EP4623728A1

EP4623728A1 - Aerosol delivery system components, systems and methods

Info

Publication number: EP4623728A1
Application number: EP24168409.1A
Authority: EP
Inventors: Bingquan Li; Qixian CAO
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-29
Filing date: 2024-04-04
Publication date: 2025-10-01
Also published as: CN120713292A

Abstract

An aerosol delivery system comprising an aerosol generator (48) having an electrically conductive surface (49) for generating aerosol from aerosol-generating material by resistance heating in use, the system comprising an electrically conductive element 100 for connecting the conductive surface to a power supply, wherein the conductive element comprises a neck 115 and a head 112, the head for contacting the conductive surface of the aerosol generator.

Description

Field

This disclosure relates to aerosol delivery systems, which may include nicotine delivery systems, and components therefor.

Background

Aerosol delivery systems such as electronic cigarettes (e-cigarettes) generally contain an aerosol generating material, such as a chamber of a solid or liquid source, which may contain an active substance and / or a flavour, from which an aerosol or vapour is generated for inhalation by a user, e.g. through heat vaporisation. An aerosol delivery system typically comprises an aerosol generation area containing an aerosol generator, e.g. a heating element, arranged to vaporise or aerosolise a portion of precursor material to generate a vapour or aerosol in the aerosol generation area. As a user inhales on the system and electrical power is supplied to the vaporiser, air is drawn into the system through an inlet hole and along an inlet air channel connecting to the aerosol generation area, where the air mixes with vaporised precursor material to form a condensation aerosol. There is an outlet channel connecting the aerosol generation area to an outlet in a mouthpiece and the air drawn into the aerosol generation area as a user inhales on the mouthpiece continues along the outlet flow path to the mouthpiece outlet, carrying the aerosol with it, for inhalation by the user.
Some electronic cigarettes may include a flavour element in the air flow path to impart additional flavours. Such systems may be referred to as hybrid devices, and the flavour element may, for example, include a portion of tobacco arranged in the air flow path between the aerosol generation area and the mouthpiece such that vapour / aerosol drawn through the device passes through the portion of tobacco before exiting the mouthpiece for user inhalation.
It is of interest to develop more reliable aerosol delivery systems that are more durable and have increased longevity.

Brief summary of the invention

A first aspect provides an aerosol delivery system comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the system comprising an electrically conductive element for connecting the conductive surface to a power supply, wherein the conductive element comprises a neck and a head, the head for contacting the conductive surface of the aerosol generator.
A second aspect provides a cartridge for an aerosol delivery system, the cartridge comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the cartridge comprising an electrically conductive element for connecting the conductive surface to a power supply, wherein the conductive element comprises a neck and a head, the head for contacting the conductive surface of the aerosol generator.
A third aspect provides a method for assembling an aerosol delivery system comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the method comprising:

providing an electrically conductive element which comprises a neck and a head, the head for contacting the conductive surface of the aerosol generator;
positioning the head in contact with the conductive surface of the aerosol generator; and
connecting the electrically conductive element to a power supply.

A fourth aspect provides an aerosol delivery system comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the system comprising an electrically conductive element for connecting the conductive surface to a power supply, wherein the conductive surface has a non-planar (e.g. variable thickness) surface profile and at least a portion of the conductive element is shaped to substantially complement at least a portion of the non-planar surface profile.
A fifth aspect provides a cartridge for an aerosol delivery system, the cartridge comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the cartridge comprising an electrically conductive element for connecting the conductive surface to a power supply, wherein the conductive surface has a non-planar (e.g. variable thickness) surface profile and at least a portion of the conductive element is shaped to substantially complement at least a portion of the non-planar surface profile.
A sixth aspect provides a method for assembling an aerosol delivery system comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, wherein the conductive surface has a non-planar (e.g. variable thickness) surface profile, the method comprising:

providing an electrically conductive element, wherein at least a portion of the conductive element is shaped to substantially complement at least a portion of the non-planar surface profile;
positioning the electrically conductive element in contact with the conductive surface of the aerosol generator; and
connecting the electrically conductive element to a power supply.

The disclosure further provides functional means corresponding to the above aspects.
In some examples, the neck of the conductive element has a narrower width and/or shallower depth than the head of the conductive element.
Generally speaking, the head is at an axial end of the conductive element, akin to the anatomy of a human body. Furthermore, in some examples, the neck is narrower than the head around a full perimeter of the head (or neck). In some examples, the neck is narrower than the head around the full perimeter of the head (or neck) by a constant amount.
In some examples, the head is shaped to contact the conductive surface of the aerosol generator at least at a central portion of the head.
In some examples, the head comprises a face for contacting the conductive surface, wherein the face is shaped to contact the conductive surface of the aerosol generator at least at a central portion of the face.
In some examples, the head is at least partially curved for contacting the conductive surface.
In some examples, the head comprises a face for contacting the conductive surface, wherein the face is substantially concave or convex.
In some examples, the head and/or the neck has a substantially cylindrical shape.
In some examples, the face is substantially concave or convex in multiple perpendicular axes.
In some examples, the head is domed or substantially spherical (which may equate to being substantially concave or convex in multiple perpendicular axes).
In some examples, the neck of the conductive element is shaped to be spaced from the aerosol generator. In some examples, the neck of the conductive element is shaped to provide a gap between the conductive element and the conductive surface of the aerosol generator. In other words, the neck of the conductive element may be configured to be spaced from the conductive surface of the aerosol generator.
In some examples, the conductive element comprises a chamfered edge at an axial end of the head that is adjacent to the neck. In some examples, the conductive element comprises a chamfered edge at an axial end of the head that is distal from the neck.
Generally speaking, the conductive element has a length along a longitudinal axis of the neck and the head. In some examples, the longitudinal axis is:

substantially perpendicular to a thickness axis of the conductive surface; and/or
substantially parallel to a direction of airflow past the conductive surface in use.

In some examples, the head extends towards the conductive surface substantially parallel to the thickness axis of the conductive surface. In some examples, the head extends towards the conductive surface substantially perpendicular to a direction of airflow past the conductive surface in use.
In some examples, the head comprises a face for contacting the conductive surface of the aerosol generator, the face having a curvature about the longitudinal axis of the conductive element.
In some examples, the conductive surface has a non-planar surface profile and at least a portion of the head is shaped to substantially complement at least a portion of the surface profile.
In some examples, the conductive surface has a variable thickness surface profile and at least a portion of the head is shaped to substantially complement at least a portion of the surface profile.
In some examples, the head comprises a face for contacting the conductive surface and the face is shaped to substantially complement the non-planar or variable thickness surface profile, optionally at least at a central portion of the face.
In some examples, the face is shaped to substantially complement the non-planar or variable thickness surface profile substantially along at least one axis, optionally substantially along multiple perpendicular axes.
In some examples, the conductive surface is thicker in an outer portion relative to an inner or central portion.
In some examples, the conductive surface comprises a substantially concave or convex surface profile. In some examples, the conductive surface comprises both a substantially concave profile and a substantially convex profile. In some examples, the conductive surface profile varies along both a first axis and a second, perpendicular axis.
In some examples, the conductive element comprises a body extending axially away from the neck. The conductive element may comprise in sequence along its length: a body, the neck, the head. In some examples, the body is wider than the neck, optionally the body is wider than the neck around a full perimeter of the neck (or body). In some examples, the body is wider than the head, optionally the body is wider than the head around a full perimeter of the head (or body).
In some examples:

a) a portion of the conductive element for contacting the conductive surface of the aerosol generator is substantially P- or T-shaped; and/or
b) the conductive element is substantially I-shaped or substantially dumbbell-shaped.

In some examples, the conductive element comprises a protrusion or recess for engaging a complementary recess or protrusion in the aerosol delivery system. In some examples, the conductive element comprises a foot for engaging a complementary recess in the aerosol delivery system. In some examples, the aerosol delivery system comprises a conductive element support having a complementary recess or protrusion configured to engage the protrusion or recess of the conductive element.
In some examples, the aerosol delivery system comprises a conductive element support configured to support at least the head of the conductive element. In some examples, the conductive element support comprises a buttress. In some examples, the support extends between the protrusion or recess on the conductive element and the head of the conductive element.
In some examples, the aerosol delivery system comprises an aerosol generator support having a recess receiving the aerosol generator. In some examples, at least a part of the aerosol generator support extends towards the neck.
In some examples, the aerosol generator support comprises a collar extending between a pair of conductive elements. In some examples, the collar surrounds an air flow path between the pair of conductive elements.
In some examples, the aerosol delivery system provides an interference fit for the conductive element between the conductive element support and the conductive surface of the aerosol generator.
In some examples, the conductive element is a unitary conductive element. In some examples, the conductive element comprises brass, optionally comprising nickel, silver and/or gold plating.
In some examples, the aerosol generator comprises a ceramic body.
In some examples, the conductive surface comprises a trace, thin-film or etched conductive surface.
In some examples, the aerosol generator comprises a wicking element and an external surface of the wicking element comprises the conductive surface. In some examples, the wicking element comprises a ceramic material.
In some examples, the conductive surface is at least partially embedded in or fused in the external surface. In some examples, the conductive surface has a maximum thickness of ≤ 0.5 mm, ≤ 0.25 mm, ≤ 0.1 mm or ≤ 0.05 mm.
In some examples, the aerosol delivery system comprises a pair of conductive elements spaced either side of an air inlet or airflow pathway to the aerosol generator. In some examples, the aerosol delivery system comprises a pair of the conductive elements configured to connect terminals on opposing sides or outer portions of the conductive surface to respective positive and negative terminals of a power supply.
In some examples the conductive surface is configured to provide a heating zone between the positive and negative terminals in use.
In some examples, the conductive surface is adjacent to an airflow path from an air inlet to an aerosol outlet. In some examples, the conductive surface is directly exposed to airflow in the airflow pathway. In some examples, the conductive surface extends into the airflow pathway. In some examples, the conductive surface is downstream of the air inlet.
In some examples, an aerosol outlet of the aerosol delivery system is at least partially axially aligned with an air inlet of the aerosol delivery system, to provide a substantially straight flow path from the inlet to the outlet.
In some examples, the aerosol delivery system is or comprises a cartridge for aerosol-generating material.
In some examples, the aerosol delivery system further comprises:

a mouthpiece; and/or
a controller for controlling supply of power to the aerosol generator; and/or
a power supply.

Brief description of the figures

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

Figure 1 is a schematic cross-section view of an aerosol delivery system;
Figures 2-4 are schematic, side cross-section views of various electrically conductive elements for connecting an electrically conductive surface of an aerosol generator to a power supply;
Figures 5-6 are a schematic perspective and side views respectively of a first electrically conductive element for connecting an electrically conductive surface of an aerosol generator to a power supply;
Figures 7-8 are a schematic perspective and side views respectively of a second electrically conductive element for connecting an electrically conductive surface of an aerosol generator to a power supply;
Figure 9 is a schematic view of an aerosol generator comprising an electrically conductive surface;
Figure 10 is a schematic perspective view of an aerosol delivery system comprising an aerosol generator having an electrically conductive surface and the first electrically conductive element for connecting the conductive surface of the aerosol generator to a power supply;
Figures 11-12 are schematic side and top (plan) views, respectively, of the system of figure 10;
Figure 13 is a schematic perspective view of an aerosol delivery system comprising an aerosol generator having an electrically conductive surface and the second electrically conductive element for connecting the conductive surface of the aerosol generator to a power supply;
Figures 14, 15a and 15b are schematic side and two top (plan) views, respectively, of the system of figure 13;
Figure 16 is a schematic, cross-section view through the aerosol delivery system of figure 13; and
Figure 17 is a schematic, perspective view of some components within the aerosol delivery system of figures 13 and 16.

Detailed description of the disclosure

Aspects and features of certain examples and embodiments are described herein. Some aspects and features may be implemented conventionally and these are not described in detail, for brevity.
The claimed invention may generally provide a sub-assembly or sub-system suitable for use in an aerosol delivery system, or configured for use in an aerosol delivery system. The sub-system may generally form part of an aerosol delivery system and in particular may form part of the reusable device and/or the consumable cartridge of a two-part system.

Introduction

Figure 1 is a cross-sectional view through an example aerosol delivery system 1 in accordance with certain embodiments of the disclosure, providing an introduction to two-part aerosol delivery systems, the components therein and their functionality.
The aerosol delivery system 1 comprises two main parts, a reusable part 2 and a replaceable / disposable consumable cartridge part 4. In normal use, the reusable part 2 and the cartridge part 4 are releasably coupled together at an interface 6. When the cartridge part 4 is exhausted or the user wishes to switch to a different cartridge part 4, the cartridge part 4 may be removed from the reusable part 2 and a replacement cartridge part 4 attached to the reusable part 2 in its place. The interface 6 may provide a structural, electrical and airflow path connection between the two parts 2, 4 and may be established in accordance with conventional techniques, e.g. based around a screw thread, magnetic or bayonet fixing with electrical contacts and openings for the electrical connection and airflow path between the two parts 2, 4 as appropriate. The specific manner by which the cartridge part 4 mounts to the reusable part 2 is not significant to the principles described herein, but for the sake of a concrete example is assumed here to comprise a magnetic coupling (not represented in figure 1). It will also be appreciated the interface 6 in some implementations may not support an electrical and / or airflow path connection between the respective parts 2, 4. For example, in some implementations an aerosol generator may be provided in the reusable part 2 rather than in the cartridge part 4, or the transfer of electrical power from the reusable part 2 to the cartridge part 4 may be wireless (e.g. based on electromagnetic induction), so that an electrical connection between the reusable part 2 and the cartridge part 4 is not needed. Furthermore, in some implementations the airflow through the electronic cigarette might not go through the reusable part 2, so that an airflow path connection between the reusable part 2 and the cartridge part 4 is not needed. In some instances, a portion of the airflow path may be defined at the interface between portions of the reusable part 2 and cartridge part 4 when these are coupled together for use.
The cartridge / consumable part 4 may, in certain embodiments, be broadly conventional. In figure 1, the cartridge part 4 comprises a cartridge housing 42 formed of a plastics material. The cartridge housing 42 supports other components of the cartridge part 4 and provides the mechanical interface 6 with the reusable part 2. The cartridge housing 42 is generally circularly symmetrical about a longitudinal axis along which the cartridge part 4 couples to the reusable part 2. In this example, the cartridge part 4 has a length of around 4 cm and a diameter of around 1.5 cm. However, the specific dimensions, geometry, overall shapes and materials used may vary.
Within the cartridge housing 42 is a chamber or reservoir 44 that contains aerosol-generating material. In the example of figure 1, the reservoir 44 stores a supply of liquid aerosol generating material and the liquid reservoir 44 has an annular shape with an outer wall defined by the cartridge housing 42 and an inner wall that defines an airflow path 52 through the cartridge part 4. The reservoir 44 is closed at each end with end walls to contain the aerosol generating material. The reservoir 44 may be formed conventionally, e.g. comprising a plastics material and/or integrally moulded with the cartridge housing 42.
The cartridge / consumable part 4 further comprises an aerosol generator 48 located towards an end of the reservoir 44, opposite to a mouthpiece outlet 50. In a two-part system such as in figure 1, the aerosol generator 48 may be in either of the reusable part 2 or the cartridge part 4. For example, in some embodiments, the aerosol generator 48 (e.g. a heater, which may be in the form of a wick and coil arrangement as shown, a distiller, which may be formed from a sintered metal fibre material or other porous conducting material, or any suitable alternative aerosol generator) may be comprised in the reusable part 2, and is brought into proximity with a portion of aerosol generating material in the cartridge part 4 when the cartridge part 4 is engaged with the reusable part 2. In such embodiments, the cartridge part 4 may comprise a portion of aerosol generating material, and an aerosol generator 48 is at least partially inserted into or at least partially surrounds the portion of aerosol generating material as the cartridge part 4 is engaged with the reusable part 2.
In the example of figure 1, a wick 46 in contact with the aerosol generator 48 extends transversely across the cartridge airflow path 52 with its ends extending into the reservoir 44 of the liquid aerosol generating material through openings in the inner wall. The openings in the inner wall of the reservoir 44 are sized to broadly match the dimensions of the wick 46 to provide a reasonable seal against leakage from the reservoir 44 into the cartridge airflow path, without unduly compressing the wick 46, which may be detrimental to its fluid transfer performance.
The wick 46 and aerosol generator 48 are arranged in the cartridge airflow path 52 such that a region of the cartridge airflow path 52 around the wick 46 and heater 48 in effect defines a vaporisation region for the cartridge part 4. Aerosol generating material in the reservoir 44 infiltrates the wick 46 through the ends of the wick extending into the reservoir 44 and is drawn along the wick by surface tension / capillary action (i.e. wicking). The aerosol generator 48 in this example comprises an electrically resistive wire coiled around the wick 46. In figure 1, the aerosol generator 48 comprises a nickel chrome alloy (Cr20Ni80) wire and the wick 46 comprises a glass fibre bundle, but the specific aerosol generator configuration is not significant to the principles described. In use, electrical power may be supplied to the aerosol generator 48 using one or more conductive elements 100 (shown but not detailed in figure 1), to vaporise an amount of aerosol generating material drawn to the vicinity of the aerosol generator 48 by the wick 46. Vaporised aerosol generating material may then become entrained in air drawn along the cartridge airflow path from the vaporisation region towards the mouthpiece outlet 50 for user inhalation.
Further details of the conductive element(s) 100 are outlined below, with reference to the subsequent figures.
As noted above, the rate at which aerosol generating material is vaporised by the aerosol generator 48 will depend on the amount (level) of power supplied to the aerosol generator 48. Thus, electrical power can be applied to the aerosol generator 48 to selectively generate aerosol from the aerosol generating material in the cartridge part 4, and furthermore, the rate of aerosol generation can be changed by changing the amount of power supplied to the aerosol generator 48, for example through pulse width and/or frequency modulation techniques.
The reusable part 2 comprises an outer housing 12 having with an opening that defines an air inlet 28 for the e-cigarette, a power source 26 (e.g. a battery) for providing operating power for the electronic cigarette, control circuitry / 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 outer housing 12 may be formed, e.g. from a plastics or metallic material and in this example has a circular cross section generally conforming to the shape and size of the cartridge part 4, to provide a smooth transition between the two parts 2, 4 at the interface 6. In this example, the reusable part 2 has a length of around 8 cm so the overall length of the e-cigarette when the cartridge part 4 and the reusable part 2 are coupled together is around 12 cm.
The air inlet 28 connects to an airflow path 51 through the reusable part 2. The reusable part airflow path 51 in turn connects to the cartridge airflow path 52 across the interface 6 when the reusable part 2 and cartridge part 4 are connected together. Thus, when a user inhales on the mouthpiece opening 50, air is drawn in through the air inlet 28, along the reusable part airflow path 51, across the interface 6, through the aerosol generation area in the vicinity of the aerosol generator 48 (where vaporised aerosol generating material becomes entrained in the air flow), along the cartridge airflow path 52, and out through the mouthpiece opening 50 for user inhalation.
The power source 26 in this example is rechargeable and may be a conventional type, e.g. of the kind normally used in electronic cigarettes and other applications requiring provision of relatively high currents over relatively short periods. The power source 26 may be recharged through a charging connector in the reusable part housing 12, for example a USB connector.
Optionally, first and/or second user input buttons 14, 16 may be provided, which in this example are conventional mechanical buttons, e.g. comprising a spring mounted component which may be pressed by a user to establish an electrical contact. The input buttons may be input devices for detecting user input and the manner in which the buttons are implemented is not significant. The buttons may be assigned functions such as switching the system 1 on and off, and/or adjusting user settings such as a power to be supplied from the power source 26 to the aerosol generator 48.
A display 24 may be provided to give a user a visual indication of various characteristics associated with the aerosol delivery system, e.g. current power setting information, remaining power source power, etc. The display may be implemented in various ways. In this example, the display 24 comprises a conventional pixilated LCD screen. In other implementations, the display may comprise one or more discrete indicators, e.g. LEDs, arranged to display information, e.g. through particular colours and/or flash sequences. More generally, the manner in which the display 24 is provided and information is displayed is not significant to the principles described herein - other embodiments may not include a visual display and/or may include other means for providing a user with information relating to operating characteristics of the system 1, e.g. using audio signalling.
A controller 22 is suitably configured / programmed to control the aerosol delivery system 1 to provide functionality as described herein, as well as for providing conventional operating functions of the system 1. The controller (processor circuitry) 22 may be considered to logically comprise various subunits / circuitry elements associated with different aspects of the operation of the system 1. In this example, the controller 22 comprises power supply 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, as well as other functional units / circuitry associated functionality in accordance with the principles described herein and conventional operating aspects, such as display driving circuitry and user input detection circuitry. The functionality of the controller 22 can be provided in various different ways, e.g. using one or more programmed programmable computer(s) and / or one or more suitably configured application-specific integrated circuit(s) / circuitry / chip(s) / chipset(s). The controller 22 may comprise an application specific integrated circuit (ASIC), CPU, microprocessor or microcontroller. The operations of a controller and other electronic components are generally controlled by software/instructions running on the controller, which may be stored in non-volatile memory, (e.g. ROM), which may be integrated into the controller, or provided separately. The controller 22 may access the ROM to load and execute individual software as and when required.
The reusable part 2 comprises an airflow sensor 30, which is electrically connected to the controller 22. In most embodiments, the airflow sensor 30 comprises a so-called "puff sensor", in that the airflow sensor 30 is used to detect when a user is puffing on the device. In some embodiments, the airflow sensor 30 comprises a switch in an electrical path providing electrical power from the power source 26 to the aerosol generator 48. In such embodiments, the airflow sensor 30 generally comprises a pressure sensor configured to close the switch when subjected to a particular range of pressures, enabling current to flow from the power source 26 to the aerosol generator 48 once the pressure in the vicinity of the airflow sensor 30 drops below a threshold value. The threshold value can be set to a value determined by experimentation to correspond to a characteristic value associated with the initiation of a user puff. In other embodiments, the airflow sensor 30 is connected to the controller 22, and the controller 22 distributes electrical power from the power source 26 to the aerosol generator 48 in dependence of a signal received from the airflow sensor 30 by the controller 22. The specific manner in which the signal output from the airflow sensor 30 (which may comprise a measure of capacitance, resistance or other characteristic of the airflow sensor, made 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 can be carried out in accordance with any approach known to the skilled person.
In the example shown in figure 1, the airflow sensor 30 is mounted to an optional printed circuit board (PCB) 31. The airflow sensor 30 may comprise any sensor configured to determine a characteristic of airflow in an airflow path 51 disposed between air inlet 28 and mouthpiece opening 50, e.g. a pressure sensor or transducer (such as a membrane or solid-state pressure sensor), a combined temperature and pressure sensor, or a microphone (e.g. an electret-type microphone), which is sensitive to changes in air pressure, including acoustical signals. The airflow sensor 30 is situated within a sensor cavity or chamber 32, which comprises the interior space defined by one or more chamber walls 34. The sensor cavity 32 comprises a region internal to one or more chamber walls 34 in which an airflow sensor 30 can be fully or partially situated. In some embodiments, the PCB 31 comprises one of the chamber walls of a sensor housing comprising the sensor chamber / cavity 32.
A deformable membrane may be disposed across an opening communicating between the sensor cavity 32 containing the sensor 30, and a portion of the airflow path disposed between air inlet 28 and mouthpiece opening 50. The deformable membrane covers the opening, and is attached to one or more of the chamber walls according to approaches described further herein.
The aerosol delivery system 1 may comprise communication circuitry configured to connect to one or more further electronic devices (e.g., a storage / charging case, or a refill / charging dock) to enable data transfer between the system 1 and further electronic device(s). The communication circuitry may be integrated into the controller 22, or implemented separately. The communication circuitry may be configured to support wired or wireless communications between the aerosol delivery system 1 and other electronic devices such as a case, a dock, a computing device such as a smartphone or PC, a base station supporting cellular communications, a relay node providing an onward connection to a base station, a wearable device, or any other portable or fixed device. The controller 22, other components within the system 1 and other devices/systems may comprise one or more processors and data processing may be performed on any of these processors or on a remote processor, the data communicated by wire or wirelessly.
Wireless communications between the aerosol delivery system 1 and a further electronic device may be configured according to data transfer protocols such as Bluetooths, ZigBee, WiFi^®, Wifi Direct, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or generally any other wireless, and/or wired, network protocol or interface. The communication circuitry may comprise any suitable interface for wired data connection, such as USB-C, micro-USB or Thunderbolt interfaces, and may comprise pin or contact pad arrangements configured to engage cooperating pins or contact pads on a dock, case, cable, or other external device which can be connected to the aerosol delivery system 1.

Electrically conductive element

As outlined above, embodiments of the claimed invention are directed to an electrically conductive element 100 for connecting an electrically conductive surface 49 of an aerosol generator 48 to a power supply 26.
Figures 2-4 are schematic, side cross-section views of various electrically conductive elements 90, 100 for connecting an electrically conductive surface 49 of an aerosol generator 48 to a power supply 26 (not shown). Generally, the conductive element 90, 100 itself may be a unitary conductive element 90, 100 (i.e. single piece construction). In some examples, the conductive element 90, 100 comprises brass, optionally comprising nickel, silver and/or gold plating. The electrically conductive element 90, 100 may be known as a thimble.
Figure 2 illustrates a first, substantially uniform electrically conductive element 90, which can be considered to have two portions:

i. a first portion 90a for contacting the conductive surface 49 of the aerosol generator 48; and
ii. a second portion 90b for connection to the power supply 26.

In figure 2, the first portion 90a comprises an axial end of the conductive element 90 for contacting the conductive surface 49 and the first portion 90a is substantially uniform, i.e. of a constant cross section - here substantially 'I'-shaped, e.g. with no distinct top/head or tail/foot. The second portion 90b in figure 2 provides an opposing axial end for contacting the power supply 26 (not shown) - here the second portion 90b is substantially an inverted T-shape, comprising a protrusion in the form of a foot (specifically, a pair of feet) 125, for engaging a complementary recess(es) 136 in the aerosol delivery system, e.g. as part of a conductive element support 130, for retaining the conductive element 90, 100 therein. Naturally, the protrusion/recess arrangement may be provided in the reverse configuration to that depicted here, i.e. the conductive element 90, 100 may comprise a recess and the aerosol delivery system 1 may comprise a complementary protrusion.
Figure 3 illustrates a second, improved electrically conductive element 100. In figure 3, the conductive element 100 comprises a first portion 110 for contacting the conductive surface 49 of the aerosol generator 48; and a second portion 120 for connection to the power supply 26 (not shown), which may be broadly similar to the second portion 90b shown in figure 2. In some examples, the portions 110, 120 may be end portions, whilst in other examples they are not end portions. The conductive element 100 of figure 3 comprises a neck 115 adjoining or connected to a head 112, the head 112 being at an axial end of the conductive element 100, the head 112 for contacting the conductive surface 49 of the aerosol generator 48. The conductive element 100 has a length along a longitudinal axis of the neck 115 and the head 112. The neck 115 has a narrower width and/or shallower depth, which is perpendicular to the width, than the head 112. In other words, the neck 115 may be narrower in one or two axes perpendicular to the axial extent (length) of the neck-head arrangement. The head 112 thus extends beyond the neck 115 for making contact with the conductive surface 49. In some examples, the neck 115 is narrower than the head 112 around a full perimeter of the head 112. In some examples, the neck 115 is narrower than the head 112 around the full perimeter of the head 112 by a constant amount. This may be achieved by manufacturing, for example, using a lathe process, the head 112 and the neck 115 having the same cross-sectional profile, such as square, circle, triangle or squircle etc., and be concentric.
As shown in figures 3 and 4, the conductive element 100 may also comprise a second portion having a body 120 extending axially away from the neck 115 for securing the conductive element 100 in the conductive element support 130, thus comprise in sequence along its length: a body 120, the neck 115, the head 112. In some examples, the body 120 is wider than the neck 115 and/or the head 112, optionally wider than the neck 115 and/or head 112 around a full perimeter of the neck 115 and/or head 112 respectively. As noted above, in some examples, the second portion comprising body 120 may be akin to the second portion 90b shown in figure 2.
Figure 4 illustrates another example of the conductive element 100 of figure 3, with a differently-shaped head 112. The cross-sectional view of the first portion of the conductive element 100 may be substantially P-shaped as shown in figure 3 or T-shaped as shown in figure 4. Furthermore, the conductive element 100 as a whole may be substantially 'I'-shaped, comprising both a top/head and a tail/foot (in contrast to the uniform, constant cross-section 'I'-shape of figure 2, not having a top/head or a tail/foot). In other examples, the conductive element 100 as a whole may be substantially dumbbell-shaped, where a dumbbell-shape has a taller top/head or a tail/foot compared to an I'-shaped section, such as that shown for the conductive surface 49 in figure 9. The dumbbell-shape may optionally comprise a tapering top/head and/or tail/foot. The dumbbell-shape may be symmetrical or non-symmetrical.
The head 112 may comprise a face 113, best shown in figure 7, for contacting the conductive surface 49, optionally wherein the face 113 is shaped to contact the conductive surface 49 of the aerosol generator 48 at least at a central portion of the face 113.
Figures 5 and 6 are a schematic perspective and side views respectively of a first electrically conductive element 90 for connecting an electrically conductive surface 49 of an aerosol generator 48 to a power supply 26, illustrating the features of figure 2 in more detail. In particular, the overall cross-sectional shape of both portions 90a, 90b is a rounded rectangle or square, also known as a squircle, best shown in figure 5, where the second portion 90b comprises the protrusion 125 also having a squircle cross-section. In use, the first portion 90a of the conductive element 90 extends into an aerosol generation area and thus is exposed to aerosol generation. Depending on the materials used, the conductive element may therefore release particulates during aerosol generation which could impact purity and hence taste. If the conducive element touches the body of the aerosol generator 48, then this may increase emissions, which is undesirable.
Figures 7 and 8 are a schematic perspective and side views respectively of a second electrically conductive element 100 for connecting an electrically conductive surface 49 of an aerosol generator 48 to a power supply 26. These figures illustrate the features of figure 4 in more detail. The examples of figures 3, 4, 7 and 8 provide numerous improvements over the arrangement of figures 2, 5 and 6. As outlined above, in figures 3-4 and 7-8, the conductive element 100 comprises a neck 115 and a head 112, the head 112 for contacting the conductive surface 49 of the aerosol generator 48.
In figures 7 and 8, the head 112, neck 115 and body 120 are all cylindrical, thus the cross-sectional shape of the head 112, neck 115 and body 120 is a circle and the neck 115 has a narrower width w_neck (in the x-axis) and shallower depth d_neck (in the y-axis) than both the head 112 (w_head , d_head) and the body 120 (w_body , d_body). In this example, the head 112 is curved for contacting the conductive surface 49, here by virtue of the circular cross-section, where the head 112 comprises a convex face 113 for contacting the conductive surface 49. More generally, the head 112 / face 113 may be substantially concave or convex, including substantially concave or convex in multiple perpendicular axes, including domed or substantially spherical (which may equate to being substantially concave or convex in multiple perpendicular axes) in concave or convex forms (such as ball and socket joints, having complementary convex and concave parts).
The illustrated arrangement of the conductive element 100 in figures 7 and 8 provides notable benefits over the conductive element 90 illustrated in figures 5 and 6, particularly because whilst the head 112 (or face 113) of the conductive element 100 contacts the conductive surface 49 of the aerosol generator 48 in use, the neck 115 of the conductive element 100 provides a gap or space between the (rest of the) conductive element 100 and the conductive surface 49 of the aerosol generator 48. In other words, the neck 115 of the conductive element 100 may be configured, such as shaped, to be spaced from the conductive surface 49 and/or the aerosol generator 48 in use. Accordingly, the head 112 / face 113 may be the only contact portion of the conductive element 100 for contacting the conductive surface 49 of the aerosol generator 48, i.e. the neck 115 may be stepped away from the conductive surface 49 to provide the gap. The conductive element 100 may comprise a chamfered edge at i) an axial end of the head 112 that is adjacent to the neck 115; and/or ii) an axial end of the head 112 that is distal from the neck 115, as shown. The conductive element 100 may also comprise a chamfered edge at an axial end of the body 120 adjacent to the neck 115, as shown. These features may reduce the risk of protruding edges, further complement the shape of the conductive surface 49 and/or aid assembly, particularly if the conductive element 100 is inserted into position axially. As is described further later, these features are particularly beneficial when the conductive surface 49 of the aerosol generator 48 is non-planar, to promote contact.
By comparison, the examples of figures 3-4 and 7-8 also provide a slightly reduced surface area extending into the aerosol generation area and thus exposed to aerosol generation. Accordingly, these examples are further beneficial over that of figures 2 and 5-6 by reducing the contact surface area for potentially releasing particulates during aerosol generation, which could impact purity and hence taste.
Figure 9 is a schematic view of an aerosol generator 48 comprising an electrically conductive surface 49, which will now be described in more detail. The electrically conductive surface 49 is configured to generate aerosol from aerosol-generating material by resistance heating in use. The aerosol generator 48 itself may comprise a body and the conductive surface 49. In some examples, the aerosol generator 48 comprises a ceramic body, which may be a porous body for retaining and transporting aerosol-generating material to the conductive surface 49, e.g. from a reservoir 44, for generating aerosol therefrom. Alternatively, the aerosol generator body itself may provide the reservoir 44. An aerosol generator seal 70 may be provided around the aerosol generator 48, e.g. to contain the aerosol-generating material. In other examples, the aerosol generator 48 comprises a wick or wicking element 46 and an external surface of the wicking element 46 comprises the conductive surface 49. In some examples, the wicking element 46 comprises a ceramic material. In some examples, the conductive surface 49 comprises a trace, thin-film or etched conductive surface 49. The conductive surface 49 may be at least partially embedded in or fused in the external surface.
The conductive surface 49 may have a maximum thickness of ≤ 0.5 mm, ≤ 0.25 mm, ≤ 0.1 mm or ≤ 0.05 mm.
As noted above, the conductive surface 49 may have any shape or profile. In some examples, it may be planar, i.e. substantially flat, having a substantially uniform thickness, whilst in other examples, it may be non-planar, e.g. curved with a constant thickness, and/or having a variable thickness providing a non-planar surface (thickness here being along the x-axis direction shown in figure 9). In particular, the conductive surface 49 may have a non-planar (e.g. curved) surface profile, optionally by having a variable thickness. The conductive surface 49 may have any shape or profile in the other axes, i.e. in the z-y plane shown in figure 9, where the surface 49 is depicted as having a general dumbbell-shape in the z-y plane. In other examples, such as in figure 17, the surface 49 comprises two substantially rectangular contact regions for contacting the conductive elements 100, interconnected by an S-shaped portion. Advantageously, at least a portion of the head 112 of the conductive element 100 may be shaped to substantially complement at least a portion of the surface profile of the surface 49. For example, the contacting face 113 of the head 112 may be shaped to substantially complement the non-planar surface profile, such as (at least) at a central portion of the face 113. In some examples, the face 113 is shaped to substantially complement the surface profile substantially along at least one axis, optionally substantially along multiple perpendicular axes.
Various implementations will now be described with reference to figures 10-12 and 13-15b. Figure 10 is a schematic perspective view of an aerosol delivery system comprising an aerosol generator 48 having an electrically conductive surface 49 and an electrically conductive element 90 for connecting the conductive surface 49 of the aerosol generator 48 to a power supply 26 (not shown). Figures 11 and 12 are schematic side (z-x axes) and top (plan, x-y axes) views, respectively, of the system of figure 10.
As shown in figures 11 and 12, the conductive surface 49 in this example is substantially concave, where the surface 49 is thicker in an outer portion relative to an inner or central portion. Here, the conductive surface 49 has a profile varying along multiple perpendicular axes (shown as concave here in both the side and plan views, thus having a profile varying along both the z- and y-axes respectively). More generally, the conductive surface 49 may have any shape, including a substantially concave and/or convex surface profile, including both a substantially concave profile and a substantially convex profile. In some examples, the conductive surface 49 profile varies along both a first axis and a second, perpendicular axis.
The conductive element 90 as shown in figure 11 and 12 does not have a head 112 and neck 115 arrangement and is therefore prone to make unreliable / unstable contact with the typically thin and/or non-planar conductive surface 49. This unreliable/unstable contact may mean that the conductive element 90 contacts the body of the aerosol generator 48 instead of the surface 49, which increases power consumption and generates undesirable emissions.
As shown in figures 10 and 12 and also in figures 13, 15a-b, aerosol delivery systems disclosed herein may generally comprise a pair of conductive elements 90, 100 spaced either side of an air inlet or airflow pathway to the aerosol generator 48. In some implementations, the pair of conductive elements 90, 100 are connected to terminals on opposing sides or (outer) portions of the conductive surface 49 and to positive and negative terminals of a power supply 26 such that currents are conducted from the conductive elements 90, 100 to the conductive surface 49. The conductive surface 49 may thus provide a heating zone between the positive and negative terminals in use. Again, as shown in figure 12, 15a and 15b, each contact face 113 of the pair of conductive elements 90, 100 may contact the conductive surface 49 at respective outer portions thereof.
Figure 13 is another schematic perspective view of an aerosol delivery system 1 comprising an aerosol generator 48 having an electrically conductive surface 49 and an electrically conductive element 100 for connecting the conductive surface 49 of the aerosol generator 48 to a power supply 26, where the conductive element 100 comprises a neck 115 and a head 112, the head 112 for contacting the conductive surface 49 of the aerosol generator 48. Generally speaking, the aerosol delivery system 1 may be, or comprise, a consumable cartridge 4 having aerosol-generating material. The cartridge 4 may be replaceable, e.g. for use in a two-part aerosol delivery system 1 having a separate reusable control part 2 and/or power supply 26, or the inverse: the aerosol delivery system 1 may comprise the reusable control part 2 and/or power supply 26 and be designed for use with or comprise a replaceable cartridge part 4 having aerosol-generating material.
Figures 14, 15a and 15b are schematic side and two top (plan) views, respectively, of the system 1 of figure 13. By comparison to the example of figures 11 and 12, the head 112 and neck 115 configuration of the conductive element 100 in figures 14-15b provides an improved, more stable and reliable contact between the conductive element 100 and the conductive surface 49. Again, as shown in figures 3-4 and 8 in particular, the conductive element 100 has a length along a longitudinal axis of the neck 115 and the head 112. In figures 13 and14, it can be seen that the longitudinal axis (z-axis) may be substantially perpendicular to a thickness axis (x-axis) of the conductive surface 49. Figure 14 also illustrates how the head 112 may extend towards the conductive surface 49 substantially parallel to the thickness axis (x-axis) of the conductive surface 49. In this example, the head 112 also projects / extends towards the conductive surface 49 substantially perpendicular to a direction of airflow past the conductive surface 49 in use, as is discussed later with respect to figures 16 and 17.
These features promote stable electrical contact between the head 112 of the conductive element 100 and the conductive surface 49, helping to reduce the risk of the conductive element 100 making contact with the body of the aerosol generator 48 rather than the conductive surface 49, which may be very thin. More stable electrical contact beneficially provides a more reliable and consistent experience for a user of the system 1. Furthermore, this arrangement provides more tolerance for the assembly process, not requiring the conductive element to be installed perfectly vertically to make reliable contact with the conductive surface 49.
Figures 15a and 15b show plan views of two variants of the system 1 of figures 13 and 14, with different non-planar surface profiles for the conductive surface 49. In figure 15a, the surface profile is concave, whilst in figure 15b, the surface profile comprises both concave and convex portions. Advantageously, in both figures 15a and 15b, at least a portion of the conductive element 100 is shaped to substantially complement at least a portion of the conductive surface 49, which here has a non-planar profile having a variable thickness. In figure 15a the conductive surface 49 is thickest in the outer portions, whilst in figure 15b the trace is thickest in an inner, central portion.
Figures 15a and 15b also show a pair of conductive elements 100 spaced either side of an air inlet or airflow pathway to the aerosol generator 48. By contrast to figure 12, here at least a portion of the conductive elements 100 is shaped to substantially complement at least a portion of the surface profile. For example, a central or other portion of the contact face 113 may be shaped to contact the conductive surface 49 of the aerosol generator 48. In figures 15a and 15b, the head 112 of the conductive element 100 has a circular cross section and the face 113 for contacting the conductive surface 49 is curved, having a curvature about/around the longitudinal axis of the conductive element 100. This curvature substantially complements the outer portions of the surface profile of the conductive surface 49, thus providing more stable and reliable contact between the conductive element 100 and the conductive surface 49.
It should be appreciated that the neck-head and complementary-shape features outlined above and shown in figures 14 and 15a-15b respectively may be implemented independently or in combination.
Figure 16 is a schematic, cross-section view through the aerosol delivery system 1 of figure 13, and it more clearly illustrates how the neck 115 of the conductive element 100 may be configured to provide a gap, spacing the non-head portion of the conductive element 100 from the conductive surface 49. Put another way, only the head 112 of the conductive element contacts the conductive surface 49 of the aerosol generator 48, where the neck 115 steps inwards, away from the surface 49 and spaces the body 120 of the conductive element from the surface 49. This may prevent any surface profile variations particularly at the lower part of the conductive surface 49 or any protruding parts of the aerosol generator body from displacing the contact portion head 112 / face 113 of the conductive element 100. Figure 16 and figure 17 also more clearly illustrate the air/aerosol flow path through the system 1, where in this example the conductive elements 100 extend longitudinally (along the z-axis), both i), substantially parallel to the air/aerosol flow path (indicated by arrows in figure 16), which includes airflow past the conductive surface 49 in use; and ii) substantially perpendicular to a thickness axis of the conductive surface 49.
Figure 16 also illustrates various other possible features of the aerosol delivery system 1. In this example, the aerosol delivery system 1 comprises a conductive element support 130, here comprising a buttress 134 as shown in figure 13, which may generally be configured to support at least the head 112 of the conductive element 100, the support 130 here having a recess 136 configured to receive the protruding feet 125 of the conductive element 100. Here, the support 130 extends from the axial bottom end of the protruding feet 125 on the conductive element 100 to the top axial end of the head 112 of the conductive element 100. The aerosol delivery system 1 may provide an interference fit for the conductive element 100 between the conductive element support 130 and the conductive surface 49 of the aerosol generator 48.
As also shown in figure 16, the system 1 may further comprise an aerosol generator sealing element 70 around at least part of the aerosol generator 48, (here behind the aerosol generator 48) e.g. to contain the aerosol-generating material proximal to the conductive surface 49 or minimise wicking away therefrom; and/or an aerosol generator support 72 having a recess receiving the aerosol generator 48. In some examples, at least a part of the aerosol generator support 72 extends towards the neck 115. The conductive element 100 may be configured to avoid contact between the aerosol generator support 72 and the conductive element 100, e.g. the neck 115 of the conductive element 100 may be shaped to be spaced from and thereby provide a gap between the neck 115 and the conductive surface 49 of the aerosol generator 48. An aerosol generator support sealing element 78 may be provided around the aerosol generator support 72 to substantially contain air/aerosol flow along a flow path and/or to contain flow of aerosol-generating material from a reservoir to the aerosol generator 48.
Figure 17 is a schematic, perspective view of some components within the aerosol delivery system 1 of figures 13 and 16. The conductive surface 49 is downstream of an air inlet of/to the aerosol delivery system 1 and the conductive elements 100 extend longitudinally, both i), substantially parallel to the air/aerosol flow path (indicated by arrows in figure 17) from the inlet 28 to an aerosol outlet 50 and ii) substantially perpendicular to a thickness axis of the conductive surface 49. An aerosol outlet from/of the aerosol delivery system 1 may be at least partially or fully axially aligned with the air inlet of/to the system 1, to provide a substantially straight flow path from the air inlet to the aerosol outlet. This may beneficially aid efficiency, reducing losses such as via condensation along the pathway.
Figure 17 additionally illustrates that the aerosol generator support 72 that has a recess receiving the aerosol generator 48 may comprise a collar 74 extending between a pair of conductive elements 100 spaced either side of an air inlet or airflow pathway to the aerosol generator 48. As shown, the collar 74 may surround an air flow path between the pair of conductive elements 100. Finally, figure 17 also more clearly shows how the conductive surface 49 is adjacent to the airflow path and may be directly exposed to airflow in the airflow pathway, or the pathway may be configured to draw generated vapour/aerosol into the airflow pathway. In some examples, the conductive surface 49 extends into the airflow pathway, i.e. constricts the pathway.
In some examples, the conductive elements 100 are received in the system 1 axially. Referring to figures 16-17, the conductive elements 100 may be inserted/installed substantially parallel to the airflow pathway, with the feet 125 abutting against the conductive element support recess 136 and providing an interference fit, and/or a retaining element (not shown) may be used to secure the conductive elements 100. A housing may be provided to enclose the conductive elements 100 in the system 1.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. Any functions of a processor (e.g. controller) may be shared between processors on the various devices/systems in the wider system and/or a remote server. It is to be understood that 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 utilised 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, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. Protection may also be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.

Terminology

Delivery System

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

combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material);
non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and
aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

Combustible Aerosol Provision System

According to the present disclosure, a "combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar. In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

Non-Combustible Aerosol Provision System

According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent. In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

Aerosol-Free Delivery System

In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.
In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

Active Substance

In some embodiments, the substance to be delivered comprises an active substance. The 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, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In one embodiment the active substance is a legally permissible recreational drug. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.
Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v.,Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v.,Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

Flavours

In some embodiments, the substance to be delivered comprises a flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

Aerosol-generating material

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants. 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 material.
The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free. The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The aerosol-generating material may comprise more than one film, and the thickness described herein may refer to the aggregate thickness of those films.
The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material. The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.
The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

Aerosol-former material

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

Functional material

The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

Substrate

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support 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

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

Susceptor

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

Aerosol-modifying agent

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent. The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

Aerosol generator

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as 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 an aerosol to be generated 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 vapour delivery systems) such as nebulisers or e-cigarettes. Throughout the following description the term "e-cigarette" or "electronic cigarette" may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol delivery system / device and electronic aerosol delivery system / device. Furthermore, and as is common in the technical field, the terms "aerosol" and "vapour", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably.
Aerosol delivery systems (e-cigarettes) often, though not always, comprise a modular assembly comprising a reusable device part and a replaceable (disposable/consumable) cartridge part. Often, the replaceable cartridge part will comprise the aerosol generating material and the vaporiser (which may collectively be called a 'cartomizer') and the reusable device part will comprise the power supply (e.g. rechargeable power source) and control circuitry. It will be appreciated these different parts may comprise further elements depending on functionality. For example, the reusable device part will often comprise a user interface for receiving user input and displaying operating status characteristics, and the replaceable cartridge device part in some cases comprises a temperature sensor for helping to control temperature. Cartridges are electrically and mechanically coupled to the control unit for use, for example using a screw thread, bayonet, or magnetic coupling with appropriately arranged electrical contacts. When the aerosol generating material in a cartridge is exhausted, or the user wishes to switch to a different cartridge having a different aerosol generating material, the cartridge may be removed from the reusable part and a replacement cartridge attached in its place. Systems and devices conforming to this type of two-part modular configuration may generally be referred to as two-part systems/devices.
It is common for electronic cigarettes to have a generally elongate shape. For the sake of providing a concrete example, certain embodiments of the disclosure will be taken to comprise this kind of generally elongate two-part system employing disposable cartridges. However, it will be appreciated that the underlying principles described herein may equally be adopted for different configurations, for example single-part systems or modular systems comprising more than two parts, refillable devices and single-use disposables, as well as other overall shapes, for example based on so-called box-mod high performance devices that typically have a boxier shape. More generally, it will be appreciated certain embodiments of the disclosure are based on aerosol delivery systems which are operationally configured to provide functionality in accordance with the principles described herein and the constructional aspects of systems configured to provide the functionality in accordance with certain embodiments of the disclosure is not of primary significance.
Throughout the disclosure, the terms 'substantially', 'approximately' and 'about' should be considered to mean within +/- 10% unless indicated otherwise.

Index to reference numerals

1: aerosol delivery system
2: reusable part
4: cartridge part
6: interface between reusable part and cartridge part
12: reusable part housing
14, 16: user input buttons
20: user programming circuitry
22: controller
24: display
26: power source
28: air inlet
30: airflow sensor
31: printed circuit board (PCB)
32: sensor cavity or chamber
34: chamber wall
42: cartridge housing
44: chamber or reservoir
46: wick
48: aerosol generator
49: aerosol generator conductive surface
50: mouthpiece outlet
51: airflow path through reusable part
52: airflow path through cartridge
70: aerosol generator sealing element
72: aerosol generator support
74: aerosol generator collar
78: aerosol generator support sealing element
90: uniform conductive element
100: conductive element
110: conductive element first portion (for aerosol generator)
112: conductive element head
113: conductive element contact face
115: conductive element neck
120: conductive element second portion or body (for power supply)
125: conductive element foot
130: conductive element support
134: conductive element support buttress
136: conductive element support recess

Claims

An aerosol delivery system comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the system comprising an electrically conductive element for connecting the conductive surface to a power supply, wherein the conductive element comprises a neck and a head, the head for contacting the conductive surface of the aerosol generator.
The aerosol delivery system of claim 1, wherein the neck of the conductive element has a narrower width and/or shallower depth than the head of the conductive element.
The aerosol delivery system of any preceding claim, wherein the head is at least partially curved for contacting the conductive surface.
The aerosol delivery system of any preceding claim, wherein the neck of the conductive element is shaped to be spaced from the aerosol generator.
The aerosol delivery system of any preceding claim, wherein the conductive element comprises a chamfered edge at an axial end of the head that is adjacent to the neck.
The aerosol delivery system of any preceding claim, wherein the head extends towards the conductive surface substantially perpendicular to a direction of airflow past the conductive surface in use.
The aerosol delivery system of any preceding claim, wherein the conductive surface has a variable thickness surface profile and at least a portion of the head is shaped to substantially complement at least a portion of the surface profile.
The aerosol delivery system of any preceding claim, wherein the conductive surface is thicker in an outer portion relative to an inner or central portion.
The aerosol delivery system of any preceding claim, wherein the conductive surface comprises a substantially concave or convex surface profile.
The aerosol delivery system of any preceding claim, wherein:
a. a portion of the conductive element for contacting the conductive surface of the aerosol generator is substantially P- or T-shaped; and/or

b. the conductive element is substantially I-shaped or substantially dumbbell-shaped.
The aerosol delivery system of any preceding claim, comprising a pair of conductive elements spaced either side of an air inlet or airflow pathway to the aerosol generator.
The aerosol delivery system of any preceding claim, wherein the conductive surface is adjacent to an airflow path from an air inlet to an aerosol outlet.
The aerosol delivery system of any preceding claim, wherein an aerosol outlet of the aerosol delivery system is at least partially axially aligned with an air inlet of the aerosol delivery system, to provide a substantially straight flow path from the inlet to the outlet.
A cartridge for an aerosol delivery system, the cartridge comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the cartridge comprising an electrically conductive element for connecting the conductive surface to a power supply, wherein the conductive element comprises a neck and a head, the head for contacting the conductive surface of the aerosol generator.
A method for assembling an aerosol delivery system comprising an aerosol generator having an electrically conductive surface for generating aerosol from aerosol-generating material by resistance heating in use, the method comprising:
providing an electrically conductive element which comprises a neck and a head, the head for contacting the conductive surface of the aerosol generator;

positioning the head in contact with the conductive surface of the aerosol generator; and

connecting the electrically conductive element to a power supply.