a length and a thickness (height), of the solid bodies, each exceeds 2 mm. In this way the solid bodies are unable to enter the space within the consumable between the walls of the tank an assembly (normally a coil and wick assembly).

It is more preferable that the width, the length and the height of the solid bodies are each greater than the distance between the outlet seal and the walls of the tank. Preferably the one or more bodies comprise a width, a length and a height which are each greater than 5 mm, in size. In this way the solid bodies are unable to enter the space within the consumable between the walls of the tank an assembly (normally a coil and wick assembly).

Preferably the one or more bodies comprise at least one dimension greater than 2 mm. Preferably the one or more bodies comprise at least one dimension greater than 5 mm. More preferably the one or more bodies comprise at least one dimension greater than 8 mm.

Preferably the one or more bodies comprise a length in a range of 8 to 25 mm. Preferably the one or more bodies comprise a length in the range 5 to 40 mm. Preferably the one or more bodies comprise a width in a range of 2 to 25 mm.

Preferably the solid additive is provided in the form of one or more bodies that, comprise one or more cavities through which said liquid may flow and/or are shaped to form interstitial spaces through which said liquid may flow, such that blocking of the flow of liquid aerosol-forming substrate (fluid) through the consumable by said solid additive is prevented.

Typically the consumable comprises a vapourization means that is in the form of a heating device. Preferably the heating device comprises a coil and wick, which may be provided as an assembly; the assembly may form a wall of the tank of a consumable, normally the lower wall of the tank.

The liquid aerosol-forming substrate is stored in a tank of a consumable.

Preferably the solid additive provides a means to add or remove components from the liquid aerosol-forming substrate. There are problems associated with using solid material to add or remove material(s) to a liquid aerosol-forming substrate (a vapourisable liquid), i.e. when solid materials are located in the consumable they may block the vapourization means (normally by blocking the wick). The present invention seeks to alleviate this problem.

The term solid additive is used to refer to solid bodies that normally, but not always, comprise materials that are to be added to a liquid aerosol-forming substrate contained within a tank of a consumable; in some instances the solid additive may remove materials from the liquid aerosol-forming substrate. However, most preferably the solid additive is used to add materials to the liquid aerosol-forming substrate. Preferably the solid additive adds one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals, to the liquid aerosol-forming liquid.

In some embodiments, a solid additive may be totally soluble in the liquid aerosol-forming substrate, and may contain one or more materials that is/are to be added to the liquid aerosol-forming substrate. Alternatively the solid additive may comprise one or more components that are soluble in the liquid and/or one or more components that are insoluble in the liquid, i.e. soluble components may be combined with insoluble components that act to facilitate the formation of suitable solid bodies. If the solid additive is totally soluble then it is preferable that the outermost portion of the additive comprises a material that dissolves more slowly than the inner portion of the additive.

The skilled person will appreciate that the bodies may comprise a wide range of shapes, including but not limited to the shapes mentioned below. The bodies used having cross-sectional profiles (across their width) that include, but are not limited to: generally “V” or “W” shaped, generally “S” or “M” shaped, generally “U” shaped, generally “N” shaped, angular, semi-circular, curved, convex, concave, wave shaped, castellated, or branched, for example. These bodies are preferably comprise elongate bodies.

When planar bodies are used the bodies may comprise cavities, in the form of perforations; this ensures that fluid can flow through, as well as around, the planar bodies and thus any resistance to the movement of the liquid aerosol-forming substrate in a tank is minimised. Additionally the inclusion of cavities (in the form of perforations) provides a means for fluid to pass through two or more planar bodies if they form a stack within the tank of a consumable.

The bodies used may be provided in the form of wavy (ribbed) bodies, i.e. bodies that comprise ridges and troughs across their surface and/or may also comprise cross-sectional profiles of the type discussed above. Such bodies may be provided in the form of sheets. Ridges and troughs may be provided as wavy (smoothly rising and falling undulations) or as angular ridges/ribs by the use of repeating units of the shapes described above, for instance repeating “V” or “W” shaped units.

The solid additive may comprise bodies that are not elongate, they are instead of uniform dimensions in relation to their length, width and height, e.g. they may be cuboid or spheroid in shape.

Elongate bodies comprising cavities (more preferably lumens) may, for example, comprise shapes (when viewed in cross-section across their width) that is/are triangular, rectangular, square, circular, ovoid, star shaped, or that comprise multi-sided shapes such as pentagons, hexagons, heptagons, octagons, nonagons, etc. or such bodies may have irregular shapes.

Preferably the solid additive comprises one or more bodies and said bodies comprise one or more shapes chosen from: elongate; spheroidal; ellipsoidal; spherical; planar; irregular, pellet; spaghetti; cuboid; and/or pyramidal. In respect of a sphere it will be appreciated that the length, width and height of the sphere correspond to its diameter. In respect of a spheroidal body the length and width of the body will be the same, but the height will differ. For an ellipsoidal body the height, length and width will all be different.

The bodies used may comprise the general polygonal shapes discussed above, but wherein one of the sides of the body are missing, and/or or sections of walls are missing, to allow liquid to enter (and to pass through) the interior of the body.

Irregularly shaped bodies comprising cavities or without cavities may be utilised. Bodies that are spherical, spheroidal or ellipsoidal in shape may be used.

More preferably the solid additive comprises one or more bodies in the form of elongate and/or planar bodies. It will be appreciated that for planar bodies the height of the body will correspond to the thickness of the planar body.

Preferably the solid additive comprises one or more bodies in the form of planar bodies.

More preferably the planar bodies further comprise cavities in the form of perforations to allow liquid to flow through the plane of the body. Such cavities (perforations) further increase the surface area of the one or more bodies. Additionally the inclusion of cavities (in the form of perforations) provides a means for fluid to pass through two or more planar bodies if they form a stack within a tank.

Preferably the bodies comprise at least one ribbed surface, in order to maximise the interstitial spaces provided.

The use of elongate bodies comprising cavities and planar shapes assists in maximising the surface area of the solid additive that is exposed to the liquid aerosol-forming substrate.

Any of the previously mentioned shapes of bodies may further comprise cavities (preferably in the form of lumen) and/or one or more channels/recesses located in the surface of the bodies. As mentioned above the skilled person will appreciate that a wide range of shapes of bodies, beyond those mentioned above may be employed in the present invention.

Preferably the solid additive comprises one or more bodies comprising one or more cavities through which the liquid aerosol-forming substrate may flow. The use of the term flow indicates that the liquid aerosol-forming substrate is readily able to enter and leave or pass through the cavities. If, for instance, insufficient liquid is present in the tank to completely immerse the one or more solid bodies then fluid will still enter and leave the cavities as the consumable is rotated and moved during its use and if stored in the pocket of a user.

Preferably the solid additive comprises one or more elongate bodies. The provision of solid additives as elongate bodies assists in preventing the solid bodies from blocking the wick and/or passing through the wick and into the heating coil.

Preferably the one or more bodies comprise a length in the range 2 to 40 mm. Alternatively the one or more bodies comprise a length in a range of 4 to 30 mm.

Most preferably the one or more bodies comprise a length in a range of 8 to 24 mm. In most cases providing bodies of this length will result in the bodies being orientated such that they are not perpendicular to the flow of air through the consumable. Bodies of this length will tend to be orientated such that they are positioned generally parallel to the flow direction of air through the consumable, i.e. generally parallel to the longitudinal axis of the tank. This assists in aiding the flow of the liquid through the bodies and into the vapourization means whilst avoiding blocking of the vapourization means which is in most cases a coil and wick assembly. Furthermore the use of larger bodies, and particularly bodies comprising the lengths specified above prevents the solid material from reaching the coil and from entering the wick. Particularly advantageous in this respect are bodies having a length in the range of 8 to 24 mm.

The one or more bodies of the solid additive preferably has a width in a range of 2 to 25 mm. Alternatively, the one or more bodies of the solid additive have a width in a range of 6 to 21 mm. Most preferably the one or more solid bodies have a diameter in a range of 8 to 14 mm.

The width of the solid additive used may be varied depending on the materials that the solid additive is manufactured from and the material(s) that is/are to be released from the additive. The use of solid additives having the widths specified above further assist in preventing the blocking/blinding of the wick.

Preferably the one or more bodies of the solid additive have a thickness or a height in a range of 0.5 to 5 mm. The one or more bodies of the solid additive may have a thickness or a height in a range of 0.5 to 3.0 mm. Most preferably the one or more bodies of the solid additive have a thickness or a height in a range of 0.5 to 2.0 mm.

The use of solid additives in the form of one or more bodies that comprise a cavity, and/or a plurality of bodies that are shaped to form interstitial spaces, means that the liquid aerosol-forming substrate can pass through the body/bodies, either via the cavity and/or through the interstitial spaces between adjacent bodies. In this way the blinding (clogging/blocking) of the wick by the solid additive is prevented as liquid can pass around or through the solid bodies and into the wick, a layer of solid material through which the liquid cannot pass is not formed by the use of such solid bodies of the type disclosed herein.

The cavity is preferably provided in the form of a lumen that has openings (apertures) at either end and/or at two or more locations along the length the body/bodies. The use of bodies/a body comprising lumens is preferred, i.e. hollow tubes that run the length of an elongate body, the tubes are preferably open (i.e. have apertures) at either end. Lumens of this type have the advantage that they provide for a more efficient flow of liquid aerosol-forming substrate through the elongate body as there is less resistance to the flow of liquid. It is preferable that the apertures at the end of the cavity correspond in cross-section to the cavity.

At least two apertures are provided in the body to allow the passage of liquid through the lumen, although additional openings may be provide in the side walls of the body. Alternatively openings may be provided at various locations along the length of the lumen, and the ends of the tube may be sealed.

Preferably one or more bodies are shaped to form the interstitial spaces, and may further comprise one or more recesses in the exterior surface. The inclusion of such recesses means that, when the bodies settle and/or are compacted together, the recesses form the interstitial spaces and/or the recesses may form additional interstitial spaces between adjacent bodies.

When the solid additive comprises one or more cavities each cavity preferably has a diameter in the range of 0.5 mm to 4 mm. Preferably the one or more bodies comprise one or more cavities each having a diameter in the range 0.5 to 2.5 mm. More preferably the one or more bodies comprise one or more cavities each having a diameter in the range 0.5 to 2 mm. More preferably the one or more bodies comprise one or more cavities each having a diameter in the range of 1 mm to 3 mm. Most preferably the one or more bodies comprise one or more cavities each having a diameter in the range 1 to 2 mm.

When the solid additive comprises a cavity, the cavity preferably has a diameter of 1 mm or greater. More preferably the cavity has a diameter of 2 mm or greater. When a body comprises multiple cavities then the cavities preferably have a diameter in the range of 1 mm to 4 mm.

The use of cavities of the sizes detailed above facilitates the flow of the consumable liquid into and out the liquid aerosol-forming substrate.

The skilled addressee will appreciate that if a body is provided in the form of a hollow body then the wall thicknesses of the body will be different to the overall height of the body; the height of the body will obviously be greater than the wall thicknesses. In the cases where a body comprises one or more cavities it is preferable that the height of the body as a whole is in the ranges detailed below to facilitate the use of such bodies in the tank of a consumable.

Preferably the one or more bodies comprise a height and/or a wall thickness in a range of 0.5 to 5 mm. More preferably the one or more bodies comprise a height and/or a wall thickness in a range of 0.5 to 2.5 mm. More preferably the one or more bodies comprise a height and/or a wall thickness in a range of 0.5 to 1.5 mm.

Bodies comprising a height or wall thickness in the ranges detailed above facilitate the release of materials from the bodies or the absorption of materials into said bodies.

Generally speaking, the use of solid additives comprising one or more bodies having wall thickness or thickness/height (when no cavities are present) in a range of 0.5 to 3 mm is preferred to ensure that the materials contained in the additive bodies are completely released into the liquid aerosol-forming substrate by the penetration of said liquid into the solid additive.

Bodies comprising a height or wall thickness in the ranges detailed above facilitate the release of materials from the bodies or the absorption of materials into said bodies.

The rate of release of components from the solid additive may be controlled to some extent by varying the thickness and or wall thickness of the additive. The use of solid additive having one or more bodies that are thicker or have thicker walls is preferred when a slower release of the components present in the additive is/are required.

Solid additives comprising bodies that have thinner walls or that are not as thick are preferred when a quicker release of the components present in the solid additive is required.

When the solid additive comprise cavities, the walls of the cavities are preferably of a consistent cross-section across their width, along the length of the body.

It is most preferable, where appropriate, that the longest axis of the body/bodies of the solid additive is a maximum of ten times the length of the shortest axis, the shortest axis may be a reference to the thickness of the body.

Preferably the solid additive comprises one or more bodies that have been extruded and/or rolled and/or stamped and/or pressed and/or crushed and/or injection moulded and/or cast.

Most preferably the additive comprises bodies that have been extruded. The use of an extrusion process facilitates the manufacture of elongate bodies, in particular bodies comprising cavities, the cavities are preferably provided in the form of open ended lumens.

An extrusion process is preferably used to manufacture the solid additive in the form of bodies that comprise cavities or are cavity free (i.e. solid bodies that comprise no cavities).

When the one or more bodies of the solid additive are provided by means of an extrusion process additive(s) such as plastics, binders or copolymers (such as Polyethylene Glycol) as well as tobacco-based additives may be included in the extruded solid additive. These extrusion process additive(s) help to retain the shape of the solid additive and also resist breakdown of the solid additive in the pod during use of the consumable and/or during the manufacture of the solid additive and/or the consumable.

The solid additive may comprise one or more of; a body with no cavity; a body with one or more cavities; a mesh; a compressed powder; a foam; a porous material; and/or a perforated material.

The one or more bodies of the solid additive may be provided with one or more or more cavities that form flow channels along which a liquid aerosol-forming substrate may pass.

The one or more bodies of the solid additive may be provided by use of a porous material, and such porous materials may comprise one or more of the following:

- i) be shaped to form interstitial spaces; and/or,
- ii) comprise cavities (which may be in the form of pores) through which a liquid aerosol-forming substrate may pass; and/or,
- iii) comprise pores that form channels (on the surface of the porous body) along which a liquid aerosol-forming substrate may pass

The passage of the liquid aerosol-forming substrate through the interstitial spaces and/or the cavities and/or channels of the porous material is sufficient to avoid the impeding of the flow of the liquid to the wick. This a general requirement of the solid additive disclosed herein.

Preferably the additive comprises organic material(s) and/or inorganic material(s).

When the additive comprises one or more inorganic materials, the inorganic material may comprise polymer, glass, ceramic or metal, for example.

The inorganic material may, for instance, be used as a carrier for an organic material, i.e. an organic material could be sorbed onto the surface, or absorbed into an inorganic material such that the organic material is released into the liquid aerosol-forming substrate after the additive is placed within said substrate. Different organic materials may be utilised in the same manner.

Preferably the solid additive comprises one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals. The skilled addressee will appreciate that the solid body is used to add additional components to the liquid aerosol-forming substrate such as flavourants, flavour enhancers, nicotine and additional chemicals to the liquid aerosol-forming substrate in the tank of a consumable.

Preferably the additional chemicals include chemicals for providing colour or odour to the liquid aerosol-forming substrate.

Preferably the one or more bodies comprise tobacco or extracts of tobacco.

The solid additive can be used to add nicotine, flavour or extra chemicals, to act as a catalyst, to remove certain chemicals or foreign bodies or to act as a non-reactive agitator (for example in the case of shake-to-activate consumables).

In some embodiments, the solid additive may be soluble (such that it will fully solubilise into the liquid aerosol-forming substrate), replaceable (such that something dissolves into the liquid and/or something is removed from the liquid) and/or permanent (such that the additive will stay in the tank (reservoir) for the life of the reservoir).

Preferably the organic and/or inorganic material(s) is/are provided as one or more of a coating or partial coating, and/or is/are located in a layer, and/or is/are located within a cavity of the one or more bodies. The organic and inorganic materials may simply be mixed together to form the one or more bodies of the solid additive.

More preferably the inorganic material acts as a carrier for one or more organic materials that are to be added to a liquid aerosol-forming substrate of a consumable. The organic and/or inorganic material of the additive, in particular when the organic material is a flavourant, may be provided as a miscible or soluble coating applied to a body (the body acts as a physical carrier) which transfers the organic/inorganic material to liquid aerosol-forming substrate when the body is submerged in said liquid. The organic/inorganic material may be a provided as a full or partial coating. Alternatively the component may be located inside a hollow cavity, or in a recess of a body, of one or more bodies that are shaped to form interstitial spaces,

The solid additive may comprise a coating on a body and/or a layer within a body, wherein the coating or layer comprises a material that is to be added to the liquid aerosol-forming substrate.

In some embodiments, the solid additive may be formed from one or more materials that are totally soluble in the liquid aerosol-forming substrate.

The solid additive may comprise tobacco to infuse nicotine into the liquid aerosol-forming substrate. The nicotine being infused into the liquid aerosol-forming substrate by the contact of the tobacco, located within the additive, with the liquid being a long enough period of time for the nicotine to diffuse from the tobacco and into the liquid. The additive may also be used as a flavour additive or flavour booster by diffusing in the same way.

The additive may act as a catalyst by stimulating the reaction between two liquids contained in the liquid aerosol-forming substrate.

Alternatively, the additive may be provided as a non-reactive agitator that is used to assist the mixing together of two liquids which separate over time, e.g. for use in consumables that comprise shake-to-activate components). In such cases the additive may comprise one or more bodies. However, the use of a plurality of bodies may be preferred.

The additive may also act to collect, absorb or attract chemicals; it may function in this way by acting as a filter. Preferably the solid additive comprises carbon to collect, absorb or attract chemicals.

For example, carbon black may be located within the body of the additive or alternatively in a cavity within the body.

The solid additive may remove foreign bodies, such as metallic particles, from the liquid aerosol-forming substrate, i.e. the additive may comprise magnetised materials in order to remove particles of iron, cobalt or nickel from a liquid aerosol-forming substrate. Metallic particles in the liquid aerosol-forming substrate may originate from the vaporizer (heater).

Preferably the organic material comprises tobacco and/or extracts from tobacco. When the additive comprises tobacco, for example, various manufacturing processes may be used to provide the bodies for the solid additive in a suitable shape. The formulation (composition) of the bodies will be dependent upon the manufacturing process. When additive bodies are formed using non-pressed processes, the tobacco (that may comprise particles of tobacco) may be mixed with other constituents such as sap, juice or other extract(s) from the tobacco plant to help form the required bodies. In this way the one or more bodies of the solid additive may be manufactured such that they comprise only constituents derived from tobacco plants, i.e. the solid additive comprises only pure and natural components.

The solid additive may be formed from one or more of ground tobacco leaf, reconstituted tobacco or similar tobacco alternatives. The tobacco additive may contain up to 20% Nicotine, however a level of nicotine of 7% is optimal. A solid additive comprising tobacco particles may transfer up to 50 mg/ml of nicotine into a liquid aerosol-forming substrate (e-liquid formulation).

According to the present invention there is also provided a solid additive for a consumable for a smoking substitute device as described above. Thus, according to a second aspect of the first proposal of the invention there is provided a solid additive, characterised in that the solid additive is provided in the form of one or more bodies that are sized to prevent the solid additive blocking the flow of liquid through the consumable.

According to a third aspect of the first proposal of the invention there is provide the use of a solid additive for a consumable described above wherein the additive is placed in a tank of a consumable, said tank being used to retain liquid aerosol-forming substrate. The additive is located in the liquid aerosol-forming substrate (vapourisable liquid) in order to add materials to, or to remove materials from, said liquid.

Embodiments of the invention may provide a consumable for a smoking substitute, which contains a liquid aerosol-forming substrate (vapourisable liquid), wherein the liquid aerosol-forming substrate comprises a solid additive further comprising a solid tobacco-derived material in a nicotine-containing solution obtained from nicotine-free liquids. In particular, such embodiments may provide a vaping smoking substitute system which does not require the consumer to purchase a purified nicotine-containing liquid. In this way a vaping smoking substitute system which does not require the consumer to handle a purified nicotine-containing liquid may be provided.

The present invention may also provide a consumable which includes a nicotine-containing liquid aerosol-forming substrate (e-liquid) in which the nicotine is clearly tobacco-derived and as such would not necessarily be classified as a pharmaceutical product.

The liquid aerosol-forming substrate may comprise a solid additive in the form of one or more bodies comprising solid tobacco-derived material in which the liquid component contains nicotine which has been released from the solid tobacco-derived material in the solid additive.

Embodiments of the invention may also provide a consumable for a smoking substitute device which contains a liquid aerosol-forming substrate, wherein the liquid aerosol-forming substrate comprises a tobacco-infused liquid which contains a solid additive further comprising solid tobacco-derived material derived from a tobacco plant having a dry nicotine content of at least 4% by weight.

Further embodiments of the invention may provide a consumable for a smoking substitute device which contains a liquid aerosol-forming substrate, wherein the liquid aerosol-forming substrate contains a solid additive further comprising tobacco-derived material in a nicotine-containing-solution which comprises propylene glycol and glycerine in a ratio within the range of 10:90 to 90:10 by volume.

In embodiments of the invention, a solid additive may provide further technical effects such as providing a means to supply information to a user, for instance different shapes and colours of solid additives may be used to indicate that the solid additive comprises different components, e.g. a square could indicate a strawberry flavour, a triangle could indicate a high nicotine content, the colour green could be used to indicate that the additive comprises tobacco, etc. The use of such shapes may also provide a consumable that has aesthetic appeal to a user.

It will be appreciated by the skilled person that all aspects described in relation to the first aspect of the first proposal of the present invention also apply equally in respect of the second and/or third aspects of the first proposal of the present invention.

Optional features of the apparatus aspect of the first proposal of the invention will now be set out. These are applicable singly or in any combination with any aspect of the first proposal of the invention. An example of this apparatus aspect is illustrated in the accompanying drawings and discussed in more detail below.

The consumable may include a mouthpiece, and a wick that may extend from the aperture in which the wick is located in a direction substantially towards the mouthpiece. The mouthpiece may be located at or towards an opposite end of the consumable to the coil and wick assembly. The mouthpiece is generally the highest point of the consumable, when the consumable is in use, hence in use solid matter tends to settle at the bottom of the consumable and hence has the potential to block the wick.

The consumable may include an outlet, which is fluidly connected to the coil and wick assembly, and a seal, which seals the outlet to the oil and wick assembly, and to which the clip is attached. The outlet may be referred to as a chimney or airway tube, and acts to draw the vapourised liquid from the coil towards the mouthpiece.

The coil and wick assembly may have a second aperture, which fluidly connects the cavity to the tank, and the wick may extend from the coil through both the first aperture and the second aperture into the tank. The second aperture may be on an opposite side of the coil and wick assembly to the first aperture. Such a second aperture, with a corresponding second wick portion, may help ensure that even if the first aperture and first wick portion become clogged some portion of the wick is still exposed to the liquid in the tank.

Preferably the solid additive comprising the tobacco-derived material is visible in the substrate, such that this identifies the nicotine as being obtained from a tobacco source. Preferably the solid additive comprising the solid tobacco-derived material is visible in the consumable. Preferably the solid additive comprising the solid tobacco-derived material is visible in the smoking substitute device.

Typically the liquid aerosol-forming substrate may contain a solid additive comprising at least 20 mg of solid tobacco-derived material per ml of total liquid components. The total amount of solid may be adjusted in dependence upon the concentration of nicotine required in the substrate. Preferably the liquid aerosol-forming substrate contains a solid additive comprising at least 25 mg, more preferably at least 30 mg, still more preferably 35 mg and especially at least 40 mg of solid tobacco-derived material per ml of total liquid. Optionally this may correspond to the total amount of solid additive in the aerosol-forming substrate, such that the substrate is substantially free of solid materials which are not derived from tobacco, such as solids intended solely for flavouring.

When an aim of the invention is to provide a nicotine-containing solution as a component of the liquid aerosol-forming substrate, the amount of tobacco-derived solid material provided in the substrate by the solid additive may be greater than that required simply for providing aroma or flavouring to the substrate.

Conveniently the liquid aerosol-forming substrate may contain solid additive comprising up to 130 mg or up to 125 mg of solid tobacco-derived material per ml of total liquid. Preferably the solid additive in the liquid aerosol-forming substrate contains up to 120 mg or 115 mg, more preferably at up to 110 mg, further preferably up 105 mg and especially up to 100 mg of solid tobacco-derived material per ml of total liquid.

The liquid aerosol-forming substrate may contain 0.1 to 20% by weight of a solid material (for example an additive) contained within a solid additive especially of the tobacco-derived solid material. Often the liquid aerosol-forming substrate may contain at least 1% by weight, alternatively at least 2% by weight, or at least 3% and especially at least 4% by weight of a solid material (for example an additive) contained within a solid additive. In some embodiments the aerosol-forming substrate may contain up to 19% or 18% by weight of solid material of a solid material (for example an additive) contained within a solid additive, preferably up to 17% or 16% and more preferably up to 15% by weight of solid material of a solid material (for example an additive) contained within a solid additive.

Suitably the liquid aerosol-forming substrate may contain at least 1.0 mg/ml of nicotine. Often the liquid aerosol-forming substrate may contain at least 1.5 mg/ml, or at least 1.8 mg/ml, more preferably at least 2.0 mg/ml. Some embodiments may contain at least 2.5 mg/ml, or at least 2.8 mg/ml of nicotine, more preferably at least 3.0 mg, most preferably at least 3.2 mg and especially at least 3.5 mg of nicotine per ml of total liquid. The amount of nicotine present can be determined by HPLC methods as known in this technical field.

Typically the maximum amount of nicotine in the liquid aerosol-forming substrate would be 7.0 mg/ml, preferably 6.5 mg/ml, more preferably 6.0 mg/ml, and further preferably 5.5 mg/ml. The nicotine may be in the form of the free base or a salt.

The liquid component of the aerosol-forming substrate may comprise one or more aerosol formers, optionally together with flavourings. Preferred flavourings may be in liquid form.

In some embodiments, it is not necessary to include extracts of purified nicotine in the substrate. The aim may be to include only nicotine obtained released from tobacco-derived material contained within a solid additive. In this regard, any nicotine components in the aerosol-forming substrate may be tobacco-derived (from tobacco contained within a solid additive) and thus the substrate is substantially free of purified nicotine extracts.

Thus, in some embodiments it may be preferred that the nicotine-containing solution in the aerosol-forming substrate is obtained from nicotine-free base liquids. Preferred liquid “base” starting materials include polyols or polyhydric alcohols, optionally together with water. Preferred liquid “base” starting materials include one or more selected from propylene glycol, glycerine and water.

Preferably the liquid component of the aerosol-forming substrate includes at least polypropylene glycol and glycerine. Such combinations have been found to be advantageous in order to achieve good dispersion of solid material throughout the liquid component, together with a liquid component having a density which is less likely to result in leakages from the consumable.

In preferred embodiments the liquid component comprises propylene glycol and glycerine in a ratio within the range of 10:90 to 90:10 by volume, preferably 20:80 to 80:20, more preferably 25:75 to 75:25, more preferably 30:70 to 70:30, and most preferably 40:60 to 60:40 by volume. Preferably the liquid component comprises propylene glycol and glycerine in a ratio within the range of 10:90 to 90:10 by weight, preferably 20:80 to 80:20, more preferably 25:75 to 75:25, more preferably 30:70 to 70:30, and most preferably 40:60 to 60:40 by weight.

The liquid component may optionally contain water or it may be essentially free of water. In cases where water is included, it is preferred that the substrate contains 0.1 to 10%, preferably 0.1 to 7%, more preferably up to 6%, further preferably up to 5%, more preferably up to 4% and especially up to 3% water, by volume and/or by weight. Water may be introduced as part of a flavouring component.

Particularly preferred aerosol-forming substrates contain up to 70% by weight, more preferably up to 65% and especially up to 60% by weight of propylene glycol. Preferably the substrates contain at least 25% and more preferably at least 30% by weight of propylene glycol. Particularly preferred aerosol-forming substrates contain up to 70% by weight, more preferably up to 65% and especially up to 60% by weight of glycerine. Preferably the substrates contain at least 25% and more preferably at least 30% by weight of glycerine. Preferably a glycerine component is vegetable glycerine.

The tobacco-derived material incorporated into the one or more bodies of the solid additive can take various forms. It may optionally be in the form of tobacco leaf, tobacco stem, tobacco powder and tobacco dust, for example. The tobacco-derived material may be treated to various process conditions prior to being incorporated into the solid additive. For example it may be washed and dehydrated, optionally by freeze drying.

It is advantageous to select tobacco-derived material from a tobacco plant which has a naturally occurring high nicotine level in order to produce a liquid aerosol-forming substrate which has an effective concentration of nicotine. Preferably the liquid aerosol-forming substrate comprises a tobacco-infused liquid which contains a solid additive that comprises solid tobacco-derived material obtained from a tobacco plant having a nicotine content of at least 3% by weight, especially 3.5% or 4% by weight, preferably at least 4.5% by weight, more preferably at least 5% by weight, still more preferably at least 5.5% by weight and most preferably at least 6% by weight. Conveniently the tobacco plant may have a nicotine content of up to 8% by weight, especially up to 7.5% by weight.

Preferably the solid additive comprises tobacco-derived material which is finely ground or milled to form a dust or powder which preferably has a maximum dimension of at least 2 mm prior to its incorporation into the solid additive. In this way the release of nicotine from the solid additive may be maximised. More preferably the material incorporated into the solid additive has a maximum dimension of no more than 1.5 mm and most preferably no more than 1.2 mm.

The use of very small tobacco-derived solids is possible when such materials are incorporated into solid additive of the type disclosed herein, as problems with clogging of a wick are avoided. Conveniently the tobacco-derived material incorporated into the solid additive is larger than 0.02 mm, preferably larger than 0.03 mm, more preferably larger than 0.04 mm, even more preferably larger than 0.05 mm, further preferably larger than 0.06 mm and especially larger than 0.07 mm.

Preferably the liquid aerosol-forming substrate is visible to the user when it is in the consumable. This helps to confirm that the nicotine in the solution is a tobacco-derived product and as such would not generally be classified as a pharmaceutical product.

According to some preferred embodiments the consumable forms part of a closed system device. In this regard the liquid aerosol-forming substrate and the solid additive may be stored in sealed tank which is provided with at least part of a vapourization mechanism, for example a heating element. The consumable may be disposable, such that the tank is not intended to be refilled or replaced after use.

Preferably the consumable is a cartomizer. Within the broad class of cartomizers, the consumable may be described as a clearomizer if the liquid storage tank includes a window such that the liquid aerosol-forming substrate is visible to the consumer.

In other embodiments the consumable may be a component of an open system device. For example the liquid aerosol-forming substrate (vapourisable liquid) may be stored in a refillable cartridge or in another liquid storage container for supply to a refillable cartridge; the filter disclosed herein may be incorporated as a component of a refillable cartridge or as part of a liquid storage container.

The invention also provides methods for preparing a liquid aerosol-forming substrate as defined in any aspect of the first proposal of the present invention.

The invention also provides methods for manufacturing a consumable as defined in any aspect of the first proposal of the present invention.

Any feature of one aspect of the first proposal of the invention may be applied to other aspects of the first proposal invention, in any appropriate combination.

Second Proposal

According to a first aspect of a second proposal of the invention there is provided a consumable for a smoking substitute device, the consumable comprising:

- a filter;
- a tank for storing vapourisable liquid; and
- a tank outlet,
- wherein the filter is disposed in the tank and retains solid material in the vapourisable liquid within said tank, characterised in that the direction of flow of liquid through the filter is substantially perpendicular to the direction of settlement of the solid material in the consumable under gravity.

The term “the direction of settlement of the solid material in the consumable” refers to the direction in which the solid material in the consumable settles, under gravity, when the consumable is, in particular, stored prior to its sale and stored during transport. The direction of settlement of the solid material in the tank of a consumable during storage may also correspond to the direction of settlement of the solid material when a user operates a substitute smoking device comprising a consumable. Similarly if a user stores a substitute smoking device in a pocket, such that the mouthpiece of the device is uppermost then, in most cases, the direction of settlement of the solid material in the tank will correspond to the direction of settlement of the solid material in the consumable during storage, as discussed above.

The upper end of the tank is normally located adjacent the mouthpiece of the substitute smoking device and the lower end of the tank is distal from the mouthpiece. Normally the outlet of the tank is located at the lower end of the tank that is distal from the mouthpiece.

The skilled addressee will appreciate that the filter may be sized and positioned such that the solid in a vapourisable liquid in a tank of a consumable may be compressed into a first zone of the tank that is separated, by the filter, from a second zone of the tank that comprises the tank outlet. This type of arrangement may be beneficial as a means of slowing or stopping the release of material(s) contained within the solid. Alternatively the filter may be sized and positioned such that sufficient volume is provided within the tank to allow the solid to move freely within a first zone of the tank that is separated, by the filter, from a second zone of the tank comprising the tank outlet. This type of arrangement may be utilised when a prolonged period of time is required to enable the solid to release the material(s) contained therein into the vapourisable liquid.

The filter removes solid material from the vapourisable liquid that passes through it and thus prevents this solid material from reaching (and potentially blocking) the tank outlet. The tank outlet is normally provided in the form of one or more openings that provide egress for the vapourisable liquid from the tank. The tank outlet preferably comprises one or more fluid transport means that transfer the vapourisable liquid from the tank to a vapourization means. The fluid transport means is/are normally in the form one or more wicks. When a tank of a consumable is provided with a wick(s) as the fluid transport means, then the wick(s) is/are located in an aperture(s) that form(s) the tank outlet. The vapourization means is preferably provided as a heater in the form of a coil and wick assembly. The coil and wick assembly preferably forms a lower wall of the tank. When the vapourization means is provided as a coil and wick assembly then the aperture(s) in which the wick(s) is/are located form(s) the tank outlet.

The term substantially perpendicular is used to indicate that the flow of liquid through the filter is at an angle in the range between 75° and 105° relative to the direction of settlement of the solid material in the consumable, under gravity. More preferably the flow of liquid through the filter is at an angle in the range between 80° and 100,° or still more preferably at an angle in the range between 85° and 95°, relative to the direction of settlement of solid in the consumable. Most preferably the filter is positioned such that the flow of liquid through the filter is perpendicular to the direction of settlement of solid in the consumable, i.e. at an angle of 90°.

When the flow of liquid through the filter is substantially perpendicular to the direction of settlement of the solid material in the consumable, under gravity, as described above, the face of the filter or “filter face” through which the fluid to be filtered passes is usually orientated vertically/parallel (or substantially vertical/parallel) relative to the direction of gravity; this being the case during storage of the consumable (and often in cases when a user operates a device comprising such a consumable and the bottom of the tank is pointed downwards). The filter face may also be referred to as the filtration means. In this way solid material in the vapourisable liquid does not collect on the filter face due to gravity. Solid material would collect on the filter face if the flow of liquid through the filter (via the filter face) was generally parallel to the direction of settlement of the solid material in the consumable under gravity (this direction of settlement is also normally parallel to the airflow path through the consumable) wherein the filter face would be orientated generally perpendicular to the direction of gravity. It is therefore advantageous that the filter face of the filter, through which the liquid passes, is positioned parallel (or substantially parallel) to the direction of settlement of the solid material in the consumable under gravity; or parallel (or substantially parallel) to the direction of the flow of air through the consumable. The filter face of the filter is the part of the filter that removes the solid material from the vapourisable liquid, i.e. the portion of the filter comprising pores/openings that are used to remove (filter) the solid from the liquid. The filtration means (filter face) may be provided in the form of one or more filter membranes or as apertures provided in the body of a filter. Preferably the filter face comprises an angle between 75° and 105° relative to the direction of settlement of the solid material in the consumable, i.e. the area of the filter that forms the filter face is preferably at an angle between 75° and 105° relative to the direction of settlement of the solid material in the consumable. More preferably the filter face is at an angle in the range between 80° and 100°, or still more preferably at an angle in the range between 85° and 95°, and most preferably at angle of 90 (perpendicular) relative to the direction of settlement of solid in the consumable.

Arranging the flow of liquid through the filter, as described above, assists in preventing the blinding (blocking) of the filter, in use, because solid material (normally in the form of particles) retained by the filter is not held in place on the filter by gravity. Solid material may be drawn onto the filter face of the filter when vapourisable liquid is drawn through the filter. Subsequently when the substitute smoking device is stored, such that liquid is no longer being drawn through the filter, with the mouthpiece of the device uppermost, then gravity draws the solid material downwards (towards the bottom of the tank) and thus away from the surface of the filter face of the filter.

Preferably the consumable comprises an air inlet, a vapourization means, and an outlet (a chimney) that define the path for airflow through the consumable. The air inlet being disposed at a first end (lower end) of the outlet of the consumable. The upper end (second end) of the outlet being adjacent the end of the consumable that is engageable with a mouthpiece. The lower end of the outlet is located at the end of the tank nearest the electrical contacts and the air inlet(s) of the consumable. The direction of the airflow through the consumable being from the lower end of the outlet to the upper end of the consumable.

Preferably the direction of the flow of liquid through the filter is substantially perpendicular to the direction of the airflow through the consumable.

The filter is preferably shaped such that it separates the fluid transport means from any solid that may be located in a vapourisable liquid that is contained within the tank. More preferably the filter is shaped such that it encloses the fluid transport means. The fluid transport means is usually provided in the form of one or more wicks that comprise part(s) of a vapourization means in the form of a coil and wick assembly.

The flow path through the consumable is normally a path for airflow through the consumable, i.e. the path that the flow of air follows through the consumable.

If the filter is positioned such that the direction of the flow of liquid through the filter corresponds generally to the direction of settlement of the solid material in the consumable under gravity (i.e. normally parallel to the longitudinal axis of the tank) then in use any solid material that is retained by the filter will tend to be kept in place on the filter by gravity; thus a filter orientated in this way is prone to blocking across its surface. This problem may become particularly acute when a consumable comprising a tank containing a vapourisable liquid and a solid is stored for a long period of time prior to use. During such storage periods, the consumable will normally be stored, in its packaging, in an orientation such that solid material in the tank of the consumable will settle, under gravity, onto the filter face of the filter or the face of a filter membrane. Hence, any solid material (particularly fine particles) will tend to form a compacted mass on the face of a filter or filter membrane that is positioned such that the vapourisable liquid passes through the filter or filter membrane in a direction that is parallel (or even generally parallel) to the direction of settlement of the solid material in the consumable under gravity, i.e. parallel to the flow direction of the airflow through the smoking device/consumable. Thus orientating the face of the filter(s) (or the filter membrane(s)) such that it is perpendicular to the direction of settlement of the solid material in the consumable under gravity causes blinding of the face of the filter/filter membrane(s).

Preferably the filter face of the filter through which the vapourisable liquid passes, is positioned parallel to the direction (general direction) of the airflow through the consumable.

The use of such filters allows solid materials to be included in the vapourisable liquid contained in the tank and to be subsequently removed from the liquid prior to its contact with the fluid transport means. Hence, solid tobacco, solid flavourings and other solid materials may be safely added to the vapourisable liquid. The use of a filter removes the risk that these solid materials will block the fluid transport means which is normally a wick and/or come into contact with the heater of a vapourization means.

The filter may be manufactured from one or more materials chosen from plastics materials, metals, ceramic materials and/or glass. These materials are self-supporting and so do not require support from a filter body or the like to enable them to be located within a tank containing a liquid to be vapourised, such that the filter can remove solid material from a vapourisable liquid prior to its exposure to a vapourization means. Filters formed from these materials may be shaped and sized to form an interference fit with the interior of the tank. Metal materials that are used may be in the form of a mesh, e.g. a wire mesh.

Any material that is resistant to the components in the vapourisable liquid and, if necessary the heat generated by the heater, may be used. The plastics materials that are used to manufacture the body are preferably chosen from the group comprising PVC (polyvinyl chloride), HDPE (high-density polyethylene), PP (polypropylene) or PC polycarbonate.

The use of a filter allows vapourisable liquid to pass through the filter or a filter membrane, but prevents solid particles passing through said filter or filter membrane which may block the wick and/or be burnt by contact with the vapourization means (e.g. a heating coil) thus creating an unpleasant experience for a user.

The consumable may further comprise a mouthpiece, the mouthpiece comprising a mouthpiece outlet. The mouthpiece being in fluid communication with the tank by means its engagement with a second end of the outlet of the consumable.

The vapourization means is located at the opposite end of the tank to the end that is adjacent to the mouthpiece of the consumable.

The filter may be positioned at any point in the tank, such that it removes solid material from the vapourisable liquid prior to its vapourization. It is preferable that the filter is arranged such that all of the liquid contained in the tank is filtered until the liquid in the tank is substantially exhausted.

The filter preferably further comprises a body. The body preferably separates the fluid transport means from a first zone in the tank that comprises the vapourisable liquid and solid material. The fluid transport means being located in a second zone in the tank that comprises filtered vapourisable liquid that contains no solid material. In this way any solid material present in the tank is removed from the vapourisable liquid before it reaches the liquid transport means, i.e. a wick or vapourization means which is normally a coil and wick assembly. The body is preferably shaped to enclose the fluid transport means thus reducing the risk of solid material entering the second zone in the tank.

The body of the filter may be manufactured from one or more of a plastic materials and/or metals and/or ceramics and/or glass.

Preferably the filter is provided in the form of a body comprising a plurality of integral pores to retain solid material. The pores retain solid material whilst allowing fluid to pass through the pores, i.e. the pores form a filtration means (or filter face).

Preferably the pores have a diameter in a range of 0.1 to 2 mm.

More preferably the pores have a diameter in a range of 0.1 to 1 mm.

The pores may have a diameter in the range 0.1 to 0.6 mm.

Most preferably the pores have a diameter in the range 0.2 to 0.3 mm.

The skilled person will appreciate that the size of the pores must not be so small that they cause significant resistance to the flow of liquid through the filter and thus through the consumable. To some extent, this problem may be alleviated by increasing the number of pores that are provided.

If the filter is formed by means of an injection moulding process then the pores may be formed as part of this process. Alternatively the pores may be formed in the filter by means of processes such as milling, drilling, micro-drilling, laser cutting, electron-beam drilling or EDM (Electro Discharge Machining).

The filter may comprise a filtration means in the form of one or more filter membrane(s) and/or a plurality of pores provided in the body of the filter that remove solid material from a liquid.

The filter body may be provided with one or more filter membrane aperture(s) sized to receive one or more filter membranes.

Preferably the filter membrane(s) comprises one or more of a filter cloth, a filter screen, a ceramic filter, and/or a metal filter; the metal filter may be in the form of a mesh.

The filter membrane may comprise one or more layers chosen from a mesh and/or a fibrous material and/or a woven material and/or one a non-woven material.

The filter membrane may comprise one or more layers of a metal and/or a non-metal.

Preferably the size of the pores in the filter membrane are in the range of 0.02 to 2 mm. The pores in the filter membrane may be in the range 0.05 to 1 mm.

More preferably the size of the pores in the filter membrane are in the range of 0.05 to 0.6 mm. Pores in this size range are particularly preferred as they remove solid particles of sizes that are most likely to be used to add material(s) to vapourisable liquid whilst still allowing the ready passage of the vapourisable liquid through the filter during use of a consumable and/or when the filter is inserted into a tank comprising liquid and solid.

The size of the pores in the filter membrane may be in the range 0.2 to 0.3 mm.

The references above to pore size relate to the maximum dimension of the pore. The skilled addressee will appreciate that the pores provided in filters are not always circular in shape. This is particularly true in respect of meshes where the pores are often generally rectangular or square in shape. The pores may even be irregularly shaped.

The filter preferentially retains particles in the size range of 0.05 to 2 mm. Particles in the size range 0.05 to 1 mm may be retained by the filter. More preferably particles in the size range 0.05 to 0.6 mm are retained by the filter. Most preferably particles in the size range 0.2 to 0.3 mm are retained by the filter.

The filter membrane is preferably formed from a woven wire mesh of equal or uneven spacing. A stainless steel mesh comprising “316 stainless steel (marine grade)” and/or “304 stainless steel” is a suitable material, as these steels have adequate resistance to the vapourisable liquid in the reservoir. Other materials from which the membrane may be manufactured include, but are not limited to, aluminium, nickel-chromium-molybdenum alloy, HDPE (high-density polyethylene), LDPE (low-density polyethylene), PP (polypropylene), PETG (polyethylene terephthalate glycol), PMP (polymethylpentene/poly(4-methyl-1-pentene), POM (polyoxymethylene), PS (polystyrene), PVC (polyvinyl chloride), FEP (fluorinated ethylene propylene), PTFE (polytetrafluoroethylene), PVDF (polyvinylidene fluoride/polyvinylidene difluoride), EPDM (ethylene propylene diene monomer rubber), FPM/FKM (fluoroelastomers), NBR (nitrile rubber/acrylonitrile butadiene rubber) or silicone or silica.

Preferably when the filter membrane is in the form of a mesh, the mesh screen size is in the range of no. 400 to no. 10 (i.e. the nominal sieve opening is in the range 0.037 mm to 2 mm). More preferably when the filter membrane is in the form of a mesh, the mesh screen size is in the range of no. 270 to no. 30 (i.e. the nominal sieve opening is in the range 0.053 mm to 0.595 mm). Most preferably when the filter membrane is in the form of a mesh, the mesh screen size is in the range of no. 70 to no. 50 (i.e. the nominal sieve opening is in the range 0.21 mm to 0.297 mm).

Preferably one or more seals (tank seal(s), (normally in the form of gasket(s)) is/are located between the filter (or the filter body) and the interior of the tank, in order to form a tight seal between said filter and the wall of the tank. In use, the position of the filter (or filter body) within the tank is fixed. The filter (filter body) may be retained in a fixed position by the provision of such a seal; the seal prevents the passage of vapourisable liquid (containing solid material from the interior of the tank (in a first zone of the tank)) located between the end of the filter and the interior walls of the tank, from passing into the area of the tank (a second zone) in which the tank outlet(s) is/are located. In this way the passage of solid material into the outlets and thereafter into the vapourization means is avoided.

The seal may be provided as an integral component of the filter (normally as part of a filter body), for instance the seal may be formed on the filter by means of an over-moulding process. Similarly a seal, if required, may be provided to prevent the passage of vapourisable liquid between an outlet (chimney) of the consumable, and the side walls of an opening in the filter or filter body in which said outlet is located. This seal (outlet seal) may also be provided by means of an over moulding process. The tank seal and outlet seal may be formed as part of the same overmolding process.

Such seals are preferably provided in the form of one or more gaskets.

The seals may be manufactured from any material that is resistant to the components in the vapourisable liquid and, if necessary, the heat generated by a heater.

The seals may be manufactured from an elastomeric material. The elastomeric material may be a natural or synthetic rubber and/or ethylene/propylene diene monomer and/or fluoropolymer elastomeric materials and the like. The material used must be resistant to the components in the vapourisable liquid and, if necessary the heat generated by a heater.

Adhesive may be utilised to retain the position of the filter within the tank and also to act as an alternative sealing means to the seal(s) mentioned above, i.e. the adhesive may fix the position of the filter in the tank; and also prevent the passage of vapourisable liquid between the side walls of the filter body and the interior walls (normally the side walls of the tank), and thus into the vapourization means. Similarly adhesive(s) may be used to prevent the passage of vapourisable liquid between an outlet (chimney) and the side walls of an aperture through which the outlet passes. The adhesive used may comprise one or more adhesive(s) chosen from the group comprising cyanoacrylates, acrylics, epoxies, urethanes, elastomers, silicones and epoxy or methyl methacrylate. The filter may be affixed to the base of the tank, such that the liquid transport means is enclosed by the filter, by the use of adhesive such that a seal is not required between the filter and the side walls of the tank.

Preferably the filter provides a settlement area to receive solid material. The filter is preferably shaped such that solid material that settles, under gravity, builds up in a settlement area, within the tank, that is separate from the where the filtration means is located, i.e. separate from the filter membrane and/or porous area of the filter that removes the solid material from the vapourisable liquid.

The filter is preferably connected to the interior of the tank by means of interference fit. The filter is preferably provided as a unit that connects to the interior of the tank, such that the insertion of the filter into the tank fixes the position of the filter within said tank.

The filter may be moulded into the consumable by means of an insert or over-moulding process. Other alternative approaches are to affix the filter to the consumable by the use of adhesives, heat staking, ultrasonic welding, vibration welding or by the use of mechanical means such as a threaded fastener, clip(s) or rivet(s).

The filter and tank may be shaped such that when the filter is inserted into the tank and an interference fit is formed between the tank and filter. This interference fit may be formed, for instance, by a narrowing of an end of the interior of the tank within an interference fit is formed between the filter the interior wall of the tank. The filter may be inserted into the tank of a consumable before or after the vapourisable liquid is placed in the tank.

Preferably the filter is releasably connected to the consumable. In this way the recycling and/or reuse of a filter/filter body may be facilitated.

Preferably the filter is formed as an integral part of the consumable. The filter may be formed as part of the tank of the consumable by use of injection moulding or overmolding, or the like.

Preferably the one or more filter membranes may be attached to the filter body by means of an insert or over-moulding process. Another alternative approach is to affix the filter membrane to the filter body by the use of adhesives, heat staking, ultrasonic welding, vibration welding or by the use of mechanical means such as a threaded fastener, clip(s) or rivet(s).

Preferably the filter or filter body is rigidly attached to the tank, i.e. the filter may be provided as an integral component of the “consumable or tank of the consumable”.

According to the present invention there is provided a filter for a consumable as described above.

According to a second aspect of the second proposal of the invention there is provided a filter to retain solid material in a vapourisable liquid in a tank of a consumable for a smoking substitute device, characterised in that the filter is arranged such that the direction of flow of a liquid through the filter is substantially perpendicular to the direction of settlement of the solid material in the consumable under gravity.

According to a third aspect of the second proposal of the invention there is provided a filter to remove solid material from a vapourisable liquid in a tank of a consumable, characterised in that the direction of the flow of liquid through the filter is substantially perpendicular to the axial direction between the upper end of the tank and the lower end of the tank.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the filter is configured to enclose one or more tank outlets of said tank. The filter is preferably configured (i.e. shaped) to enclose the one or more tank outlets that are provided in the tank of a consumable.

The tank outlet may comprise one or more apertures in which a fluid transport means is located. Preferably the fluid transport means is provided in the form of one or more wicks, the one or more wicks being located in one or more apertures within the tank. When a coil and wick assembly is used in the consumable then the one or more apertures in which the wick(s) is/are located constitute the tank outlet.

Embodiments of the invention may provide a filter to retain solid material in a tank for a consumable characterised in that the filter is inserted into a fixed position within the tank and enables substantially all of the vapourisable liquid in the tank to be filtered and used.

Preferably this is achieved by the use of one or more filtration means that allow substantially all of the vapourisable liquid to pass through said filtration means and to the tank outlet. This may be achieved, for instance, by the filtration means being provided such that no unfiltered liquid is retained between the walls of the tank and the walls of the filter, i.e. the filter may be shaped such that all the vapourisable liquid located between the walls of the tank and the filter is directed through the filter. In this way all of the vapourisable liquid located in the tank may be used without the outlet of the tank (the wick) becoming blocked.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the filter comprises a first filtration means, and a second filtration means wherein the vapourisable liquid in the tank initially passes through the first filtration means and subsequently passes through the second filtration means. In this way the vapourisable liquid may be filtered twice before it reaches the tank outlet. The first filtration means and the second filtration means preferably comprise porous areas and/or filter membrane(s).

Preferably the pores/openings in the first filtration means are larger than the pores/openings in the second filtration means. In this way larger particles may initially be removed from the vapourisable liquid by the first filtration means, and then smaller particles are subsequently removed by the second filtration means. Hence, the solid material that is filtered from the vapourisable liquid is distributed over two filtration means and the chance of the filter becoming blocked is reduced.

Preferably the size of the larger openings/pores in the first filtration means are in the range of 0.1 to 2 mm.

Preferably the size of the larger openings/pores in the first filtration means have a diameter in a range of 1 to 2 mm.

Preferably the size of the smaller openings/pores in the second filtration means have a diameter in a range of 0.05 to 1 mm.

More preferably the size of the openings/pores in the second filtration means are in the range of 0.05 to 0.6 mm.

More preferably still the size of the openings/pores in the second filtration means are in the range of 0.2 to 0.6 mm

Most preferably the size of the openings/pores in the second filtration means are in the range 0.2 to 0.3 mm.

It is preferable that the filter comprises larger openings/pores in the first filtration means having a diameter in a range of 1 to 2 mm and that the openings/pores in the second filtration means have a diameter in a range of 0.2 to 0.3 mm.

The use of a filter provides a cost effective method to filter solids from a vapourisable liquid.

The filter used may be specifically chosen to filter particles of a particular size from a vapourisable liquid. Finer particles may be readily filtered from a vapourisable liquid by the use of appropriately sized pores which may be provided in the form of mesh(es).

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the filter is provided as an integral component of the tank. This approach simplifies the assembly of the consumable and thus reduces manufacturing costs.

Preferably the tank comprises a filter that is formed by means of an injection or overmolding process.

The tank is preferably adapted to engage with the filter by use of an interlocking mechanism, i.e. a snap fit may be used to engage the filter with the tank such that the filter becomes an integral component of the tank.

Preferably the filter is provided as an integral component of one or more walls of the tank, i.e. the filter may be provided as part of the side walls of the tank.

The filter is preferably provided as part of an integral component that forms one or more walls of the tank and that further comprises a fluid transfer means, e.g. the lower wall of the tank may be formed separately from the rest of the tank and may further comprise a fluid transport means (such as a wick) and in addition to the filter.

More preferably the filter comprises an integral component of a vapourization means. The filter is still more preferably provided as an integral component of a coil and wick assembly. The tank of the consumable preferably comprises a lower wall in the form of a vapourization means which further comprises the filter. The vapourization means is preferably in the form of a coil and wick assembly. Providing the filter as part of a vapourization means, and more preferably as a coil and wick assembly, facilitates the insertion of the filter into the tank. Additionally this approach also avoids any risk of contamination of the coil and wick assembly by solid that may be present in a tank into which the coil and wick assembly comprising the filter is inserted. Furthermore this approach can be used to ensure that a good seal is formed between the filter and vapourization means thus further reducing the risk of the vapourization means (such as a coil and wick assembly) being contaminated with a solid material that is present in a vapourisable liquid located in the tank of a consumable.

The filter may be provided as part of a vapourization means by use of an injection moulding process or an overmolding process.

Preferably the filter is formed as an integral component of the side walls of the tank of the consumable. The filter may be provided as part of the sidewalls of the tank, preferably by means of an injection moulding process or an overmolding process.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable comprising a vapourization means, characterised in that the vapourization means further comprises said filter. It is advantageous that the vapourization means incorporates the filter as this can facilitate the assembly of the consumable by allowing the filter and the vapourization means to be inserted into the tank as a single unit. Preferably the vapourization means forms a wall of the tank, which more preferably is the lower wall of the tank.

The vapourization means is preferably in the form of a coil and wick assembly.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, wherein the filter comprises one or more filtration means and the tank comprises one or more tank outlets, characterised in that the filter provides a filtration means located in close proximity with each of one or more tank outlets. The association of a porous area and/or filter membrane with each tank outlet has a synergistic effect in that a continuous and steady flow of vapourisable liquid is provided to each of the one or more tank outlets. The filtration means (filter face) comprises the apertures/openings through which the vapourisable liquid passes when it is filtered.

The one or more tank outlets are preferably provided with one or more fluid transfer means that are preferably in the form of one or more wicks. Furthermore, this arrangement also facilitates the use of longer wicks.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the direction of flow of the liquid through the filter is substantially perpendicular to an axial direction between the top of the tank that is proximal to a mouthpiece and the bottom of the tank that is distal to the mouthpiece. The top of the tank of a consumable is the end of the tank that is proximal to the mouth piece, and the bottom of the tank is the end of the tank that is distal to the mouthpiece. The outlet of the tank of a consumable is normally located in the bottom of the tank to allow the transfer of the vapourisable liquid from the tank; when a wick is used to transfer the vapourisable liquid from the tank then the wick is located in the bottom of the tank.

The term substantially perpendicular is used to indicate that the flow of liquid through the filter is at an angle in the range between 75° and 105° relative to an axial direction between the top of the tank that is proximal to a mouthpiece and the bottom of the tank that is distal to the mouthpiece. More preferably the flow of liquid through the filter is at an angle in the range between 80° and 100° relative to an axial direction between the top of the tank that is proximal to a mouthpiece and the bottom of the tank that is distal to the mouthpiece. More preferably the flow of liquid through the filter is at an angle in the range between 85° and 95° relative to an axial direction between the top of the tank that is proximal to a mouthpiece and the bottom of the tank that is distal to the mouthpiece. The direction of settlement of the solid material in the consumable under gravity corresponds to the direction of airflow through the consumable when such an airflow is provided through said consumable.

Most preferably the filter is positioned such that the flow of liquid through the filter is perpendicular to an axial direction between the top of the tank that is proximal to a mouthpiece and the bottom of the tank that is distal to the mouthpiece, i.e. at an angle of 90°.

Preferably the filter is positioned such that the flow of liquid through the filter is substantially perpendicular to the air-flow through the consumable. The term air-flow being a reference to the overall direction of the flow of air through the consumable.

The filter is preferably provided as a component that engages with the vapourization means by use of an interference fit or use of interlocking parts.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the filter is retained within the tank by means of a push-fit mechanism between the filter and one or more of the interior walls of the tank.

A push-fit mechanism is a mechanism that allows a first component to be engaged with a second component by the insertion of a part of the first component into an appropriately configured opening in the second component. The insertion of the first component into the second component results in the engagement of the two parts to form a liquid tight seal between the two components.

Preferably the push-fit mechanism is provided in the form of an interference fit between the wall(s) of the tank and the filter. Alternatively, the push-fit mechanism may further comprise a locking mechanism that engages when the first part is inserted into the second part, in the present case the filter comprises the first part and the tank comprises the second part.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the face of the filter is substantially perpendicular to an axial direction between the top of the tank that is proximal to a mouthpiece and the bottom of the tank that is distal to the mouthpiece.

Embodiments of the invention may provide a filter to retain solid material in a vapourisable liquid in a tank of a consumable, characterised in that the filter membrane is curved to prevent the solid material collecting on the filter face of the filter.

Optional features of the apparatus aspect of the second proposal of the invention will now be set out. These are applicable singly or in any combination with any aspect of the second proposal of the invention. An example of this apparatus aspect is illustrated in the accompanying drawings and discussed in more detail below.

The consumable may include a mouthpiece, and a wick that may extend from the aperture in which the wick is located in a direction substantially towards the mouthpiece. The mouthpiece may be located at or towards an opposite end of the consumable to the coil and wick assembly. The mouthpiece is generally the highest point of the consumable, when the consumable is in use, hence in use solid matter tends to settle towards the bottom of the consumable and hence may block the tank outlet which may be in the form of a wick.

The consumable may include an outlet which is fluidly connected to the coil and wick assembly, and a seal, which seals the outlet to the coil and wick assembly, and to which the clip is attached. The outlet may be referred to as a chimney or airway tube, and acts to draw the vapourised liquid from the coil towards the mouthpiece.

The coil and wick assembly may have a second aperture, which fluidly connects a cavity to the tank, and the wick may extend from the coil through both the first aperture and the second aperture into the tank. The second aperture may be on an opposite side of the coil and wick assembly to the first aperture. Such a second aperture, with a corresponding second wick portion, may help ensure that even if the first aperture and first wick portion become clogged some portion of the wick is still exposed to the liquid in the tank.

According to some preferred embodiments the consumable forms part of a closed system device. In this regard the liquid aerosol-forming substrate may be stored in sealed tank which is provided with at least part of a vapourization mechanism, for example a heating element. The consumable may be disposable, such that the tank is not intended to be refilled or replaced after use.

It will be appreciated by the skilled person that any feature of one aspect of the second proposal of the invention may be applied to other aspects of the second proposal of the invention, in any appropriate combination.

Third Proposal

Accordingly, a first aspect of a third proposal of the invention provides a consumable for a smoking substitute device, the consumable comprising a vapourization means which includes a wick, and a tank which contains a liquid aerosol-forming substrate and a solid additive, characterised in that the solid additive is in the form of a body that is adapted to engage with engagement means located in the tank to retain the additive in position within the tank.

A solid additive may be provided to modify the physical and/or chemical characteristics of a liquid aerosol-forming substrate, either directly and/or indirectly, for example.

In the present invention, blocking of the flow of liquid aerosol-forming substrate through the consumable to the vapourization means by solid additives may be prevented. Also, blocking of the vapourization means by displaced solids may be prevented.

In the present invention, problems mentioned above may be overcome by the use of a solid additive in the form of one or more bodies that are adapted to engage with engagement means located in the tank to retain the additive in a fixed position within the tank. This is to inhibit or prevent movement of the solid additive into a location or orientation that results in blocking of the flow of liquid through the consumable.

The obstruction of flow of a solid-containing liquid through a consumable is in most cases caused by the blocking of the wick that is located within the tank of a consumable. This may be caused by a build-up of fine particles of solid material/powder on the surface of the wick. For example, powdered solids normally form a layer on the surface of the wick such that the vapourisable liquid is prevented from passing into the main body of the wick.

In the present invention the use of bodies that are retained in position within the tank means that a layer of powdered solid material does not form on the surface of the wick such that blocking of the wick is prevented. Thus, preferably the tank of the consumable does not contain suspended solids that are able to move freely within the liquid aerosol-forming substrate. Typically, the present consumable does not require a filter for restraining the solid additive to avoid clogging of the wick.

The consumable comprises a vapourization means that is in the form of a heating device which includes a wick. Preferably the heating device comprises a coil and wick, which may be provided as an assembly; the assembly may form a wall of the tank of a consumable, normally the lower wall of the tank. The liquid aerosol-forming substrate which contains a solid additive is stored in a tank of the consumable.

The term solid additive is used to refer to solid bodies that normally, but not always, comprise materials that are to be added to a liquid aerosol-forming substrate (vapourisable liquid) contained within a tank of a consumable; in some instances the solid additive may remove materials from the liquid aerosol-forming substrate for example, the solid additive may include a catalyst that removes components from the liquid aerosol-forming substrate

Most preferably the solid additive is used to add materials to the liquid aerosol-forming substrate. Preferably the solid additive adds one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals to the liquid aerosol-forming liquid.

In some embodiments, the solid additive may ultimately be totally soluble in the liquid aerosol-forming substrate and may contain one or more components that is/are to be added to the liquid aerosol-forming substrate. Alternatively the solid additive may comprise one or more components that are soluble in the liquid and/or one or more components that are insoluble in the liquid, i.e. soluble components may be combined with insoluble components that act to facilitate the formation of suitable solid bodies. If the solid additive is totally soluble then it is preferable that the outermost portion of the additive comprises a material that dissolves more slowly than the inner portion of the additive.

The present invention also facilitates the addition of extra materials to a liquid aerosol-forming substrate in a carefully controlled manner (as a solid additive) as opposed to adding a powder or granular material to the tank of a consumable in a less controlled manner. The dosing of materials may be more carefully controlled by the use of a solid additive in accordance with the present invention.

Preferably a solid additive is provided in the form of a body that is adapted to engage with engagement means provided on the tank. For example, a body may be provided with surface formations configured to engage with corresponding or complementary formations located within the tank. Preferably, engagement means are provided on one or more walls of the tank.

Alternatively, or additionally, a solid additive body may be adapted to engage with an opening of the tank provided for filing and/or refilling of the tank with liquid aerosol-forming substrate.

Alternatively, or additionally, a solid additive body may be adapted to engage with a component of a vapourizer assembly.

Alternatively, or additionally, a solid additive body may be adapted to engage with a sealing element for the tank.

Alternatively, or additionally, a solid additive body may be adapted to engage with an air flow chimney/outlet of the consumable.

Preferably a solid additive body is adapted to engage with multiple engagement means located within the tank.

Preferably a solid additive body is adapted to engage with at least two different components of the consumable.

Preferably a solid additive body is adapted to engage with engagement means located within the tank by means of one or more selected from an interference fit, a push fit, a sliding fit, a snap fit and/or a screw fit.

Preferably the solid additive comprises one or more bodies that have been extruded and/or rolled and/or stamped and/or pressed and/or crushed and/or injection moulded and/or cast.

An extrusion process is preferably used to manufacture the solid additive bodies. When the one or more bodies of the solid additive are provided by such methods, including by means of an extrusion, process additive(s) such as plastics, binders or copolymers (such as Polyethylene Glycol) as well as tobacco-based additives may be included in the extruded solid additive. These extrusion process additive(s) help to retain the shape of the solid additive and also resist breakdown of the solid additive in the tank during use of the consumable and/or during the manufacture of the solid additive and/or the consumable.

The shape of a solid additive may take a variety of forms. For example, a solid additive may comprise one or more bodies which comprise one or more shapes chosen from elongate; spheroidal; ellipsoidal; spherical; planar; irregular; pellet; spaghetti; cuboid; and/or pyramidal, for example.

Bodies having cross-sectional profiles (across their width) include, but are not limited to: generally “V” or “W” shaped, generally “S” or “M” shaped, generally “U” shaped, generally “N” shaped, angular, semi-circular, curved, convex, concave, wave shaped, castellated, branched or generally straight. Preferably the bodies are elongate bodies.

The solid additive may also comprise bodies that are not elongate, but are instead of uniform dimensions in relation to their length, width and height, e.g. they may be cuboid or spheroid in shape.

The solid additive may comprise one or more of; a body with no cavity; a body with one or more cavities; a mesh; a compressed powder; a foam; a porous material; and/or a perforated material, for example. The bodies may comprise cavities, in the form of perforations; this ensures that fluid can flow through, as well as around, the planar bodies and thus any resistance to the movement of the liquid aerosol-forming substrate in a tank is minimised. Additionally, the inclusion of cavities (in the form of perforations) provides a means for fluid to pass through two or more planar bodies if they form a stack within the tank of a consumable.

The one or more bodies of the solid additive may be provided with one or more or more cavities that form flow channels along which a liquid aerosol-forming substrate may pass to avoid the impeding of the flow of the liquid to the wick.

Preferably the solid additive comprises one or more bodies that are elongate and/or planar bodies. The use of elongate bodies and planar shapes assists in maximising the surface area of the solid additive that is exposed to the liquid aerosol-forming substrate.

Preferably the additive comprises organic material(s) and/or inorganic material(s).

When the additive comprises one or more inorganic materials, the inorganic material may comprise polymer, glass, ceramic or metal, for example.

The inorganic material may, for instance, be used as a carrier for an organic materials, i.e. an organic material could be sorbed onto the surface, or absorbed into an inorganic material such that the organic material is released into the liquid aerosol-forming substrate after the additive is placed within said substrate. Different organic materials may be utilised in the same manner.

Preferably the solid additive comprises one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals. The skilled addressee will appreciate that the solid body is used to add components such as flavourants, flavour enhancers, nicotine and additional chemicals to the liquid aerosol-forming substrate in the tank of a consumable.

Preferably the additional chemicals include chemicals for providing colour or odour to the liquid aerosol-forming substrate.

In some embodiments, the solid additive may be soluble (such that it will fully solubilise into the liquid aerosol-forming substrate), replaceable (such that something dissolves into the liquid) and something is removed from the liquid) and/or permanent (such that the additive will stay in the tank (reservoir) for the life of the reservoir).

More preferably the inorganic material acts as a carrier for one or more organic materials that are to be added to a liquid aerosol-forming substrate of a consumable. The organic and/or inorganic material of the additive, in particular when the organic material is a flavourant, may be provided as a miscible or soluble coating applied to a body (the body acts as a physical carrier) which transfers the organic/inorganic material to liquid aerosol-forming substrate when the body is submerged in said liquid. The organic/inorganic material may be a provided as a full or partial coating. Alternatively, the component may be located inside a hollow cavity, or in a recess of a body, of one or more bodies that are shaped to form interstitial spaces,

The solid additive may comprise a coating on a body and/or a layer within a body, wherein the coating or layer comprises a material that is to be added to the liquid aerosol-forming substrate.

In some embodiments, the one or more bodies of the solid additive may comprise tobacco or extracts of tobacco. The solid additive may comprise tobacco to infuse nicotine into the liquid aerosol-forming substrate. The nicotine being infused into the liquid aerosol-forming substrate by the contact of the tobacco, located within the additive, with the liquid being a long enough period of time for the nicotine to diffuse from the tobacco and into the liquid. The additive may also be used as a flavour additive or flavour booster by diffusing in the same way.

The additive may act as a catalyst by stimulating the reaction between two liquids contained in the liquid aerosol-forming substrate.

Alternatively, the additive may also act to collect, absorb or attract chemicals; it may function in this way by acting as a filter. Preferably the solid additive comprises carbon to collect, absorb or attract chemicals. For example, carbon black may be located within the body of the additive or alternatively in a cavity within the body.

Preferably the organic material comprises tobacco and/or extracts from tobacco. When the additive comprises tobacco various manufacturing processes may be used to provide the bodies for the solid additive in a suitable shape. The formulation (composition) of the bodies will be dependent upon the manufacturing process. When additive bodies are formed using non-pressed processes, the tobacco (that may comprise particles of tobacco) may be mixed with other constituents such as sap, juice or other extract(s) from the tobacco plant to help form the required bodies. In this way the one or more bodies of the solid additive may be manufactured such that they comprise only constituents derived from tobacco plants, i.e. the solid additive comprises only pure and natural components.

A solid additive may provide further technical effects such as providing a means to supply information to a user, for instance different shapes and colours of solid additives may be used to indicate that the solid additive comprises different components, e.g. a square could indicate a strawberry flavour, a triangle could indicate a high nicotine content, the colour green could be used to indicate that the additive comprises tobacco, etc. The use of such shapes may also provide a consumable that has aesthetic appeal to a user.

According to the present invention there is also provided a solid additive for a consumable as described above.

Thus, according to a second aspect of the third proposal of the invention there is provided a solid additive, that is added to a tank of a consumable of a smoking substitute device wherein the tank contains a liquid aerosol-forming substrate, characterised in that the solid additive is provided in the form of one or more bodies that are adapted to engage with engagement means located in the tank for fixing the additive in position within the tank. The additive may be retained in position in order to prevent it blocking the flow of the liquid aerosol-forming substrate through the consumable and thus clogging of a wick by the solid additive is prevented.

According to a third aspect of the third proposal of the invention there is provided the use of a solid additive for a consumable as described above wherein the additive is secured within a tank of the consumable by engagement between the additive and engagement means provided in the tank. The additive may be located in the liquid aerosol-forming substrate (vapourisable liquid) in order to add materials to or to remove materials from the liquid.

The solid additive may be provided as one or more bodies that are not free floating in the tank of a consumable.

It will be appreciated by the skilled person that all aspects described in relation to the first aspect of the third proposal of the present invention also apply/apply equally in respect of the second and third aspects of the third proposal.

The consumable may include a mouthpiece, and a vapourization means such as a coil and wick assembly. The mouthpiece may be located at or towards an opposite end of the consumable to the coil and wick assembly. The coil and wick assembly may have a cavity, and apertures which fluidly connect the cavity to the tank, and the wick may extend from the coil through the apertures into the tank.

The consumable may include an outlet, which is fluidly connected to the coil and wick assembly, and a seal, which seals the outlet to the coil and wick assembly. The outlet may be referred to as a chimney or airway tube, and acts to draw the vapourised liquid from the coil towards the mouthpiece.

In other embodiments the consumable may be a component of an open system device. For example the liquid aerosol-forming substrate may be stored in a refillable cartridge or in another liquid storage container for supply to a refillable cartridge.

The invention also provides methods for preparing a liquid aerosol-forming substrate as defined in any aspect of the third proposal of the present invention. The invention also provides methods for manufacturing a consumable as defined in any aspect of the third proposal of the present invention.

In addition the invention concerns the use of a liquid aerosol-forming substrate as defined in any aspect of the third proposal of the present invention in the manufacture of a consumable for a smoking substitute device.

Any feature of one aspect of the third proposal of the invention may be applied to other aspects of the third proposal of the invention, in any appropriate combination.

Fourth Proposal

According to a first aspect of a fourth proposal of the invention there is provided a consumable for a smoking substitute device which contains a liquid aerosol-forming substrate located in a tank of the consumable, wherein the liquid aerosol-forming substrate comprises a solid additive, characterised in that the solid additive is provided in the form of one or more bodies that comprise one or more cavities through which said liquid aerosol-forming substrate may flow, and/or are shaped to form interstitial spaces through which said liquid aerosol-forming substrate may flow, such that blocking of the flow of liquid aerosol-forming substrate through the consumable by the solid additive is prevented.

Typically the consumable comprises a vapourization means which includes a wick which is in fluid communication with the tank containing the liquid aerosol-forming substrate comprising a solid additive.

The present invention may also facilitate the addition of components (materials) to a liquid aerosol-forming liquid (liquid aerosol-forming substrate) in a carefully controlled manner (as a solid additive) as opposed to adding a powder or granular material to the tank of a consumable in a less controlled manner. The dosing of materials may be more carefully controlled by the use of a solid additive. In some instances the solid additive may remove materials from the liquid aerosol-forming substrate, for example, the solid additive may include a catalyst that removes components from the liquid aerosol-forming substrate.

The obstruction of flow of liquid through the consumable is, in most cases, caused by a build of solid material (usually in the form of powder) on the wick of the consumable. The solid material normally forms a layer of said material on the surface of the wick such that the vapourisable liquid is prevented from passing into the main body of the wick.

The present invention avoids the problem of the wick becoming blocked/clogged by providing a solid additive that comprises one or more bodies further comprising cavities or bodies that are shaped to form interstitial spaces such that even if a layer of the solid additive was to form on the wick the passage of liquid through the solid would still continue. In the majority of cases the consumable comprises a vapourization means that is in the form of a heating device that comprises the wick. Preferably the heating device comprises a coil and wick, which may be provided as an assembly. Typically, a consumable does not require a filter for restraining the solid additive to avoid clogging of the wick.

The aerosol-forming substrate (vapourisable liquid) is stored in a tank of a consumable.

The term solid additive is used to refer to solid bodies that normally, but not always, comprise materials (components) that are to be added to a liquid aerosol-forming substrate (vapourisable liquid) contained within a tank of a consumable; in some instances the solid additive may remove materials from the liquid aerosol-forming substrate. However, most preferably the solid additive is used to add materials to the liquid aerosol-forming substrate. Preferably the solid additive adds one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals to the liquid aerosol-forming liquid.

In some embodiments, the solid additive may ultimately be totally soluble in the liquid aerosol-forming substrate, and may contain one or more materials that is/are to be added to the liquid aerosol-forming substrate. Alternatively the solid additive may comprise one or more components that are soluble in the liquid and/or one or more components that are insoluble in the liquid, i.e. soluble components may be combined with insoluble components that act to facilitate the formation of suitable solid bodies. If the solid additive is totally soluble then it is preferable that the outermost portion of the additive comprises a material that dissolves more slowly than the inner portion of the additive.

The present invention facilitates the addition of extra materials to a liquid aerosol-forming substrate in a carefully controlled manner (as a solid additive) as opposed to adding a powder or granular material to the tank of a consumable in a less controlled manner. The dosing of materials may be more carefully controlled by the use of a solid additive.

Preferably the one or more bodies that are shaped to form the interstitial spaces further comprise one or more recesses in the exterior surface. The inclusion of such recesses means that, when the bodies settle and/or are compacted together, the recesses form the interstitial spaces and/or the recesses may form additional interstitial spaces between adjacent bodies.

The skilled person will appreciate that the bodies used to form interstitial spaces may comprise a wide range of shapes, including but not limited to the shapes mentioned below. The bodies used having cross-sectional profiles (across their width) that include, but are not limited to: generally “V” or “W” shaped, generally “S” or “M” shaped, generally “U” shaped, generally “N” shaped, angular, semi-circular, curved, convex, concave, wave shaped, castellated, or branched. These bodies are preferably comprise elongate bodies

When planar bodies are used the bodies may comprise cavities, in the form of perforations; this ensures that fluid can flow through, as well as around, the planar bodies and thus any resistance to the movement of liquid aerosol-forming substrate in a tank is minimised. Such cavities (perforations) further increase the surface area of the one or more bodies. Additionally the inclusion of cavities (in the form of perforations) provides a means for fluid to pass through two or more planar bodies if they form a stack within the tank of a consumable.

The solid additive may comprise bodies that are not elongate, they are instead of uniform dimensions in relation to their length, width and height, e.g. they may be cuboid or spheroid in shape.

Preferably the solid additive comprises one or more bodies wherein said bodies comprise one or more shapes chosen from: elongate; spheroidal; ellipsoidal; spherical; planar; irregular, pellet; spaghetti; cuboid; and/or pyramidal. In respect of a sphere it will be appreciated that the length, width and height of the sphere correspond to its diameter. In respect of a spheroidal body the length and width of the body will be the same, but the height will differ. For an ellipsoidal body the height, length and width will all be different.

Irregularly shaped bodies comprising cavities may be utilised.

Bodies that are spherical, spheroidal or ellipsoidal in shape may be used.

Preferably the one or more bodies comprise a length in the range 2 to 40 mm. Alternatively the one or more bodies comprise a length in a range of 4 to 30 mm.

The one or more bodies of the solid additive preferably has a width in a range of 2 to 25 mm. Alternatively the one or more bodies of the solid additive have a width in a range of 6 to 21 mm. Most preferably the one or more solid bodies have a width in a range of 8 to 14 mm.

The width of the solid additive used may be varied depending on the materials that the solid additive is manufactured from and the material(s) that is/are to be released from the additive. The use of solid additives having the diameters specified above further assist in preventing the blocking/blinding of the wick.

Preferably the one or more bodies of the solid additive have a thickness or a height in a range of 0.5 to 5 mm. Preferably the one or more bodies of the solid additive have a thickness or a height in a range of 0.5 to 3 mm. Most preferably the one or more bodies of the solid additive have a thickness or a height in a range of 0.5 to 2 mm.

The use of a solid additive comprising solid bodies of the dimensions disclosed above assists in preventing the blocking of the wick as the build-up of a layer of solid material on the wick is avoided.

When the solid additive comprises one or more cavities each cavity has a diameter in the range of 0.5 mm to 4 mm.

Preferably the one or more bodies comprise one or more cavities each having a diameter in the range 0.5 to 2.5 mm. More preferably the one or more bodies comprise one or more cavities each having a diameter in the range 0.5 to 2 mm. More preferably the one or more bodies comprise one or more cavities each having a diameter in the range of 1 mm to 3 mm. Most preferably the one or more bodies comprise one or more cavities each having a diameter in the range 1 to 2 mm.

Preferably the solid additive comprises a cavity and the cavity has a diameter of 1 mm or greater. More preferably the cavity has a diameter of 2 mm or greater.

When a body comprises multiple cavities then the cavities preferably have a diameter in the range of 1 mm to 4 mm.

The use of cavities of the sizes detailed above facilitates the flow of the consumable liquid into and out the liquid aerosol-forming substrate.

The skilled addressee will appreciate that if a body is provided in the form of a hollow body then the wall thicknesses will be different to the overall height of the body; the height of the body will obviously be greater than the wall thickness. In the cases where a body comprises one or more cavities it is preferable that the height of the body as a whole is in the ranges detailed above to facilitate the use of such bodies in the tank of a consumable.

Preferably the walls of bodies comprising cavities have a thickness in the range of 0.5 to 5 mm. More preferably the walls of bodies comprising cavities have a thickness in the range of 0.5 to 2 mm. Most preferably the walls of bodies comprising cavities have a thickness in the range of 0.5 to 1.5 mm.

Generally speaking, the use of solid additives comprising one or more bodies having a thickness/height (when no cavities are present) or wall thicknesses, in a range of 0.5 to 3 mm is preferred to ensure that the materials contained in the additive bodies are completely released into the liquid aerosol-forming substrate by the penetration of said liquid into the solid additive.

Bodies comprising a height or wall thickness in the ranges detailed above facilitate the release of materials from the bodies or the absorption of materials into said bodies.

Solid additives comprising bodies that have thinner walls or that are not as thick are preferred when a quicker release of the components present in the solid additive is required.

When the solid additive comprises cavities walls the walls of the cavities are preferably of a consistent cross-section across their width, along the length of the body.

Preferably the solid additive comprises one or more bodies that have been extruded and/or rolled and/or stamped and/or pressed and/or crushed and/or injection moulded and/or cast.

An extrusion process is preferably used to manufacture the solid additive in the form of bodies that comprise cavities or are cavity free (i.e. solid bodies that comprise no cavities).

The solid additive may comprise one or more of; a body with no cavity; a body with one or more cavities; a mesh; a compressed powder; a foam; a porous material; and/or a perforated material.

The one or more bodies of the solid additive may be provided with one or more or more cavities that form flow channels along which a liquid aerosol-forming substrate may pass.

The one or more bodies of the solid additive may be provided by use of a porous material, but such porous materials must comprise one or more of the following:

- i) be shaped to form interstitial spaces; and/or,
- ii) comprise cavities (which may be in the form of pores) through which a vapourisable liquid may pass; and/or,
- iii) comprise pores that form channels (on the surface of the porous body) along which a liquid aerosol-forming substrate may pass

The passage of the liquid aerosol-forming substrate through the interstitial spaces and/or the cavities and/or channels of the porous material must be sufficient to avoid the impeding of the flow of the liquid to the wick. This a general requirement of the solid additive disclosed herein.

Preferably the additive comprises organic material(s) and/or inorganic material(s).

When the additive comprises one or more inorganic materials, the inorganic material may comprise polymer, glass, ceramic or metal, for example.

Preferably the solid additive comprises one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals. The skilled addressee will appreciate that the solid body is used to add components such as flavourants, flavour enhancers, nicotine and additional chemicals to the liquid aerosol-forming substrate in the tank of a consumable.

Preferably the additional chemicals include chemicals for providing colour or odour to the liquid aerosol-forming substrate.

In some embodiments, the solid additive may be soluble (such that it will fully solubilise into the liquid aerosol-forming substrate), replaceable (such that something dissolves into the liquid) and something is removed from the liquid) and/or permanent (such that the additive will stay in the tank (reservoir) for the life of the reservoir).

The solid additive may comprise a coating on a body and/or a layer within a body, wherein the coating or layer comprises a material that is to be added to the liquid aerosol-forming substrate.

In some embodiments, the solid additive may be formed from one or more materials that are totally soluble in the liquid aerosol-forming substrate.

The one or more bodies of the solid additive may comprise tobacco or extracts of tobacco. The solid additive may comprise tobacco to infuse nicotine into the liquid aerosol-forming substrate. The nicotine being infused into the liquid aerosol-forming substrate by the contact of the tobacco, located within the additive, with the liquid being a long enough period of time for the nicotine to diffuse from the tobacco and into the liquid. The additive may also be used as a flavour additive or flavour booster by diffusing in the same way.

The additive may act as a catalyst by stimulating the reaction between two liquids contained in the liquid aerosol-forming substrate.

For example, carbon black may be located within the body of the additive or alternatively in a cavity within the body.

According to the present invention there is provided there is provided a solid additive for a consumable as described above. Thus, according to a second aspect of the fourth proposal of the invention there is provided a solid additive, that is added to a tank of a consumable of a smoking substitute device wherein the tank contains a liquid aerosol-forming substrate, characterised in that the solid additive is provided in the form of one or more bodies that comprise one or more cavities through which a liquid aerosol-forming substrate may flow, and/or are shaped to form interstitial spaces through which said liquid aerosol-forming substrate may flow, such that blocking of the flow of the liquid aerosol-forming substrate through the consumable by the solid additive is prevented.

According to embodiments of the invention there is provided a solid additive for a consumable as described above wherein the additive is placed in a tank of a consumable said tank being used to retain a liquid aerosol-forming substrate. The additive is located in the liquid aerosol-forming substrate (vapourisable liquid) in order to add materials to or to remove materials from said liquid.

The solid additive may be provided as one or more bodies that do not float and/or are free floating in the tank of a consumable.

It will be appreciated by the skilled person that all aspects of the fourth proposal described in relation to the first aspect of the present invention also apply/apply equally in respect of the second and/or third aspects of the fourth proposal of the present invention.

Optional features of the apparatus aspect of the fourth proposal of the invention will now be set out. These are applicable singly or in any combination with any aspect of the fourth proposal of the invention. An example of this apparatus aspect is illustrated in the accompanying drawings and discussed in more detail below.

The consumable may include a mouthpiece, and a wick that may extend from the aperture in which the wick is located substantially towards the mouthpiece. The mouthpiece may be located at or towards an opposite end of the consumable to the coil and wick assembly. The mouthpiece is generally the highest point of the consumable, when the consumable is in use, hence in use solid matter tends to settle at the bottom of the consumable and hence has the potential to block the wick.

The liquid aerosol-forming substrate may contain 0.1 to 20% by weight of a solid material (for example an additive) contained within a solid additive, especially of the tobacco-derived solid material. Often the liquid aerosol-forming substrate may contain at least 1% by weight, alternatively at least 2% by weight, or at least 3% and especially at least 4% by weight of a solid material (for example an additive) contained within a solid additive. In some embodiments the aerosol-forming substrate may contain up to 19% or 18% by weight of solid material of a solid material (for example an additive) contained within a solid additive, preferably up to 17% or 16% and more preferably up to 15% by weight of solid material of a solid material (for example an additive) contained within a solid additive.

The liquid component of the aerosol-forming substrate may comprise one or more aerosol formers, optionally together with flavourings. Preferred flavourings may be in liquid form.

Preferably the solid additive comprises tobacco-derived material is finely ground or milled to form a dust or powder which preferably has a maximum dimension of less than 2 mm prior to its incorporation into the solid additive. In this way the release of nicotine from the solid additive may be maximised. More preferably the material incorporated into the solid additive has a maximum dimension of no more than 1.5 mm and most preferably no more than 1.2 mm.

The use of very small tobacco-derived solids is possible when such materials are incorporated into solid additive of the type disclosed herein, as problems with clogging of a wick are avoided. Conveniently the tobacco-derived material incorporated into the solid additive is larger than 0.2 mm, preferably larger than 0.03 μm, more preferably larger than 0.040 mm, even more preferably larger than 0.05 mm, further preferably larger than 0.06 mm and especially larger than 0.07 mm.

Employing tobacco-derived material in the form of a powder or dust increases the surface area of the solid material which enhances the release of nicotine from the tobacco contained in the solid additive into a solution. The release of nicotine may also be enhanced by subjecting the solid additive comprising tobacco-derived material to elevated conditions of temperature.

An aerosol-forming substrate according to embodiments of the invention may comprise a solid additive comprising solid tobacco-derived material in a nicotine-containing solution obtained by extracting nicotine from the solid additive comprising the tobacco-derived material under conditions of elevated temperature and/or agitation.

The invention also provides methods for preparing a liquid aerosol-forming substrate as defined in any aspect of the fourth proposal of the present invention.

The invention also provides methods for manufacturing a consumable as defined in any aspect of the fourth proposal of the present invention.

In addition the invention concerns the use of a solid additive as defined in any aspect of the fourth proposal of the present invention in the manufacture of a consumable for a smoking substitute device.

Any feature of one aspect of the fourth proposal of the invention may be applied to other aspects of the fourth proposal of the invention, in any appropriate combination.

Fifth Proposal

According to a first aspect of a fifth proposal of the invention there is provided a consumable for a smoking substitute device, the consumable comprising:

- a filter;
- a tank, for storing vapourisable liquid; and,
- optionally the consumable comprises an outlet 604 in fluid communication with the tank, wherein the filter is disposed in the tank and retains solid material in the vapourisable liquid within said tank, and characterised in that the filter is engageable with the interior walls of the tank, and/or the outlet of the consumable when said outlet is present, to fix the position of the filter in said tank.

The filter removes solid material from vapourisable liquid that passes through it and thus prevents this solid material from reaching (and potentially blocking) the tank outlet (i.e. the tank outlet of the tank). The tank outlet is normally provided in the form of one or more openings that provide egress for the vapourisable liquid from the tank. When the vapourization means is provided as a coil and wick assembly then the aperture(s) in which the wick(s) is/are located form(s) the tank outlet.

The filter removes solid material from the vapourisable liquid that passes through it and thus prevents the solid material from reaching the wick of a consumable and/or the vapourization means of the substitute smoking device, which is preferably a heater provided in the form of a coil and wick, which may be provided as an assembly. Such solid materials may block the wick and/or be burnt by contact with the vapourization means (e.g. heater normally in the form of a heating coil) thus creating an unpleasant experience for a user.

The consumable preferably comprises an outlet in fluid communication with the tank; and, an air inlet, wherein the air inlet and the outlet define a path for airflow through the consumable, the filter being engageable with the interior walls of the tank and/or the outlet to fix the position of the filter in said tank. The engagement of the filter with the outlet (chimney), of a consumable, can provide additional stability in respect of fixing the location of the filter within the tank.

In most cases the consumable will comprise an air inlet, a vapourization means, and an outlet that define the path for the flow of fluid through the consumable, the air inlet being disposed at an end (a first end) of the outlet.

The filter effectively separates the wick/vapourization means from any solid that may be located in a liquid contained within the tank.

The skilled person will appreciate that in most cases, but not in all cases, the filter will be constructed such that its position is fixed by engagement of the filter with the interior walls of the consumable rather than with the outlet. The walls provide a larger surface area with which the filter can engage as compared to the outlet. Thus the filter may be more rigidly fixed in position by engagement with the walls of the tank as opposed to engagement with the outlet. The filter usually engages with the side walls of the tank. Engagement of the filter with the outlet, as well as the walls of the tank may further assist in fixing/retaining the location of the filter within the tank. The filter is fixed in position by engagement of the walls of the tank with the filter such that the position of the filter within the tank does not change once the filter is inserted in the tank.

The filter may be manufactured from one or more materials chosen from plastics materials, metals, ceramic materials and/or glass. Metal materials that are used may be in the form of a mesh, e.g. a wire mesh. These materials are self-supporting and so do not require support from a filter body or the like to enable them to be located within a tank containing a liquid to be vapourised, such that the filter can remove solid material from a vapourisable liquid prior to its exposure to a vapourization means. The use of an insertable filter has the advantage that a filter may be readily manufactured for insertion into the tank of any existing consumable. The provision of a filter, as disclosed herein, can ensure that the solid material present in a vapourisable liquid may be removed before the liquid reaches the tank outlet of a consumable. In this way blocking of the outlet (or a wick) is avoided and the risk that solid material may enter the vapourization means is also removed.

The consumable may further comprise a mouthpiece, the mouthpiece comprising a mouthpiece outlet. The mouthpiece being in fluid communication with the tank by means of its engagement with a second end of the outlet of the consumable.

The vapourization means is located at the opposite end of the tank to the end that is adjacent to the mouthpiece of the consumable.

The filter may be positioned at any point in the tank, such that it removes solid material from the vapourisable liquid prior to its vapourization.

Preferably the filter comprises a body, the filter is provided as a unit that may be inserted into the tank of a consumable. The use of a body may facilitate the formation of a tighter fit between the body of the filter and walls of the tank.

The filter may comprise one or more elongate members.

The filter may be provided with one or more elongate members (leg(s)) that extend from the filter or a filter body. The leg(s) may engage with other components of the consumable. In this way the legs may be used to determine the location of the filter within the tank or to assist in fixing the filter (or optionally other components of the consumable) in a particular location within the tank. The leg(s) may, for instance, engage one or more of: the walls of the tank; a seal that is used to seal the coil and wick assembly to the outlet; the coil and wick assembly; and/or any other components that may be located in the tank; and/or other means that may be provided within the tank of the consumable to receive the elongate member(s), in particular the end(s) of the member(s). The elongate member(s) may engage the end wall of the tank that is distal from the wick and/or vapourization means.

Preferably the filter may be provided in the form of a body comprising integral apertures to retain solid material. The apertures in the filter body allow liquid to pass through the filter body whilst retaining solid material. Sufficient liquid must be able to pass through the apertures to allow the consumable to operate in a normal. Hence in most cases a single aperture is unlikely to filter sufficient liquid to allow the consumable to operate in a normal way, although there may be instances when a single aperture in the filter body may suffice.

If the filter is formed by means of an injection moulding process then the apertures may be formed as part of this process. Alternatively the apertures may be formed in the filter by means of processes such as milling, drilling, micro-drilling, laser cutting, electron-beam drilling or EDM (Electro Discharge Machining).

More preferably the apertures have a diameter in a range of 0.1 to 2 mm.

More preferably the apertures have a diameter in a range of 0.1 to 1 mm.

Alternatively the filter comprises at least one filter membrane.

Preferably the filter membrane comprises one or more of a filter cloth, a filter screen, a ceramic filter, and/or a metal filter; the metal filter may be in the form of a mesh.

The filter membrane may comprise one or more layers chosen from a mesh and/or a fibrous material and/or a woven material and/or one a non-woven material.

The filter membrane may comprise one or more layers of a metal and/or a non-metal.

The filter membrane is preferably formed from a woven wire mesh of equal or uneven spacing. A stainless steel mesh comprising “316 stainless steel (marine grade)” and/or “304 stainless steel” is a suitable material, as theses steels have adequate resistance to the vapourisable liquid in the reservoir. Other materials from which the membrane may be manufactured include, but are not limited to, aluminium, nickel-chromium-molybdenum alloy, HDPE (high-density polyethylene), LDPE (low-density polyethylene), PP (polypropylene), PETG (polyethylene terephthalate glycol), PMP (polymethylpentene/poly(4-methyl-1-pentene), POM (polyoxymethylene), PS (polystyrene), PVC (polyvinyl chloride), FEP (fluorinated ethylene propylene), PTFE (polytetrafluoroethylene), PVDF (polyvinylidene fluoride/polyvinylidene difluoride), EPDM (ethylene propylene diene monomer rubber), FPM/FKM (fluoroelastomers), NBR (nitrile rubber/acrylonitrile butadiene rubber) or silicone or silica.

The filter membrane may be attached to the filter body by means of an insert or over-moulding process. Another alternative approach is to affix the filter to the filter body by the use of adhesives, heat staking, ultrasonic welding, vibration welding or by the use of mechanical means such as a threaded fastener, clip(s) or rivet(s).

Preferably the size of the apertures in the filter membrane are in the range of 0.2 to 2 mm.

More preferably the size of the apertures in the filter membrane are in the range of 0.05 to 0.6 mm.

Most preferably the apertures in the filter membrane are in the range 0.2 to 0.3 mm.

The skilled person will appreciate that the size of the apertures must not be so small that they cause significant resistance to the flow of liquid through the filter and thus through the consumable. To some extent, this problem may be alleviated by increasing the number of apertures that are provided.

A seal, preferably in the form of a gasket, may be located between the filter and the interior of the tank.

Preferably one or more seals (tank seal(s), normally in the form of gasket(s)) is/are located between the filter (or the filter body) and the wall of the tank, in order to form a tight seal between said filter and the wall of the tank, and to fix the position of the filter within the tank. In use, the position of the filter (or filter body) within the tank is fixed such that the position of the filter does not move once the filter is located within the tank. The filter (filter body) may be retained in a fixed position by the provision of such a seal (gasket); the seal (gasket) prevents the passage of vapourisable liquid (and any solid material contained therein) to the vapourization means (e.g. a coil and wick) assembly.

The seal (gasket) may be provided as an integral component of the filter (filter body), for instance the seal may be formed on the filter by means of an over-moulding process. It is preferable that such a seal is not used, and instead a suitable interference fit (between the filter and the tank walls) is used to fix the position of the filter; as this has advantages in respect of manufacturing and costs. The seal may be provided by means of an overmolding process.

A seal (normally in the form of a gasket), if required, may be provided to prevent the passage of vapourisable liquid between an outlet of the consumable and the side walls of an opening in the filter or filter body in which said outlet is located. This seal (outlet seal) may be provided by means of an overmolding process. The tank seal and outlet seal may be formed as part of the same overmolding process.

Adhesive may be utilised to retain the position of the filter within the tank and also to act as an alternative sealing means to the seals (gaskets) mentioned above, i.e. the adhesive may fix the position of the filter in the tank; and also prevent the passage of vapourisable liquid between the side walls of the filter body and the interior walls of the tank, and thus into the vapourization means. Similarly adhesive(s) may be used to prevent the passage of vapourisable liquid between an outlet and the side walls of an aperture through which the outlet passes. The adhesive used may comprise one or more adhesive(s) chosen from the group comprising cyanoacrylates, acrylics, epoxies, urethanes, elastomers, silicones and epoxy or methyl methacrylate.

The seal may also be formed by means of heat welding if the filter (filter body) is manufactured from plastics materials.

Alternative means of forming the seal between the filter (filter body) and the tank include the use of adhesives, heat staking, ultrasonic welding, vibration welding.

The filter may be formed as an integral part of the consumable. The filter may be formed as part of the consumable by the use of injection moulding or the like, so as to reduce manufacturing time and costs.

The filter is preferably connected to the interior of the tank by means of an interference fit.

The filter and tank may be shaped such that when the filter is inserted into the tank an interference fit is formed between the tank and filter, this may be due, for instance, to a narrowing of one end of the interior of the tank with which a portion of the filter and/or a filter body form an interference fit. The interference fit fixes the position of the filter in the tank by means of the friction due to the engagement of the filter with the walls of the tank.

The engagement of the filter with the walls of the tank may be provided by means of a push-fit mechanism. A push-fit mechanism is a mechanism that allows a first component to be engaged with a second component by the insertion of a part of the first component into an appropriately configured opening in the second component. The insertion of the first component into the second component results in the engagement of the two parts to form a liquid tight seal between the two components.

The filter may be releasably connected to the consumable. This may assist in respect of recycling.

The filter membrane may be moulded into the filter body by means of an insert or over-moulding process.

Other alternative approaches to affix the filter membrane to the filter body include the use of adhesives, heat staking, ultrasonic welding, vibration welding or by the use of mechanical means such as a threaded fastener, clip(s) or rivet(s).

According to the present invention there is provided a filter for a consumable as described above.

According to a second aspect of the fifth proposal of the invention there is provided a filter for removing solid material from a vapourisable liquid in a tank of a consumable of a smoking substitute device, characterised in that the filter is fixed in position within the tank by the engagement of the filter with the walls of the tank and/or optionally an outlet of the consumable.

According to a third aspect of the fifth proposal of the invention there is provide a filter insertion tool for inserting a filter into a tank of a consumable for a smoking substitute device, the filter insertion tool comprising a means to initially retain the filter, and to subsequently release the filter following the engagement of the filter with the walls of the tank.

Preferably the filter insertion tool further comprises an outlet sealing means. Preferably the outlet sealing means is moveable relative to the filter retaining means. The outlet sealing means is to provide a seal to an outlet, said outlet normally in the form of a chimney of a consumable. The outlet sealing means may be slideable and/or spring loadable in order that a constant pressure is applied to the outlet sealing means and thus vapourisable liquid is prevented from entering the outlet.

Preferably the filter insertion tool further comprises a liquid venting means. The liquid venting means preferably being provided as a component of the filter retaining means. Preferably the means to retain the filter and the outlet sealing means are provided as elongate members, preferably in the form of arms.

The filter insertion tool may be manufactured from one or more of metals, plastics materials and/or ceramics. The plastics materials that are used to manufacture the body are preferably chosen from the group comprising PVC (polyvinyl chloride), HDPE (high-density polyethylene), PP (polypropylene) or PC polycarbonate.

According to a fourth aspect of the fifth proposal of the invention there is provided a method for inserting a filter into a consumable for a smoking substitute device characterised in that it comprises the steps of:

- i) engaging the filter with a filter insertion tool, locating the filter at an opening of a tank, wherein the tank optionally comprises an outlet;
- ii) inserting the filter into the tank until the filter engages with the walls of the tank and/or optionally an outlet of the consumable when present; and,
- iii) subsequently withdrawing the filter insertion tool from the tank such that the filter is retained within the tank due to its engagement with said tank walls and/or the outlet, and thus the filter is disengaged from the filter insertion tool.

Preferably the tank contains a solid, or a solid and liquid.

Preferably, when the tank contains a solid, or a solid and liquid, the engagement of the filter with the filter insertion tool also engages an outlet sealing means of the filter insertion tool with the outlet of the consumable, such that a first end of the outlet sealing means seals said end of the outlet of the consumable. The outlet sealing means is disengaged from the outlet of the consumable by the withdrawal of the filter insertion tool from the tank of the consumable.

The filter may be retained on the filter insertion tool by means of the engagement of arm(s) (provided as part of the tool) that comprise filter engagement means (normally located at the end(s) of the arm(s) that engage with apertures that are formed in the filter.

The use of a filter provides a cost effective method to filter solids from a vapourisable liquid.

Optional features of this apparatus aspect of the fifth proposal of the invention will now be set out. These are applicable singly or in any combination with any aspect of the fifth proposal of the invention. An example of this apparatus aspect is illustrated in the accompanying drawings and discussed in more detail below.

The consumable may include a mouthpiece, and the wick may extend from the aperture in which the wick is located in a direction substantially towards the mouthpiece. The mouthpiece may be located at or towards an opposite end of the consumable to the coil and wick assembly. The mouthpiece is generally the highest point of the consumable, when the consumable is in use, hence in use solid matter tends to settle at the bottom of the consumable and hence may block the wick.

Further apparatus aspects of the fifth proposal of the invention concern a consumable for a smoking substitute device adapted for vaping a liquid aerosol-forming substrate as defined in any aspect of the fifth proposal of the present invention and a vaping smoking substitute device configured for vaping a liquid aerosol-forming substrate as defined in any aspect of the fifth proposal of the present invention.

In this regard, difficulties may arise when utilizing vapourisable liquids which comprise a suspension of solid material as clogging of the solids can occur around the wick which can reduce or even cut off contact of the wick with the vapourisable liquid. This may occur when the user inhales from a device in which a coil and wick assembly is at a lowermost point of the tank.

Any feature of one aspect of the fifth proposal of the invention may be applied to other aspects of the fifth proposal of the invention, in any appropriate combination.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:

FIG. 1(a) shows an example smoking substitute device in accordance with each of the proposals of the present invention;

FIG. 1(b) shows the main body of the smoking substitute device of FIG. 1(a) without the consumable in accordance with each of the proposals of the present invention;

FIG. 1(c) shows the consumable of the smoking substitute device of FIG. 1(a) without the main body in accordance with each of the proposals of the present invention;

FIG. 2(a) is a schematic view of the main body of the smoking substitute device of FIG. 1(a) in accordance with each of the proposals of the present invention;

FIG. 2(b) is a schematic view of the consumable of the smoking substitute device of FIG. 1(b) in accordance with each of the proposals of the present invention;

FIG. 3 shows a cross-sectional view of a consumable of the smoking substitute device in accordance with each of the proposals of the present invention.

FIG. 4 is a cross-sectional view of a coil and wick assembly in accordance with each of the proposals of the present invention;

FIG. 5 is a cross-sectional view of a further coil and wick assembly in accordance with each of the proposals of the present invention;

FIG. 6 is a cross-sectional view of the coil and wick assembly of FIG. 4 as installed in a tank in accordance with each of the proposals of the present invention;

FIG. 7 is illustrates a coil and wick assembly in accordance with each of the proposals of the present invention;

FIGS. 8a to 8f provide end views of a number different shaped bodies that may be utilised as solid additives in accordance at least with the first and fourth proposals of the present invention;

FIGS. 9a to 9f provides end views of a number different shaped bodies that may comprise cavities and be used as solid additives in accordance at least with the first proposal and fourth proposals of the present invention;

FIG. 10a provides a perspective view of a “V” shaped body in accordance at least with the first and fourth proposals of the present invention;

FIG. 10b provides a perspective view of a ribbed body in accordance at least with the first and fourth proposals of the present invention.

FIG. 11 provides a perspective view of a solid additive in the form of a hollow body comprising a square cross-sectional shape and a cavity with open ends in accordance at least with the first and fourth proposals of the present invention;

FIG. 12 provides a perspective view of a solid additive in the form of a hollow body comprising a square cross-sectional shape wherein a plurality of cavities run the length of the body in accordance at least with the first and fourth proposals of the present invention;

FIG. 13 provides perspective view of a solid additive in the form of a hollow body comprising a square cross-sectional shape wherein a cavity runs along the length of the body, but the ends are sealed and multiple openings are provided to the cavity along the sides of the body in accordance at least with the first and fourth proposals of the present invention;

FIG. 14a provides a plan view of a solid additive in the form of an irregular shaped body in accordance at least with the first and fourth proposals of the present invention;

FIG. 15 illustrates a solid additive in the form of a generally spherical body that comprises channels in its surface in accordance at least with the first and fourth proposals of the present invention;

FIG. 16 provides a perspective view of a solid additive in the form of a body with a generally square cross-sectional shape that comprises channels along its surface in accordance at least with the first and fourth proposals of the present invention;

FIGS. 17a, 17b and 17c illustrate a solid additives in the form of a generally spherical body in accordance with at least the first proposal of the present invention.

FIG. 18 shows a cross-sectional view of a consumable of the smoking substitute device containing a solid additives in the form of a plurality of generally ellipsoidal bodies at least in accordance at least with the first and fourth proposals of the present invention.

FIG. 19 shows a further cross-sectional view of a consumable of the smoking substitute device containing an alternative solid additives in the form of a plurality of generally spherical bodies in accordance at least with the first proposal of the present invention.

FIG. 20 shows a further cross-sectional view of a consumable of the smoking substitute device containing an alternative solid additives in the form of a plurality of larger generally spherical bodies in accordance at least with the first proposal of the present invention.

FIG. 21 provides a perspective view of a filter in accordance at least with the second proposal of the present invention;

FIG. 22 provides a side view of bottom end of a filter in accordance at least with the second proposal of the present invention;

FIG. 23 provides a plan view of the top end of a filter in accordance at least with the second proposal of the present invention;

FIG. 24 provides a plan view of a first gasket/seal in accordance at least with the second proposal of the present invention;

FIG. 25 provides a plan view of a second gasket/seal (an outlet gasket) in accordance at least with the second proposal of the present invention;

FIG. 26 provides a perspective view of an alternative filter in accordance at least with the second proposal of the present invention;

FIG. 27 provides a photograph of a filter in accordance at least with the second proposal of the present invention;

FIG. 28 shows a cross-sectional view of a consumable of the smoking substitute device comprising a filter in accordance at least with the second proposal of the present invention;

FIGS. 29 to 35 are cross-sectional views of various consumables showing alternative arrangements for a solid body additive that is retained in position within the tank in at least accordance with the third proposal of the present invention;

FIG. 36 provides a perspective view of a filter in accordance at least with the fifth proposal of the present invention;

FIG. 36a provides a perspective view of a second filter in accordance at least with the fifth proposal of the present invention;

FIG. 37 provides a perspective view of a filter comprising legs in accordance at least with the fifth proposal of the present invention;

FIG. 38 is an illustration of a filter in accordance at least with the fifth proposal of the present invention;

FIG. 39 is an illustration of a filter comprising legs in accordance at least with the fifth proposal of the present invention;

FIG. 40a is an illustration showing a perspective view of a tool used to insert filters into the tanks of consumables (a filter insertion tool) in accordance at least with the fifth proposal of the present invention;

FIG. 40b is an illustration showing a perspective view of a second end of the filter insertion tool engaged with a filter in accordance at least with the fifth proposal of the present invention;

FIG. 40c is an illustration showing a perspective view of a second end of the filter insertion tool engaged with a filter in accordance at least with the fifth proposal of the present invention;

FIG. 40d is an illustration showing a second perspective view of the second end of the filter insertion tool engaged with a filter in accordance at least with the fifth proposal of the present invention;

FIG. 41 is an illustration of a filter insertion tool engaged with a filter that is located within a tank of a consumable for containing vapourisable liquid in accordance at least with the fifth proposal of the present invention;

FIG. 42 is an illustration of a filter located within a tank of a consumable for containing vapourisable liquid in accordance at least with the fifth proposal of the present invention;

FIG. 43 provides a plan view of a first gasket/seal in accordance at least with the fifth proposal of the present invention;

FIG. 44 provides a plan view of a second gasket/seal (an outlet sealing means) in accordance at least with the fifth proposal of the present invention;

FIG. 45 provides a cross-sectional view along the length of a filter engagement arm of an insertion tool in accordance at least with the fifth proposal of the present invention;

FIG. 46 provides a cross-sectional view along the length of an outlet sealing arm of an insertion tool in accordance at least with the fifth proposal of the present invention; and,

FIG. 47 is an illustration of a tank of a consumable showing a filtered and unfiltered liquid, separated by a filter in accordance at least with the fifth proposal of the present invention;

DETAILED DESCRIPTION AND FURTHER OPTIONAL FEATURES

Proposals of the present invention, and their subsidiary aspects and embodiments, 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. 1(a) shows an example 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 this example, the smoking substitute device 110 is a closed system vaping device, wherein the consumable 150 includes a sealed tank or liquid reservoir 156 and is intended for one-use only.

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

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

FIG. 1(c) 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. 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 light 126 may be configured to illuminate when the smoking substitute device 110 is activated.

The consumable 150 includes a mouthpiece (not shown) at a top end 152 of the consumable 150, as well as one or more air inlets (not shown in FIG. 2) 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 more generally a “cartomizer”.

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

Further features of the apparatus are shown in FIGS. 2 to 6 and described in more detail below.

Features of an example smoking substitute device will now be described in more detail.

FIG. 2(a) is a schematic view of the main body 120 of the smoking substitute device 110.

FIG. 2(b) is a schematic view of the consumable 150 of the smoking substitute device 110.

As shown in FIG. 2(a), the main body 120 includes a power source 140, 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 140 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 the mobile device 2, e.g. via Bluetooth®. To this end, the wireless interface 134 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. As discussed above, the wireless interface 134 may be configured to communicate wirelessly with the remote server 2.

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 140 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). When the main body 120 is not physically coupled to the consumable 150, the electrical interface may be configured to receive power from the charging station 6. 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 flavour 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 include the optional light 126 discussed above.

The additional components 138 of the main body 120 may, if the power source 140 is a rechargeable battery, include a charging port configured to receive power from the charging station 6. 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 6 such that a separate charging port is not required.

The additional components 138 of the main body 120 may, if the power source 140 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 6 (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. 2(b), the consumable 150 includes the tank 156 for the liquid aerosol-forming substrate (e-liquid), 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 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 therefore electrically couple the main body 120 to the consumable 150 when the main body 120 is physically coupled to the consumable 150. In this way, electrical energy (e.g. in the form of an electrical current) is able to be supplied from the power source 140 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 140. In one example, the heating device 162 may include 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 vapour.

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.

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 140 to the heating device 162 (via electrical interfaces 136, 166), which may cause the heating device 162 to heat e-liquid drawn from the tank 156 to produce a vapour 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 FIGS. 1 and 2 shows just one example implementation of a smoking substitute device, and that other forms of smoking substitute device could be used.

By way of example, an open system vaping device which includes a main body, a refillable tank, and a mouthpiece could be used, instead of the smoking substitute device 110. One such open system vaping device is the blu PRO™ e-cigarette discussed above.

As further 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. Broadly, the consumable comprises a tank 156 within which is: a seal 400; heating device, in this example a coil and wick assembly 302; and an outlet 604. The outlet fluidly connects the coil and wick assembly 302 to the mouthpiece 166.

The tank is provided by an outer casing of the consumable. The coil and wick assembly 302 broadly comprises an outer shell with one or more apertures. These apertures are filled with a wick material, so that liquid may only ingress the coil and wick assembly from the tank via capillary action. The wick material passes through or proximal to a coil, which is connected to one or more electrical contacts. By providing an electrical current to the one or more contacts, the coil may be heated and so the liquid within the wick material vapourised. The coil and wick assembly 302 is connected to the air inlet 164 of the consumable, so that when the user draws on the mouthpiece 166, a flow of air passes from the air inlet through the coil and wick assembly thereby drawing with it vapourised liquid. This mixed flow of air and vapourised liquid then passes up the outlet 604, in this example a chimney or tube, before exiting the consumable 150 via mouthpiece 166. It is important then that liquid may only enter the coil and wick assembly via the one or more apertures and then, only via the wick.

A silicone seal 400 seals the coil and wick assembly 302 to the outlet 604, at a first end of the outlet 605. This seal ensures that liquid within the tank 156 cannot pass directly into the outlet 604. Instead, in use, vapourisable liquid is wicked into the coil and wick assembly by the wick, e.g. via capillary action, and vapourised by the coil within. Therefore the outlet 604 should only receive vapourised liquid.

FIG. 4 shows a cross-sectional view of a coil and wick assembly 302. The coil and wick assembly may form the heater of any of the preceding consumables 150. The coil and wick assembly is disposed within the tank 156, at a bottom end thereof opposite to the mouthpiece 166. The coil and wick assembly is connected to the mouthpiece via an outlet, or chimney. The coil and wick assembly may form a lower wall of the tank, i.e. it may at least partially define the interior volume of the tank.

Broadly, the coil and wick assembly is formed from a housing 304, in which are first 305a and second 305b apertures or wick apertures. Within a cavity 310, provided by the housing, is a coil 306 e.g. coil of electrical wire, connected to first 308a and second 308b electrical contacts. These contacts are connectable to the battery of the main device 110, and so provide power to the coil.

An outlet aperture 309 is located proximal to the coil 306. When installed within the consumable, the outlet aperture is sealed from the liquid containing volume of the tank and is fluidly connected to an outlet. The outlet fluidly connects the cavity 310 of the coil and wick assembly to the mouthpiece. A wick 307 is provided through the coil, and through each of the first and second apertures. The wick acts to substantially seal the cavity 310 of the coil and wick assembly from free flowing liquid in the tank. Thus, liquid can only enter the cavity 310 by capillary action i.e. by being wicked in via the wick. The wick extends from the apertures, in a direction away from the electrical contacts to leave exposed regions 307a and 307b respectively.

The coil and wick assembly has an outlet aperture 309, which is positioned above the coil i.e. on an opposing side of the coil to the electrical contacts, in an uppermost surface of the coil and wick assembly. This outlet aperture is connected to the outlet discussed previously, which allows vapourised liquid to travel to the mouthpiece. The wick may have a length, as measured from one end to an opposing end, of more than 2 cm. For example, the wick may have a length of around 3 cm.

At a lower end of the consumable, i.e. one nearest the electrical contacts, is an air inlet 164. In use, the user draws on the mouthpiece which causes air to flow in through air inlet 164. This airflow draws with it vapourised liquid from the wick contained within the coil 306 (which is heated); and the airflow, now containing vapourised liquid, travels up an outlet and into the mouthpiece whereby it is inhaled. Whist the air inlet in this example is shown as a single air inlet disposed between the electrical contacts, instead there may be plural air inlets disposed between respective electrical contacts and an edge region of the coil and wick assembly. Further alternatively, there may be a single air inlet which extends across a width of the device thereby defining a channel. The channel may be bridged, across its width, by the first and second electrodes.

FIG. 5 shows a variant coil and wick assembly, where like reference numerals denote like features.

A notable difference between FIG. 4 and FIG. 5 is the inclusion of first 402a and second 402b clips, which are attached to a seal 400. The seal 400 seals an outlet (not shown) to the coil and wick assembly, so that vapourised liquid can pass there between. The first and second clips retain the exposed portions of wick in a position distal from the electrical contacts and proximal to the seal. For clarity, in FIG. 5 the outlet aperture 309 is omitted. However it will be appreciated that there is an outlet aperture present which allows the flow of vapourised liquid within the cavity 310 through a portion of the seal 400 and onwards to the outlet. Whilst the clip in this example is attached to the seal, it may be that the clip is attached to an upper region of the coil and wick assembly (i.e. between the aperture and the seal) or to a portion of the outlet. By varying the location of the clip, the consumable is able to accommodate a range of wick lengths.

The overall/general direction of the airflow through the device is indicated by the arrow on FIG. 6.

FIG. 6 shows the coil and wick assembly of FIG. 4, as installed in the consumable 150. As can be seen, the coil and wick assembly 302 forms a lower wall of the tank 156 and so at least partially defines the liquid containing volume thereof. The tank 156 in this example is filled with an aerosol-forming substrate in the form of a vapourisable liquid which contains a solid suspension. As a result, when the consumable 150 is orientated such that the mouthpiece is higher than the coil and wick assembly (as is the case in FIG. 6) solid tobacco-derived sediment 602 may accumulate around the coil and wick assembly. The portions of the wick 307a and 307b extend above where this sediment may accumulate, and so will generally be exposed to the liquid within the tank 156. As shown in the Figure, an outlet 604 is provided which is sealed to the coil and wick assembly via a seal (omitted for clarity). The Arrow indicates the air flow through the consumable.

FIG. 7 is an illustration of a coil and wick assembly similar to that shown in FIG. 5. Like features are denoted by like reference numerals.

The clip assembly can be more clearly seen in this view, with a main body 502 positioned around the seal 400. First 402a and second 402b clips extend from the main body on opposing sides of the coil and wick assembly 302.

As mentioned above there are problems associated with using solid materials to add or remove materials to a liquid aerosol-forming substrate (a vapourisable liquid) that is located in the tank of a consumable for a smoking substitute device. Such consumables normally comprise a vapourization means which is normally a heater. The heater is normally in the form of a coil and wick assembly. When solid materials are located in the consumable they may block the vapourization means (normally by blocking the wick).

Proposal 1

In the present invention according to the first proposal a solid additive in the form of one or more bodies is located within a tank of a consumable. The bodies sized (large in size) such that they cannot form a layer of material on a wick located within the tanks and thus cause the wick to become blocked/clogged.

FIG. 19 shows a cross-sectional view of a consumable of the smoking substitute device containing a solid additives in the form of a plurality of generally spherical bodies.

In a first embodiment of the invention according to the first proposal it is preferable that the width, the length and the height (which in this case corresponds to the thickness, as the spheres are not hollow) of the one or more bodies, as generally indicated by 792, see FIG. 19, that comprise the solid additive, each exceeds (is greater than) 2 mm, i.e. the diameter of the generally spherical bodies exceeds 2 mm. These bodies are placed in the liquid aerosol-forming substrate located in a tank 156 of a consumable 150. Bodies of this size are unable to enter the space, as generally indicated by 791 (see FIG. 3) within the consumable 150 between the lower side walls of the tank 790a and the walls of the coil and wick assembly 162a, as illustrated in FIG. 19. Hence blocking of the wick by the bodies of the solid additive is prevented. Elongate bodies of the type discussed above and those bodies illustrated in FIGS. 8a to 8d, 9, 11, 12, 13, 14a, 14, 15 and 16 are all suitable for use in respect of this embodiment of the first proposal of the invention when their widths, lengths and heights (or thicknesses in the case of bodies that are not hollow) each exceed 2 mm.

The solid bodies 792 are manufactured using the manufacturing means discussed above.

In a second embodiment of the invention according to the first proposal the width, length and height, of the solid bodies each exceeds (is greater than) 5 mm, i.e. the diameter of the generally spherical bodies exceeds 5 mm. These bodies are placed in the liquid aerosol-forming substrate located in a tank 156 of a consumable 150. Solid bodies of this size are unable to enter the space, as generally indicated by 793, within the consumable 150 between the side walls of the tank 790 and the coil and wick assembly. In this way any contact between the wick and the solid additive is prevented. Elongate bodies of the type shown in FIGS. 8a to 8d, 9, 11, 12, 13, 14a, 14, 15 and 16 are suitable in respect of this embodiment of the first proposal of the invention, when their widths, lengths and heights (or thicknesses in the case of bodies that are not hollow) each exceed 5 mm.

FIG. 8 provides views of the ends of a number different shaped bodies that may be utilised as solid additives in accordance with the first proposal of the present invention. The bodies shown in FIG. 8 are viewed directly from one end of the bodies (end-on) and have the same uniform shape along their length.

The one or more bodies of the solid additive may comprise one or more cavities through which said liquid may flow and/or are shaped to form interstitial spaces through which said liquid may flow. In this way, such blocking of the flow of liquid aerosol-forming substrate through the consumable by said solid additive is prevented.

FIG. 9 provides views of the ends of a number of further shaped bodies that comprise cavities (759, in the form of lumens). The cavities 759 have a uniform diameter along their length, i.e. the bodies illustrated comprise the same shape along the length of their body when viewed in cross-section. These shaped bodies may be used as solid additives in accordance with the first proposal of the present invention.

FIGS. 8a to 8f provide end views of a number different shaped bodies that may be utilised as solid additives, in accordance with the first proposal of the present invention.

FIGS. 9a to 9f provides end views of a number different shaped bodies that may comprise cavities and be used as solid additives, in accordance with the first proposal of the present invention.

For the planar body indicated in FIG. 8a the wall thickness of the body is represented by “a”, and the thickness and height of the body correspond. The skilled person will appreciate that for bodies that comprise no cavity the thickness of the bodies will correspond to their height. For the bodies illustrated in FIGS. 8b to 8f, and the bodies illustrated in FIG. 9 the height of the bodies is represented by “b”.

End views of a number different shaped bodies that comprise cavities (759, in the form of lumens) of a uniform diameter along their length are illustrated in FIG. 9, i.e. the bodies illustrated comprise the same shape along the length of their body when viewed in cross-section.

The widths of the bodies are represented by “c” on FIGS. 8, 9, 10a and 10b.

The length of the bodies illustrated in FIGS. 10a and 10b are represented by “d”.

The skilled person will appreciate that the one or more bodies of the solid additives may comprise a wide range of shapes, including but not limited to the shapes mentioned herein. The bodies are preferably elongate in nature having cross-sectional profiles that include, but are not limited to: planar (see FIG. 8a), generally “V” (see FIG. 8b) or “W” shaped, generally “S” (see FIG. 8C), or “M” shaped, generally “U” shaped (see FIG. 8C), generally “N” shaped (see FIG. 8f), angular (see FIG. 8d), generally semi-circular (see FIG. 8e), curved, convex, concave, wave shaped, castellated, or branched. Bodies of these particular shapes tend to pack such that interstitial spaces are formed between adjacent bodies. Spherical, spheroidal and ellipsoidal shaped bodies are also preferred shapes for the bodies. Similarly interstitial spaces are formed between bodies of these shapes. The formation of interstitial spaces is advantageous as it facilitates the passage of the vapourisable between the bodies of a solid additive when a plurality of bodies are present Additionally, the shapes detailed above may comprise cavities along their length “d”, see FIGS. 10a and 10b below, or as cavities in the form of perforations that pass through the plane of the body of the shapes concerned, see FIGS. 10a and 10b below.

Solid additives comprising bodies with cavities (more preferably lumens) are preferably provided in the form of elongate-polygons having cross-sectional shapes that are, for instance, triangular, rectangular (see FIG. 9b), square (see FIG. 9b), circular (see FIG. 9C), ovoid (see FIG. 9d), star shaped (see FIG. 9f), or comprise bodies have multiple sides such as pentagons, hexagons (see FIG. 9e), heptagons, octagons, nonagons; irregular, angular, semi-circular, curved, convex, concave, wave shaped, castellated, branched, spherical, spheroidal and ellipsoidal shaped bodies that comprise cavities may also be used.

The use of bodies comprising lumen(s) (as the cavity) is preferred, i.e. hollow tubes that are open at both ends and that preferably run the length of an elongate body. Lumens of this type have the advantage that they provide for an efficient flow of liquid through the elongate body as there is less resistance to the flow of liquid.

FIG. 10a provides a perspective view of an elongate “V” shaped body that may be used as a solid additive. The body 750 has a “V” shape when viewed “end on” (or in cross-section across the width of the body) and is of a uniform thickness along its length. The skilled addressee will appreciate that the other shaped bodies, as illustrated in FIGS. 8 and 9, similarly extend longitudinally away (have a length “d”) from the ends of the bodies that are illustrated shown. The “V” shaped body in FIG. 10a also comprises a width “c”, a height “b”, and a length “d”.

FIG. 10b provides a perspective view of a ribbed body. The ribbed body 750 when viewed from its end comprises a series of “V” shaped bodies that are joined together along their length to provide a generally planar structure comprising ribs 755. The body illustrated 750 further comprises cavities perforations (cavities) 756 which further facilitate the passage of vapourisable liquid through the body. The body illustrated in FIG. 10a also comprises a width “c”, a height “b” and a length “d”.

FIG. 11 provides a perspective view of a solid additive in the form of a hollow body comprising a square cross-sectional shape and open ends. The body comprises four walls 752 that form a square shaped body 750, when the body is viewed end on. The open ends of the body form apertures, one of which is generally indicated by 751, to the interior of the body 750. A corresponding aperture, not shown, is provided at the opposite end of the body 750.

FIG. 12 provides a perspective view of a solid additive in the form of a hollow body 750 comprising a square cross-sectional shape wherein a plurality of cavities (four cavities) run the length of the body. The four cavities terminate in four apertures 751 that are visible at one end of the body 750, as shown in FIG. 12. The opposite end of the body 750 comprises four corresponding apertures that are not visible. The use of multiple cavities assists the passage of liquid through wider bodies whilst still facilitating the solubilisation of additives located within the solid body 750, i.e. the solubilisation of additives is facilitated by minimising the distance to the midpoint of the side walls from the faces of the cavity 757, and of the exterior walls 758 of the body 750 to the midpoint(s) of the body located farthest from said walls.

FIG. 13 provides perspective view of a hollow body comprising a square cross-sectional shape wherein a cavity runs the length of the body, and multiple openings (apertures) to the cavity are provided, but wherein the ends of the cavity are sealed. Multiple openings (apertures) 751 are provided to the cavity along the exterior walls 758 of the body 750. The hollow body 750 shown in FIG. 13 comprises a square shaped cross-section and a cavity (not visible) that runs the length of the body 750. Multiple openings (apertures) 751 to the cavity are provided along the exterior walls 758 of the body 750. Solid additives in the form of bodies that comprise one or more openings along their length may have closed ends, as illustrated in FIG. 13.

FIG. 14a provides a plan view of a solid additive in the form of an irregular shaped body 750. The irregular shaped body 750 comprises a plurality of interconnected openings (apertures) 751 that pass thorough said body 750 to form cavities. The cavities provided may comprise two apertures connected to each other to form a single tube or multiple apertures may be connected together to form a series of interconnected tubes.

The bodies used may comprise the general polygonal shapes as discussed above, but wherein one of the sides of the body are missing.

FIG. 14b provides perspective view of a solid additive in the form of a hollow body comprising a generally hexagonal cross-sectional shape wherein a cavity runs the length of the body and one side of the body is absent. The missing side of the body enables the cavity, as generally indicated by 759, to be seen. The cavity 759 runs along the length of the body 750. The omission of a side of the body further facilitates the passage of liquid into, through and out of the body 750.

As mentioned above the skilled person will appreciate that a wide range of shapes of bodies, beyond those mentioned above may be employed in the first proposal of the present invention.

Any of the previously mentioned shapes of bodies detailed above may further comprise one or more channels/recesses in their outermost (or inner) surface.

FIG. 15 illustrates a solid additive in the form of a generally spherical body that comprises channels in its surface. The generally spherical body 750 comprises a series of channels 753 located in the surface of the body. These channels 753 facilitate the flow of liquid aerosol-forming substrate around the body 750 and thus effectively form additional interstitial space between adjacent bodies. Spherical, spheroidal and ellipsoidal bodies may be used to provide solid additives in the form of pellets. The surfaces of these bodies may further comprise channels, not shown. The use of such channels is particularly preferred when the bodies used are spherical in shape and do not comprise cavities; as spherical bodies have a tendency to pack more closely than spheroidal or ellipsoidal shaped bodies.

FIG. 16 provides a perspective view of a solid additive in the form of a body with a generally square cross-sectional shape that comprises channels along its surface. The hollow body 750 shown in FIG. 16 comprises a square shaped cross-section and has four channels 753 located in the exterior side walls 758 of said body. Each of the channels 753 runs the length of an elongate face of the body 750.

FIGS. 17a,b and c provides perspective views of a solid additive 750 which may be in the form of a generally spherical body (in the case where axes x, y, and z have equal lengths) or an ellipsoid shape (in which axes are of different lengths).

FIG. 18 illustrate a consumable containing a coil and wick assembly 302 and solid additives 750 which can move within liquid 754 but are of a sufficient size that they do not block passage of liquid to the wick.

The solid additive may be totally soluble in the liquid aerosol-forming substrate, and may contain one or more materials that is/are to be added to the liquid aerosol-forming substrate. The solid additive may also comprise one or more components that are insoluble in the liquid. If the solid additive is totally soluble then it is preferable that the outermost portion of the additive comprises a material that dissolves more slowly than the inner portion of the additive.

The solid additive may add one or more components (materials) chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or may provide means to remove chemicals from the liquid aerosol-forming substrate.

The additional chemicals that may be added using a solid additive include chemicals for providing colour and/or odour to the liquid aerosol-forming substrate.

The solid additive can also act as a non-reactive agitator (for example in the case of shake-to-activate consumables). In other embodiments of the invention of the first proposal the solid additive may be:

- soluble—such that it will fully solubilise into the liquid aerosol-forming substrate; and/or,
- replaceable—such that something dissolves into the liquid and something is removed from the liquid; and/or,
- permanent—such that the additive will stay in the tank (reservoir) for the life of the reservoir.

The presence of solid tobacco-derived material in a consumable for a vaping smoking substitute device which employs a wick often causes problems in terms of clogging of the wick. Hence by incorporating the solid tobacco derived material into one or more bodies of a solid additive such problems are prevented or at least significantly alleviated. FIGS. 4 to 7 of the accompanying drawings illustrate some modifications to a vaping smoking substitute device that have been used as an alternative means to alleviate such difficulties-such modifications may be used in addition to the use of the solid additives disclosed herein.

While the first proposal of the invention 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 first proposal of the invention 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 first proposal of the invention.

Proposal 2

Proposal 2, which presents a further solution to the problem of solid material in a consumable clogging the wick is provided below.

FIG. 21 provides a perspective view of a filter as generally indicated by 701, in accordance with the second proposal of the present invention. The filter has a body 702 which incorporates two filter membrane apertures, 713 (one of which is visible on FIG. 21, the second filter membrane being located on the opposing side of the filter) that are sized to receive filter membrane 703.

The first end of the filter 704 has an opening as generally indicated by 705, the interior of the opening comprises a shape corresponding to the shape of the heating device (vapourization means) of a consumable 150, i.e. the opening is shaped to receive (and enclose) a vapourization means. In the present case the vapourization means is provided as a heating device in the form of a coil and wick assembly.

FIG. 22 provides a plan view of the first end (bottom end) 704 of the filter. FIG. 23 provides a plan view of the second end (top end) 708 of a filter.

Referring now to FIGS. 22 and 23 it can be seen that the interior walls 706 of the body 702 adjacent the opening 705 are shaped to enclose a coil and wick assembly (the heating device).

FIG. 24 provide a side view of a first gasket (first seal) 711 which may be located around the side walls 707 at the first end of the body 704, i.e. the walls 707 at the first end of the body 704 that are adjacent, in use, to the heating device. Such a gasket 711, may be used to ensure a tight seal is formed between the filter body 702 and the interior reservoir wall of the tank 156 that retains the liquid to be vapourised, i.e. the gasket 711 ensures that no liquid passes between the walls of the tank 156 and the body of the filter 702. Although, such a gasket may not be required if a tight fit (an interference fit) is formed between the walls of the tank and the body of the filter, as illustrated in FIG. 28—see below.

The second end, as generally indicated by 708, of the filter 701, as shown in FIGS. 21 and 23, comprises a second opening 709 that is sized to receive the outlet 604 of a consumable 150. A plan view of a second gasket (second seal), 712 is shown in FIG. 25. This second gasket may be used to ensure that a tight seal is formed between the interior of the second opening 709 and the outlet 604, i.e. the second gasket may act an outlet sealing means. Although, the use of a second gasket may not be required if the filter is manufactured such that the second opening forms a tight fit around the outlet, as illustrated in FIG. 28—see below.

FIG. 26 shows an alternative embodiment of a filter in accordance with the second proposal of the present invention wherein the filter body generally corresponds to the first embodiment, but wherein no filter membrane is provided. In this second embodiment of the second proposal of the present invention a plurality of pores 710 are provided in the filter body 702 as an alternative to a filter membrane, thus the parts of the body comprising the pores provide a filter face/filtration means. In this way the manufacture of the filter may be simplified and the manufacturing costs reduced.

In use the filter 701 is located such that it encloses the coil and wick assembly. A first gasket 711 may be used to ensure that vapourisable liquid containing solid, in the tank cannot pass between the wall of the tank 156 and the body of the filter 702. A second gasket may be used to prevent the vapourisable liquid from passing between the outlet and the second aperture. In this way the vapourisable liquid in the tank passes through the filter membrane 703, or through pores 710 provided in the filter body 702, to the coil and wick assembly 162. However, any solid material in the tank 156 is retained therein (in a first zone of the tank, as generally indicated by 730 in FIG. 28) by the filter 701 and so is prevented from blocking the wick (located in a second zone of the tank, as generally indicated by 732 in FIG. 28) or contacting the coil.

FIG. 27 provides a photograph of a filter 701 in accordance with the second proposal of the present invention that corresponds generally to the filter illustrated in FIG. 21. The filter comprises a body 702 and a filter membrane 703 located within an aperture 713. A recessed portion may be provided around the aperture 713 into which the filter membrane 703 is affixed by use of adhesive or other known means.

FIG. 28 shows a cross-sectional view of a consumable of the smoking substitute device comprising a filter. The consumable comprises a filter 701 of the type illustrated in FIGS. 21 and 27. It can be seen from FIG. 28 that the walls of the filter at the first end of the body 707 form a tight seal with the walls of the tank 790 such that no additional seal is required. Similarly the body of filter 701 forms a tight seal with the outlet 604 such that no additional seal is required.

The direction of the flow of liquid through the filter membrane 703 of the filter 701 is indicated by the arrows “A” on FIGS. 21 and 28; the direction of the flow of liquid through the walls of the filter (via the apertures 710) in FIG. 26, are also indicated by arrows “A”. The direction indicated by the arrows “A” is perpendicular to the direction of flow of air through the consumable as indicated by the arrows 606 and 608 (as shown in FIG. 6). The skilled addressee will appreciate that direction of the flow of liquid through the filter membrane of the filter as indicated by the arrows “A” is also substantially perpendicular to the direction of settlement of the solid material in the consumable under gravity. In use, a mixture of solid material and vapourisable liquid 755 are located in a first zone 730 within the tank. The filtered liquid 726, from which solid material has been removed, is located in a second zone 732 within the tank 156. The first zone 730 and the second zone 732 are separated by a filter 701 through which liquid passes in the direction of arrow “A”.

The skilled addressee will further appreciate that the face of the filter membrane (or the walls of the filter), through which the liquid passes, is positioned parallel to the direction of the airflow through the consumable.

To install the filter in a consumable 150, the tank 156 is filled to a predetermined level with a vapourisable liquid. The liquid may contain solid material or it may be the case that over time solid material will be deposited from the liquid, and this solid needs to be removed from the liquid prior to its vapourization. The filter 701 is then inserted into the tank and may be retained in place by an interference fit formed between the walls of the tank and the filter, the interference fit being tight enough to prevent the passage of solid material around the sides of the filter. A vapourization means that form the bottom wall of the tank is then inserted into place.

The filter may be inserted into the tank as part of a filtering assembly that comprises the filter 701 and the vapourization means (in this case a coil and wick assembly 302). The filter 701 may be connected to the vapourization means by use of an interlocking mechanism (such as a “snap-fit”) that is formed between the two components. Alternatively an adhesive may be used to connect the two components. The interlocking mechanism preferably provides a tight seal between the vapourization means and the filter such that no separate seal is required to prevent solid material passing around the filter and into the vapourization means.

In respect of the filter 701 illustrated in FIG. 28 a settlement space, as generally indicated by 728, is provided between the vertical section of the side wall 729 of the filter 701, and the side wall of the tank 790. This space 728 receives the solid material that settles out from the vapourisable liquid under gravity. In this way any solid material that settles in the settlement space 728 of the tank 156 does not obstruct the filter membrane 703, this can be advantageous when the settled solid has a tendency to form a solid mass.

In respect of most filters, it is preferable that the filter is arranged such that substantially all of the vapourisable liquid containing solid material, in a tank, may be filtered and removed from the tank. This may be achieved by the use of filter membrane or filter area(s) (area(s) comprising apertures located in a filter body that form a filter face/filtration means), that removes solid material from the vapourisable liquid, extending to as low a position as possible within the tank. The filter membrane(s) or filter area(s), preferably extend to such an extent that no unfiltered liquid is retained between the walls of the tank and the walls of the filter. In this way all of the vapourisable liquid located in the tank may be used without the outlet of the tank (the wick) becoming blocked.

The filter 701 illustrated in FIG. 28 is particularly suited for use with the type of elongate wicks (307a, 307b, fluid transport means) described above, and as illustrated in FIGS. 4 to 6. This is because a filter membrane 703 is provided in close proximity to each of the elongate wicks (307a, 307b) and this arrangement facilitates the rapid filtration of solid from a vapourisable liquid, such that the filtered vapourisable liquid is freely available to each of the wicks.

The filters disclosed above provide a means by which solid materials may be added to a vapourisable liquid located in the tank of a consumable, but wherein the solid may be removed from the liquid prior to the liquid reaching the wick and/or the vapourization means.

While the second proposal of the invention 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 second proposal of the invention 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 second proposal of the invention. For example the filter may be manufactured entirely from a filter membrane, such as a wire mesh or a ceramic material.

As previously mentioned, the filter may be retained in a fixed position by the provision of a seal located around the ends of the side walls 707 of the filter body 702. Adhesive may be utilised to retain the position of a seal or seals on a filter; the seal being used to prevent the passage of vapourisable liquid between the ends of the side walls 707 of the filter body 702 and the interior walls (the side walls 790) of the tank 156. Similarly adhesive may be used to retain a seal on a filter body that prevents the passage of vapourisable liquid between the side walls of the opening in the filter aperture 709 and the outlet 605.

Alternatively the lower face 721 of the filter body 702 may be attached to the base of the tank that is provided in the form of a heater assembly by the use of adhesive or other fixing means.

Proposal 3

In the third proposal of the present invention a solid additive is provided in the form of a body that is adapted to engage with engagement means located in the tank to retain the additive in position within the tank. As a result the solid additive does not move freely within the liquid aerosol-forming substrate and the potential for blocking of the wick is reduced.

FIG. 29 is a cross-sectional view of a consumable illustrating a solid additive body 750a located around the outlet/chimney 604. The solid additive comprises a body 750a in the form of a tobacco extrusion provided with a cavity having a shape and internal dimensions which are a close match to the shape and external dimensions of the outlet 604 such that there is an interference fit between the outlet 604 and the additive body 750a to retain the additive in position within the tank. The solid additive 750a is in contact with liquid components 764 in the aerosol-forming substrate such that the additive can modify the chemical and/or physical characteristics of the liquid components. The solid additive body may allow some passage of liquid components therethrough (for example by the provision of pores/channels), but the body cannot move freely within the tank and therefore does not block passage of liquid to the wick.

FIG. 30 is a cross-sectional view of another example consumable illustrating a solid additive body 750b that is an interference fit with internal tank side walls 790 to retain the body in position in the tank. The body 750b is also provided with a cavity which is an interference fit with the outlet 604.

Such arrangements for retaining a solid additive in place in a consumable are useful as they need not require modification of the tank walls or outlet in order to provide engagement means to engage with the solid additive, provided that the size and shape of the additive is appropriately selected to be an interference fit in the tank. Alternatively, surface formations may be provided on the tank walls, or other components in the consumable, such as a seal, outlet/chimney or refilling port for the tank. Surface formations may take the form of male/male, female/female or male/female connections.

FIG. 31 is a cross-sectional view of another example consumable illustrating a solid additive 750c that is engaged with a refilling port 770 of a tank. In this illustration, the tobacco extrusion includes a recess that is configured for engaging with a protrusion at the refilling port.

FIG. 32 is a cross-sectional view of another example consumable illustrating a solid additive body 750d that is an interference fit on a sealing element 400. In a similar arrangement a solid body could be arranged as an interference fit on a coil and wick assembly.

FIG. 33 is a plan view of an extruded solid body 750e that engages with surface formations 795 provided in a side wall of the tank. This is an example of a modification made to a tank side wall in order to provide the engagement means to engage and retain the solid body 750e. Such an arrangement is suitable for use with a solid body having a more complicated profile than that illustrated above. This permits for more complicated surface profiles which could be useful for increasing the surface area of the solid additive body in contact with the liquid components.

FIG. 34 is a cross-sectional view of further example consumable illustrating a solid additive body 750f that is retained by engagement means provided by multiple components in the consumable, including the refilling port 770 and seal 400. Thus, a recess 761 is provided at one end of the solid additive body to engage with refilling port 770. At the other end of 750f a projection 762 is provided to engage in a corresponding recess 405 in the seal 400. Such an arrangement may be useful for more firmly securing the solid additive in position in the tank.

FIG. 35 is a cross-sectional view of a further example consumable illustrating a solid additive 750g that is sized appropriately to be retained in position between the tank wall 790, the outlet 604 and seal 400 to restrict movement of the solid body additive and prevent it from contacting the wick. Thus, this illustrates that the engagement means can provide three or more points of contact between components of the consumable and the solid additive body. This can be beneficial to more rigidly hold the solid additive body in position in the tank and to reduce the likelihood of the additive body being displaced or dislodged during transit or use, for example.

The liquid component of the aerosol-forming substrate may comprise one or more aerosol formers, optionally together with flavourings.

In preferred embodiments of the third proposal of the present invention the liquid component comprises propylene glycol and glycerine in a ratio within the range of 10:90 to 90:10 by volume, preferably 20:80 to 80:20, more preferably 25:75 to 75:25, more preferably 30:70 to 70:30, and most preferably 40:60 to 60:40 by volume. Preferably the liquid component comprises propylene glycol and glycerine in a ratio within the range of 10:90 to 90:10 by weight, preferably 20:80 to 80:20, more preferably 25:75 to 75:25, more preferably 30:70 to 70:30, and most preferably 40:60 to 60:40 by weight.

A tobacco-derived material incorporated into one or more bodies can take various forms. It may optionally be in the form of tobacco leaf, tobacco stem, tobacco powder and tobacco dust, for example. The tobacco-derived material may be treated to various process conditions prior to being combined with base liquids. For example it may be washed and dehydrated, optionally by freeze drying.

It is advantageous to select tobacco-derived material from a tobacco plant which has a naturally occurring high nicotine level in order to produce a liquid aerosol-forming substrate which has an effective concentration of nicotine. Preferably the liquid aerosol-forming substrate comprises a tobacco-infused liquid which contains solid tobacco-derived material obtained from a tobacco plant having a nicotine content of at least 3% by weight, especially 3.5% or 4% by weight, preferably at least 4.5%, more preferably at least 5% by weight, still more preferably at least 5.5% by weight and most preferably at least 6% by weight. Conveniently the tobacco plant may have a nicotine content of up to 8 wt %, especially up to 7.5 wt %.

While the third proposal of the invention 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 third proposal of the invention 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 third proposal of the invention.

Proposal 4

In the fourth proposal of the present invention a solid material is located within a tank of a consumable, but said solid material is provided in the form of one or more bodies that comprise one or more cavities through which said liquid may flow and/or are shaped to form interstitial spaces through which said liquid may flow. In this way, blocking of the flow of liquid aerosol-forming substrate through the consumable by said solid additive is prevented.

FIG. 8 provides views of the ends of a number different shaped bodies that may be utilised as solid additives in accordance with the fourth proposal of the present invention. The bodies shown in FIG. 8 are viewed directly from one end of the bodies (end-on) and have the same uniform shape along their length.

FIGS. 8a to 8e provide end views of a number different shaped bodies that may be utilised as solid additives, in accordance with the fourth proposal of the present invention.

FIGS. 9a to 9f provides end views of a number different shaped bodies that may comprise cavities and be used as solid additives, in accordance with the fourth proposal of the present invention.

For the planar body indicated in FIG. 36a the wall thickness of the body is represented by “a”, and the thickness and height of the body correspond. The skilled person will appreciate that for bodies that comprise no cavity the thickness of the bodies will correspond to their height. For the bodies illustrated in FIGS. 8b to 8e, and the bodies illustrated in FIG. 9 the height of the bodies is represented by “b”.

The widths of the bodies are represented by “c” on FIGS. 8, 9, 10a and 10b.

The length of the bodies illustrated in FIGS. 10a and 10b are represented by “d”.

The skilled person will appreciate that the one or more bodies of the solid additives used to form interstitial spaces may comprise a wide range of shapes, including but not limited to the shapes mentioned herein. The bodies may preferably be elongate in nature having cross-sectional profiles that include, but are not limited to: planar (see FIG. 8a), generally “V” (see FIG. 8b) or “W” shaped, generally “S” (see FIG. 8C), or “M” shaped, generally “U” shaped (see FIG. 8C), generally “N” shaped (see FIG. 8e), angular (see FIG. 8d), generally semi-circular (see FIG. 8e), curved, convex, concave, wave shaped, castellated, or branched. Bodies of these particular shapes tend to pack such that interstitial spaces are formed between adjacent bodies. Spherical, spheroidal and ellipsoidal shaped bodies are also preferred shapes for the bodies. Similarly interstitial spaces are formed between bodies of these shapes. Additionally, the shapes detailed above may comprise cavities along their length “d”, see FIGS. 10a and 10b below, or as cavities in the form of perforations that pass through the plane of the body of the shapes concerned, see FIGS. 10a and 10b below.

FIG. 12 provides a perspective view of a solid additive in the form of a hollow body 750 comprising a square cross-sectional shape wherein a plurality of cavities (four cavities) run the length of the body. The four cavities terminate in four apertures 751 that are visible at one end of the body 750, as shown in FIG. 12. The opposite end of the body 750 comprises four corresponding apertures that are not visible. The use of multiple cavities assists the passage of liquid through wider bodies whilst still facilitating the solubilisation of additives located within the solid body 750; the solubilisation of additives is facilitated by minimising the distance to the midpoint of the side walls from the faces of the cavity 757, and from the faces of the exterior walls 758 of the body 750, to the midpoint(s) of the walls of the body.

The bodies used may comprise the general polygonal shapes as discussed above, but wherein one of the sides of the body are missing.

As mentioned above the skilled person will appreciate that a wide range of shapes of bodies, beyond those mentioned above may be employed in the fourth proposal of the present invention.

Any of the previously mentioned shapes of bodies detailed above may further comprise one or more channels/recesses in their outermost (or inner) surface.

FIG. 17 illustrate solid bodies which may be spherical (when axes x, y and z are equal) or ellipsoidal if the axes are different. Ridges are provided on the surfaces of the solid bodies. FIG. 18 illustrates bodies 750 in the liquid aerosol-forming substrate 754 in a tank 156. The solid bodies are provided with cavities to permit flow of liquid 754 to the coil and wick assembly 302.

In use the solid additive is located in the tank 156 of a consumable 150 containing liquid aerosol-forming substrate (vapourisable liquid). In this way the solid additive may add and/or remove materials from/to the liquid aerosol-forming substrate. The solid additive may be totally soluble in the liquid aerosol-forming substrate, and may contain one or more materials that is/are to be added to the liquid aerosol-forming substrate. The solid additive may also comprise one or more components that are insoluble in the liquid.

The additional chemicals that may be added using a solid additive include chemicals for providing colour and/or odour to the liquid aerosol-forming substrate.

The solid additive can also act as a non-reactive agitator (for example in the case of shake-to-activate consumables).

In other embodiments of the fourth proposal of the invention the solid additive may be:

- soluble—such that it will fully solubilise into the liquid aerosol-forming substrate; and/or, replaceable—such that something dissolves into the liquid and something is removed from the liquid; and/or, permanent-such that the additive will stay in the tank (reservoir) for the life of the reservoir.

While the fourth proposal of the invention 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 fourth proposal of the invention 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 fourth proposal of the invention.

Proposal 5

FIG. 36 provides a perspective view of a filter as generally indicated by 701, in accordance with the fifth proposal of the present invention. FIG. 38 is an illustration of a type of filter shown in FIG. 36.

The filter 701 has a body 702 which incorporates two apertures, as generally indicated by 713, within which filter membranes 703 are located. The apertures (filter membrane apertures) 713 also comprise a bevelled portion 719 at their outermost end which is located on the upper surface of the body, as generally indicated by 720. The body 702 may be manufactured from plastics materials and/or metals and/or ceramics and/or glass. The plastics materials that are used to manufacture the body are preferably chosen from the group comprising PVC (polyvinyl chloride), HDPE (high-density polyethylene), PP (polypropylene) or PC polycarbonate.

An opening 709 is provided to receive an outlet of a consumable. The opening 709 being sized to allow the outlet 604 of a consumable to pass through during the manufacture of the consumable. However, the opening is sized such that a tight enough fit is provided between the outlet and the walls of the opening (aperture) 709 to prevent the passage of liquids and/or solids between the outlet and the opening when the consumable is in use. The opening 709 comprises a bevelled portion 719b located on the upper surface of the body 720. The bevelled portion 719b facilitates the insertion of an outlet sealing arm 805 into the aperture of the filter body 701, see later.

The body 702 of the filter 701 is shaped such that when it is inserted into the tank of a consumable, an interference fit is formed between the interior walls (normally the side walls 790) of the tank 156 and the side walls 714 of the filter 702. The interference fit being of sufficient tightness such that no solid and/or liquid may pass between the walls of the tank 156 and the side walls 714 of the body of the filter 702.

During manufacture of the filter 701, the filter membranes 703 may be located within the body 702 by means of two slots that are cut into the body 702. The slots are subsequently filled (and thus sealed) by the use of known means, such that the filter membranes are retained in place e.g. by the use of adhesive, the skilled person will appreciate that the surfaces of the filter membranes need to be kept free of the sealing material.

Reference is now made to FIG. 36 which provides a perspective view of a filter and FIG. 37 which provides a perspective view of a filter comprising legs.

In FIGS. 36 and 37, two recesses 716 are visible in the position corresponding to where the slots have been filled. In the event that a sufficiently tight seal cannot be formed between the interior walls of the tank 156 and the side walls 714 of the filter 702, a gasket (seal) 711, see FIG. 43, may be used to form the required seal between the walls of the tank and the body of the filter 702. The recesses 716 may assist in maintaining the location of the gasket 711 on the side walls of the filter body 702 during assembly of the consumable.

The skilled person will appreciate that other means may be used to locate the filters membranes 703 in the apertures 713. However, recesses 716 may still be provided in the filter body 702 to receive (and maintain the position) of a gasket 711.

Reference is now made to FIG. 44 which provides a plan view of a second gasket/seal (an outlet sealing means).

If required, a second gasket (seal) 712, as shown in FIG. 44; may be located between the walls of the outlet aperture 709 and the outlet 604.

Reference is now made to FIG. 39 which is an illustration of a filter comprising legs.

In a second embodiment of the fifth proposal of the invention, as illustrated in FIGS. 37 and 39 the filter body 702 further comprises two legs (elongate members) 715. The legs 715 are attached to the lower surface 717 of the filter body 702. In use the legs 715 are sized such that they extend from the filter body 702 and abut the silicone seal 400 that seals the coil and wick assembly to the outlet 604, at a first end of the outlet. In this way the position of the filter 701 within the tank is further stabilised. The legs may help in determining the position/depth to which the filter is inserted in the tank or assist in maintaining the filter in a fixed position. The legs 715 may wrap around the outlet (chimney) 604 which further assists in fixing the position of the filter within the tank.

FIG. 36a provides a perspective view of another alternative filter.

FIG. 36a shows a third embodiment of the fifth proposal of the invention wherein a filter 701 is provided in the form of a body 702 comprising integral apertures 780, i.e. the apertures 780 are provided in the body itself. The apertures 780 pass from the upper surface of the filter body 720 to the lower surface of the filter body 717. The apertures 780 are sized to remove solid material from a vapourisable liquid. Typically the apertures have a diameter in a range of 0.1 to 2 mm or more preferably in a range of 0.1 to 1 mm.

FIG. 40a is an illustration showing a perspective view of a tool used to insert filters into the tanks of consumables (a filter insertion tool).

FIG. 40b is an illustration showing a perspective view of one end of the filter insertion tool.

FIG. 40c is an illustration showing a perspective view of a second end of the filter insertion tool engaged with a filter.

FIG. 40d is an illustration showing a second perspective view of the second end of the filter insertion tool engaged with a filter.

The filter insertion tool (as generally indicated by 800) comprises a body 801 from which a pair of elongate arms 802 extend. The arms (filter engagement arms) 802 extend from the lower surface of the body 803. The arms are arranged parallel to each other and located such that the ends of the arms 804 may be engaged with the filter membrane apertures 713 of a filter. The ends of the arms 804 (that are distal from the body 801) are cylindrical in shape and terminate in dome shaped tips 809. The ends of the arms 804 are located relative to each other, and shaped such that, they may be engaged with the filter membrane apertures 713 to form an interference fit between the arms 802 and the walls of the filter membrane apertures 718.

FIG. 45 provides a cross-sectional view along the length of a filter engagement arm 802 of an insertion tool. An open ended hollow tube 808 runs along the length of each of the arms 802, from the tip 809 of the arm, and then through the body 801 to the upper surface of the body 806 thus providing hollow tubes 808 that are open at their ends.

The interior of the filter arms may be coated with a hydrophobic material to ensure that any liquid that enters the arms is quickly drained when the tool is withdrawn from a vapourisable liquid, see later.

FIG. 46 provides a cross-sectional view along the length of an outlet sealing arm of an insertion tool.

A third arm (outlet sealing/blocking arm) 805 is provided which is located between the two elongate arms 802.

The third arm 805 is positioned between the pair of arms 802 such that when the elongate arms 802 engage with the filter membrane apertures 713 of a filter, the third arm 805 is aligned with the outlet aperture 709 of the filter. The end 817 of third arm 805, that is distal from the body 801, is dome shaped such that in use it engages with and seals (blocks) the end of an outlet 604 of a consumable 150. As mentioned earlier, the bevelled portion 719b facilitates the insertion of an outlet sealing arm 805 into the aperture of the filter body 701. The third arm 805 comprises a section that passes through an aperture 811 in the body 801 of the filter insertion tool and a further portion 815 that protrudes beyond the upper surface of the body 806.

A retaining pin 812 passes through a pin retaining aperture 813 in the protruding portion of the third arm 815.

A spring 807, is located on the third arm (outlet sealing arm) 805 between the body 801, and a wider end portion of the arm 816 that is wider than the spring. The third arm 805 is maintained in its location within the body 801 by the pin 812 and the abutment of the spring 807 with the wider end portion of the third arm 816.

The outlet sealing arm 805 is spring loaded by the means described above. In this way when pressure is applied to the end of the third arm 817 that is distal from the body 801, the arm retracts in the direction of the body, due to the pressure applied to the spring 807. In this way the end of the outlet 604 is blocked by the end of the outlet blocking arm and vapourisable liquid is prevented from entering the outlet.

A filter 701 is inserted into the tank 156 of a consumable 150 for a smoking substitute device by use of the filter insertion tool 800 by means of the following steps:

- i) The filter 701 is located on the filter insertion apparatus (tool) 800, by means of the engagement of the arms 802 of the tool with the apertures (filter membrane apertures) 713. The bevelled portions 719 of the apertures 713 facilitate the insertion of the end of the arms 802 into said apertures 713.
- ii) The filter 701 is then appropriately positioned in the opening of a tank 156 that contains a vapourisable liquid, such that the outlet sealing means (the outlet sealing arm) 805 engages with a first end of an outlet 605 and thus the outlet 604 is sealed by the outlet sealing means 805. The vapourisable liquid may contain a solid or a solid may be deposited from the liquid over time.
- i) The filter insertion apparatus (tool) 801 is then used to insert the filter into the interior of the tank 156, until the filter 701 engages with the walls of the tank 156 and/or the outlet.

As the filter is inserted into the tank the original location of the end of outlet sealing arm 817 is maintained by the compression of the spring 807. The position of the filter 701 may be fixed (held in place) by the engagement of the shaped filter 701 with the walls of the tank 156 and/or by engagement of the filter with the outlet. FIG. 41 is an illustration of a filter 701 located within the tank 156 of a consumable 150 for containing vapourisable liquid.

The filter insertion apparatus is subsequently withdrawn from the tank and the outlet sealing means (outlet sealing arm/third arm) disengages from the first end of the outlet. The position of the filter is retained within the tank due to its engagement with said tank walls and/or the outlet.

FIG. 42 is an illustration of a filter 701 located within the tank 156 of a consumable 150 for containing vapourisable liquid, a section of the wall of the tank 156 has been removed to allow the location of the filter to be more readily seen.

If the filter 701 comprises legs 715 then the filter insertion tool may further comprise voids (not shown) that are sized to receive the legs 715 within the filter insertion tool 800.

The legs 715 of the filter may, in alternative embodiments of the fifth proposal of the invention, be inserted into a tank such that they extend from the filter body 702 and abut the end of the tank, i.e. the end of the tank that is distal from the vapourization means.

FIG. 47 is an illustration of a tank of a consumable 150 showing a filtered and unfiltered liquid, separated by a filter.

FIG. 47 shows a tank of a consumable 150 containing a filter 701, and at one end of the consumable a vapourisable liquid 900 containing solid is visible. The filter 701 separates the filtered liquid 901 from the unfiltered liquid 900 within the tank.

The filter in the tank comprises legs 715 which are located alongside the outlet 604 and abut the silicone seal 400. It can be seen that the liquid comprising the solid 900 is retained in the upper third of the tank whilst liquid that has been filtered by the filter is located in the tank on the side of the coil and wick assembly 162. The skilled person will appreciate that the filter may be positioned at a position within the tank such that the liquid containing the solid 900 is located within a larger or smaller region of the tank.

While the fifth proposal of the invention 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 fifth proposal of the invention 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 fifth proposal of the invention.

For example the main body of the filter may be manufactured entirely from a filter membrane, such as a wire mesh or a ceramic material.

Further Aspects & Embodiments

Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of the proposals disclosed herein may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. That is, the features of any given proposal may suitably be combined with each other and also the features of one proposal may suitably be combined with the features of another proposal.

The following numbered paragraphs contain statements of combinations of inventive technical features herein disclosed.

Proposal 1

- 1. A consumable 150 for a smoking substitute device 110 which contains a liquid aerosol-forming substrate, wherein the liquid aerosol-forming substrate comprises a solid additive 750, characterised in that the solid additive 750 is provided in the form of one or more bodies 750, 792 that are sized to prevent the solid additive blocking the flow of liquid through the consumable 150.
- 2. A consumable 150 according to paragraph 1 wherein the one or more bodies 750, 792 comprise a width, a length and a height which are each greater than 2 mm.
- 3. A consumable 150 according to paragraphs 1 or 2 wherein the one or more bodies 750, 792 comprise a width, a length and a height which are each greater than 5 mm.
- 4. A consumable 150 according to any one of paragraphs 1 to 3 wherein the one or more bodies 750, 792 comprise at least one dimension greater than 5 mm.
- 5. A consumable 150 according to any one of paragraphs 1 to 4 wherein the one or more bodies 750, 792 comprise a length in the range 5 to 40 mm.
- 6. A consumable 150 according to any one of paragraphs 1 to 5 wherein the one or more bodies 750, 792 comprise a width in a range of 2 to 25 mm.
- 7. A consumable 150 according to paragraphs 1, 4, 5 or 6 wherein the one or more bodies 750, 792 comprise a height and/or a wall thickness in a range of 0.5 to 5 mm.
- 8. A consumable 150 according to any one of paragraphs 1 to 7 wherein the solid additive 750 comprises one or more bodies 750, 792 and said bodies comprise one or more shapes chosen from: elongate; spheroidal; ellipsoidal; spherical; planar; irregular, pellet; spaghetti; cuboid; and pyramidal.
- 9. A consumable 150 according to paragraph 8 wherein the solid additive 750 comprises one or more bodies 750, 792 in the form of elongate and/or planar bodies.
- 10. A consumable 150 according to any one of paragraphs 1 to 9 wherein the solid additive 750 comprises one or more bodies 750, 792 comprising one or more cavities through which the liquid aerosol-forming substrate may flow.
- 11. A consumable 150 according to any one of paragraphs 1 to 10 wherein the one or more bodies 750, 792 comprise at least one ribbed surface.
- 12. A consumable 150 according to any one of paragraphs 1 to 11 wherein the solid additive 750 adds one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals to the liquid aerosol-forming liquid.
- 13. A consumable 150 according to any one of paragraphs 1 to 12 wherein the one or more bodies 750,792 comprise tobacco and/or extracts of tobacco.
- 14. A solid additive 750 for a consumable 150 according to any one of paragraphs 1 to 13.
- 15. Use of a solid additive 750 for a consumable 150 according to any one of paragraphs 1 to 14 wherein the additive 750 is placed in a tank of a consumable 156, said tank 156 being used to retain liquid aerosol-forming substrate.

Proposal 2

- 16. A consumable 150 for a smoking substitute device 110, the consumable 150 comprising:
- a filter 701;
- a tank 156 for storing vapourisable liquid 755, 756; and
- a tank outlet 604, wherein the filter 701 is disposed in the tank 156 and retains solid material in the vaporisable liquid 755 within said tank 156, characterised in that the direction of flow of liquid through the filter 701 is substantially perpendicular to the direction of settlement of the solid material in the consumable under gravity.
- 17. A consumable 150 according to paragraph 16 wherein the filter 701 comprises a body 702.
- 18. A consumable 150 according to paragraph 16 or 17 wherein the filter 701 is provided in the form of a body 702 comprising integral pores 710 to retain solid material.
- 19. A consumable 150 according to paragraph 18 wherein the pores 710 have a diameter in a range of 0.1 to 2 mm.
- 20. A consumable 150 according to paragraph 18 wherein the pores 710 have a diameter in a range of 0.1 to 1 mm.
- 21. A consumable 150 according to paragraph 16 or 17 wherein the filter 701 comprises at least one filter membrane 703.
- 22. A consumable 150 according to paragraph 21 wherein the filter membrane 703 comprises one or more layers of a filter screen, a filter cloth, a ceramic filter, and/or a metal mesh.
- 23. A consumable 150 according to paragraph 21 or 22 wherein the size of the pores 710 in the filter membrane 703 are in the range of 0.02 to 2 mm, such as 0.05 to 0.6 mm.
- 24. A consumable 150 according to paragraph 21 or 22 wherein the size of the pores 710 in the filter membrane 703 are in the range 0.2 to 0.3 mm.
- 25. A consumable 150 according to any one of paragraphs 16 to 24 wherein one or more seals (711, 712) is/are located between the filter 701 and the interior of the tank 156.
- 26. A consumable 150 according to any one of paragraphs 16 to 25 wherein the filter 701 is releasably connected to the consumable 150.
- 27. A consumable 150 according to any one of paragraphs 16 to 25 wherein the filter 701 is formed as an integral part of the consumable 150.
- 28. A filter to retain solid material in a vapourisable liquid 755 in a tank 156 of a consumable 150 for a smoking substitute device 110, characterised in that the filter 701 is arranged such that the direction of flow of a liquid 756 through the filter 701 is substantially perpendicular to the direction of settlement of the solid material in the consumable 150 under gravity.
- 29. A filter 701, to remove solid material from a vapourisable liquid 755 in a tank 156 of a consumable 150, characterised in that the direction of the flow of liquid 756 through the filter 701 is substantially perpendicular to the axial direction between the upper end of the tank 173 and the lower end of the tank 172.
- 30. A filter 701 according to paragraph 28 or 29, characterised in that the filter 701 is adapted to engage with the tank 156 of a consumable 150 by means of a push-fit mechanism.

Proposal 3

- 31. A consumable for a smoking substitute device, the consumable comprising a vaporisation means 302 which includes a wick 307; and a tank 156 which contains a liquid aerosol-forming substrate 754 and a solid additive 750;
- characterised in that the solid additive is provided in the form of a body that is adapted to engage with engagement means located in the tank 156 to retain the additive in position within the tank.
- 32. A consumable 150 according to paragraph 31 wherein the body is adapted to engage with engagement means provided on the tank.
- 33. A consumable 150 according to paragraph 31 or 32 wherein the body is adapted to engage with an opening of the tank provided for filing and/or refilling of the tank with liquid.
- 34. A consumable according to any one of paragraphs 31 to 33 wherein a body is adapted to engage with a component of a vaporiser assembly.
- 35. A consumable according to any one of paragraphs 31 to 34 wherein a body is adapted to engage with a sealing element for the tank.
- 36. A consumable according to any one of paragraphs 31 to 35 wherein a body is adapted to engage with an air flow chimney of the consumable.
- 37. A consumable according to any one of paragraphs 31 to 36 wherein a body is adapted to engage with multiple engagement means located within the tank.
- 38. A consumable according to paragraph 37 wherein a body is adapted to engage with at least two different components of the consumable.
- 39. A consumable according to any one of paragraphs 31 to 38 wherein a body is provided with surface formations configured to engage with corresponding or complementary formations located within the tank.
- 40. A consumable according to any one of paragraphs 31 to 39 wherein the body is adapted to engage with engagement means located within the tank by means of one or more selected from an interference fit, a push fit, a sliding fit, a snap fit and/or a screw fit.
- 41. A consumable according to any one of paragraphs 31 to 40 wherein the solid additive comprises one or more bodies that have been extruded and/or rolled and/or stamped and/or pressed and/or crushed and/or injection moulded and/or cast.
- 42. A consumable according to any one of paragraphs 31 to 41 wherein the solid additive comprises one or more of: a body with no cavity; a body with one or more cavities; a mesh; a compressed powder; a foam; a porous material; and/or a perforated material.
- 43. A consumable according to any one of paragraphs 31 to 42 wherein the solid additive comprises:
- (i) organic material(s) and/or inorganic material(s); and/or
- (ii) one or more components chosen from tobacco, extracts from tobacco, a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemical, and/or means to remove chemicals.
- 44. A solid additive that is added to a tank of a consumable of a smoking substitute device wherein the tank contains a liquid aerosol-forming substrate, characterised in that the solid additive is provided in the form of a body that is adapted to engage with engagement means located in the tank for fixing the additive in position within the tank.
- 45. Use of a solid additive for a consumable according to any one of paragraphs 31 to 44 wherein the additive is secured within a tank of the consumable by engagement between the additive and engagement means provided in the tank.

Proposal 4

- 46. A consumable 150 for a smoking substitute device which contains a liquid aerosol-forming substrate located in a tank of the consumable, wherein the liquid aerosol-forming substrate comprises a solid additive 750, characterised in that the solid additive 750 is provided in the form of one or more bodies 750, that comprise one or more cavities 759 through which said liquid aerosol-forming substrate may flow, and/or are shaped to form interstitial spaces through which said liquid aerosol-forming substrate may flow, such that blocking of the flow of the liquid aerosol-forming substrate through the consumable 150 by the solid additive is prevented.
- 47. A consumable 150 according to paragraph 46 wherein the bodies 750 shaped to form the interstitial spaces further comprise one or more recesses 753 in their exterior surface.
- 48. A consumable 150 according to paragraph 46 or 47 wherein the solid additive 750 comprises one or more elongate bodies.
- 49. A consumable 150 according to paragraph 48 wherein the one or more bodies 750 comprise a length in the range 2 to 40 mm.
- 50. A consumable 150 according to any one of paragraphs 46 to 49 wherein the one or more bodies 750 comprise a width in a range of 2 to 25 mm.
- 51. A consumable 150 according to any one of paragraphs 46 to 50 wherein the one or more bodies 750 comprise a thickness or a height in a range of 0.5 to 5 mm.
- 52. A consumable 150 according to any one of paragraphs 46 to 51 wherein the solid additive 750 comprises one or more bodies 750 that further comprise one or more cavities 759 each having a diameter in the range 1 to 2 mm.
- 53. A consumable 150 according to any one of paragraphs 46 to 52 wherein the solid additive 750 comprises one or more bodies 750 that have been extruded and/or rolled and/or stamped and/or pressed and/or crushed and/or injection moulded and/or cast.
- 54. A consumable 150 according to any one of paragraphs 46 to 53 wherein the solid additive 750 comprises one or more of; a body 750 with no cavity; a body 750 with one or more cavities; a mesh; a compressed powder; a foam; a porous material; and/or a perforated material.
- 55. A consumable 150 according to any one of paragraphs 46 to 54 wherein the solid additive 750 comprises organic material(s) and/or inorganic material(s).
- 56. A consumable 150 according to paragraph 55 wherein the solid additive 750 comprises one or more components chosen from a flavourant, a flavour enhancer, nicotine, a catalyst, additional chemicals, and/or means to remove chemicals.
- 57. A consumable 150 according to paragraph 55 or 56 wherein the organic and/or inorganic material(s) is/are provided as one or more of a coating or partial coating, and/or is/are located in a layer, and/or is/are located within a cavity of the one or more bodies.
- 58. A consumable 150 according to any one of paragraphs 55 to 57 wherein the solid additive 750 comprises organic material in the form of tobacco and/or extracts from tobacco.
- 59. A solid additive 750, that is added to a tank 156 of a consumable 150 of a smoking substitute device 110 wherein the tank 156 contains a liquid aerosol-forming substrate, characterised in that the solid additive 750 is provided in the form of one or more bodies 750 that comprise one or more cavities 759 through which a liquid aerosol-forming substrate may flow, and/or are shaped to form interstitial spaces through which said liquid aerosol-forming substrate may flow, such that blocking of the flow of the liquid aerosol-forming substrate through the consumable 150 by the solid additive 750 is prevented.
- 60. Use of a solid additive 750 for a consumable 150 according to any one of paragraphs 46 to 59 wherein the additive is placed in a tank 156 of a consumable 150 said tank 156 being used to retain a liquid aerosol-forming substrate.

Proposal 5

- 61. A consumable 150 for a smoking substitute device 110, the consumable 150 comprising:
  - a filter 701;
  - a tank 156, for storing vapourisable liquid; and,
  - optionally the consumable comprises an outlet 604 in fluid communication with the tank 156,
  - wherein the filter 701 is disposed in the tank 156 and retains solid material in the vaporisable liquid within said tank 156, and characterised in that the filter 701 is engageable with the interior walls of the tank 790, and/or the outlet 604 of the consumable when said outlet is present, to fix the position of the filter 701 in said tank 156.
- 62. A consumable 150 according to paragraph 61 wherein the filter 701 comprises a body 702.
- 63. A consumable 150 according to paragraph 61 or 62 wherein the filter 701 comprises one or more elongate members 715.
- 64. A consumable 150 according to paragraph 62 or 63 wherein the filter 701 is provided in the form of a body 702 comprising integral apertures 780 to retain solid material.
- 65. A consumable 150 according to paragraph 64 wherein the apertures 710 have a diameter in a range of 0.1 to 2 mm.
- 66. A consumable 150 according to paragraph 64 wherein the apertures 710 have a diameter in a range of 0.1 to 1 mm.
- 67. A consumable 150 according to any one of paragraphs 61 to 63 wherein the filter 701 comprises at least one filter membrane 703.
- 68. A consumable 150 according to paragraph 67 wherein the filter membrane 703 comprises one or more layers of a filter screen, a filter cloth, a ceramic filter, and/or a metal mesh.
- 69. A consumable 150 according to paragraph 67 or 68 wherein the size of the apertures 713 in the filter membrane 703 are in the range of 0.02 to 2 mm.
- 70. A consumable 150 according to paragraph 67 or 68 wherein the size of the apertures 713 in the filter membrane 703 are in the range of 0.05 to 0.6 mm.
- 71. A filter 701 for removing solid material from a vapourisable liquid in a tank of a consumable 150 of a smoking substitute device 101, characterised in that the filter is fixed in position within the tank by the engagement of the filter with the walls of the tank and/or optionally an outlet of the consumable 150.
- 72. A filter insertion tool 800 for inserting a filter 701 into the tank of a consumable 150 for a smoking substitute device 101, the filter insertion tool 800 comprising a means 802 to initially retain the filter, and to subsequently release the filter 701 following the engagement of the filter with the walls of the tank.
- 73. A filter insertion tool 800 according to paragraph 72 wherein the filter insertion tool further comprises an outlet sealing means 805 that is moveable relative to the filter retaining means 802.
- 74. A method for inserting a filter 701 into a consumable 150 for a smoking substitute device 101 characterised in that it comprises the steps of:
- engaging the filter 701 with a filter insertion tool 800, locating the filter at an opening of a tank, wherein the tank optionally comprises an outlet 605;
- inserting the filter 701 into the tank 156 until the filter engages with the walls of the tank 790 and/or optionally an outlet 604 of the consumable when present; and,
- subsequently withdrawing the filter insertion tool from the tank 156 such that the filter is retained within the tank 156 due to its engagement with said tank walls 790 and/or the outlet, and thus the filter is disengaged from the filter insertion tool.

LIST OF FEATURES

- 110 Smoking substitute device
- 120 Main body
- 122 Top end of main body
- 124 Bottom end of main body
- 126 Light
- 128 Slot
- 130 Control unit
- 132 Memory
- 134 Wireless interface
- 136 Electrical interface
- 138 Additional component
- 140 Power source
- 150 Consumable
- 152 Top end of consumable
- 154 Bottom end of consumable
- 156 Tank
- 158 Window
- 160 Electrical interface
- 162 Heating device (coil and wick assembly)
- 162
  a Side walls of heating device
- 164 Air inlet
- 166 Mouthpiece
- 168 Additional components
- 170
  a,b Aperture for clip
- 172 Lower end of the tank
- 173 Upper end of the tank
- 302 Coil and wick assembly
- 304 Tank Housing/Housing of coil and wick assembly
- 305
  a,b Apertures
- 306 Coil
- 307,307a,b Wick
- 308
  a,b Electrical contacts
- 309
  a,b Clip
- 310 Cavity
- 312 Mouthpiece chamber
- 314
  a,b Mouthpiece outlets
- 315 Tanking Housing
- 400 Outlet seal/Silicone seal
- 402
  a,b Clip
- 502 Clip main body
- 602 Sediment
- 604 Outlet (chimney)
- 605 First end of the outlet
- 606, 608 Air flow
- 701 Filter
- 702 Filter body
- 703 Filter membrane
- 703
  a First filter membrane
- 703
  b Second filter membrane
- 704 First end of the filter
- 705 Opening in first end of the filter
- 706 Interior walls of the body
- 707, Side walls at the first end of the body (the section of the sidewalls adjacent the heater)
- 708 Second end of the filter
- 709 Second opening (outlet aperture)
- 710 Pores
- 711 First seal (gasket)
- 712 Second seal (gasket)
- 713 Aperture to receive a filter membrane (filter membrane aperture)
- 714 Side walls of the filter
- 715 Elongate members
- 716 Recesses
- 717 Lower surface of the filter body
- 718 Walls of the filter membrane apertures
- 719 Bevelled portion of filter membrane apertures
- 720 Upper surface of filter body
- 721 Lower face of the filter
- 723 Area of pores forming a filter face
- 725 Vapourisable liquid containing solid material
- 726 Vapourisable liquid that has been filtered
- 726
  a Vapourisable liquid that contains only smaller particles following an initial filtration
- 727 Tank outlet
- 728 Settlement Space
- 729 Vertical section of the side wall of the filter
- 730 First zone of tank
- 732 Second zone of tank
- 750 Solid additive (or bodies thereof)
- 751 Aperture in solid additive body
- 752 Walls of the body
- 753 Channels in body wall
- 754 Liquid
- 755 Ribs
- 756 Perforations
- 757 Side walls of cavity
- 758 Exterior walls of body
- 759 Cavity
- 761 Recess
- 762 Projection
- 764 Liquid components of aerosol-forming substrate
- 770 Refilling port
- 780 Apertures
- 790 Side walls of the tank
- 790
  a Lower side walls of the tank
- 791 Space between side walls and heater assembly
- 792 Solid bodies
- 793 Space between side walls and outlet
- 795 Formations on side wall of tank
- 800 Filter insertion tool
- 801 Body of the filter insertion tool
- 802 Filter engagement arms
- 803 Lower surface of the body
- 804 Ends of the arms
- 805 Outlet sealing arm, third arm
- 806 Upper surface of the filter insertion tool
- 807 Spring
- 808 Hollow tube
- 809 Dome shaped tips of the filter engagement arms of the filter insertion tool
- 810 Section of third arm located within the body of a filter insertion tool.
- 811 Aperture in the body of a filter insertion tool
- 812 Pin

Number	Date	Country	Kind
21199689.7	Sep 2021	EP	regional
21199692.1	Sep 2021	EP	regional
21199696.2	Sep 2021	EP	regional
21199699.6	Sep 2021	EP	regional
21199702.8	Sep 2021	EP	regional

SMOKING SUBSTITUTE SYSTEM

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

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Abstract

Description

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Priority Claims (5)

PCT Information