EP4684660A1

EP4684660A1 - Material delivery subsystems, systems and methods

Info

Publication number: EP4684660A1
Application number: EP24190049.7A
Authority: EP
Inventors: Dominic Conrad Woodcock; Theresa O'DONNELL; Thomas VICKERY; Ross Anthony CABOT; Andrew Allan Burton; Nicole EAST; Christopher Wright; Joanna SOFFE; Samuel ESSAM; Kelly O'ROURKE; Chloe WINNINGTON; Nadir HERMES; Sophie ICETON; Katiane ROCHA DE OLIVEIRA; David Bishop
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-07-22
Filing date: 2024-07-22
Publication date: 2026-01-28
Also published as: WO2026022465A1

Abstract

A material delivery system (1) comprising a reservoir (44, 144) for retaining aerosol-generating or sensory material; and first and second capillary materials (146a, 146b) configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path (52) for receipt by a user, wherein the second capillary material is exposed to the flow path and separates the first capillary material from the flow path; and the first capillary material has a lower average porosity than the second capillary material.

Description

Field

This disclosure relates to delivery systems, which may include aerosol delivery systems such as nicotine delivery systems.

Background

Aerosol delivery systems such as electronic cigarettes (e-cigarettes) generally contain an aerosol generating material, such as a chamber of a source solid or liquid, 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.
A potential drawback of existing delivery systems is of their relative inflexibility to control the aerosol which is delivered to the user during use. A further drawback is that certain sensory materials such as flavouring and/or additives which are configured to be delivered to a user may be more effectively delivered at different environmental/temperature conditions than others. Various approaches are described herein which seek to help address or mitigate some of these issues, using a system in which first and second reservoirs of differing materials may be provided, to allow a first aerosol to be generated from first aerosol-generating material from the first reservoir, and a second material delivered to the user from a second reservoir, optionally as a second aerosol.
WO2023139369 , incorporated herein by reference, discloses an aerosol provision system for generating an aerosol. The aerosol provision system comprises a first reservoir for storing a first aerosol-generating material, wherein the aerosol provision system is configured to generate a first aerosol using the first aerosol-generating material. The aerosol provision system also comprises a second reservoir for storing an active substance, or second aerosol-generating material such that the aerosol provision system is configured to generate a second aerosol using the second aerosol-generating material. In this way, the first aerosol may be generated in a way which then allows the second aerosol, or active substance, to then be either added to, mixed with, and/or supplied alongside the first aerosol in a way which allows the user to effectively customise to what extent this first aerosol, which is delivered to the user, is supplemented with the second aerosol/active substance. Protection may be sought for any features disclosed in WO2023139369 in combination with the present disclosure.

Brief summary of the invention

In one aspect, there is provided a material delivery system comprising a reservoir for retaining aerosol-generating or sensory material; and first and second capillary materials configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path for receipt by a user, wherein the second capillary material is exposed to the flow path and separates the first capillary material from the flow path; and the first capillary material has a lower average porosity than the second capillary material.
In another aspect, there is provided a cartridge for a delivery system, the cartridge comprising a reservoir for retaining aerosol-generating or sensory material; and first and second capillary materials configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path for receipt by a user, wherein the second capillary material is exposed to the flow path and separates the first capillary material from the flow path; and the first capillary material has a lower average porosity than the second capillary material.
In another aspect, there is provided a material delivery system comprising a reservoir for retaining aerosol-generating or sensory material; and a capillary material configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path for receipt by a user, the capillary material having a first end, distal from the flow path and a second end, exposed to the flow path, wherein the first end of the capillary material has a lower average porosity than the second end of the capillary material.
In some examples, the reservoir, the first capillary material and/or the second capillary material are removable/replaceable. In some examples, the reservoir, the first capillary material and/or the second capillary material comprises a semi-permeable membrane.
In some examples, the delivery system is or comprises a removable/replaceable cartridge.
In some examples, the reservoir is refillable.
In some examples, the second capillary material is exposed to, optionally extending into, the flow path. In some examples, the flow path is an aerosol flow path downstream of an aerosol generator.
In some examples, the flow path comprises or adjoins an aerosol flow path from an aerosol generator. In some examples, the capillary material is configured to transport aerosol-generating or sensory material to the flow path for entrainment into aerosol flow from the aerosol generator.
In some examples, the reservoir comprises the first capillary material and/or the second capillary material.
In some examples, the reservoir stores a portion of the aerosol-generating or sensory material freely. In some examples, the first capillary material is fluidly connected between a chamber, storing aerosol-generating or sensory material freely, and the second capillary material.
In some examples, the first capillary material extends into the reservoir or chamber. In some examples, the first and/or second capillary materials partially, substantially or fully fill(s) the reservoir. In some examples, the aerosol-generating or sensory material, the reservoir, the first capillary material and/or the second capillary material is/are unheated, or heated.
In some examples, the reservoir comprises a chamber for storing aerosol-generating or sensory material freely and the first capillary material surrounds or extends into an outlet from the chamber to the first capillary material.
In some examples, the chamber is removable/replaceable. In some examples, the reservoir or chamber comprises multiple outlets to the first capillary material.
In some examples, the first capillary material contacts, surrounds or extends into each outlet from the chamber.
In some examples, the chamber comprises multiple outlets to the first capillary material, each outlet having a different orientation or non-parallel axis of extent.
In some examples, the chamber comprises multiple outlets to the first capillary material, including two or three outlets having mutually perpendicular orientations or axes of extent.
In some examples the first capillary material surrounds a chamber for storing aerosol-generating or sensory material freely; and/or the second capillary material surrounds the first capillary material.
In some examples the first capillary material is annular, surrounding a chamber for storing aerosol-generating or sensory material freely; and/or the second capillary material is annular, surrounding the first capillary material.
In some examples, the first and/or second capillary material(s) comprise(s) a polymer material with micropores.
The first capillary material has a porosity, functionally related to a pore size (diameter) that is suitable for conveying aerosol-generating or sensory material to the second capillary material by capillary action. The second capillary material also has a porosity, functionally related to a pore size (diameter) that is suitable for receiving aerosol-generating or sensory material from the first capillary material by capillary action. The first and second capillary materials may help control (e.g. restrict) evaporation and/or transportation of the aerosol-generating or sensory material, which may be highly volatile.
In some examples, the first capillary material has an overall average porosity of ≤ 5%, ≤ 10%, ≤ 15%, ≤ 20% or ≤ 25%.
In some examples, the first capillary material has a smaller average pore diameter than the second capillary material.
In some examples, the first capillary material has an average pore diameter of ≤ 10%, ≤ 5%, ≤ 2% or ≤ 1% of the average pore diameter of the second capillary material.
In some examples, the first capillary material has an average pore diameter of 0.1-100 µm, optionally 0.1-25 µm, 0.1-10 µm, 0.1-5 µm or 0.2-1 µm.
In some examples, the first capillary material comprises or consists of cellulose acetate.
In some examples, the second capillary material has an overall average porosity of ≥ 25%, ≥ 30%, ≥ 40%, ≥ 50%, ≥ 60%, ≥ 70%, ≥ 80% or ≥ 90%; or ≤ 50%, ≤ 45%, ≤ 40%, ≤ 35%, ≤ 30%, ≤ 25% or ≤ 20%.
In some examples, the second capillary material has an average pore diameter of 1-1000 µm, optionally 10-250, 35-100 or 35-50 µm.
In some examples, the second capillary material comprises or consists of polyurethane foam
In some examples, the delivery system configured to receive or further comprising an aerosol generator configured to generate aerosol from aerosol-generating material, wherein:

a. the system comprises a flow path from an aerosol outlet of the aerosol generator to a mouthpiece; and
b. the second capillary material is configured to transport aerosol-generating or sensory material to the flow path, downstream of the aerosol outlet of the aerosol generator, for entrainment into the aerosol flow path, for receipt by a user.

In some examples, the aerosol generator is configured to generate aerosol from a first aerosol-generating material and the capillary material is configured to transport a second aerosol-generating or sensory material to the flow path, downstream of the aerosol outlet, wherein the second aerosol-generating or sensory material is different to the first aerosol-generating material. The first and second materials may be supplied independently. For aerosol-generating materials, the first and second aerosols may be generated independently.
In some examples, provided is an aerosol delivery system, optionally further comprising aerosol-generating material.
In some examples, the capillary material has a first end in or proximal to a chamber for retaining aerosol-generating or sensory material freely.
In some examples, the porosity has a porosity gradient, varying from:

a. small pores in the first capillary element or at the first end of the capillary element, proximal to the reservoir, to
b. large pores in the second capillary element or at the second end of the capillary element, proximal to or in the flow path.

In some examples, the average pore diameter varies from small or smaller pores in the first capillary element or at the first end of the capillary element, distal from the flow path, to large or larger pores in the second capillary element or at the second end of the capillary element, exposed to the flow path. In some examples, the average pore diameter varies to provide an average pore diameter gradient. In some examples, the gradient is substantially linear.
In some examples, the capillary material is compressible and compressed in the system to provide the different porosities / average pore diameters or the porosity gradient / average pore diameter gradient.
In one aspect, there is provided an aerosol delivery system comprising a reservoir for retaining aerosol-generating or sensory material, the reservoir comprising: a flexible and/or deformable reservoir wall and a capillary material configured to transport the aerosol-generating or sensory material to a flow path for receipt by a user, wherein the reservoir is compressible, for displacing the aerosol-generating or sensory material towards the flow path.
In another aspect, there is provided a cartridge for an aerosol delivery system, the cartridge comprising a reservoir for retaining aerosol-generating or sensory material, the reservoir comprising: a flexible and/or deformable reservoir wall and a capillary material configured to transport the aerosol-generating or sensory material to a flow path for receipt by a user, wherein the reservoir is compressible, for displacing the aerosol-generating or sensory material towards the flow path.
In some examples, the reservoir comprises a chamber for storing the aerosol-generating or sensory material freely and the capillary material surrounds and/or extends into an outlet from the chamber to the capillary material.
In some examples, the reservoir is compressible for displacing the aerosol-generating or sensory material into the capillary material, for transportation from the capillary material to the flow path.
In some examples, the reservoir is compressible to aid transport of aerosol-generating or sensory material from the reservoir to the flow path. In some examples, the reservoir is compressible to resupply the capillary material with aerosol-generating or sensory material from the chamber.
In some examples, comprising multiple flexible and/or deformable reservoir walls.
In some examples, the reservoir is compressible in two or more perpendicular axes.
In some examples, the reservoir comprises two opposing flexible and/or deformable reservoir walls.
In some examples, the flexible and/or deformable reservoir wall is an external wall, compressible by a user.
In some examples, an external wall of the system comprises, contacts and/or surrounds the flexible and/or deformable reservoir wall.
In some examples, the flexible and/or deformable reservoir wall extends away from a main body of the system and is compressible by a user.
In some examples, the reservoir is substantially cylindrical. In some examples, a compressible portion of the reservoir is substantially cylindrical. In some examples, the reservoir or compressible portion is sized to be compressible by a user's fingers.
In some examples, the reservoir has an external width or diameter of 5-30 mm, 10-20 mm or substantially 15 mm.
In some examples, comprising an actuator configured to compress the reservoir and/or the capillary material, to displace the aerosol-generating or sensory material towards the flow path.
In some examples, the actuator is operable manually by a user and/or the system comprises a controller configured to control the actuator electronically, in response to user input or automatically. In some examples, the flow path comprises or adjoins an aerosol flow path from an aerosol generator. In some examples, the capillary material is configured to transport aerosol-generating or sensory material to the flow path for entrainment into aerosol flow from the aerosol generator.
In some examples, configured to receive or further comprising an aerosol generator configured to generate aerosol from aerosol generating material, wherein:

a. the system comprises a flow path from an aerosol outlet of the aerosol generator to a mouthpiece; and
b. the capillary material is configured to transport aerosol-generating or sensory material to the flow path, downstream of the aerosol outlet of the aerosol generator, for entrainment into the aerosol flow path, for receipt by a user.

In some examples, the reservoir comprises:

a. a first capillary material configured to retain aerosol-generating or sensory material; and
b. a second capillary material configured to receive aerosol-generating or sensory material from the first capillary material and transport it to the flow path.

In some examples:

a. the reservoir wall comprises a polymer material; and/or
b. the capillary material(s) comprise(s) a polymer material with micropores.

In some examples, the first capillary material or a first end of the capillary material, distal from an outlet of the reservoir, has an average porosity or average pore diameter that differs from the average porosity or average pore diameter of the second capillary material or at a second end of the capillary material, exposed to the flow path and separating the first capillary material or first end of the capillary material from the flow path.
In some examples, the average pore diameter varies from small or smaller pores in the first capillary element or at the first end of the capillary element, distal from the flow path, to large or larger pores in the second capillary element or at the second end of the capillary element, exposed to the flow path. In some examples, the average pore diameter varies to provide an average pore diameter gradient. In other examples, the average pore diameter varies from large or larger pores in the first capillary element or at the first end of the capillary element, distal from the flow path, to small or smaller pores in the second capillary element or at the second end of the capillary element, exposed to the flow path.
In some examples, the average pore diameter within the capillary material(s) varies to provide an average pore diameter gradient.
In one aspect, there is provided an aerosol delivery system comprising: an aerosol generator configured to generate aerosol from a first, aerosol-generating material; and a pressure delivery mechanism configured to deliver a second material under pressure into a flow path of aerosol generated by the aerosol generator.
In another aspect, there is provided a method of generating aerosol for user inhalation using first and second materials, comprising generating aerosol from a first, aerosol-generating material using an aerosol generator; and delivering a second material into a flow path of aerosol generated by the aerosol generator under pressure, for entrainment into the aerosol flow path, for receipt by a user.
In some examples, the second material is a second aerosol-generating material or a sensory material. In some examples, the pressure delivery mechanism comprises a spray delivery mechanism.
In some examples, the first aerosol-generating material is different to the second aerosol-generating material. The first and second aerosols may be generated independently.
In some examples, the second material is heated prior to being delivered into the flow path of aerosol generated by the aerosol generator. In some examples, the system comprises a heating element configured to preheat the second material. In some examples, the delivery mechanism comprises the heating element. In some examples, the second material is heated to substantially room temperature (generally 15-25°C, e.g. substantially 15, 20 or 25°C) or body temperature (generally 35-40°C, e.g. substantially 35, 36, 37, 38, 39 or 40°C).
In some examples, the second material is delivered unheated.
In some examples, the delivery mechanism comprises an atomizer, a valve, a nozzle, a biasing element, an electromagnet and/or a solenoid.
In some examples:

a. the aerosol generator is configured to generate aerosol from a first, aerosol-generating material by heating the first, aerosol-generating material; and
b. the pressure delivery mechanism is configured to deliver the second material, unheated, into a flow path of aerosol generated by the aerosol generator.

In some examples, the delivery mechanism comprises a pressurised reservoir for retaining the second material.
In some examples, the delivery mechanism comprises a pressure mechanism configured to pressurise the reservoir or second material in use.
In some examples, the delivery mechanism is configured to deliver the second material into the flow path of aerosol generated by the aerosol generator, upstream from a mouthpiece for a user.
In some examples, the delivery mechanism is configured to deliver the second material into the flow path of aerosol generated by the aerosol generator at least 5 mm or at least 10 mm upstream from a mouthpiece for a user.
In some examples, the delivery mechanism is configured to direct the second material:

a. substantially perpendicular to the flow path of aerosol generated by the aerosol generator; or
b. substantially away from the mouthpiece.

In some examples, the delivery mechanism comprises a venturi tube.
In some examples, the second material is drawn into air flow through the venturi tube. In some examples, inhalation by a user on the system draws the second material into the aerosol flow.
In some examples, the delivery mechanism comprises a pump or plunger.
In some examples, the plunger is operable manually, e.g. by the user. In some examples, the pump comprises a micropump, a piston pump, a plunger pump, a diaphragm pump and/or a peristaltic pump.
In some examples, the second material is electrostatically charged. In some examples, the aerosol delivery system comprises an electrostatic charge generator configured to electrostatically charge the second material.
In some examples, the system comprises:

a. a reservoir for retaining a second material; and
b. a capillary material for transporting the second material from the reservoir to the delivery mechanism.

In some examples, the reservoir and/or the capillary material comprises a polymer material and/or a semi-permeable membrane.
In some examples, the system comprising a controller configured to control the aerosol generator and the delivery mechanism independently.
In some examples, the delivery mechanism is mechanically controlled. In some examples, the delivery mechanism is electronically controlled.
In some examples, the aerosol delivery system comprises:

a. a replaceable cartridge containing the first aerosol-generating material and optionally the aerosol generator; and/or
b. a replaceable cartridge containing the second material.

In some examples, the aerosol delivery system comprises a reusable device configured to receive:

a. a replaceable cartridge containing the first, aerosol-generating material; and/or
b. a replaceable cartridge containing the second material.

In some examples, the system further comprising:

a. a power source; and/or
b. a controller configured to control the aerosol generator and/or the delivery mechanism.

In some examples, the reusable device or the cartridge comprises the delivery mechanism.
In some examples, the second material is retained in the system or cartridge freely or in a capillary material.
In some examples:

a. the system comprises a flow path from an aerosol outlet of the aerosol generator to a mouthpiece; and
b. the delivery mechanism is configured to deliver the second material into the flow path, downstream of the aerosol outlet of the aerosol generator, for entrainment into the aerosol flow path, for receipt by a user.

A further example comprises an aerosol provision system for generating an aerosol, wherein the aerosol provision system comprises:

a first reservoir for storing a first aerosol-generating material, wherein the aerosol provision system is configured to generate a first aerosol using the first aerosol-generating material; and
a second reservoir for storing active substance(s), wherein the second reservoir comprises a second formulation, wherein the second formulation comprises one or more active substance(s) having boiling points in the range of from about 50 °C to about 300 °C; and
wherein the aerosol provision system comprises an outlet for delivering the second formulation from the second reservoir to a user of the aerosol provision system; and
wherein the second reservoir does not comprise an atomiser, a vaporiser, a heater/heating element, and/or a propellant.

In some examples, the second reservoir further comprises a porous substrate material.
A further example comprises an aerosol provision system for generating an aerosol, wherein the aerosol provision system comprises:

a first reservoir for storing a first aerosol-generating material, wherein the aerosol provision system is configured to generate a first aerosol using the first aerosol-generating material; and
a second reservoir for storing active substance(s), wherein the second reservoir comprises a second formulation and a porous substrate material, wherein the second formulation comprises one or more active substance(s); and

wherein the aerosol provision system comprises an outlet for delivering the second formulation from the second reservoir to a user of the aerosol provision system,
wherein the second reservoir does not comprise an atomiser, a vaporiser, a heater/heating element, and/or a propellant; and
wherein the porous substrate material comprises a sponge material, a fibrous material or combinations thereof, wherein the sponge material is formed of polyvinyl chloride, polyethylene, polyurethane, polyester or combinations thereof and the fibrous material is formed of cellulose acetate, polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials, polysaccharide polymers or a combination thereof.

In some examples, the second formulation comprises a carrier constituent, wherein the carrier constituent comprises one or more solvents.
In some examples, the carrier constituent consists of the one or more solvents.
In some examples, the one or more solvents comprises a proportion of the second formulation in the range of 1% to 50% of the second formulation.
In some examples, the one or more solvents are selected from the group consisting of ethanol, benzyl alcohol, propylene glycol or combinations thereof; preferably wherein the one or more solvents are selected from the group consisting of ethanol, benzyl alcohol or combinations thereof.
In some examples, the one or more solvents is ethanol.
In some examples, the one or more solvents is benzyl alcohol.
In some examples, the one or more active substances have boiling points in the range of from about 50 °C to about 300 °C.
In some examples, the active substance(s) have a boiling point in the range of from about 100 °C to about 300 °C.
In some examples, the active substance(s) have a vapour pressure of from about 0.0001 mmHg to about 15 mmHg; preferably wherein the active substance(s) have a vapour pressure of from about 0.0001 mmHg to about 12 mmHg.
In some examples, the second formulation contained within the second reservoir is configured to deliver substantially all of one or more active substances in the gas-phase.
In some examples, the porous substrate material comprises a sponge material, a fibrous material or combinations thereof; preferably wherein the porous substrate material consists of a sponge material, a fibrous material or combinations thereof.
In some examples, the sponge material is formed of polyvinyl chloride, polyethylene, polyurethane, polyester or combinations thereof; preferably wherein the sponge material consists of polyurethane. In some examples, the fibrous material is formed of cellulose acetate, polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof; preferably wherein the fibrous material consists of cellulose acetate.
In some examples, an airflow path extends through the porous substrate material towards the outlet, the porous substrate material comprising an upstream end further from the outlet and a downstream end closer to the outlet; and
wherein the second formulation is comprised within the porous substrate material and the concentration of the second formulation in the substrate material increases from the upstream end to the downstream end.
In some examples, the aerosol provision system comprises:

a third reservoir for storing active substance(s), wherein the third reservoir comprises a third formulation, wherein the third reservoir does not comprise an atomiser, a vaporiser, a heater/heating element, and/or a propellant; and
a selector component operable to move between a first configuration and a second configuration, wherein in the first configuration airflow from the second reservoir to the outlet is inhibited and airflow from the third reservoir to the outlet is facilitated, and wherein in the second configuration airflow from the third reservoir to the outlet is inhibited and airflow from the second reservoir to the outlet is facilitated.

In some examples, the selector component is operable to move between the first configuration and the second configuration by a rotational motion of the selector component between the first configuration and the second configuration.
In some examples, the selector component is operable to move between the first configuration and the second configuration by a detachment action in which the selector component is detached from the aerosol provision system and a reattachment action in which the selector component is attached to the aerosol provision system in the first configuration or the second configuration.
In some examples, the selector component is operable to move into a third configuration, wherein in the third configuration airflow from the second reservoir to the outlet is facilitated and airflow from the third reservoir to the outlet is facilitated.
In some examples, the selector component comprises the second reservoir and the third reservoir.
In some examples, the third formulation comprises one or more active substance(s) having boiling points in the range of from about 50 °C to about 300 °C and a carrier constituent, wherein the carrier constituent comprises one or more solvents.
In some examples, the third reservoir comprises a third porous substrate material.
In some examples, the second formulation and the third formulation are different.
A further example comprises a consumable, for use with an aerosol provision system, wherein the consumable comprises the second reservoir for storing active substance(s) and wherein the consumable is configured to be releasably coupled to the aerosol provision system.
In some examples, the consumable comprises the third reservoir for storing active substance(s), and wherein the consumable comprises the selector component.
A further example comprises an assembly comprising a consumable and an aerosol provision system.
In some examples, the aerosol provision system further comprises an aerosol provision device which comprises a section configured to receive the first reservoir that includes an interface arranged to cooperatively engage with an interface from the first reservoir so as to releasably couple the first reservoir to the aerosol provision device.
A further example comprises a method of providing a storage portion for an aerosol provision system, the method comprising:

providing a porous substrate material having a first end and a second end, separate from the first end,
dispersing a second formulation into the first end of the porous substrate material, the second formulation comprising an active substance and a carrier constituent for the active substance, wherein the carrier constituent comprises one or more solvents; and
locating the porous substrate material in an airflow path of the aerosol provision system such that the first end is closer than the second end to an outlet of the airflow path.

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.
The invention further provides corresponding functional means and additional embodiments as claimed in the dependent claims.

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 for delivering a first aerosol-generating material;
Figure 2 is a schematic cross-section view of the aerosol delivery system of figure 1, additionally comprising a delivery system for delivering a second material;
Figure 3 is a schematic cross-section view of another delivery system for delivering a first aerosol-generating material and a second material;
Figure 4 is a schematic perspective view of a chamber for a delivery system;
Figure 5 is a schematic perspective view of a reservoir for a delivery system;
Figures 6-7 are schematic cross-section views of a capillary material for a delivery system;
Figures 8-10 are schematic cross-section views of delivery systems comprising a compressible reservoir; and
Figures 11-12 are schematic cross-sections view of delivery systems comprising a pressure delivery mechanism.

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 invention may generally provide a sub-assembly or sub-system suitable for use in a delivery system such as an aerosol delivery system or aerosol-free delivery system, or configured for use in an aerosol delivery system or aerosol-free delivery system. The sub-system may generally form part of a delivery system and in particular may form part of the reusable device and/or a consumable cartridge of a multi-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 (sometimes referred to as a control unit) and a replaceable / disposable consumable cartridge part 4 (sometimes referred to as a consumable or an article). 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 system 1 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 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 a flow 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, which in this example is 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 flow 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 flow path 52, 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 flow path 52 such that a region of the flow 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 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.
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 an opening that defines an air inlet 28 for the system 1, a power source 26 (e.g. a battery) for providing operating power for the system 1, control circuitry / controller 22 for controlling and monitoring the operation of the system 1, 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 system 1when the cartridge part 4 and the reusable part 2 are coupled together is around 12 cm. However, the specific dimensions, geometry, overall shapes and materials used may vary.
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 flow 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 flow 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 system 1. 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). 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. The sensor cavity 32 comprises a region internal to one or more chamber walls in which an airflow sensor 30 can be fully or partially situated. In some embodiments, the PCB 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 Bluetooth^®, 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.

Multi-material delivery

Figure 2 is a cross-sectional view through an example delivery system 1 in accordance with certain embodiments of the disclosure, providing an introduction to delivery systems configured to deliver multiple different materials, particularly from separate reservoirs. The system 1 may be an aerosol delivery system 1, configured to deliver one or more materials as an aerosol for inhalation by a user, or an aerosol-free delivery system 1, configured to deliver a sensory material (impacting one or more senses of the human body, particularly those of taste, smell and even touch (mouth feel)) not in aerosol form to a user. Of particular interest are aerosol delivery systems delivering at least one material as an aerosol, supplemented by a second material which may be delivered in aerosol or non-aerosol form. The second material may be delivered together with or separately to the first material. Second materials are further described below.
As illustrated in figure 2, the system 1 may comprise a reusable device part 2 (such as that described for figure 1), a first cartridge part 4a (such as that described for figure 1) and a second cartridge part 4b. The second cartridge part 4b may be a system in itself and may be releasably connectable to existing wider systems, e.g. using an interference fit, or, in other examples, a single cartridge part 4 may comprise both cartridge parts 4a and 4b. In a simple form, the second cartridge part 4b may comprise a removable attachment or insert for an existing (e.g. conventional) aerosol delivery system, or integrated therewith, the second cartridge part 4b having a second reservoir 144 for storing a second material. The second cartridge part 4b may comprise an attachment / insert for an existing mouthpiece of an existing aerosol delivery system e.g. for attachment to an external surface of the existing mouthpiece, or an internal insert. The second cartridge part 4b may or may not receive air from an air inlet, passing through the second cartridge part 4b. The attachment / insert may surround an existing mouthpiece outlet or flow path through the system, e.g. forming an internal or external collar around the outlet or flow path, or form/comprise a mouthpiece itself. The second reservoir 144 may take any suitable form, including an impregnated substrate material (such as paper or card or a porous material), e.g. impregnated with a solid, liquid, gel or gas second material.
In the figure 2 example, the second cartridge part 4b comprises a second reservoir 144 for storing a second material, which may comprise a second aerosol-generating or sensory material, which may include a non-aerosol-generating material, and is further defined below. The overall system 1 is configured to generate aerosol comprising the second material (in aerosol or non-aerosol form), for receipt (e.g. smelling or inhaling) by a user. The second cartridge 4b stores and releases/delivers the second material to a flow path 52, for receipt by the user at the mouthpiece outlet 50. The flow path 52 may comprise / adjoin a first flow path 52a from the aerosol generator 48 or comprise a second flow path 52b. The mouthpiece outlet 50 may thus receive materials from a single or multiple flow paths. The mouthpiece outlet 50 may comprise one or multiple openings. The opening(s) may receive material(s) from a single or multiple flow paths as discussed in WO2023139369A1 with reference to figure 9 variants A-C, including e.g. a single opening receiving materials from multiple flow paths; multiple openings receiving materials from multiple flow paths; or a single opening receiving multiple materials from a single flow path. Optionally, a second aerosol generator 148 may be configured to generate a second aerosol from the second (aerosol-generating) material, e.g. by vibration and/or heating, for supplementing the first aerosol generated by the (first) aerosol generator 48. The second cartridge part 4b thus provides a second (downstream) material for a user which may be mixed with and/or supplied alongside the first (upstream) aerosol. The user may customise delivery of the first and/or second materials.
In the figure 2 example, the second reservoir 144 is annular, akin to the first reservoir 44. In other examples, the second reservoir 144 may comprise multiple second reservoirs 144 (such as multiple discrete reservoirs 144 arranged radially), which may retain multiple different materials. The second reservoir 144 may store some or all of the second material freely, and/or in or on one or more substrate materials, such as a capillary material 146 (e.g., a porous substrate material), described further later. A flow path may extend through the capillary material 146 towards the outlet, the capillary material 146 comprising an upstream end further from the outlet and a downstream end closer to the outlet. The second material is comprised within the capillary material 146 and its concentration therein may increase from the upstream end to the downstream end.
The system 1 may comprise a first air inlet 28 for supplying air to the first aerosol generator 48 (see figure 1) and a second air inlet 128 for separately supplying air to the second reservoir (see figure 11) and/or the second aerosol generator 148. Providing two separate air inlets 28, 128, may assist with providing a fresh source of air to the second reservoir 144 / second aerosol generator 148, and/or allow for different air flow rates to be delivered. In other examples, no second air inlet 128 is provided. In further examples (not shown), aerosol generated by the first aerosol generator 48 flows through the second reservoir 144, optionally through any capillary material 146, to entrain the second material. In some examples, the system 1 is configured to supply the second material downstream of the location at which the first aerosol is generated, such that this delivery of the second material does not impact any initial generation of the first aerosol by the system 1. Beneficially, the second cartridge 4b may allow the user to customise to what extent the first aerosol is supplemented with the second material as part of an end aerosol delivered to the user.
In some examples, the first and/or second reservoirs 44, 144 comprise an air inlet 28, 128 in the form of an aperture or an air permeable membrane 180. The air inlet(s) 28, 128 may allow for pressure equalisation (air flow into the reservoir 44, 144) as material is consumed from the reservoir 44, 144. The air inlet(s) 28, 128 may substantially prevent aerosol-generating or sensory material leaving the reservoir 44, 144 through the air inlet(s) 28, 128. The air inlet(s) 28, 128 may comprise a one-way valve. In some examples, the air inlet(s) 28, 128 may provide an access port for refilling the reservoir 44, 144, e.g. using a plunger or syringe. In some examples, the reservoir 44, 144 comprises a removable end closure. The end closure may provide access to the reservoir 44, 144 and/or capillary material(s) 146, which may be interchangeable / replaceable.
The subsequent sets of examples may incorporate one or more aspects outlined above, providing notable benefits.

Capillary materials

As outlined above, a reservoir for storing aerosol-generating and/or sensory material for a user may store some or all of the material freely, e.g. in a chamber 145 and/or in one or more capillary materials 146, such as a porous substrate material, which may act as a wicking material. The capillary or porous substrate material 146 may generally comprise a polymer material with micropores. Suitable capillary material(s) 146 may be manufactured using a phase separation process, a sintering process or a sol-gel process to provide suitable pores to transport aerosol-generating material.
In some examples, the capillary or porous substrate material 146 comprises or consists of a sponge material, a fibrous material or combinations thereof, optionally wherein the sponge material is formed of polyvinyl chloride, polyethylene, polyurethane, polyester or combinations thereof and/or the fibrous material is formed of cellulose acetate, polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials, polysaccharide polymers or a combination thereof. Optionally, the sponge material consists of polyurethane and/or the fibrous material consists of cellulose acetate.
The subsequent sets of examples may incorporate one or more aspects outlined above, providing notable benefits.

Second material/substance

As outlined above, the second material may comprise any material or substance, such as a (second) aerosol-generating and/or sensory material, including those defined in the terminology paragraphs below, particularly an 'active' substance and/or a 'flavour' material (which may or may not be an aerosol-generating material, for generating a second, distinct aerosol).
In some examples, the second material/substance may specifically include or specifically exclude one or more active substances (as defined below), particularly nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
In some examples, the second material/substance does not consist essentially of water. In some examples, the second material/substance is not water-based, i.e. contains less than 50% water, particularly less than 40%, less than 30, less than 20% or less than 10% water, more particularly less than 5%, less than 4%, less than 3%, less than 2% or less than 1% water.
In some examples, the second material is delivered to the mouthpiece unheated, which may provide a key distinction to the first, aerosol-generating material, which is typically (but not always) heated to generate vapour, which is entrained into air flow to form an aerosol. In some examples, both the first and second materials are heated, but to different temperatures. For example, the system may comprise a heating element and be configured to heat the second material to a second temperature above ambient, but below the temperature at which significant vaporization would take place, such as ≤ 50°C, ≤ 60°C, ≤ 70°C, ≤ 80°C, ≤ 90°C, ≤ 100°C, ≤ 110°C, ≤ 120°C, ≤ 130°C, ≤ 140°C or ≤ 150°C, i.e. much lower than the typical operating temperatures of 200-250°C for existing aerosol generators as might be used to heat the first aerosol-generating material. Hence, in some examples, the system may be configured to generate the first aerosol at a first temperature e.g. by heating the first aerosol-generating material to a first temperature; and deliver the second material at a second temperature, optionally by heating the second material to a second temperature, wherein the first temperature is greater than the second temperature, e.g. with a differential of ≥ 50°C, ≥ 60°C, ≥ 70°C, ≥ 80°C, ≥ 90°C, ≥ 100°C, ≥ 110°C, ≤ 120°C, ≥ 130°C, ≥ 140°C or ≥ 150°C. The second material may be heated directly, e.g. using a dedicated heating element, or passively, e.g. from conducted / convected / radiated heat from heating the first aerosol-generating material.
It will be appreciated that the temperature at which either of the first aerosol is generated and/or the second material is delivered may vary depending on the composition of the respective materials and that certain substances within an e-liquid for an e-cigarette may have different properties or characteristics at different temperatures. Accordingly, certain materials/substances may be provided in one or multiple of the reservoirs, to suit the temperatures they will be subjected to in use.
The second material may be highly volatile, thus readily vaporise into a flow path, such as the first (aerosol) flow path 52a from the aerosol generator 48. In particular, the formulation of the second material may comprise one or more active and/or other (e.g. flavour) substance(s) having boiling points in the range of from about 50°C to about 300°C, or from about 100°C to about 300°C, and optionally a carrier constituent comprising one or more solvents. In some examples, the formulation of the second material consists of one or more substance(s) having a boiling point in the range of from about 50°C to about 300°C, or from about 100°C to about 300°C, and optionally a carrier constituent comprising one or more solvents. In some examples, one or more of the active and/or other substance(s) has a boiling point outside of the range of about 50°C to about 300°C (e.g. lower than 50°C or greater than 300°C). In some examples, the overall formulation has a boiling point in the range of from about 50°C to about 300°C. In some examples, the second formulation is an azeotrope-like or an azeotrope formulation. In other words, the one or more active and/or other substances and the optional carrier constituent may combine to form an azeotropic solution (composition or mixture). In some examples, the active and/or other substance(s) may individually have a boiling point outside of the range of about 50°C to about 300°C, but when provided in a formulation with other substances (e.g. a solvent, active and/or other substances) the boiling point may be adjusted by the presence of the other substances to be within the range of about 50°C to about 300°C (see for example, the discussion of azeotropic and azeotropic-like formulations below). In some examples, the carrier constituent consists of the one or more solvents. In some examples, the formulation of the second material is configured to deliver substantially all of one or more active substances in the gas phase.
As used herein, the term "azeotrope-like" relates to compositions that are strictly azeotropic or that generally behave like azeotropic mixtures. An azeotropic mixture is a system of two or more components in which the component concentration of a liquid composition and vapor composition are equal at the stated pressure and temperature. In practice, this means that the components of an azeotropic mixture have a constant-boiling or essentially constant-boiling points and generally cannot be thermodynamically separated during a phase change. The vapor composition formed by boiling or evaporation of an azeotropic mixture is identical, or substantially identical, to the original liquid composition. Thus, the concentration of components in the liquid and vapor phases of azeotrope-like compositions change only minimally, if at all, as the composition boils or otherwise evaporates. In contrast, boiling or evaporating non-azeotropic mixtures changes the component concentrations in the liquid phase. That is to say the active and/or other substance(s) and the optional carrier constituent form a solution which has approximately the same relative proportions in both a liquid and a vapour phase. In other words, if a liquid solution comprising the active and/or other substance and the carrier constituent transitions to a vapour phase, the constituent parts of the resultant vapour phase will be the same as those of the initial liquid solution.
In some examples, the one or more solvents constitutes a proportion of the second formulation in the range of 1% to 50% of the second formulation (e.g. the second formulation comprises of from about 1 %w/w to about 50%w/w of the one or more solvent(s)). In some examples, the solvent in the range of 1% to 50% is benzyl alcohol or phenyl carbinol. In particular, benzyl alcohol is preferred over other solvents due to its low potency or aroma activity (e.g. in terms of smell).
In some examples, the active constituent or substance may comprise one or more physiologically and/or olfactory active constituents which are included in the second material in order to achieve a physiological and/or olfactory response in the user. The active constituent or substance may for example be selected from nutraceuticals and nootropics. The active constituent may be naturally occurring or synthetically obtained. The active constituent may comprise for example nicotine, caffeine, taurine, theine, a vitamin such as B6 or B12 or C, melatonin, a cannabinoid, or a constituent, derivative, or combinations thereof. The active constituent may comprise a constituent, derivative or extract of tobacco or of another botanical. In some embodiments, the active constituent is a physiologically active constituent and may be selected from nicotine, nicotine salts (e.g. nicotine ditartrate/nicotine bitartrate), nicotine-free tobacco substitutes, other alkaloids such as caffeine, or mixtures thereof.
In some examples, the active and/or other substance(s) may comprise an aliphatic compound (e.g. a form of compound having a relatively stable long chain structure). For example, the active and/or other substance(s) may comprise a carbon chain having a chain length of at least 8. In some examples, the active and/or other substance(s) do not comprise a compound including or formed of a benzene ring (e.g. an activated benzene ring), which may be considered relatively unstable at least in comparison to aliphatic compounds (e.g. the active and/or other substance(s) may not include an aromatic compound). For example, the active and/or other substance(s) may comprise an olfactory active constituent comprising one or more aliphatic compounds and / or the active and/or other substance(s) do not comprise an aromatic compound. Furthermore, in some examples, the active and/or other substance(s) do not comprise a compound including oxygen sensitive ingredients such as unsaturated aldehydes and carboxylic acids.
In some examples, the one or more solvents are selected from the group consisting of ethanol, benzyl alcohol, propylene glycol or combinations thereof; optionally wherein the one or more solvents are selected from the group consisting of ethanol, benzyl alcohol or combinations thereof.
In some examples, the active and/or other (e.g. flavour) substance(s) have a vapour pressure of from about 0.0001 mmHg to about 15 mmHg; optionally wherein the active and/or other (e.g. flavour) substance(s) have a vapour pressure of from about 0.0001 mmHg to about 12 mmHg. In some examples, the second material consists of substance(s) having a vapour pressure of from about 0.0001 mmHg to about 15 mmHg; optionally wherein the substance(s) have a vapour pressure of from about 0.0001 mmHg to about 12 mmHg.
In some examples, a porous substrate material comprising a sponge material, such as a polyurethane sponge, is preferred in combination with an active and/or other substance having a boiling point in the range between 158°C and 180°C and also a vapour pressure between 0mmHg and 3.8mmHg, and / or an active and/or other substance having a boiling point in the range between 130°C and 160°C and also a vapour pressure between 9mmHg and 12mmHg, without a carrier constituent or with a carrier constituent comprising Benzyl Alcohol in the range of 1% to 50% by weight of the second formulation. In particular the above combination provided improved delivery. In some examples, a porous substrate material comprising a sponge material, such as a polyurethane sponge, is preferred in combination with an active and/or other substance having a boiling point in the range between 158°C and 180°C and a vapour pressure of greater than 3.8mmHg, and / or an active and/or other substance having a boiling point in the range between 130°C and 160°C and also a vapour pressure between 3.8mmHg and 9mmHg or greater than 12mmHg and a fixative comprising a compound having a vapour pressure of less than 2mmHG.
Without being bound by theory, by providing a consumable in which an active and/or other substance having properties that enable delivery of an aerosol without heating of the substance (as described above, e.g. a boiling in the range between 158°C and 180°C and with a vapour pressure between 0mmHg and 3.8mmHg, or a boiling point in the range between 130°C and 160°C and with a vapour pressure between 9mmHg and 12mmg), the presence of carbonyls and metals in the aerosol to be delivered is reduced (e.g. in comparison to a heated consumable having the same formulation).
The following sets of examples are each particularly, but not exclusively, suitable for supplying / delivering only a small amount of a second material (which may be highly volatile) to a flow path such as an aerosol stream from an aerosol generator, whilst the bulk of the second material remains contained with minimal exposure to air, to restrict evaporation and prolong longevity.

Varying porosity capillary material

A first set of examples will now be described, first with reference to figure 3, in which a delivery system 1, 4b comprises one or more capillary materials 146 for transporting material in or from a reservoir 144 to a reservoir outlet 154 into a flow path 52, for receipt by a user, wherein the porosity of the capillary material(s) 146 varies. This first set of examples is particularly suitable for transporting an aerosol-generating or sensory material that is highly volatile, such as a 'second material' described above, and may be used in (e.g. provided as a cartridge for) multi-material delivery systems.
In some examples, the capillary material 146 has a first end 146a distal from the outlet 154 /flow path 52 and a second end 146b at the outlet 154, exposed to (e.g. proximal, adjacent to or in) the flow path 52. In some examples, the capillary material 146 comprises multiple discrete parts, such as a first capillary material 146a, distal from the outlet 154 / flow path 52 and a second capillary material 146b at the outlet 154, exposed to the flow path 52, where the second capillary material 146b separates the first capillary material 146a from the outlet 154 / flow path 52. Accordingly, references to the 'first capillary material 146a' and the 'second capillary material 146b' may generally be used interchangeably with 'the first end of the capillary material 146' and 'the second end of the capillary material 146', respectively. The features described herein are applicable to both a single capillary material 146 having two ends 146a, 146b and two (or more) separate capillary materials 146a, 146b.
Figure 3 is a schematic cross-section view of an aerosol delivery system 1 for delivering a first, aerosol-generating material and a second material to a user at a mouthpiece outlet 50. The core features of this example are in the material delivery (sub)system 4b, which may comprise a removable / replaceable cartridge 4b for a wider delivery system 1. In figure 3, the wider multi-material aerosol delivery system 1 additionally includes a reusable device part 2 (such as that described for figure 1) and a first cartridge part 4a with an aerosol generator 48 configured to generate aerosol from a first, aerosol-generating material (such as that described for figure 1), hence cartridge 4b is a second cartridge for the wider system 1. In some examples, the system 1 comprises a flow path 52a from an aerosol outlet of the aerosol generator 48 to a mouthpiece and the second capillary material 146b is configured to transport aerosol-generating or sensory material to the flow path 52a, downstream of the aerosol outlet of the aerosol generator 48, for entrainment into the aerosol flow path 52a, for receipt by a user. The first and second materials may be different and/or may be supplied independently. For first and second aerosol-generating materials, the first and second aerosols generated therefrom (respectively) may be generated independently.
In contrast to the system 1 of figure 2, in figure 3 the second cartridge 4b is annular and surrounds the first cartridge 4a. As shown in figure 3, the (second) cartridge 4b comprises a (second) reservoir 144 for retaining (second) aerosol-generating or sensory material, and first and second capillary materials 146a, 146b configured to transport the aerosol-generating or sensory material in the reservoir 144 to the flow path 52, for receipt by a user. In this example, the reservoir 144 comprises a chamber 145 having an open volume for storing the aerosol-generating or sensory material freely, as well as the first and second capillary materials 146a, 146b.
The first capillary material 146a is fluidly connected to the aerosol-generating or sensory material stored freely in the chamber 145, e.g. exposed or adjacent to the open volume or in fluid contact with an outlet 155 of the chamber 145. In figure 3, the first capillary material 146a surrounds the chamber outlet 155, whilst in other examples the first capillary material 146a may extend into and/or through the outlet 155 (e.g. as in figure 8), optionally into the chamber 145 e.g. to provide an axial wick from the chamber 145, through the outlet 155 to the second capillary material 146b. The walls of the chamber 145 may be substantially air impermeable, to prolong longevity of the second material contained therein, e.g. permitting material release (and air entry) only via the outlet 155. A free storage arrangement maximises storage volume, whilst providing reliable transportation of the material from the chamber 145 to the first capillary material 146a, which helps control flow and evaporation. In other examples, the first and/or second capillary materials 146a, 146b may substantially or fully fill the reservoir(s), i.e. the chamber 145 may be omitted.
The second capillary material 146b is exposed to the flow path 52 at an outlet 154 of the reservoir 144, for delivering the aerosol-generating or sensory material to the user. The second capillary material 146b separates/spaces the first capillary material 146a from the flow path 52 and is configured to transport the aerosol-generating or sensory material from the first capillary material 146a to the flow path 52. In this example, the aerosol-generating or sensory material thus flows sequentially from the chamber 145 to the first capillary material 146a and then to the second capillary material 146b to reach the outlet 154 of the reservoir 144.
The first capillary material 146a has a lower average porosity than the second capillary material 146b. The different capillary materials 146a, 146b may provide a step-change in porosity, or a porosity gradient, as described further below. This arrangement is particularly suitable for controlling the evaporation rate of a material that is highly volatile, such as a 'second material' described above. The lower average porosity of the first capillary material 146a, which in figure 3 is located between the chamber 145 and the second capillary material 146b, aids transportation of the material to the flow path, but with limited exposure to air, thus reducing the evaporation rate. The second capillary material 146b retains a sufficient volume of the material for supplying a few puffs, but without exposing a large volume of the material to air. Accordingly, the combination of capillary materials 146a, 146b act as a buffer, aiding to control evaporation, limiting exposure of the material in the reservoir 144 and the capillary materials 146a, 146b to air, whilst providing a flow supply to the flow path, so that the material can be entrained into a flow path through the system, for receipt by a user.
In figure 3, the system comprises an air inlet 28 which supplies air to both the first and second cartridges 4a, 4b. The air flow path 52a through the first cartridge 4a may be as explained above. The second cartridge 4b may not require air flow (e.g. depending on the material in the reservoir 144), or may comprise a second flow path 53 from the inlet 28 through the reservoir 144. In the figure 3 example, the second flow path 53 joins the first (aerosol) flow path 52a, thus the aerosol from the aerosol generator 48 may entrain the second material for delivery to a user at mouthpiece outlet 50. In other examples, the second flow path 53 may comprise a separate flow path 52b to the mouthpiece outlet 50 (as in the figure 2 arrangement). The second capillary material 146b may be exposed to, as shown, or project / extend into (not shown), the first (aerosol) flow path 52a, downstream of the aerosol generator 48, with the first aerosol flowing past the second capillary material 146b.
In some examples, the reservoirs 44, 144 may be permeable to air, such as by comprising a semi-permeable membrane 180 (not shown), to allow pressure equalisation to occur as the materials therein are consumed and/or to allow a user's inhalation to draw air through the pathway from the inlet 128 to the second flow path 53, without leaking the material contained therein, which may typically be a solid, gel or liquid. As detailed above, the cartridge 4b or system 1 may comprise a heating element (not shown), e.g. within the reservoir 144, within the capillary material 146 or proximal to the outlet 154, to warm / pre-heat the second material, typically to a different temperature to the temperature that the aerosol generator 48 heats the first, aerosol-generating material.
In figure 3, the cartridges 4a, 4b are replaceable as units, whilst in other examples, any sub-components, particularly the reservoir 144 or the/each capillary material 146a, 146b may be removable/replaceable individually or collectively. This allows the user to switch out different materials upon depletion or otherwise as it suits, to provide a different experience. The first and/or second reservoirs 44, 144 may be refillable, for convenience. Furthermore, whilst the cartridge 4b is indicated as an annular cartridge having a single reservoir 144, in other examples, multiple cartridges or individual sub-components (as above) may be provided, to provide multiple materials to the end user - e.g. multiple cartridges 4b may be arranged radially around one or more first cartridge(s) 4a.
Figure 4 is a schematic perspective view of a chamber 145 for a delivery system. In figure 4, the chamber 145 comprises a volume having multiple outlets 155 to a capillary material 146 (not shown). The capillary material 146 may generally contact, surround or extend into each outlet 155 from the chamber 145. The outlets 155 may have different orientations or non-parallel axes of extent, which beneficially provides resupply of the capillary material 146 under the influence of gravity in multiple orientations. In some examples, there are multiple perpendicular outlets 155.
In figure 4, the outlets 155 comprise 3 sets of mutually perpendicular outlets 155:

2 opposing axial end outlets 155a (only 1 shown in figure 4 due to perspective) having an axis of extent along a length L of the cylindrical chamber 145; and
8 radial outlets, comprising:
- ∘ 4 outlets 155b, comprising 2 outlets spaced along the length of the reservoir (at 25% 75% of the total length L) with radially opposing outlets 180° offset around the circumference (not shown in figure 4 due to perspective); and
- ∘ 4 outlets 155c, each radially offset from the above 4 outlets 155b by 90°, comprising 2 outlets spaced along the length of the reservoir (at 25% 75% of the total length L), also with radially opposing outlets 180° offset around the circumference (also not shown in figure 4 due to perspective).

Figure 5 is a schematic perspective view of a reservoir 144 for a delivery system, comprising a chamber 145 (optionally as shown in figure 4) surrounded by a first capillary material 146a, where the first capillary material 146a is surrounded by a second capillary material 146b. Beneficially, this arrangement may provide transport of the material stored within the chamber 145 to the first and second capillary materials 146a, 146b under the influence of gravity in any orientation. In this particular example, the chamber 145 is cylindrical and so the first and second capillary materials 146a, 146b are annular (or hollow having a cylindrical open inner), but any shapes may be used.
As outlined above, in this first set of examples, the first capillary material 146a has a lower average porosity than the second capillary material 146b. The first capillary material 146a has a porosity, functionally related to a pore size (diameter) that is suitable for conveying aerosol-generating or sensory material to the second capillary material 146b by capillary action. The second capillary material 146b also has a porosity, functionally related to a pore size (diameter) that is suitable for receiving aerosol-generating or sensory material from the first capillary material 146a by capillary action. The second capillary material 146b is more air permeable than the first capillary material 146a, releasing the second material to the flow path for receipt by the user, whilst the first capillary material 146a re-supplies the second capillary material 146b. The first and second capillary materials 146a, 146b may help control (e.g. restrict) evaporation and/or transportation of the aerosol-generating or sensory material, which may be highly volatile.
In particular examples, the first capillary material 146a has an overall / average porosity of ≤ 5%, ≤ 10%, ≤ 15%, ≤ 20% or ≤ 25%. In some examples, the second capillary material 146b has an overall average porosity of ≥ 25%, ≥ 30%, ≥ 40%, ≥ 50%, ≥ 60%, ≥ 70%, ≥ 80% or ≥ 90%; or ≤ 50%, ≤ 45%, ≤ 40%, ≤ 35%, ≤ 30%, ≤ 25% or ≤ 20%. As noted above, porosity is functionally related to pore diameter and in some examples, the first capillary material 146a has a lower / smaller average pore diameter than the second capillary material 146b. In some examples, the first capillary material 146a has an average pore diameter of ≤ 10%, ≤ 5%, ≤ 2% or ≤ 1% of the average pore diameter of the second capillary material 146b. In some examples, the first capillary material 146a has an average pore diameter of 0.1-100 µm, optionally 0.1-25 µm, 0.1-10 µm, 0.1-5 µm or 0.2-1 µm. These may be considered 'small' or 'smaller' pore sizes. In particular, the first capillary material 146a may comprise or consist of cellulose acetate. In some examples, the second capillary material 146b has an average pore diameter of 1-1000 µm, optionally 10-250, 35-100 or 35-50 µm. These may be considered 'large' or 'larger' pore sizes. In particular, the second capillary material 146b may comprise or consist of polyurethane foam.
Figures 6-7 are schematic cross-section views of a capillary material 146 for a delivery system and illustrate further examples, here where the capillary material 146 comprises a first end 146a, distal from the flow path 52 and a second end 146b, exposed to the flow path 52, wherein the first end 146a of the capillary material 146 has a lower average porosity than the second end 146b. In some examples, the first end 146a is in or proximal to a chamber 145 for retaining aerosol-generating or sensory material freely. The capillary material 146 may comprise a single part / piece (figure 6) or multiple discrete parts / pieces (figure 7). In some examples, the multiple capillary materials 146 comprise different core materials, whilst in others, one or more regions of the same core material are treated to provide different porosities at the first and second ends 146a, 146b. For example, one end may be coated or impregnated with adhesive, to reduce porosity / permeability. In other examples, the porosity can be altered by compression, e.g. utilising one or more pieces of the same uncompressed core material, and compressing an end or discrete piece of the capillary material to reduce porosity / permeability.
In figure 6, a uniform (e.g. rectangular or cylindrical) cross-section of capillary material 146 is compressed to alter its porosity / permeability. The system may comprise a recess for the capillary material 146 to receive it in a compressed state, such as to compress one end of the capillary material 146 relatively more than the other end, providing the porosity variation in-situ. In figure 6, the capillary material is compressed at the first end more than the second end to form an overall trapezoidal shape such that the first end 146a has a lower average porosity than the second end 146b. This example beneficially provides a porosity gradient (as opposed to a step change between the first and second capillary materials 146a, 146b as shown in figures 3 and 5), which here is a linear gradient from the first end 146a to the second end 146b. In other examples, the gradient is not linear.
Figure 7 also illustrates a porosity gradient from a first end 146a to a second end 146b, having four distinct / discrete sections. As outlined above, the sections may be derived from the same capillary material 146, e.g. by compressing the different portions in-situ to different extents or utilising multiple discrete capillary materials. The porosity gradient varies from small pores in the first capillary element 146a or at the first end 146a of the capillary element 146, to large pores in the last capillary element 146b or at the second end 146b of the capillary element 146. In some examples, the average pore diameter varies from small or smaller pores in the first capillary element 146a or at the first end of the capillary element 146a, to large or larger pores in the last capillary element 146b or at the second end of the capillary element 146b. The average pore diameter may vary to provide an average pore diameter gradient, which may be linear or non-linear.

Compressible reservoir

A second set of examples will now be described, in which a delivery system comprises a compressible reservoir 244 for retaining aerosol-generating or sensory material, the reservoir 244 comprising a capillary material 146a and a flexible and/or deformable reservoir wall 247. The reservoir 244 may be partially or fully elastically compressible, which may partially or fully return to its original shape, or partially or fully plastically compressible, remaining at least partially deformed, for displacing the material towards a flow path 52 via the capillary material 146, for receipt by a user. Any part of the wall may be compressible and the system may comprise multiple compressible walls 247, such as two opposing walls 247 each comprising a compressible part. The delivery system may be in the form of a cartridge 4b for an aerosol delivery system, optionally a wider system 1, e.g. further comprising a first aerosol-generating cartridge part 4a and/or a reusable device part 2. This set of examples is particularly suitable for controlling the flow of an aerosol-generating or sensory material that is highly volatile, such as a 'second material' described above, and may be used in (e.g. provided as a cartridge for) multi-material delivery systems.
The compressible reservoir 244 may comprise a chamber 245 for storing aerosol-generating or sensory material freely, configured to re-supply the capillary material 146, which acts as a buffer between the chamber 245 and the flow path 52, so that the material can be entrained into a flow path 52 through the system 1. The flow path 52 may be an air flow path, or an aerosol flow path from an aerosol generator 48, for receipt by a user. The capillary material(s) 146 may be as described above, hence the same reference numerals are used. Again, where multiple capillary materials 146 are used, they may have different porosities, as above, e.g. where a first capillary material 146a distal from an outlet 254 of the reservoir 244 or distal from the flow path 52 has a lower average porosity than a second capillary material 146b located at the outlet 254, exposed to (e.g. proximal, adjacent to, or in) the flow path 52. For the avoidance of doubt, the various features outlined above such as varying porosity may optionally be utilised with this second set of examples. Notably, in contrast to the above, when used with a compressible reservoir 244, the first capillary material 146a may instead have a higher average porosity than the second capillary material 146b.
Figure 8 is a schematic cross-section view of an delivery system in the form of a cartridge 4b, comprising a compressible reservoir 244 having a flexible and/or deformable reservoir wall 247 and a capillary material 146 configured to transport aerosol-generating or sensory material through the reservoir 244 from a chamber 245 to a flow path 52, for receipt by a user. Although not detailed, the wider system 1 may comprise a first aerosol-generating cartridge part 4a and/or a device part 2 (e.g. as separable components as per figures 1 and 2, or in an integrated system).
In figure 8, the reservoir 244 comprises a chamber 245 having a volume for storing aerosol-generating or sensory material freely, and a capillary material 146. In this example, the capillary material 146 comprises first and second materials 146a, 146b, akin to the first set of examples above, configured to retain aerosol-generating or sensory material and transport it to the flow path 52. In this example, the first capillary material 146a surrounds and extends through an outlet 255 of the chamber 245 and the reservoir 244 is compressible for displacing the aerosol-generating or sensory material into the capillary materials 146a, 146b from the chamber 245, aiding transportation to the flow path 52. The compressible nature of the reservoir 244 effectively provides re-supply of the capillary material 146 with aerosol-generating or sensory material from the chamber 245.
In the figure 8 example, the reservoir 244 comprises multiple flexible and/or deformable reservoir walls 247, here comprising two opposing external axial walls 247a along a length of the chamber 245 and around a portion of the first capillary material 146a; and a perpendicular external end wall 247b of the chamber 245. Accordingly, in this example, the reservoir 244 is compressible in two or more perpendicular axes. Although figure 8 shows flexible and/or deformable reservoir walls 247 around only a portion of the first capillary material 146a, in other examples, the flexible and/or deformable walls surround any combination of the chamber 245, the first capillary material 146a and/or the second capillary material 146b, each in part or wholly. For example, the flexible and/or deformable walls 247 may surround only the chamber 245 and not the first capillary material 146a. In further examples, the flexible and/or deformable walls 247 fully surround the first capillary material 146a, which may beneficially allow the user to resupply the second capillary material 146b rapidly whilst the second capillary material 146b still restricts flow to maintain a consistent material delivery, and/or surround a portion or an entirety of the second capillary material 146b, so that the user may increase the material delivery/flow rate to the flow path 52 directly.
The flexible and/or deformable reservoir wall(s) 247 may be made from any suitable material, such as a polymer material. In figure 8, the flexible and/or deformable reservoir walls 247 are all external walls of both the cartridge system 4b and the wider system 1, and are compressible by a user. Generally, the reservoir wall(s) 247 may extend away from / project beyond a main body of the system 1, such as projecting away from a housing 12 of a control part 2 and/or projecting away from a housing 42 of a first cartridge part 4a). In other examples, an external wall of the system 1 comprises, contacts and/or surrounds the or more of the flexible and/or deformable reservoir walls 247, so that the user may compress the external wall of the system 1 to indirectly compress the flexible and/or deformable reservoir wall(s) 247 of the cartridge system 4b.
In particular, the reservoir 244 may comprise one or more squeezable walls 247, flexible and/or deformable in the manner akin to a squeezable toothpaste tube, where the walls 247 are sufficiently flexible to be readily deformed by a user squeezing the walls 247 to displace the material therein. Although this is typically elastic deformation, after squeezing, the walls 247 may nevertheless thereafter remain at least partially deformed, since there is no air inlet into a standard squeezable toothpaste tube and a limited flow path back into the tube to equalise pressure and restore the original shape. In some examples, the reservoir 244 is sized to be compressible by a user's fingers and may have an external width or diameter of 5-30 mm, 10-20 mm or substantially 15 mm. In some examples, the external width or diameter may be the external exposed or compressible width or diameter, i.e. the width or diameter of the portion of the reservoir 244 projecting beyond the main body that is compressible by a user.
Figure 8 also illustrates an optional pressurising actuator 160 configured to compress the reservoir 244, to displace the aerosol-generating or sensory material towards the flow path 52. The actuator 160 may be any suitable component configured to compress the reservoir 244, such as a biasing element or a pressure delivery mechanism 310, as described later in the third set of examples. In other examples (not shown), an actuator 160 is configured to compress the capillary element 146, and may be located within the reservoir. The actuator 160 may be operable manually by a user and/or the system 4b, 1 may comprise a controller 22 configured to control the actuator 160 electronically, in response to user input or automatically.
Similar to the figure 3 example, the system 1 may comprise a (first) aerosol generator 48 configured to generate aerosol from a (first) aerosol-generating material, where an (aerosol) flow path 52a extends from an outlet from the aerosol generator 48 to a mouthpiece outlet 50. Again, in such examples, the flow path through the reservoir 244 via the capillary material 146 may comprise or adjoin the (aerosol) flow path 52a from the (first) aerosol generator 48, whereby the capillary material(s) 146 may be configured to transport aerosol-generating or sensory material to the flow path 52a for entrainment into aerosol flow from the aerosol generator 48, or the flow path 52 may comprise a separate flow path 52b to the mouthpiece outlet 50 (as shown in figure 2). As outlined below, the aerosol generator 48 may or may not comprise a heater, e.g. comprise a vibration, pressure, or electrostatic aerosol generator 48.
Figure 8 also shows an optional (second) aerosol generator 148 for generating aerosol from the (second) aerosol-generating material. Where provided, the aerosol generator 148 may take any suitable form as described elsewhere herein, such as a heating or vibratory element. Optionally, the system 4b, 1 may comprise a heating element that warms or pre-heats without generating aerosol, as outlined above. The system 4b, 1 generally and specifically the reservoir 244 may generally take any suitable shape, such as cylindrical, replicating a traditional cigarette. In some examples, at least a compressible portion of the reservoir 244 is substantially cylindrical and/or sized to be compressible by a user's fingers.
Figures 9 and 10 are further schematic cross-section views of aerosol delivery systems 4b, 1 comprising a compressible reservoir 244. In figure 9, the aerosol delivery system 4b is again a removable and replaceable cartridge 4b that may be received by or connectable to a first cartridge 4a and a power supply 26 / control part 2. In the figure 9 example, the wider system 1 comprises a control part 2 having a housing 12 for power / control electronics and a first cartridge 4a having a housing 42. The cartridge 4b comprising the compressible reservoir 244 is an 'arm' extending away at an acute angle from the system 'body' formed by housings 12, 42, exposing two opposing deformable walls 247a which are compressible by a user for displacing the aerosol-generating or sensory material towards the flow path 52. The flow path 52 may adjoin an aerosol flow path 52a from an aerosol generator 48 within wider system 1 (e.g. in the first cartridge 4a).
Figure 10 illustrates a further example, where, in contrast to figure 9, the compressible reservoir 244 of the system 4b additionally comprises an aerosol generator 148 for generating aerosol from the aerosol-generating or sensory material and an air inlet 128 comprising a semi-permeable membrane 180 to equalise pressure within the reservoir 244 as the material is consumed. The compressible reservoir 244 may also be refillable via the air inlet 128. In this example, the system 4b also comprises a mouthpiece having an outlet 50, which may removably connect to an existing system, such as an all-in-one or multi-part wider system 1 having a separate power supply/control part 2a and/or a first cartridge 4a. The mouthpiece may provide a single or multiple outlets 50, e.g. separate outlets for each material or each aerosol generated from multiple aerosol-generating materials.
The configurations shown in figures 8-10 may extend to or be duplicated/mirrored on other (e.g. opposing) sides, such as to provide an annular arrangement, or provide multiple independent (sub)systems which might contain different materials in the respective reservoirs 244.

Pressure delivery mechanism

A third set of examples will now be described, in which a delivery system 1 comprises a pressure delivery mechanism 310 configured to deliver a second material under pressure into a flow path 52a of aerosol generated (from a first, aerosol-generating material) by an aerosol generator 48, for entrainment of the second material into the aerosol flow path 52a, for receipt by a user. This set of examples is particularly suitable for controlling the delivery of an aerosol-generating or sensory material that is highly volatile, such as a 'second material' described above. In some examples, the second material is an aerosol-generating material that differs from the first aerosol-generating material. The first and second aerosols may be generated independently.
Figure 11 is a schematic cross-section view of an aerosol delivery system 1 comprising an aerosol generator 48 configured to generate aerosol from a first aerosol-generating material and a pressure delivery mechanism 310. As will be appreciated, the arrangement of the (first) aerosol generator 48, which is shown having an air inlet 28 and receiving (first) aerosol-generating material from a first reservoir 44, which may be removable as part of a cartridge 4a, is akin to that of figure 3 above. Figure 11 also shows the system 1 in combination with a reusable device part 2, which again may also be removable. The delivery mechanism 310 is configured to deliver a second aerosol-generating material under pressure into a flow path of aerosol 52a generated by the aerosol generator 48. The delivery mechanism 310 may generally comprise any suitable mechanism, such as an atomizer, a valve, a nozzle, a biasing element, an electromagnet and/or a solenoid, as described further below. In the figure 11 example, the delivery mechanism 310 comprises a spray delivery mechanism 310a configured to spray the second material into the aerosol flow path 52a from the aerosol generator 48.
In the figure 11 example, the spray delivery mechanism 310a comprises an annular pressurised reservoir 344 and a nozzle 325 at an outlet 354 of the reservoir 344. The pressurised reservoir 344 itself may take any suitable form, e.g. be pre-pressurised during manufacture, or be pressurised in use. In particular, the system 1 may comprise a pressurising mechanism configured to pressurise the reservoir (or second material) in use, e.g. by supplying a compressed gas to the reservoir or exerting pressure on the reservoir. In one example, the system 1 comprises a compressible reservoir 244 as outlined above in the second set of examples, with a pressurising actuator 160 such as a biasing element or solenoid configured to compress the reservoir 244 to provide a pressurised reservoir 344. Beneficially, the nozzle 325 may aid in defining a suitable particle size, e.g. for delivery of aerosol to the mouth or lungs.
The spray delivery mechanism 310a comprising the pressurised reservoir 344 may be removable / replaceable as a unit cartridge 4b, or the pressurised reservoir 344 might be a removable / replaceable consumable in isolation. The aerosol generator 48 and the delivery mechanism 310 may be controlled, by a controller, dependent on one another (e.g. based on the same user input, such as detected inhalation by a puff sensor), or independently, e.g. in response to different user inputs.
In the figure 11 example, the aerosol generator 48 is configured to generate aerosol from a first aerosol-generating material by heating and the pressure delivery mechanism 310a is configured to deliver the second material, unheated, into a flow path 52a of aerosol generated by the aerosol generator 48 being drawn (by user inhalation) to the mouthpiece outlet 50. The reservoir 344 may comprise a capillary material 146 (e.g. as outlined above) for transporting second material to the delivery mechanism 310. The flow path 52a may be pre-heated/warmed by the aerosol generator 48 or aerosol generated thereby, providing indirect heating to the sprayed second material.
Figure 12 is a schematic cross-section view of an aerosol delivery system 1 comprising a second pressure delivery mechanism 310b. Similar to figure 11, the second system 1 comprises an aerosol generator 48 configured to generate aerosol from a first aerosol-generating material. By contrast to figure 11, the pressure delivery mechanism 310 comprises a micropump 310b configured to deliver the second material from a reservoir 144, and an optional heating element 330. In this example, the micropump 310b is reusable (so may form part of the reusable device part 2) and receives a replaceable cartridge 4b comprising the reservoir 144 of second material. The micropump 310b is configured to deliver the second material from the reservoir 144 under pressure to an outlet 154 of the reservoir 144 and into the flow path 52a from the aerosol generator 48 to the mouthpiece outlet 50. In figure 12, the optional control part 2 and first reservoir 44 may be removable and are omitted for simplicity. The second material may be pre-heated by the heating element 330, such as substantially to room temperature (generally 15-25°C, e.g. substantially 15, 20 or 25°C) or body temperature (generally 35-40°C, e.g. substantially 35, 36, 37, 38, 39 or 40°C).
In a further example (not illustrated), the system 1 comprises a pressure mechanism in the form of a plunger 310. The plunger 310 may be operable manually by a user to apply pressure to the second material in the reservoir 144, to deliver it into the flow path via an outlet 154, akin to a pump. This provides the user with direct manual control of delivery of the second material.
In a further example (not illustrated), the second material is electrostatically charged. The material may be delivered under pressure from the reservoir 144 in a manner similar to a rail gun, comprising two rails with a 'projectile' (the second material) between, where current is passed down one rail and back along the other rail, creating a magnetic field. The (charged) material is perpendicular to the magnetic field so experiences a Lorentz force, spraying the material out of the reservoir 144. The material may be pre-charged or the system 1 may comprise an electrostatic charge generator configured to electrostatically charge the second material in use, e.g. using a charge roller or corona wire, as used in laser printers.
In another example (not illustrated), the pressure delivery mechanism 310 comprises a venturi tube, having a constricted or necked portion with a reduced cross-sectional area, having a higher flow velocity but lower static pressure than the upstream portion. The reservoir 144 of second material may be exposed to the constricted portion of the aerosol flow path 52a, and flows into the aerosol flow path under pressure due to the lower static pressure in the constricted portion. Inhalation by a user on the mouthpiece outlet 50 may also draw the second material into the aerosol flow path 52a.
In the above examples, the pressure delivery mechanism 310 is configured to deliver the second material into the flow path 52a upstream from the mouthpiece outlet 50, in any direction relative to the aerosol path 52a. The second material may generally be delivered at any angle relative to the aerosol flow path 52a, including fully aligned with the flow path (i.e. with substantially 0° offset therefrom), partially aligned (i.e. with substantially 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70 or 75° offset), substantially perpendicular (e.g. substantially 80, 85, 90, 95 or 100° offset), partially opposing, (i.e. with substantially 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70 or 75° offset from directly opposing flow) or substantially opposing the flow path (i.e. with substantially 180° offset). In some examples, the pressure delivery mechanism 310 is configured to direct the material substantially perpendicular to the flow path of aerosol or substantially away from the mouthpiece outlet 50, e.g. back towards the aerosol generator 48, to promote mixing with the aerosol. The pressure delivery mechanism 310 may be configured to deliver the second material at least 5 mm or at least 10 mm upstream from the outlet 50. Although aerosol from the aerosol generator 48 will typically warm the second material as they meet in the flow path 52a, providing pre-heating (as in the figure 12 example) and/or delivery upstream of the outlet 50 may reduce the risk of the second material being perceived as cold by the user (particularly if sprayed, cooling by expansion).

Other features

The system 1 may be modular, i.e. any one or more sub-components of the system 1 may be removable / replaceable. In particular, each reservoir 44, 144, 244, 344 may be independently removable / replaceable, optionally with or without any associated capillary material(s) 146, aerosol generator(s) 48, 148 or delivery mechanism 310. Similarly, any capillary material(s) 146, aerosol generator(s) 48, 148 and/or delivery mechanisms 310 may each be removable / replaceable in isolation or as part of a sub-system. In particular, the reservoir or cartridge may comprise a removable closure such as an end cap to provide hot-swappable reservoirs or capillary materials. Furthermore, each reservoir 44, 144, 244, 344 may be air permeable, e.g. comprising an air inlet having a semi-permeable membrane 180, e.g. made of PTFE PMA-20, to permit pressure equalisation without leaking material contained therein. The reservoir 44, 144, 244, 344 may be independently refillable, such as in-situ via an air inlet 28, 128 (which may comprise a semi-permeable membrane 180) to the reservoir.
For the avoidance of doubt, although the above examples illustrate and describe material delivery systems in combination with an aerosol delivery system, the material delivery system is contemplated in isolation, particularly as an aerosol-free delivery system, an aerosol delivery system, or a cartridge for / containing aerosol-generating or sensory material for use with an aerosol-free or aerosol delivery system, e.g. supplementing aerosol generated by an aerosol delivery system using an aerosol generator with a second material, in aerosol or non-aerosol form.
For the avoidance of any doubt, this disclosure explicitly encompasses permutations of features disclosed within the application as filed, particularly utilising variable porosity capillary materials with a compressible reservoir and/or a pressure delivery mechanism.
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: 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
32: sensor cavity or chamber
42: cartridge housing
44: first reservoir (for first aerosol-generating material)
46: wick
48: aerosol generator
50: mouthpiece outlet
51: air flow path through reusable part
52: first flow path
53: second flow path
128: second air inlet (for second reservoir)
144: second reservoir (for second aerosol-generating material)
145: chamber
146: capillary material
148: second aerosol generator (for second aerosol-generating material)
154: second reservoir outlet
155: chamber outlet
160: actuator
170: heater element
180: permeable membrane
244: compressible reservoir
245: chamber
255: chamber outlet
247: deformable reservoir wall
310: pressure delivery mechanism
325: nozzle
330: heating element
344: pressurised reservoir
354: pressurised reservoir outlet

Claims

A material delivery system comprising:
a. a reservoir for retaining aerosol-generating or sensory material; and

b. first and second capillary materials configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path for receipt by a user, wherein:
i. the second capillary material is exposed to the flow path and separates the first capillary material from the flow path; and

ii. the first capillary material has a lower average porosity than the second capillary material.
The system of claim 1, wherein the reservoir comprises the first capillary material and/or the second capillary material.
The system of any preceding claim, wherein the reservoir comprises a chamber for storing aerosol-generating or sensory material freely and the first capillary material surrounds or extends into an outlet from the chamber to the first capillary material.
The system of claim 3, wherein the chamber comprises multiple outlets to the first capillary material, each outlet having a different orientation or non-parallel axis of extent.
The system of any preceding claim, wherein:
a. the first capillary material surrounds a chamber for storing aerosol-generating or sensory material freely; and/or

b. the second capillary material surrounds the first capillary material.
The system of any preceding claim, wherein the first and/or second capillary material(s) comprise(s) a polymer material with micropores.
The system of any preceding claim, wherein the first capillary material has an overall average porosity of ≤ 5%, ≤ 10%, ≤ 15%, ≤ 20% or ≤ 25%.
The system of any preceding claim, wherein the first capillary material has a smaller average pore diameter than the second capillary material.
The system of any preceding claim, wherein the first capillary material has an average pore diameter of 0.1-100 µm, optionally 0.1-25 µm, 0.1-10 µm, 0.1-5 µm or 0.2-1 µm.
The system of any preceding claim, wherein the second capillary material has an average pore diameter of 1-1000 µm, optionally 10-250, 35-100 or 35-50 µm.
The delivery system of any preceding claim, configured to receive or further comprising:
a. an aerosol generator configured to generate aerosol from aerosol-generating material, wherein:
i. the system comprises a flow path from an aerosol outlet of the aerosol generator to a mouthpiece; and

ii. the second capillary material is configured to transport aerosol-generating or sensory material to the flow path, downstream of the aerosol outlet of the aerosol generator, for entrainment into the aerosol flow path, for receipt by a user.
An aerosol delivery system, comprising the system of any preceding claim, optionally further comprising aerosol-generating material.
A cartridge for a delivery system, the cartridge comprising:
a. a reservoir for retaining aerosol-generating or sensory material; and

b. first and second capillary materials configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path for receipt by a user, wherein:
i. the second capillary material is exposed to the flow path and separates the first capillary material from the flow path; and

ii. the first capillary material has a lower average porosity than the second capillary material.
A material delivery system comprising:
a. a reservoir for retaining aerosol-generating or sensory material; and

b. a capillary material configured to transport aerosol-generating or sensory material in or from the reservoir to a flow path for receipt by a user, the capillary material having a first end, distal from the flow path and a second end, exposed to the flow path, wherein:
i. the first end of the capillary material has a lower average porosity than the second end of the capillary material.
The system of any preceding claim, wherein the porosity has a porosity gradient, varying from:
a. small pores in the first capillary element or at the first end of the capillary element, proximal to the reservoir, to

b. large pores in the second capillary element or at the second end of the capillary element, proximal to or in the flow path.