CN117898475A

CN117898475A - Aerosol delivery subsystem

Info

Publication number: CN117898475A
Application number: CN202310118980.4A
Authority: CN
Inventors: 迪安·考恩; 许晓枫; 刘红强; 李瑞凡
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2022-10-19
Filing date: 2023-02-03
Publication date: 2024-04-19
Also published as: CN117898476A; GB202307362D0; CN117898489A

Abstract

The present application relates to an aerosol delivery subsystem comprising a mounting bracket configured to receive a power source, the power source having a body with a pair of electrodes extending therefrom, the bracket comprising a first tubular or cylindrical portion having a pair of apertures configured to receive the pair of electrodes and present the pair of electrodes for connection at ends of the bracket; and a second portion including a second portion of the tubular sidewall extending around only a portion of the circumference of the bracket and having a cavity configured to receive the power supply body.

Description

Aerosol delivery subsystem

Technical Field

The present disclosure relates to aerosol delivery systems, such as, but not limited to, nicotine delivery systems including electronic cigarettes, tobacco Heating Products (THPs), and hybrid systems. More particularly, the present disclosure relates in part to component mounting brackets for aerosol delivery subsystems.

Background

Aerosol delivery systems, such as electronic cigarettes (e.g., electronic cigarettes), typically contain an aerosol-generating material, such as a chamber of a source solid or source liquid, which may contain an active substance and/or a fragrance, from which an aerosol or vapor is generated, such as by thermal evaporation, for inhalation by a user. Thus, the aerosol delivery system will typically comprise an aerosol-generating region comprising an aerosol generator (e.g. a heating element) arranged to vaporise or aerosolize a portion of the precursor material to generate a vapour or aerosol in the aerosol-generating region. When a user inhales on the device and supplies power to the evaporator, air is drawn into the device through the inlet aperture and along an inlet air passage connected to an aerosol-generating region where the air mixes with the vaporized precursor material to form a condensed aerosol. An outlet channel is provided that connects the aerosol-generating region to an outlet in the mouthpiece and when a user inhales on the mouthpiece, air drawn into the aerosol-generating region continues along an outlet flow path to the mouthpiece outlet, carrying the aerosol with the air for inhalation by the user. Some electronic cigarettes may also include a flavor element in the airflow path through the device to impart additional flavor. Such devices may sometimes be referred to as mixing devices, and the flavour element may, for example, comprise a portion of tobacco disposed in the airflow path between the aerosol-generating region and the mouthpiece such that aerosol/condensed aerosol drawn through the device passes through the portion of tobacco before exiting the mouthpiece for inhalation by a user.

It is of interest to develop methods that enable easier assembly, repair and/or recycling of aerosol delivery systems to increase production efficiency, improve sustainability and reduce wastage. Various approaches are described herein that seek to help solve or mitigate at least some of these problems.

Terminology

Conveying system

As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user in use, and includes:

combustible aerosol supply systems, such as cigarettes, cigarillos, cigars, tobacco for pipes or for self-wrapping or for self-manufacturing cigarettes (based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials);

A non-combustible aerosol supply system that releases compounds from an aerosol-generating material without burning the aerosol-generating material, such as an electronic cigarette, a tobacco heating product, and a mixing system, to generate an aerosol using a combination of aerosol-generating materials; and

An aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including but not limited to lozenges, chewing gums, patches, products including inhalable powders, and oral products such as oral tobacco including snuff or wet snuff, wherein the at least one substance may or may not include nicotine.

Combustible sol supply system

In accordance with the present disclosure, a "combustible" aerosol supply system is an aerosol supply system in which the constituent aerosol-generating materials of the aerosol supply system (or components thereof) are combusted or ignited during use in order to deliver at least one substance to a user.

In some embodiments, the delivery system is a combustible sol supply system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

In some embodiments, the present disclosure relates to a component for use in a combustible sol supply system, such as a filter, a filter rod, a filter segment, a tobacco rod, an overflow, an aerosol modifier release component, such as a capsule, a thread or a bead, or a paper, such as a forming paper, tipping paper or cigarette paper.

Non-combustible sol supply system

According to the present disclosure, a "non-combustible" aerosol supply system is an aerosol supply system in which the constituent aerosol-generating materials of the aerosol supply system (or components thereof) do not burn or ignite and at least one substance is delivered to a user.

In some embodiments, the delivery system is a non-combustible sol supply system, e.g., a powered non-combustible sol supply system.

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as a vapor smoke device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

In some embodiments, the non-combustible sol supply system is an aerosol generating material heating system, also referred to as a heated non-combustion system. One example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, wherein one or more of the aerosol-generating materials may be heated. Each aerosol-generating material may be in the form of a solid, liquid or gel, for example, and may or may not contain nicotine. In some embodiments, the mixing system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

In general, a non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply device.

In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustible sol supply device. These consumables are sometimes referred to in this disclosure as articles of manufacture.

In some embodiments, a non-combustible sol supply system, such as a non-combustible sol supply device thereof, may include a power source and a controller. The power source may be, for example, an electrical power source or an exothermic source. In some embodiments, the heat-generating source comprises a carbon matrix that may be energized to distribute power in the form of heat to the aerosol-generating material or the heat-transfer material in proximity to the heat-generating source.

In some embodiments, the non-combustible aerosol supply system may include a region for receiving a consumable, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, a consumable for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

No aerosol delivery system

In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance orally, nasally, transdermally, or in another manner to a user without forming an aerosol, including but not limited to lozenges, chewing gums, patches, products including inhalable powders, and oral products, such as oral tobacco including snuff or wet snuff, wherein the at least one substance may or may not include nicotine.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolized. Any of the materials may include one or more active components, one or more flavoring agents, one or more aerosol former materials, and/or one or more other functional materials, as appropriate.

Active substances

In some embodiments, the substance to be delivered comprises an active substance. An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (e.g., B6 or B12 or C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives or extracts of tobacco, hemp or other plants.

In some embodiments, the active comprises nicotine. In some embodiments, the active comprises caffeine, melatonin, or vitamin B12.

As described herein, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

As described herein, the active substance may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, husks, and the like. Or the material may comprise an active compound naturally occurring in plants, which is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, flakes, or the like.

Examples of plants are tobacco, eucalyptus, star anise, hemp, cocoa, hemp, fennel, lemon grass, peppermint, spearmint, black leaf tea, chamomile, flax, ginger, gingko, hazelnut, hibiscus, bay, licorice, green tea, mate, orange peel, papaya, rose, sage, tea (e.g., green tea or black tea), thyme, clove, cinnamon, coffee, star anise (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elder, vanilla, wintergreen, perilla plant, turmeric root powder, sandalwood, coriander leaf, bergamot, orange flower, myrtle, blackcurrant, valerian, pimelin, nutmeg, dammarlin, olive, lemon balm, basil, parsley, bergamot, whip, tarragon, geranium, ginseng, gin, tea, tetramic acid, tea, red sage, kums, kudzuvine, combinations of any of them. The mint may be selected from the following mint varieties: peppermint, egypt peppermint, basil, peppermint c.v., spearmint, peppermint, pineapple, spearmint c.v., and apple peppermint.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is tobacco. In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from the group consisting of camellia sinensis and fennel.

Flavoring agent

In some embodiments, the substance to be delivered comprises a flavoring agent. As used herein, the terms "flavoring" and "fragrance" refer to materials that can be used to create a desired taste, aroma, or other somatosensory in a product for an adult consumer, as permitted by local regulations. Which may include naturally occurring flavor materials, plants, extracts of plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, japanese white magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, japanese mint, star anise (anise), cinnamon, turmeric, indian spice, asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, du Linbiao wine, bouillon, scotch whiskey, juniper, glory, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, bitter cardamom, nutmeg, bergamot, geranium, arabian tea leaves, blueberry, kiwi fruit, and the like) sorghum, betel leaf, coriander, pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry blossom, cinnamon, coriander, cognac, jasmine, ylang, sage, fennel, mustard, green pepper, ginger, coriander, coffee, hemp, peppermint oil from any variety of mentha plants, eucalyptus, star anise, cocoa, lemon grass, red bean, flax, ginkgo leaf, hazelnut, hibiscus, bay, mate, orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elder, basil, bay leaf, cumin, oregano, capsicum, rosemary, saffron, lemon peel, peppermint, steak, turmeric, coriander, myrtle, black currant, valerian, spanish sweet pepper, nutmeg dried skin, damianne, cinnamon, cuttlefish, olive, lemon balm, lemon basil, nori onion, celery, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugar and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. It may be a imitation, synthetic or natural ingredient or a mixture thereof. It may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes a flavoring component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring component extracted from tobacco. In some embodiments, the flavoring agent comprises a flavor component extracted from cannabis.

In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in lieu of the aromatic or gustatory nerve, and these may include agents that provide a heating, cooling, tingling, numbing effect. Suitable thermal agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

Aerosol generating material

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated or energized in any other manner. The aerosol-generating material may for example be in solid, liquid or gel form, which may or may not contain an active substance and/or a fragrance. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid (e.g., liquid) within their interior. In some embodiments, the aerosol-generating material may comprise, for example, from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional materials.

Aerosol former material

The aerosol former material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenyl acetate, glycerol tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

Functional material

The one or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

Matrix body

The material may be present on or in a carrier to form a matrix. The carrier may be or comprise, for example, paper, card, cardboard, recombinant material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the carrier comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

Consumable product

A consumable is an article comprising or consisting of an aerosol-generating material, part or all of which is intended to be consumed by a user during use. The consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may also comprise an aerosol generator, such as a heater, which in use releases heat to cause the aerosol-generating material to generate an aerosol. The heater may for example comprise a combustible material, a material which is heatable by electrical conduction, or a susceptor.

Susceptor

A susceptor is a material that can be heated by penetration with a varying magnetic field (e.g., an alternating magnetic field). The susceptor may be an electrically conductive material such that its penetration by a varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material such that penetration thereof by a varying magnetic field results in hysteresis heating of the heating material. The susceptor may be electrically conductive and magnetic such that the susceptor may be heated by two heating mechanisms. The device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

Aerosol modifier

An aerosol-modifying agent is a substance typically located downstream of the aerosol-generating region that is configured to modify the generated aerosol, for example by altering the taste, flavor, acidity or another characteristic of the aerosol. The aerosol modifier may be disposed in an aerosol modifier release member operable to selectively release the aerosol modifier. For example, the aerosol modifier may be an additive or an adsorbent. For example, the aerosol modifiers may include one or more of fragrances, colorants, water, and carbon adsorbents. For example, the aerosol modifier may be a solid, a liquid, or a gel. The aerosol modifier may be in powder, wire or particulate form. The aerosol modifier may be free of filter material.

Aerosol generator

An aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy in order to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause aerosol generation from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The present disclosure relates to aerosol delivery systems (which may also be referred to as vapor delivery systems), such as nebulizers or e-cigarettes. In the following description, the term "e-cigarette" or "e-cigarette" may be used at times, but it will be understood that this term may be used interchangeably with aerosol delivery system/device and electronic aerosol delivery system/device. Furthermore, as is common in the art, the terms "aerosol" and "vapor" and related terms such as "evaporation," "volatilization," and "aerosolization" are often used interchangeably.

Aerosol delivery systems (e-cigarettes) typically, although not always, comprise a modular assembly comprising a reusable device portion and replaceable (disposable/consumable) cartridge components. Typically, the replaceable cartridge component will include an aerosol-generating material and a vaporiser (which may be collectively referred to as a "vaporiser"), and the reusable device portion will include a power supply (e.g. a rechargeable power supply) and control circuitry. It will be understood that these different parts may include additional elements depending on the function. For example, the reusable device portion will typically include a user interface for receiving user input and displaying operating status features, and the replaceable cartridge device portion in some cases includes a temperature sensor for helping control temperature. The cartridge is electrically and mechanically coupled to the control unit for use, for example using threads, bayonet or magnetic coupling with suitably arranged electrical contacts. When the aerosol-generating material in the cartridge is exhausted, or when the user wishes to switch to a different cartridge having a different aerosol-generating material, the cartridge may be removed from the reusable component and a replacement cartridge attached in its place. Systems and devices conforming to this type of two-piece modular configuration may generally be referred to as two-piece systems/devices.

Electronic cigarettes typically have a generally elongated shape. To provide a specific example, certain embodiments of the present disclosure will be considered to include such a generally elongated two-piece system employing disposable cartridges. However, it will be appreciated that the basic principles described herein may equally be applied to different configurations, such as single-piece systems or modular systems comprising more than two parts, refillable devices and single-use disposable articles, as well as other general shapes, for example based on so-called box-mode high performance devices that typically have a box-like shape. More generally, it will be understood that certain embodiments of the present disclosure are based on aerosol delivery systems that are operatively configured to provide functionality in accordance with the principles described herein, and that the constructional aspects of the system configured to provide functionality in accordance with certain embodiments of the present disclosure are not of primary importance.

Disclosure of Invention

The present invention provides aerosol delivery subsystems, systems, and methods as claimed.

The claimed invention generally provides a subassembly or subsystem 100 suitable for use in an aerosol delivery system 1 or configured for use in an aerosol delivery system 1.

In some embodiments, the subsystem 100 includes a stand 110 and may generally form part of the aerosol delivery system 1, in particular may form part of the reusable device component 2 and/or the consumable cartridge component 4 in a two-piece system, or may form part of the disposable aerosol delivery system 1. The stent may include a number of functional features including, but not limited to: an integral end cap for sealing the liquid in the reservoir; a retention member for receiving the electrical contact pins; a seal between the container/reservoir and the battery compartment; firmly supporting the battery within the housing; and one or more through holes for the air flow.

Drawings

Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

fig. 1 is a schematic cross-sectional view of an aerosol delivery system 1 including a support 110 according to some embodiments of the present disclosure.

Fig. 2,3, and 4 are schematic perspective views of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a bracket 110 in more detail.

Fig. 5 is a vertical cross-sectional view of the aerosol delivery subsystem 100 of fig. 4.

Fig. 6 is a schematic side view of a modular power supply for the aerosol delivery subsystem 100, according to some embodiments of the present disclosure.

Fig. 7 is an exploded perspective view of an aerosol delivery system 1 according to some embodiments of the present disclosure.

Fig. 8 is a schematic side view of an assembled aerosol delivery system 1 according to some embodiments of the present disclosure.

Fig. 9 is a schematic diagram of an assembly process for an aerosol delivery system 1 according to some embodiments of the present disclosure.

Fig. 10, 11, 12, and 13 are schematic perspective views of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a second bracket 110.

Fig. 14 is a cross-sectional view of an aerosol delivery system including the second bracket of fig. 10-13.

Detailed Description

Various aspects and features of certain examples and embodiments are described herein. Some aspects and features of certain examples and embodiments may be conventionally implemented and are not described in detail for the sake of brevity. Accordingly, it will be appreciated that various aspects and features of the apparatus and methods discussed herein, which are not described in detail, may be implemented in accordance with any suitable conventional techniques.

Fig. 1 is a cross-sectional view of an example aerosol delivery system 1, which provides an introduction to a two-piece aerosol delivery system, components therein, and functions thereof, according to certain embodiments of the present disclosure. The system 1 includes a bracket 110 according to some embodiments of the present disclosure. The bracket 110 will be described in detail later with reference to the following drawings.

The aerosol delivery system 1 comprises two main components, namely a reusable component 2 and a replaceable/disposable consumable cartridge component 4. In normal use, the reusable part 2 and the cartridge part 4 are releasably coupled together at the interface 6. When the cartridge component 4 is exhausted or the user simply wishes to switch to a different cartridge component 4, the cartridge component 4 may be removed from the reusable component 2 and the replacement cartridge component 4 attached in place to the reusable component 2. The interface 6 provides structural, electrical and air flow path connections between the two components 2, 4 and may be established according to conventional techniques, for example based on screw threads, magnetic or bayonet fastening, with suitably arranged electrical contacts and openings for suitably establishing electrical connection and air flow paths between the two components 2, 4. The particular manner in which the cartridge component 4 is mechanically mounted to the reusable component 2 is not important to the principles described herein, but for the purposes of the specific example it is assumed here that a magnetic coupling (not shown in fig. 1) is included. It will also be appreciated that the interface 6 may not support electrical and/or airflow path connections between the respective components 2, 4 in some implementations. For example, in some implementations, the aerosol generator may be provided in the reusable component 2 instead of in the cartridge component 4, or the transmission of power from the reusable component 2 to the cartridge component 4 may be wireless (e.g., based on electromagnetic induction) such that an electrical connection between the reusable component 2 and the cartridge component 4 is not required. Furthermore, in some implementations, the airflow through the e-cigarette may not pass through the reusable component 2, such that an airflow path connection between the reusable component 2 and the cartridge component 4 is not required. In some cases, when the reusable component 2 and the cartridge component 4 are coupled together for use, a portion of the airflow path may be defined at the interface between these portions.

The cartridge/consumable part 4 may be widely conventional according to certain embodiments of the present disclosure. In fig. 1, the cartridge component 4 comprises a cartridge housing 42 formed of a plastics material. The cartridge housing 42 supports the other components of the cartridge component 4 and provides a mechanical interface 6 with the reusable component 2. The cartridge housing 42 is generally circularly symmetric about a longitudinal axis along which the cartridge component 4 is coupled to the reusable component 2. In this example, the cartridge component 4 has a length of about 4cm and a diameter of about 1.5 cm. However, it will be appreciated that the specific geometry, and more generally the overall shape and materials used, may be different in different implementations.

Within the cartridge housing 42 is a chamber or reservoir 44 containing an aerosol-generating material. In the example schematically illustrated in fig. 1, the reservoir 44 stores a supply of liquid aerosol-generating material. In this example, the liquid reservoir 44 has an annular shape with an outer wall defined by the cartridge housing 42 and an inner wall defining an airflow path 52 through the cartridge component 4. The reservoir 44 is closed at each end with an end wall to contain aerosol-generating material. The reservoir 44 may be formed in accordance with conventional techniques, for example it may comprise a plastics material and be integrally moulded with the cartridge housing 42.

The cartridge/consumable part 4 further comprises an aerosol generator 48 positioned towards the end of the reservoir 44 opposite the mouthpiece outlet 50. It will be appreciated that in a two-piece system such as that shown in fig. 1, the aerosol generator 48 may be in either the reusable component 2 or the cartridge component 4. For example, in some embodiments, an aerosol generator 48 (e.g., a heater, which may be in the form of a core and coil arrangement as shown, a distiller, which may be formed of sintered metal fiber material or other porous conductive material, or any suitable alternative aerosol generator) may be included in the reusable component 2 and brought into proximity with a portion of the aerosol generating material in the cartridge component 4 when the cartridge component 4 is engaged with the reusable component 2. In such an embodiment, the cartridge component 4 may comprise a portion of the aerosol-generating material and the aerosol generator 48 comprising the heater is at least partially inserted into or at least partially surrounds the portion of the aerosol-generating material when the cartridge component 4 is engaged with the reusable component 2.

In the example of fig. 1, the core 46 in contact with the aerosol generator 48 extends transversely across the cartridge airflow path 52, the ends of which extend into the reservoir 44 of liquid aerosol-generating material through openings in the inner wall of the reservoir 44. The opening in the inner wall of the reservoir 44 is sized to match the size of the core 46 extensively to provide a reasonable seal against leakage from the liquid reservoir 44 into the cartridge airflow path without over-compressing the core 46, which could compromise its fluid transfer performance.

The core 46 and the aerosol generator 48 are arranged in the cartridge airflow path 52 such that the area of the cartridge airflow path 52 around the core 46 and the heater 48 effectively defines the evaporation area of the cartridge component 4. The aerosol-generating material in the reservoir 44 permeates the core 46 through the end of the core that extends into the reservoir 44 and is drawn along the core by surface tension/capillary action (i.e. wicking). In this example, the aerosol generator 48 comprises a resistive wire coiled around the core 46. In the example of fig. 1, the heater 48 comprises a nichrome (Cr 20Ni 80) wire and the core 46 comprises a glass fiber bundle, but it will be appreciated that the particular aerosol generator configuration is not important to the principles described herein. In use, electrical power may be supplied to the aerosol generator 48 to evaporate a quantity of aerosol generating material (aerosol generating material) drawn into the vicinity of the aerosol generator 48 through the core 46. The vaporized aerosol-generating material may then become entrained in the air drawn along the cartridge airflow path from the vaporization region toward the mouthpiece outlet 50 for inhalation by the user.

As mentioned above, the rate at which the aerosol-generating material is evaporated by the aerosol generator 48 will depend on the amount (level) of power supplied to the aerosol generator 48, and thus power may be applied to the aerosol generator 48 to selectively generate aerosol from the aerosol-generating material in the cartridge component 4, and furthermore the rate of aerosol generation may be varied by varying the amount of power supplied to the aerosol generator 48, for example by pulse width and/or frequency modulation techniques.

The reusable part 2 comprises a housing 12 having an opening defining an air inlet 28 for an electronic cigarette; a power supply 26 (e.g., a battery) for providing operating power for the electronic cigarette; a control circuit/controller 22 for controlling and monitoring the operation of the electronic cigarette; a first user input button 14; a second user input button 16; and a visual display 24. The device component 2 also includes a mounting bracket 110 (not shown in fig. 1) configured to receive the power source 26, and is described in more detail later with reference to subsequent figures.

The housing 12 may be formed of, for example, a plastics or metallic material and in this example has a circular cross-section that generally conforms to the shape and dimensions of the cartridge component 4 so as to provide a smooth transition between the two components 2,4 at the interface 6. In this example, the reusable part 2 has a length of about 8cm, so that the overall length of the e-cigarette is about 12cm when the cartridge part 4 and the reusable part 2 are coupled together. However, as already noted, it will be appreciated that the overall shape and dimensions of an electronic cigarette implementing embodiments of the present disclosure are not critical to the principles described herein.

The air inlet 28 is connected to the air flow path 51 through the reusable part 2. When the reusable part 2 and the cartridge part 4 are connected together, the reusable part airflow path 51 is in turn connected to the cartridge airflow path 52 through the interface 6. Thus, when a user inhales on the mouthpiece opening 50, air is drawn through the air inlet 28, along the reusable component airflow path 51, through the mouthpiece 6, through the aerosol generating region adjacent the aerosol generator 48 (where vaporized aerosol generating material is entrained in the airflow), along the cartridge airflow path 52, and out through the mouthpiece opening 50 for inhalation by the user.

In this example, the power source or supply 26 is rechargeable and may be of a conventional type, such as those commonly used in electronic cigarettes and other applications that require relatively high current to be provided for a relatively short period of time. The power supply 26 may be recharged through a charging connector (e.g., a USB connector) in the reusable component housing 12. In an embodiment, the power supply 26 has a body with a pair of electrodes extending therefrom, as shown, for example, in fig. 6.

A first user input button 14 and/or a second user input button 16 may be provided, which in this example is a conventional mechanical button, for example comprising a spring-loaded member that may be pressed by a user to establish electrical contact. In this regard, an input button may be considered an input device for detecting user input, and the particular manner in which the button is implemented is not important. Buttons may be assigned to functions such as turning on and off the aerosol delivery system 1 and adjusting user settings (e.g., power supplied from the power supply 26 to the aerosol generator 48). However, including user input buttons is optional, and in some embodiments buttons may not be included.

A display 24 may be provided to provide a visual indication to the user of various characteristics associated with the aerosol delivery system, such as current power setting information, remaining power supply power, and the like. The display may be implemented in various ways. In this example, display 24 comprises a conventional pixelated LCD screen that may be driven to display desired information in accordance with conventional techniques. In other implementations, the display may include one or more discrete indicators, such as LEDs, arranged to display desired information, such as by a particular color and/or sequence of flashes. More generally, the manner in which the display 24 is provided and the information is displayed to the user using the display is not critical to the principles described herein. For example, some embodiments may not include a visual display and/or may include other means for providing information to a user related to the operating characteristics of the aerosol delivery system, for example, using an audio signal, or may not include any means for providing information to a user related to the operating characteristics of the aerosol delivery system.

The controller 22 is suitably configured/programmed to control operation of the aerosol delivery system 1 to provide functionality according to embodiments of the present disclosure as further described herein, as well as for providing conventional operational functionality of the aerosol delivery system 1 consistent with established techniques for controlling such devices. The controller (processor circuit) 22 may be considered to logically comprise various sub-units/circuit elements associated with different aspects of the operation of the aerosol delivery system 1. In this example, the controller 22 includes power control circuitry for controlling the supply of power from the power source 26 to the aerosol generator 48 in response to user input, user programming circuitry 20 for establishing configuration settings (e.g., user-defined power settings) in response to user input, and functions associated with other functional units/circuitry in accordance with principles described herein and in general operational aspects of the electronic cigarette, such as display drive circuitry and user input detection circuitry. It will be appreciated that the functionality of the controller 22 may be provided in a variety of different ways, for example using one or more suitably programmed programmable computers and/or one or more suitably configured application specific integrated circuits/chips/chipsets configured to provide the desired functionality.

The functions of the controller 22 are further described herein. For example, the controller 22 may include an Application Specific Integrated Circuit (ASIC) or microcontroller for controlling the aerosol delivery device. The microcontroller or ASIC may include a CPU or microprocessor. The operation of the CPU and other electronic components is typically controlled, at least in part, by a software program running on the CPU (or other component). Such a software program may be stored in a non-volatile memory, such as a ROM, which may be integrated into the microcontroller itself, or provided as a separate component. The CPU can access the ROM to load and execute individual software programs when needed.

The reusable part 2 includes an airflow sensor 30 electrically connected to the controller 22. In most embodiments, the airflow sensor 30 comprises a so-called "puff sensor" because the airflow sensor 30 is used to detect when a user puffs on the device. In some embodiments, the airflow sensor 30 includes a switch in the electrical path that provides power from the power source 26 to the aerosol generator 48. In such embodiments, the airflow sensor 30 typically includes a pressure sensor configured to close the switch when subjected to a particular range of pressures such that current can flow from the power source 26 to the aerosol generator 48 once the pressure in the vicinity of the airflow sensor 30 falls below a threshold. The threshold value may be set to an experimentally determined value to correspond to a characteristic value associated with the start of a user puff. In other embodiments, the airflow sensor 30 is connected to the controller 22, and the controller distributes power from the power source 26 to the aerosol generator 48 in accordance with signals received by the controller 22 from the airflow sensor 30. The particular manner in which the signal output from the airflow sensor 30 (which may include a measurement of the capacitance, resistance, or other characteristic of the airflow sensor by the controller 22) is used by the controller 22 to control the supply of power from the power source 26 to the aerosol generator 48 may be performed according to any method known to those skilled in the art.

In the example shown in fig. 1, the airflow sensor 30 is mounted to a Printed Circuit Board (PCB) 31, but this is not required. The airflow sensor 30 may include any sensor configured to determine a characteristic of the airflow in the airflow path 51 disposed between the air inlet 28 and the mouthpiece opening 50, such as a pressure sensor or transducer (e.g., a membrane or solid state pressure sensor), a combined temperature and pressure sensor, or a microphone that is sensitive to changes in air pressure including acoustic signals (e.g., an electret microphone). The airflow sensor 30 is located within a sensor cavity or chamber 32 that includes an interior space defined by one or more chamber walls 34. The sensor cavity 32 includes a region within one or more chamber walls 34 in which the airflow sensor 30 may be located, in whole or in part. In some embodiments, PCB 31 includes one of the chamber walls of a sensor housing that includes sensor chamber/cavity 32.

The deformable membrane is disposed across an opening that communicates between the sensor cavity 32 containing the sensor 30 and a portion of the airflow path disposed between the air inlet 28 and the mouthpiece opening 50. According to the methods further described herein, a deformable membrane covers the opening and is attached to one or more chamber walls.

As further described herein, the aerosol delivery system 1 comprises a communication circuit configured to enable a connection to be established with one or more further electronic devices (e.g. a storage/charging housing, and/or a refill/charging base) to enable data transmission between the aerosol delivery system 1 and the further electronic devices. In some embodiments, the communication circuitry is integrated into the controller 22, and in other embodiments, it is implemented separately (including, for example, a separate application specific integrated circuit/chip/chipset). For example, the communication circuit may comprise a module separate from the controller 22 that provides dedicated data transfer functions for the aerosol delivery device while being connected to the controller 22. In some embodiments, the communication circuit is configured to support communication between the aerosol delivery system 1 and one or more further electronic devices over a wireless interface. The communication circuit may be configured to support wireless communication between the aerosol delivery system 1 and other electronic devices, such as a housing, a base, a computing device such as a smart phone or PC, a base station supporting cellular communication, a relay node providing a forward connection to the base station, a wearable device, or any other portable or fixed device supporting wireless communication.

The wireless communication between the aerosol delivery system 1 and the further electronic device may be configured according to a data transfer protocol, such as bluetooth, zigBee, wireless communication, or the like,Wifi direct, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or substantially any other wireless and/or wired network protocol or interface. The communication circuit may comprise any suitable interface for wired data connection, such as a USB-C, micro-USB or Thunderbolt interface, and may comprise a pin or contact pad arrangement configured to engage a mating pin or contact pad on a base, housing, cable or other external device connectable to the aerosol delivery system 1. /(I)

Fig. 2,3, and 4 are schematic top, bottom, and side perspective views of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a bracket 110 in more detail.

As shown in fig. 2-4, the mount 110 is a substantially tubular or cylindrical mounting mount 110 and is configured to receive a power source 26, the power source 26 having a body with a pair of electrodes 27 (shown separately in fig. 6) extending therefrom. The bracket 110 includes a first portion (upper portion) 110a having a pair of holes 120 configured to receive the pair of electrodes 27 and present them at the ends of the bracket 110 for connection, and a second portion 110b having a cavity 130 configured to receive a power supply body. In the example embodiment of fig. 2-4, the pair of apertures 120 extend substantially axially, are configured to receive the pair of electrodes 27, and are connected at an axial end of the bracket 110 proximate the first portion 110 a. In addition, in the embodiment of fig. 2-4, the bracket 110 also includes a third lower portion 110c having an aperture for providing the air inlet 28 into the subsystem 100, with a flow path therethrough to deliver air to the aerosol generator 48 (not shown).

The first portion (upper portion) 110a generally comprises a truncated tube (or cylinder) having an open upper end for connection to the cartridge component 4 (shown in fig. 7). The first portion 110a includes a surface 140 having a platform 142 with the pair of holes 120 therethrough. In the example embodiment of fig. 3, the surface 140 is planar and extends substantially radially, and the platform 142 includes two upstanding truncated cylinders 142a, 142b, each extending substantially axially (and thus substantially perpendicular to the radial surface 140) and each having a bore 120 therethrough (thereby forming a tube). In use, the platform 142 axially spaces at least the conductive portion of the electrode 27 from the surface 140. The surface 140 further comprises a peripheral wall 144 and the (walled) surface 140 forms a trapping area for condensate in use. Thus, in use, the platform 142 axially spaces at least the conductive portion of the electrode 27 from the capture area, thereby advantageously minimizing the risk of shorting the power supply 26 in use.

The first portion 110a, the second portion 110b, and/or the third portion 110c may generally include one or more protrusions and/or recesses arranged to receive, connect to, interfere with, or interlock with an interlocking add-on. As shown in fig. 2, the first portion 110a includes a plurality of internal protrusions 145 and recesses 146 extending from the wall 144 for engaging or interlocking with complementary protrusions 245 and/or recesses 246 on the cartridge component 4 (as shown in fig. 7) to secure and/or prevent rotation of the components 2,4 relative to one another when joined. In some embodiments not shown in fig. 2-4, the outer side wall 150a of the first portion 110a includes one or more external protrusions or recesses for engagement with other components, such as the housing 200, in use. Such components may optionally include complementary protrusions or recesses.

In some embodiments (not shown), any of the portions 110 a-110 c, but in particular the first portion (upper portion) 110a, may be asymmetric in cross-section and/or when viewed proximally perpendicular to its axially extending axis. Advantageously, this may provide a one-way fit for the portion to engage with other components (e.g. the upper portion 110a engages with the cartridge component 4), which is detectable by the camera to automate assembly, i.e. the camera assembly may uniquely detect the orientation of the first portion 110a, and the robotic arm may then position/rotate it as necessary to fit to other components during assembly. The orientation of the first portion 110a may be uniquely identified by the asymmetry of the cross-section, particularly in arrangements having asymmetric or otherwise uniquely oriented visible features, i.e., the aperture 120, the circumferential wall 144, the land 142, the surface 140, and/or the protrusions and recesses 145, 146. For example, each of the apertures 120, the lands 142a, 142b, and/or the protrusions and recesses 145, 146 may have a different shape and/or size from one another.

In fig. 2 to 4, the second portion 110b forms an intermediate portion between the first portion (upper portion) 110a and the third portion (lower portion) 110 c. The second portion 110b generally includes opposed tubular side walls 150b that extend around only a portion of the circumference of the substantially tubular or cylindrical support 110, thereby providing a power cavity 130 configured to receive a power source body in use.

As shown in the example of fig. 2-4, the third portion (lower portion) 110c generally comprises a truncated tube or cylinder having an aperture for providing the air inlet 28 into the subsystem 100. The third portion 110c also includes an optional sensor cavity 32 for receiving the fluid flow sensor 30, which is surrounded by a fluid flow sensor seal 33. The third portion 110c additionally includes a flange 164 for abutting the housing 200, which is received when the system 1 is assembled (as shown in fig. 9), and a projection in the form of a shoulder 162 on the outer wall 150c of the third portion 110c, the shoulder projection 162 for engaging the housing 200 and providing an interference fit therewith, securing the housing 200 over the subsystem 100. Likewise, the other portions 110a, 110b may include protrusions, recesses, flanges, and/or shoulders for engaging or abutting other components such as the housing 200.

Fig. 3 additionally shows a baffle cavity 135 for receiving a user operable baffle 138 (not shown, see fig. 5) that is slidable to regulate the flow of air into the device through the inlet 28.

Fig. 4 shows the subsystem 100 in use, the subsystem additionally comprising a power supply 26 and an electrode 27 extending axially and protruding beyond the axial extent of the first portion 110a for connection at the axially proximal end of the stent 110. The bracket 110 in fig. 4 also includes additional recesses for receiving flexible, resilient and/or absorbent inserts 170a and 170c. In fig. 4, these include two radially extending recesses, one above and one below the power cavity 130, for receiving inserts 170a, 170c above and below the power body, respectively. The subsystem 100 further includes an insert 170b alongside the power supply body. Since the insert 170b is attached to the power supply body, a recess is not necessarily required in the bracket 110, but in further embodiments the subsystem 100 may include a recess extending axially alongside the power supply cavity 130 for receiving the insert 170b alongside the power supply body. The inserts 170 a-170 c provide a gasket between the components to provide a secure fit (e.g., to aid in an interference fit) and may be used to reduce/prevent leakage when used with liquid cartridge systems. In some embodiments, inserts 170 a-170 c include Ethylene Vinyl Acetate (EVA).

Fig. 5 is a vertical cross-sectional view of the aerosol delivery subsystem 100 of fig. 4. In addition to the features shown in fig. 4, fig. 5 shows an alternative fluid flow sensor 30 in the airflow path from the air inlet 28, and a fluid flow sensor seal 33 for sealing around the fluid flow sensor 30. In some embodiments, the sensor 30 includes a microphone or a pressure sensor. Fig. 5 also shows the baffle 38 and a baffle seal 39 for sealing around the baffle 38. In some embodiments, the seals 33, 39 comprise silicone.

Fig. 6 is a schematic side view of a modular power supply for the aerosol delivery subsystem 100, according to some embodiments of the present disclosure. Fig. 6 shows a power supply 26 comprising a body having a pair of electrodes 27 extending therefrom, the pair of electrodes being located in the pair of apertures 120 for connection to an aerosol generator 48. This arrangement thus provides an electrical and non-permanent (easily reversible) mechanical connection securing the power supply 26 within the system 1. In some embodiments, not shown in fig. 6, the electrodes comprising the pair of electrodes 27 have different shapes and/or sizes from each other to facilitate assembly, i.e., each electrode may fit in only one hole 120.

Fig. 7 is an exploded perspective view of an aerosol delivery system 1 according to some embodiments of the present disclosure. As described above, the device component 2 is itself a modular subsystem 100 and includes a component mounting bracket 110. The cartridge component 4 comprises a cartridge housing 42 containing an aerosol generating material such as tobacco (for THP systems) or a liquid containing nicotine (for electronic cigarettes) and including complementary conductive pins 227 for electrical connection to electrodes 27 of the power supply 26 to provide electrical power to an aerosol generator 48 therein. The cartridge component 4 further comprises a mouthpiece housing 60 having a mouthpiece outlet 50. As shown in fig. 9, the mouthpiece housing 60 may be separate from the cartridge housing 42.

In the example embodiment of fig. 7, both the device component 2 and the cartridge component 4 are operable to engage the housing 200 (shown in fig. 8) via an interference fit by the device component 2 and the cartridge component 4 including the protrusions 162, 262, 362. Specifically, in this example, the device component 2 includes a protrusion 162 on the distal portion 110c of the holder 110, while the cartridge housing 42 of the cartridge component 4 includes a protrusion 262, and the mouthpiece housing 60 of the cartridge component 4 includes a protrusion 362. The protrusions 162, 262, 362 extend radially to engage the housing 200 with an interference fit.

As described above with reference to fig. 2, the cartridge component 4 further includes protrusions 245 and recesses 246 for engaging or interlocking with complementary protrusions 145 and recesses 146 extending from the wall 144 of the first portion 110a to secure and/or prevent rotation of the components 2, 4 relative to one another when joined.

Fig. 8 is a schematic side view of an aerosol delivery system 1 according to some embodiments of the present disclosure. Fig. 8 shows a substantially tubular or cylindrical example of an elongate disposable or reusable e-cigarette or THP system 1 comprising a collar 210 fixedly surrounding a housing 200 of the aerosol delivery system 1. In a two-piece system such as the system of fig. 7, the housing 200 is secured over both the device component 2 and the cartridge component 4. Thus, by removing the push-fit end collar 210 and then withdrawing the bracket 110 from the housing 200 (which removes all interconnected subsystem components), the entire system 1 can be easily disassembled without the need for tools. The cartridge 4 may similarly be removed from the other end of the housing 200.

Fig. 9 is a schematic diagram of an assembly process for an aerosol delivery system 1 according to some embodiments of the present disclosure. The entire system 1 can be easily assembled and disassembled because the subsystem 100 includes the rack 110 that houses the components of the device components 2 so that these components can be commonly installed into the system 1/removed from the system 1. In some embodiments, the various components and/or parts are held by an interference fit to provide tool-free assembly.

As shown in fig. 9, the subsystem 100 receives the cartridge housing 42 at an axially proximal end of the subsystem 100, connecting the electrodes 27 to the aerosol generator 48 within the cartridge housing 42. The housing 200 is then secured to the subsystem 100 with an interference fit at the bracket projections 162 and pressed axially to abut the bracket flange 164 at the end of the bracket 110. The mouthpiece housing 60 is similarly secured to the housing 200 by an interference fit at the mouthpiece housing projection 362, thereby securing the housing 200 between the bracket flange 164 and the mouthpiece housing 60.

Fig. 10-14 illustrate another example of the present disclosure, which will now be described in more detail. For convenience, the same reference numerals from the previous examples of fig. 1-9 are used, although any features of the examples may be combined and specifically considered in combination, a detailed discussion of the various permutations is omitted for brevity.

Fig. 10-13 are schematic perspective views of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, particularly showing the second bracket 110 in more detail.

In this second example, the bracket 110 includes a tubular first portion 110a having a pair of apertures 120 configured to receive and present the pair of power terminals/electrodes 27 for connection at the ends of the bracket 110, and a second portion 110b including a tubular sidewall 150b extending around only a portion of the circumference of the bracket 110 and having a cavity 130 configured to receive a power body. The cavity 130 of the second portion 110b is formed by a tubular sidewall 150b that extends axially away from the first portion 110a, as shown in fig. 12, with the aperture 120 extending through a surface of the sidewall that spans the first portion 110 a.

The overall shape of the bracket 110 is different compared to the first example, and the second example is generally shaped like a premolars or molars, with the first portion 110a resembling a crown portion and the second portion 110b resembling a root or leg. This second example does not require either the third portion 110c or the circumferential wall 144, although these may still be provided.

The bracket 110 of fig. 10-14 includes one or more apertures 121 configured to provide an airflow path therethrough, as will be described in more detail below.

Fig. 11 shows a bracket 110 comprising a protrusion in the form of a flange 154 configured to receive or engage the aerosol generator 48 or the cartridge/atomizer. Flange 154 also includes an external protrusion 145. Fig. 14 shows a flange 154 that engages the cartridge housing 42 (circled) in use, as will be described in more detail later.

Fig. 12 shows a side view of the bracket 110 and shows that the second portion 110b includes a bridge support 115 that spaces the end of the power supply body from the first portion 110a and allows air to flow through the aperture 121.

Fig. 13 shows a subassembly 100 that additionally includes flexible, resilient and/or absorptive inserts 170a and 170c as in the previous example, and an elongated power source 26 with wiring 29 extending down from the electrode 27 around the sides of the power source body to the end cap 160. In this second example, a separate end cap 160 having a flange 164 is provided instead of the bracket 110 including the third portion 110 c.

In some arrangements, an airflow sensor 30 configured to detect airflow through the air inlet 28 in use is advantageously provided substantially at one end of the system 1, remote from the cartridge and mouthpiece 50, where the airflow sensor is unlikely to come into contact with electronic liquid or condensate. In fig. 13-14, the end cap 160 includes an air inlet 28 (shown in fig. 14) at the proximal inlet end of the subsystem, and an airflow sensor 30 is located in the airflow path from the air inlet 28 for detecting smoke as air flows into the system 1 (shown in fig. 14). The same benefit derives from the first example shown in fig. 5, wherein the third portion 110c of the bracket similarly includes the air inlet 28 and houses the sensor 30. In contrast, the arrangement of fig. 1 locates the sensor 30 on the side of the air inlet 28, proximal to the aerosol generator 48, simplifying the air inlet path and power wiring.

In fig. 13, the sensor 30 is connected to the electrode of the elongate power supply 26 by wiring 29 extending alongside the battery compartment to the electrode 27 at the distal/downstream (axial) end of the power supply 26, the elongate power supply extending longitudinally away from the sensor 30, the electrode 27 extending towards/away from the sensor 30 (and the inlet 28). In fig. 13, the wiring 29 extends between the power supply body and the bracket 110 along the right-hand side of the power supply body, and is thus held by the bracket 110. Or the wire 29 may extend alongside the power supply in alignment with the midpoint of the electrode 27, so the wire 29 may have the same length for both terminals that are remote from the sensor 30 at the furthest axial end of the power supply 26. The bracket 110 may include additional features such as a third leg to secure the wiring 29, the same terminal/electrode 27 also providing power to the aerosol generator 48 in use, which is shown in fig. 14 at the distal/downstream end of the subsystem, further away from the puff sensor 30 and the inlet 28. The subsystem may comprise a reusable device portion 2 of the aerosol delivery system 1 for use with a removable/replaceable cartridge component 4.

As best shown in fig. 13, the wiring 29 is preferably longer than the shortest path from the electrode 27 to the sensor 30, i.e., has an excess length, so that when connected, the puff sensor 30 can be axially separated from the power source 26 to aid in assembly, for example, to allow insertion/removal of the end cap 160 without damaging the connection, thereby allowing assembly of this subassembly outside of the housing/case 200 before the end cap 160 is pushed into place.

Typically, the power source 26 may have a length (extending away from the sensor 30) of 25-35mm, 35-45mm, or 45-55 mm. Assuming a typical minimum length of 15mm reliably connects the sensor 30 to the electrode/terminal 27 at the distal/downstream axial end of the power supply 26 (note that the shortest paths may have slightly different lengths for different +/-terminals), the corresponding minimum wiring lengths are 40-50mm, 50-60mm, or 60-70mm. Preferably, the wiring has an excess length of 20-30mm, 30-40mm or 40-50mm greater than this minimum "shortest path" length to allow for easy installation/removal, and thus has a length of 60-70mm, 70-80mm, 80-90mm, 90-100mm, 100-110mm or 110-120 mm. Any excess length of wiring 29 may be received in the space 166 between the end cap 160 and the power source 26 (as best seen in fig. 14—the excess length of wiring 29 may be received by coiling in the space 166). The space 166 may also contain an absorbent material 170c to capture any aerosol-generating material or condensate that may have leaked.

Fig. 14 is a cross-sectional view of an aerosol delivery system 1 according to some embodiments of the present disclosure, including the second bracket 110 of fig. 10-13. As shown, the aerosol delivery system 1 of fig. 14 includes the subsystem of fig. 13 and additional components forming the system 1.

In addition to the components shown in fig. 13, the system 1 of fig. 14 also includes an outer shell 200 surrounding the end cap 160, the bracket 110, and the cartridge housing 42. Internally, the system 1 further comprises a sealing element 133 which engages the first portion 110a of the holder and the aerosol generator 48, thereby providing a seal therebetween, and thus between the aerosol generator 48 and the power supply 26 in use. As described above, the flange 154 of the bracket 110 engages the cartridge housing 42 (is circled) to secure the cartridge to the bracket 110. The support 110 provides separation between the cartridge and the power supply 26, reducing the risk of leakage affecting the power supply 26 and the sensor 30. The system 1 further comprises a manifold 58 for directing aerosol from the aerosol generator 48 to the mouthpiece 50 at a distal downstream end of the system 1 opposite the end cap 160.

As shown in fig. 14, the air inlet 28 to the end cap 160 provides an air flow into the system 1 at its proximal inlet end. The air flow may be regulated by a baffle 38 that is slidable to regulate the air flow into the system 1 through the inlet 28, as discussed above with reference to fig. 5. The system 1 provides an airflow path therethrough that passes through the power supply 26 and to the aerosol generator 48 to entrain vapor and generate aerosol. In some examples, the bracket 110 provides an airflow path around the power supply 26, for example, by providing space between the power supply 26 and the second portion 110b and/or by providing space between the power supply 26, the bracket 110, and an inner wall of the housing 200. Such spacing may be provided, for example, by providing a radially relatively loose fit and relying primarily on axial retention, optionally with a gasket to prevent vibration, or using an interference fit (e.g., with a gasket) between the respective elements only around part of the circumference (e.g., in staggered portions). In some examples, the bracket 110 provides an airflow path therethrough from the second portion 110b to the first portion 110a by including one or more apertures 121.

As detailed herein, the bracket 110 may thus provide several functions, which may include:

electrode/terminal 27 holding power supply 26

Presenting or extending the electrodes/terminals 27 of the power supply 26

Hold power supply 26 itself

Fixed cartridge

Providing a seal between the cartridge and the power supply 26

Airflow path provided to aerosol generator/cartridge

Combining several functions into a single piece component reduces the total part count of the device, thereby helping to reduce costs and simplify the manufacturing/assembly process.

Advantageously, aspects of the arrangement disclosed herein (particularly the separation between the cartridge and the power supply 26) may allow the cartridge to include liquid that is freely stored in the reservoir, maximizing storage volume without the need for a storage medium such as cotton, which is typically used to help reduce leakage, but which itself occupies volume and absorbs a portion of the liquid that cannot be released, thus reducing effective capacity. The use of a freely stored liquid enables the reservoir to be smaller for the same volume of aerosol-generating material, thereby providing a more compact device. This space saving in the cartridge may provide space for accommodating any excess length of the wires 29 connected to the airflow sensor 30, thereby avoiding any impact on the overall size of the system 1.

In some examples, as shown in fig. 1-9, the bracket 110 additionally provides the function of an end cap 160.

The modular nature of the overall system 1, and in particular of the subsystem 100, thus allows for easy installation and removal of individual components, such as the power supply body and the electrodes 27. In existing arrangements, these connections will typically be welded and secured in place directly one after the other within the subsystem 100, and thus more time consuming and delicate to assemble and disassemble, increasing the likelihood of damage during assembly/disassembly. By providing a mounting bracket 110, the various components may be connected together as a modular subsystem 100, which may then be assembled together into the overall system 1, providing a faster, more convenient, and less damaging assembly process. Furthermore, the method is reversible and thus improves recyclability, which is particularly important for disposable devices that are typically single-use and discarded (and thus not recycled) as a complete unit. Thus, the present invention greatly improves recyclability because the various components can be easily removed and transported to the appropriate recycling center.

Although in the embodiment of fig. 1, the various components (e.g., aerosol generator 48) are shown as components of the cartridge component 4, in some embodiments these may alternatively be components of the device component 2 or subsystem 100, and the bracket 110 may include additional features for accommodating these components, such as protrusions, recesses, shelves, and/or cavities.

The steps of the disclosed methods may be performed in any suitable order.

The various embodiments described herein are only used to aid in understanding and teaching the claimed features. These embodiments are provided as representative examples of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that the advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims, or limitations on equivalents to the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention.

Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, the appropriate combination of the disclosed elements, components, features, parts, steps, modes, and the like, in addition to those specifically described herein. In addition, the present disclosure may include other inventions not presently claimed but which may be claimed in the future. Protection may be sought for any feature disclosed in any one or more of the publications cited herein in connection with the present disclosure.

Specific features A

1. An aerosol delivery subsystem comprising a substantially tubular or cylindrical mounting bracket configured to receive a power source having a body with a pair of electrodes extending therefrom, the bracket comprising:

a. a first portion having a pair of holes configured to receive a pair of electrodes and present the pair of electrodes for connection at ends of the stent; and

B. A second portion having a cavity configured to receive the power supply body.

2. The subsystem of clause 1, wherein the pair of holes:

a. extending substantially axially; and/or

B. Configured to receive the pair of electrodes and present the pair of electrodes for connection at axial ends of the stent; and/or

C. is configured such that the pair of electrodes are connected at an end of the holder near the first portion.

3. The subsystem according to any one of the preceding clauses, further comprising a third portion having:

a. an aperture for providing an air inlet into the subsystem; and/or

B. A cavity for receiving a fluid flow sensor.

4. The subsystem according to any one of the preceding clauses, wherein the bracket comprises:

a. A first upper portion having the pair of holes configured to receive the pair of electrodes and present the pair of electrodes for connection at ends of the bracket;

b. A second intermediate portion having a cavity configured to receive the power supply body; and

C. A third lower portion.

5. The subsystem according to any one of the preceding clauses, wherein the first, second and/or third portions comprise:

a. truncated cylinders or tubes; and/or

B opposed side walls extending around only part of the circumference of the substantially tubular or cylindrical stent; and/or

C. A flange or shoulder for abutting against the housing or another component; and/or

D. Protrusions and/or recesses for engagement with the housing or another component.

6. The subsystem according to any one of the preceding clauses, wherein:

a. the first upper portion and the third lower portion each comprise a truncated cylinder or tube; and

B. the second intermediate portion includes opposed tubular sides extending around only a portion of the circumference of the tube; and

C. the third lower portion includes a flange and a protrusion or recess for removably receiving and engaging the housing.

7. The subsystem according to any one of the preceding clauses, wherein the first portion comprises a surface having a platform with the pair of apertures therethrough, the platform axially spacing at least the conductive portion of the electrode from the surface in use.

8. The subsystem of clause 7, wherein:

a. the surface comprising a circumferential wall and forming a trapping region for condensate in use; and

B. The platform, in use, axially spaces at least the electrically conductive portion of the electrode from the trapping region.

9. The subsystem of clause 7 or 8, wherein the surface extends substantially radially and the platform extends substantially axially, substantially perpendicular to the radial surface, and away from the capture area.

10. The subsystem according to any one of the preceding clauses, wherein the first portion, the second portion and/or the third portion are asymmetric in cross-section.

11. The subsystem according to any one of the preceding clauses, wherein the first, second and/or third portions are asymmetric when viewed from the proximal end perpendicular to the axially extending axis.

12. The subsystem according to any one of the preceding clauses, wherein the first, second and/or third portions comprise a plurality of protrusions and/or recesses arranged to receive, connect to, interfere with or interlock with an additional component, wherein the plurality of protrusions and/or recesses are arranged to be asymmetric in cross-section.

13. The subsystem according to any one of the preceding clauses, wherein the holes of the pair of holes have different shapes and/or sizes from each other.

14. The subsystem according to any one of the preceding clauses, wherein the outer wall of the bracket comprises one or more protrusions or recesses at one or more ends thereof to engage with complementary protrusions or recesses.

15. The subsystem of any one of the preceding clauses, further comprising one or more recesses for receiving flexible, resilient and/or absorptive inserts.

16. The subsystem according to any one of the preceding clauses, comprising:

a. a recess extending radially above and/or below the cavity configured to receive the power supply body for receiving a flexible, resilient and/or absorbent insert above and/or below the power supply body; and/or

B. An axially extending recess beside the cavity configured to receive the power supply body for receiving a flexible, resilient and/or absorptive insert beside the power supply body.

17. The subsystem according to any one of the preceding clauses, further comprising:

a. A power source having a body and an electrode extending therefrom; and/or

B. A fluid flow sensor; and/or

C. a seal for sealing around the fluid flow sensor; and/or

D. A flexible, resilient and/or absorbent insert; and/or

E a housing for accommodating the bracket; and/or

F. a baffle for regulating airflow through the subsystem; and/or

G. An aerosol generator; and/or

H. a cartridge or nebulizer containing aerosol-generating material or aerosol-generating material for generating an aerosol or smoke for inhalation by a user; and/or

I. A mouthpiece; and/or

J. And a controller.

18. The subsystem of clause 17, wherein the subsystem is configured to receive a power source, a fluid flow sensor, a seal, an insert, a housing, a baffle, an aerosol generator, a cartridge or atomizer, a mouthpiece, and/or a controller in an interference fit.

19. The subsystem of clause 17 or 18, comprising a power supply, wherein the pair of electrodes comprises a positive electrode and a negative electrode that are different in shape and/or size from each other.

20. A substantially tubular or cylindrical aerosol delivery system comprising a substantially tubular or cylindrical mounting bracket according to any of the preceding clauses.

21. A set of instructions for a 3D printer configured for printing an aerosol delivery subsystem according to any of the preceding clauses.

22. A method of assembling an aerosol delivery subsystem comprising a substantially tubular or cylindrical mounting bracket and a power supply having a body with a pair of electrodes extending therefrom, the method comprising:

a. mounting the power supply body in the cavity of the bracket; and

B. the pair of electrodes are mounted in a pair of holes in the bracket, the pair of electrodes being presented for connection at the ends of the bracket.

23. An aerosol delivery subsystem comprising a substantially tubular or cylindrical mounting device configured to receive a power source having a body with a pair of electrodes extending therefrom, the cradle comprising:

a. a first device having a pair of holes configured to receive the pair of electrodes and present the pair of electrodes for connection at ends of the stent; and

B. A second device having a cavity configured to receive the power supply body.

Specific features B

1. An aerosol delivery subsystem, comprising:

a. a puff sensor at one end configured to detect, in use, an air flow through the air inlet; and

B. an elongate power source extends away from the puff sensor and has an electrode at a distal end thereof for connection to the puff sensor.

2. The subsystem of clause 1, further comprising wiring for connecting the puff sensor to the distal electrode of the power source, wherein the wiring has excess length such that the puff sensor can be axially separated from the power source when connected to aid in assembly.

3. The subsystem according to any of the preceding clauses, wherein the power source has a length extending 25-35mm, 35-45mm, or 45-55mm away from the puff sensor.

4. The subsystem of clause 2 or 3, wherein the wiring has an excess length of 20-30mm, 30-40mm, or 40-50 mm.

5. The subsystem of clause 2, 3 or 4, wherein the wiring has a length of 60-70mm, 70-80mm, 80-90mm, 90-100mm, 100-110mm or 110-120 mm.

6. The subsystem according to any one of the preceding clauses, wherein the air inlet is located at an end of the subsystem and the puff sensor is located in an airflow path from the air inlet into the subsystem.

7. The subsystem according to any one of the preceding clauses, further comprising a mounting bracket for a power supply, the bracket presenting the electrodes for connection at an end of the bracket.

8. The subsystem of any of the preceding clauses, further comprising a baffle across the air inlet for regulating the air flow through the air inlet.

9. The subsystem according to any one of the preceding clauses, wherein the baffle is slidable to regulate the air flow through the air inlet.

10. The subsystem according to any one of the preceding clauses, wherein the air inlet is located at a proximal end of the subsystem, the subsystem further comprising an aerosol generator remote from the puff sensor at a distal end of the subsystem.

11. The subsystem according to any one of the preceding clauses, wherein the puff sensor, the power source, and the aerosol generator are substantially axially aligned in the following order: puff sensor-power supply-aerosol generator.

12. A subsystem according to any preceding clause comprising a cartridge or reservoir containing aerosol-generating material.

13. The subsystem of clause 12, wherein the puff sensor, the power source, the aerosol generator, and the cartridge or reservoir are substantially axially aligned in the following order: puff sensor-power supply-aerosol generator-cartridge or reservoir.

14. The subsystem of clause 12 or 13, comprising a liquid freely stored in a cartridge or reservoir.

15. The subsystem according to any one of the preceding clauses, comprising:

a. a mounting bracket for a power supply;

b. An end cap comprising a puff sensor and an air inlet; and

C. A housing configured to receive the end cap, the mounting bracket, and the power source.

16. The subsystem of clause 15, wherein the housing provides a space for receiving wiring between the end cap and the power supply.

17. An aerosol delivery system comprising a subsystem according to any of the preceding clauses.

18. The aerosol delivery system of clause 17, comprising a mounting bracket for the power source, the bracket providing an airflow path around the power source.

19. The aerosol delivery system of clauses 17 or 18, comprising a mouthpiece, wherein the puff sensor is located substantially at a proximal end of the system, distal to the mouthpiece at an opposite distal end of the system.

20. A method of assembling an aerosol delivery subsystem, the subsystem comprising:

a. A puff sensor configured to detect, in use, an air flow through the air inlet;

b. An elongate power source extending away from the puff sensor in use and having an electrode at a distal end remote from the puff sensor;

c. a mounting bracket for a power supply, presenting electrodes for connection at an end of the bracket; and

D. Wiring for connecting the puff sensor to the electrode, the wiring passing along the length of the power supply body in use and having excess length to assist in assembly, the method comprising:

Mounting the power supply in the rack;

wiring the puff sensor to the electrode;

mounting the puff sensor in an end cap comprising an air inlet;

Positioning the cradle and the power supply in the housing; and

Securing the end cap to the housing to form the proximal end of the system, the housing providing a space between the end cap and the power source, accommodating the excess length of wiring.

Claims

1. An aerosol delivery subsystem comprising a mounting bracket configured to receive a power source, the power source having a body with a pair of electrodes extending therefrom, the bracket comprising:

a. A tubular or cylindrical first portion having a pair of apertures configured to receive the pair of electrodes and present the pair of electrodes for connection at the ends of the stent; and

B. A second portion including a tubular sidewall extending around only a portion of the circumference of the bracket and having a cavity configured to receive the body of the power source.

2. The subsystem of claim 1, wherein the pair of apertures:

a. extending substantially axially; and/or

B. a surface extending across a side wall of the first portion which is tubular or cylindrical; and/or

C. configured to receive the pair of electrodes and present the pair of electrodes for connection at axial ends of the stent; and/or

D. is configured to connect the pair of electrodes at an end of the bracket near the first portion.

3. The subsystem according to any one of the preceding claims, wherein the rack further comprises one or more apertures configured to provide an airflow path therethrough.

4. A sub-system according to any preceding claim, wherein the tubular side wall of the second portion forms a leg extending axially away from the first portion.

5. The subsystem according to any one of the preceding claims, wherein the second portion comprises a bridge support between the tubular side walls.

6. The subsystem according to any one of the preceding claims, further comprising: a sealing element for sealing between the first portion of the holder and an aerosol generator, or a reservoir, cartridge or nebulizer containing an aerosol generating material or an aerosol generating material.

7. A sub-system according to any preceding claim, wherein the first portion comprises a flange or projection configured to receive or engage an aerosol generator, or a reservoir, cartridge or nebuliser containing an aerosol generating material or aerosol generating material.

8. A subsystem according to any one of the preceding claims, wherein, in use, when connected to a power source and an aerosol generator, reservoir, cartridge or atomizer, the holder comprises or provides an airflow path for airflow through the power source to the aerosol generator, reservoir, cartridge or atomizer.

9. The subsystem according to any one of the preceding claims, wherein:

a. the first portion comprises a truncated cylinder or tube; and/or

B said second portion including opposed side walls extending only around a portion of the circumference of said bracket; and/or

C. the bracket further comprises a flange or shoulder for abutting against the housing or another component; and/or

D. the bracket further comprises one or more protrusions and/or recesses for engagement with the housing or another component.

10. A sub-system according to any preceding claim, wherein the first portion comprises a surface having a platform with the pair of apertures therethrough, the platform axially spacing at least a conductive portion of the electrode from the surface in use.

11. The subsystem of claim 10, wherein:

a. The surface comprising a circumferential wall and forming, in use, a trapping region for condensate; and

B. The platform, in use, axially spaces at least the conductive portion of the electrode from the capture region.

12. The subsystem of claim 10, wherein the surface extends substantially radially and the platform extends substantially axially, substantially perpendicular to the radial surface, and away from the capture area.

13. The subsystem according to any one of the preceding claims, wherein the first portion and/or the second portion is asymmetric in cross-section.

14. The subsystem according to any one of the preceding claims, wherein the first portion and/or the second portion is asymmetric when viewed from a proximal end perpendicular to the axially extending axis.

15. A subsystem according to any one of the preceding claims, wherein the first and/or second portion comprises a plurality of protrusions and/or recesses arranged to receive, connect to, interfere with or interlock with an additional component, wherein the plurality of protrusions and/or recesses are arranged to be asymmetric in cross-section.

16. The subsystem according to any one of the preceding claims, wherein the holes of the pair of holes have a shape and/or size different from each other.

17. A sub-system according to any preceding claim, wherein the outer wall of the bracket comprises one or more protrusions or recesses at one or more ends thereof to engage with complementary protrusions or recesses.

18. The subsystem according to any one of the preceding claims, further comprising one or more recesses for receiving flexible, resilient and/or absorbent inserts.

19. The subsystem according to any of the preceding claims, comprising:

a. A recess extending radially above and/or below the cavity configured to receive the body of the power source for receiving a flexible, resilient and/or absorptive insert above and/or below the body of the power source; and/or

B. an axially extending recess beside the cavity configured to receive the body of the power source for receiving a flexible, resilient and/or absorptive insert beside the body of the power source.

20. The subsystem according to any one of the preceding claims, further comprising:

a. A power source having a body and an electrode extending therefrom; and/or

B. A fluid flow sensor; and/or

C. A seal for sealing around the fluid flow sensor; and/or

D. A flexible, resilient and/or absorbent insert; and/or

E a housing for accommodating the bracket; and/or

F. a baffle for regulating airflow through the subsystem; and/or

G. An aerosol generator; and/or

H. a reservoir, cartridge or nebulizer containing an aerosol-generating material or aerosol-generating material for generating an aerosol or smoke for inhalation by a user; and/or

I. A mouthpiece; and/or

J. And a controller.

21. The subsystem of claim 20, wherein the subsystem is configured to receive the power source, the fluid flow sensor, the seal, the insert, the housing, the baffle, the aerosol generator, the reservoir, the cartridge or atomizer, the mouthpiece, and/or the controller in an interference fit.

22. The subsystem according to claim 20 or 21, comprising the sealing element of claim 6, and the aerosol generator, the reservoir, the cartridge or the atomizer.

23. The subsystem of claim 20 or 21, comprising the power supply, wherein:

a. The pair of electrodes includes positive and negative electrodes different from each other in shape and/or size; and/or

B. The subsystem includes an airflow path around the power source and through one or more apertures in the rack; and/or

C. the power source is held in the holder around the holder or a portion of the circumference of the power source.

24. The subsystem of claim 20, comprising the reservoir, the cartridge, or the atomizer, the reservoir, the cartridge, or the atomizer comprising a liquid freely stored therein.

25. A set of instructions for a 3D printer configured for printing an aerosol delivery subsystem according to any of the preceding claims.

26. An aerosol delivery system comprising a subsystem according to any preceding claim.

27. The aerosol delivery system of claim 26, wherein the bracket provides an airflow path around the power source.