EP4684663A1

EP4684663A1 - Delivery systems, devices and methods

Info

Publication number: EP4684663A1
Application number: EP24190056.2A
Authority: EP
Inventors: Dominic Woodcock; Theresa O'DONNELL; Thomas VICKERY; Ross CABOT; Nicole EAST; Christopher Wright; Joanna SOFFE; Samuel ESSAM; Chloe WINNINGTON; Nadir HERMES; Sophie ICETON; Katiane ROCHA DE OLIVEIRA; Andrew Allan Burton; Kelly O'ROURKE
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: WO2026022464A1

Abstract

Aerosol delivery system (1) for providing an aerosol to a user, including an aerosol-generating material storage portion (144, 148) for storing an aerosol-generating material; an aerosol generator (48) for generating an aerosol from the aerosol-generating material; an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system; and a second material storage portion (144, 148) for storing a second material. The second material storage portion comprises one or more storage media (246), configured to receive and store the second material, and configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.

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 aerosol-generating material (or 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 the release or delivery of material from the flavour element (or more generally reservoirs of a second material). Providing a second material that is readily vaporised provides good delivery of the second material for initial uses of the delivery system, but the delivery of the second material rapidly tapers off after the first few inhalations. Conversely, providing a second material that is less readily vaporised leads to relatively poor delivery of the second material, such that additional sources of energy such as a separate heater, which typically consume power, may be required to cause vaporisation of the second material. Various approaches are described herein which seek to help address or mitigate some of these issues.
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

According to a first aspect of certain embodiments there is provided an aerosol delivery system for providing an aerosol to a user, the aerosol delivery system including an aerosol-generating material storage portion for storing an aerosol-generating material; an aerosol generator for generating an aerosol from the aerosol-generating material; an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system; and a second material storage portion for storing a second material. The second material storage portion is arranged such that the second material is capable of being delivered to the outlet of the aerosol delivery system via a second material air pathway extending at least from the second material storage portion. The second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material. The one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
In some examples, the aerosol-generating material is a liquid aerosol-generating material, such as an e-liquid.
In some examples, the aerosol generator is a heater.
In some examples, the aerosol generator is provided in the air pathway so as to provide an aerosol generated from the aerosol-generating material to the air pathway.
In some examples, the second material is or comprises a flavouring and/or an active ingredient.
In some examples, the second material storage portion is removable/detachable from the aerosol delivery system.
In some examples, the second material storage portion is provided downstream of the aerosol generator and/or the second material air pathway is coupled to the air pathway at a position downstream of the aerosol generator.
In some examples, the size of the or each of the one or more storage media is smaller than the size of the second material storage portion.
In some examples, the second material storage portion defines a three-dimensional space in which the one or more storage media are held and is defined by three dimensions, and wherein each dimension of the or each of the one or more storage media is smaller than each of the three dimensions of the second material storage portion.
In some examples, the combined weight of the one or more storage media and the second material is less than a predetermined threshold.
In some examples, the predetermined threshold is 10 g or less, 5 g or less, or 1 g or less.
In some examples, the one or more storage media comprise a porous material, the porous material capable of retaining the second material in the pores of the porous material.
In some examples, the porous material includes a foam or a sponge.
In some examples, the one or more storage media comprise a plurality of spherical or approximately spherical balls, capable of holding the second material, and wherein during a user inhalation, the plurality of balls are capable of colliding with the walls of the second material storage portion and/or each other to aid in the release of the second material into the air flow through the second material storage portion.
In some examples, the one or more storage media comprises a cube or cuboidal storage medium capable of holding the second material, and wherein during a user inhalation, the cube or cuboidal storage medium is capable of colliding with the walls of the second material storage portion to aid in the release of the second material into the air flow through the second material storage portion.
In some examples, the aerosol delivery system further comprises one or more air-permeable barriers configured to permit air to flow therethrough but to prevent or restrict the passage of the one or more storage media therethrough, the one or more air-permeable barriers located so as to prevent or restrict the passage of the one or more storage media to the outlet of the aerosol delivery system.
In some examples, the air-permeable barrier is a mesh or other grid like structure, wherein openings defined by the mesh or grid-like structure are sized so as to be smaller than the dimensions of the one or more storage media.
In some examples, the one or more storage media are prevented from escaping the aerosol delivery system through the outlet of the aerosol delivery system.
In some examples, the second material air pathway extending at least from the second material storage portion has at least a region where the cross-sectional size is smaller than the dimensions of the one or more storage media.
In some examples, the one or more storage media are prevented from passing along the second material air pathway by virtue of the at least a region where the cross-sectional size is smaller than the dimensions of the one or more storage media.
In some examples, the aerosol delivery system further comprises a second material air pathway inlet, wherein the second material air pathway is arranged so as to be fluidly coupled with the second material air pathway inlet, such that when a user inhales on the aerosol delivery system, air is drawn into the second material storage portion via the second material air pathway inlet.
In some examples, the second material air pathway extends from the second material air inlet to the outlet via the second material storage portion such that, in use, inhaled air is capable of being drawn into the second material storage portion and through to the outlet to entrain the second material in the inhaled air.
In some examples, the second material air inlet is separate from an aerosol delivery system air inlet fluidly coupled to the air pathway.
In some examples, the aerosol delivery system comprises an aerosol delivery system air inlet fluidly coupled to the air pathway, and wherein the second material air inlet is the aerosol delivery system air inlet.
In some examples, at least one of the one or more air-permeable barriers is located so as to prevent or restrict the passage of the one or more storage media to the second material air pathway inlet of the aerosol delivery system.
In some examples, the one or more storage media are prevented from escaping the aerosol delivery system through the second material air pathway inlet.
In some examples, the aerosol provision system is configured to generate turbulent air flow in the second material storage portion to thereby increase the degree of motion of the one or more storage media in the second material storage portion.
In some examples, the second material air pathway is provided with one or more baffles to generate the turbulent airflow.
In some examples, the second material air pathway is shaped so as to generate the turbulent airflow, e.g., is spiral shaped.
According to a second aspect of certain embodiments there is provided an article for use with an aerosol delivery device to form an aerosol delivery system for providing an aerosol to a user, wherein the aerosol delivery system comprises an aerosol-generating material storage portion for storing an aerosol-generating material, an aerosol generator for generating an aerosol from the aerosol-generating material, and an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system, the article including a second material storage portion for storing a second material, a second material air pathway extending at least from the second material storage portion and to an outlet of the article, wherein the outlet of the article when coupled to the aerosol delivery device, is, or is fluidly coupled to, the outlet of the aerosol delivery system, such that the second material is capable of being delivered to the outlet of the aerosol delivery system, and the second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material. The one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
In some examples, in particular in some examples of the article, the second material is not a powder, wherein a powder includes fine, dry particles.
In some examples, in particular in some examples of the article, the second material is a liquid.
In some examples, in particular in some examples of the article, the second material comprises an active and/or other substance(s) having a boiling point in the range from about 50°C to about 300°C, or from about 100°C to about 300°C. In other examples, the second material comprises an active and/or other substance(s) having 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 of the second material 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.
According to a third aspect of certain embodiments there is provided an aerosol delivery device for coupling with an aerosol-generating material storage portion for storing an aerosol-generating material and a second material storage portion for storing a second material to form an aerosol delivery system for delivering an aerosol to a user, the aerosol delivery device including an air pathway capable of being fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery device; and a second material air pathway capable of being fluidly connected to the second material storage portion, and extending at least from the second material storage portion. The aerosol delivery device is configured such that the second material storage portion is capable of being arranged such that the second material is capable of being delivered to the outlet of the aerosol delivery system via the second material air pathway. The second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material, wherein the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
In some examples, the second material air pathway is configured to prevent or restrict the passage of the one or more storage media along to the second material air pathway.
According to a fourth aspect of certain embodiments there is provided a method for manufacturing an aerosol delivery system for providing an aerosol to a user, the method including providing an aerosol-generating material storage portion for storing an aerosol-generating material; providing an aerosol generator for generating an aerosol from the aerosol-generating material; providing an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system; and providing a second material storage portion for storing a second material. The second material storage portion is arranged such that the second material is capable of being delivered to the outlet of the aerosol delivery system via a second material air pathway extending at least from the second material storage portion. The second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material. The one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
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 the second cartridge part of the delivery system for delivering a first aerosol-generating material and a second material, where the second cartridge part includes a reservoir comprising a single porous substrate storing the second material;
Figure 4 is a schematic cross-section view of the second cartridge part of the delivery system for delivering a first aerosol-generating material and a second material, where the second cartridge part includes a reservoir comprising a plurality of porous substrates, each storing the second material;
Figure 5 is a schematic cross-section view of a modification of a delivery system for delivering a first aerosol-generating material and a second material, where the delivery system includes a section of the second material flow path is reduced relative to the remaining parts for preventing the passage of the porous substrate material along the second material flow path;
Figure 6 is a schematic cross-section view of a modification of a delivery system for delivering a first aerosol-generating material and a second material, where the delivery system includes one or more baffles for creating turbulent airflow through the reservoir to thereby promote movement of the one or more storage media; and
Figure 7 is an example method for manufacturing the aerosol delivery system including a second reservoir comprising one or more storage media.

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" or "inhalation sensor", in that the airflow sensor 30 is used to detect when a user is puffing or inhaling 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 and a second cartridge part 4b. The first cartridge part 4a may be substantially the same as the cartridge part 4 described in figure 1. The second cartridge part 4b may be a system in itself and may be releasably connectable to existing wider systems, such as the reusable device part 2 or first cartridge part 4a, e.g. using an interference fit. In other examples, both the first and second cartridge parts 4a and 4b may be integrally formed to provide a single cartridge part 4 that is releasably connectable to the reusable device part 2.
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 of the delivery system 1, for receipt by the user at the mouthpiece outlet 50. The second material may generally be a liquid or a particulate.
Precisely though what route the second material is delivered to the mouthpiece outlet 50 may depend on the particular implementation at hand and the arrangement of the first and second cartridge parts 4a, 4b. The second cartridge part 4b comprises a second material flow path 52b that extends at least from the reservoir 144 (and potentially via any air inlet 128 of second cartridge part 4b) to the mouthpiece outlet 50 (or one of a plurality of mouthpiece outlets 50). The second material flow path 52b may either directly pass to the or a mouthpiece outlet 50, or indirectly via the flow path 52 of the first cartridge part 4a (that is, the second material flow path 52b passes to the flow path 52 before the flow path 52 reaches the mouthpiece outlet 50). In other examples, such as that shown in figure 2, the second cartridge part 4b comprises a through flow path 52a extending through the second cartridge part 4b to a mouthpiece outlet 50 defined at the end of the second cartridge part 4b and arranged so as to couple to the flow path 52 of the first cartridge 4a. In such implementations, the second material flow path 52b may be provided in fluid communication with the mouthpiece opening 50 (or one of a plurality thereof), either directly or via the through flow path 52a of the second cartridge part 4b. In other examples, the flow path 52 of the first cartridge part 4a may pass through the reservoir 144 of the second cartridge part 4b to deliver aerosol generated by the aerosol generator 48 to, and through, the reservoir 144 before being passed along the second material flow path 52b to the mouthpiece outlet 50. In broad summary, the second material flow path 52b may be provided parallel to the flow path 52 of the first cartridge part 4a or flow path 52a of the second cartridge part 4b and either terminate at a mouthpiece opening 50 or adjoin the flow path 52 prior to terminating at a mouthpiece opening, or the second material flow path 52b may be provided sequentially after the flow path 52 or flow path 52a whereby the second material flow path 52b terminates at the mouthpiece outlet 50.
In either implementation, the second material flow path 52b is provided in fluid communication with the reservoir 144 of the second cartridge part 4b such that the second material in the reservoir 144 is able to be provided to the mouthpiece outlet 50 via the second material flow path 52b through vaporisation of the second material. The mouthpiece outlet 50 may thus receive materials from a single or multiple flow paths. 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 some implementations, the second material is capable of vaporising, at least to some degree, at room temperature. Optionally, a second aerosol generator 148 may be provided and 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. In some implementations, however, the second material is capable of vaporisation without an additional source of energy, such as heat. In such implementations, the aerosol delivery system 1 does not include a second aerosol generator 148.
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. In accordance with the present disclosure, the second reservoir 144 may store some or all of the second material in one or more storage media. The one or more storage media are explained in more detail below, but broadly may comprise one or more substrate materials, such as a capillary material 146 (e.g., a porous substrate material), capable of receiving and storing the second material thereon or therein. The second material flow path 52b may extend through the second reservoir 144 and / or substrate material / capillary material 146 towards the outlet.
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 144 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 substrate / 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.
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 in one or more storage media, such as capillary materials 146 or 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 or second material flow path 52b from reservoir 144. In particular, the formulation of the second material may comprise one or more active 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, 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 substance(s) have a vapour pressure of from about 0.0001 mmHg to about 15 mmHg; optionally wherein the active 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.

Kinetic Release

In accordance with the present disclosure, the reservoir 144 comprises one or more storage media configured to receive and store (e.g., in or on) the second material. While the second material may be volatile in some implementations, the rate at which the second material is vaporised from the one or more storage media in the absence of any external sources of energy (i.e., excluding sources other than thermal energy from an environmental temperature) may be insufficient for delivery of the second material to a user. That is, a relatively low, or zero, amount of second material may be provided in the aerosol delivered to the user in the absence of any external sources of energy, which may lead to reduced perception of the second material by the user. This may particularly be the case after several uses of the aerosol delivery system 1, for example when the second material that is more readily released / vaporised from the one or more storage media has already been withdrawn from the storage medium.
In order to help improve the release of the second material from the one or more storage media, a source of energy may be provided to the reservoir 144 / one or more storage media. In some instances, a second aerosol generator 148 (such as a heater or a vibrator) may be employed to impart thermal or kinetic energy to the second material to promote vaporisation thereof. However, such implementations typically require an electrical power source in order to operate the second aerosol generator 148, which may increase power consumption and or require a more complex arrangement to provide and control the flow of power to the second aerosol generator 148.
In accordance with the present disclosure, the aerosol delivery system 1 is configured to impart kinetic energy to the one or more storage media from a user inhalation. In particular, the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the reservoir 144. That is, the user inhalation causes this movement of the one or more storage media and, via contact with the walls of the reservoir 144 and/or other storage media, the user inhalation subsequently imparts kinetic energy to the one or more storage media to help aid in the release of the second material therefrom. In this way, a source of external energy can be applied to the one or more storage media to promote the release of the second material.
The term "movement" is intended to encompass any such physical movement of the one or more storage media. For example, movement may encompass movement in a chaotic or random pattern or path, or it may encompass movement along a predetermined or expected path. In the latter case, the movement may substantially be along a predetermined pathway that airflow through the reservoir 144 substantially follows, such as a swirling or corkscrew-type motion. Movement may generally be considered to encompass movement such as swirling, lifting, etc. of the one or more storage media in the reservoir 144.
Figure 3 schematically represents the second cartridge 4b of an aerosol delivery system 1 according to a first example. Figure 3 shows a second cartridge 4b in isolation of the remaining parts of the aerosol delivery system 1 for ease of explanation of the underlying principles of the present disclosure, but it should be appreciated that the second cartridge 4b of figure 3 may be used in any of the aerosol delivery systems 1 mentioned previously.
The second cartridge part 4b of figure 3 comprises a reservoir 144 (or more generally a second material storage portion) for storing a second material, an air inlet 128 fluidly coupled to the reservoir 144, and a second material flow path 52b extending from the air inlet 128, though the reservoir 144 and to a mouthpiece outlet (not shown in figure 3), either directly or via the flow path 52 or 52a. The reservoir 144 is a volume defined by the walls of a housing (shown schematically in figure 3).
Within the reservoir 144 is provided a substrate material 146 (which may be a porous / capillary material as described above) as an example of the one or more storage media described above. The substrate material 146 is configured to received and store the second material. For example, the substrate material 146 may be saturated in liquid second material, or may be coated or otherwise impregnated with the second material, and inserted into reservoir 144, e.g., during manufacture of the second cartridge 4b. The substrate material 146 is sized so as to be received within the volume defined by the reservoir 144 in such a way that the substrate material 146 is not tightly held and is free to move within the reservoir 144 in at least one direction. For example, in the described implementation, the reservoir 144 defines a cylindrical volume in which the substrate material 146 is positioned. The substrate material 146 may also be cylindrical and have a radius and/or a length that is smaller than the corresponding radius and/or length of the volume of the reservoir 144 to thereby provide at least one gap in either the radial and/or length/axial directions. It should be appreciated that substrate material 146 may not necessarily have the same shape as the volume defined by the reservoir 144 (for example, the substrate material 146 may instead be a cube or cuboidal shape). Broadly speaking, the volume as defined by the outer perimeter (or contours) of the substrate material 146 is set to be less than the volume defined by the reservoir 144.
In use, when a user inhales on the mouthpiece outlet 50 of the delivery system 1, air enters the reservoir 144 via the air inlet 128 and passes around and/or through the porous substrate 146 to the outlet of the reservoir 144 as it travels along the second material flow path 52b. This is schematically shown by the airflow A in figure 3. As the airflow A passes through the reservoir 144, the airflow A entrains any vaporised second material in the reservoir 144 or from the porous substrate 146 and subsequently delivers the second material in the airstream A to the mouthpiece outlet 50. However, in accordance with the present disclosure, the airflow also interacts with the porous substrate 146 to cause the porous substrate to move within the reservoir 144. For example, three white arrows are shown in figure 3 indicative of example forces that might be applied to the porous substrate 146 during use. For instance, by virtue of the user inhalation, the porous substrate 146 may move in the direction of the outlet of the reservoir 144 to subsequently hit the right-hand wall (with reference to the orientation of figure 3). Additionally, the porous substrate 146 may oscillate between the side walls of the reservoir 144 (shown by the two oppositely facing white arrows in figure 3) as the airflow A in the reservoir 144 changes during an inhalation. In this regard, the airflow A as it passes through the reservoir 144 and interacts with the surfaces of the porous substrate 146 may produce turbulent airflow which causes the porous substrate 146 to move/oscillate within the reservoir 144. By virtue of these movements of the porous substrate 146, which contains/stores the second material, impacts between the porous substrate 146 and the walls of the reservoir 144 can transfer kinetic energy to the second material helping to vaporise the second material from the porous substrate 146.
In order to allow the porous substrate 146 to move within the reservoir 144, the combined weight of the porous substrate 146 and second material should be set that a typical user inhalation provides sufficient force to cause the porous substrate 146 to move within the reservoir 144. The precise value of the combined weight will be dependent on a number of factors, including the inhalation strength of a given user, the dimensions of the reservoir 144 and the dimensions of the flow path 52 / configuration of the first and second cartridge parts 4a, 4b. Through empirical testing or computer simulation, it is possible to identify the maximum combined weight of the porous substrate 146 and second material that is capable of being moved by a user inhalation. However, by way of example, the combined weight of the porous substrate 146 and second material may not exceed 10g, may not exceed 5g, may not exceed 2g, or may not exceed 1g.
The reservoir 144 of the second cartridge 4b of figure 3 includes an inlet opening 144a and an outlet opening 144b. These openings 144a, 144b allow for fluid communication of the second material flow path 52b with the reservoir 144. In the example of figure 3, to prevent the porous substrate 146 from exiting the reservoir 144 via the inlet opening 144a and/or via the outlet opening 144b, the porous substrate 146 is sized such that the porous substrate 146 is, physically, unable to pass through the openings 144a, 144b. In some examples, all dimensions (e.g., length, width, height, etc.) of the porous substrate 146 are greater than the dimensions of the openings 144a, 144b. In other examples, at least two of the dimensions of the porous substrate 146 are greater than the dimensions of the openings 144a, 144b, provided that the porous substrate 146 is unable to be orientated in the reservoir 144 during use such that it is able to pass through the openings 144a, 144b.
In alternative implementations, the openings 144a, 144b may be provided with an air-permeable barrier element (not shown), such as a mesh or a grid-like structure or the like, or a permeable membrane, that permits air / second material to flow through the barrier element but that prevents or restricts the porous substrate 146 from passing through the barrier element and through the openings 144a, 144b. It should be appreciated that the barrier element(s) may be located along the second material flow path 52b and not necessarily at the inlet opening 144a and outlet opening 144b.
Figure 4 schematically shows a second cartridge 4b of an aerosol delivery system 1 according to a second example. Figure 4 will be generally understood from figure 3, and similarly shows a second cartridge 4b in isolation of the remaining parts of the aerosol delivery system 1 for ease of explanation of the underlying principles of the present disclosure, but it should be appreciated that the second cartridge 4b of figure 4 may be used in any of the aerosol delivery systems 1 mentioned previously. Only the differences herein will be explained.
In figure 4, the cylindrical porous substrate 146 has been replaced with a plurality of spherical porous substrates 246 (or spherical balls). The spherical porous substrates 246 may not necessarily be perfectly spherical, but may be approximately spherical account for manufacturing tolerances (e.g., within ±10% of a sphere). In any case, the reservoir 144 in this implementation comprises a plurality of spherical porous substrates 246 as an example of a plurality of storage media (although it should be appreciated that the porous substrates 246 may take any shape). The porous substrates 246 are each similarly configured to receive and store the second material (e.g., saturated in liquid second material, coated or otherwise impregnated with the second material). In this example, each of the porous substrates 246 are substantially smaller than the volume defined by the reservoir 144 (that is, each of the dimensions of individual porous substrates 246 are less than the dimensions of the volume defined by the reservoir 144. Moreover, the combined volume of all of the porous substrates 246 is set to be less than the volume defined by the reservoir 144. In this implementation, the porous substrates 246 are similarly held within the reservoir 144 such that they are free to move within the reservoir 144. Although each of the porous substrates 246 are significantly smaller than the reservoir 144, the total number of porous substrates 246 held in the reservoir 144 is such that at least some gaps exist to enable the porous substrates 246 to move within the reservoir 144. In other words, the porous substrates 246 are not packed tightly into the reservoir 144 such that they are unable to move within the reservoir 144.
In a similar manner, in use, when a user inhales on the mouthpiece outlet 50 of the delivery system 1, air enters the reservoir 144 via the air inlet 128 and passes around and/or through the porous substrates 246 to the outlet of the reservoir 144 as it travels along the second material flow path 52b. This is schematically shown by the airflow A in figure 4. As the airflow A passes through the reservoir 144, the airflow A entrains any vaporised second material in the reservoir 144 or from the porous substrates 246 and subsequently delivers the second material in the airstream A to the mouthpiece outlet 50. In the implementation of figure 4, it should be appreciated that the porous substrates 246 may present a greater total surface area that the airflow A may interact with, as compared to the porous substrate 146 of figure 3. As such, this configuration in figure 4 may enable greater amounts of the second material to be withdrawn from (i.e., vaporised from) the porous substrates 246 by virtue of the airflow passing over a greater surface area of the porous substrates 246.
This aside, the airflow A also interacts with the porous substrates 246 to cause the porous substrates 246 to move within the reservoir 144. This is broadly similar to the situation in the implementation of figure 3 except in this situation each of the individual porous substrates 246 is significantly smaller and therefore significantly lighter than the porous substrate 146 of figure 3. In this case, a relatively smaller force may be applied (e.g., through user inhalation) to generate even small movements of the porous substrates 246 which may otherwise not agitate the porous substrate 146 in the implementation of figure 3, and/or greater movements of the porous substrates 246 may be possible at larger applied forces. Moreover, the porous substrates 246 are each individually capable of movement (e.g., as indicated schematically by the white arrows shown for one of the individual porous substrates 246). Hence, not only may each porous substrate 246 move by a relatively greater amount (e.g., distance) as compared to the porous substrate 146 of figure 3, but the porous substrates 246 may experience a greater number of collisions (e.g., not only with the front/rear and side walls of the reservoir 144, but also with other porous substrates 246). Accordingly, as compared to the implementation of figure 3, there may be relatively more collisions, and thus relatively more second material, released by the transfer of kinetic energy to the second material thereby helping to vaporise the second material from the porous substrates 246.
As described above, in order to allow the porous substrates 246 to move within the reservoir 144, the combined weight of each individual porous substrate 246 and second material should be set that a typical user inhalation provides sufficient force to cause the porous substrates 246 to move within the reservoir 144. The precise value of the combined weight will be dependent on a number of factors, including the inhalation strength of a given user, the dimensions of the reservoir 144 and the dimensions of the flow path 52 / configuration of the first and second cartridge parts 4a, 4b. Through empirical testing or computer simulation, it is possible to identify the maximum combined weight of each of the porous substrates 246 and second material that is capable of being moved by a user inhalation. However, by way of example, the combined weight of each of the porous substrates 246 and second material may not exceed 1g, may not exceed 0.5g, may not exceed 0.2g, or may not exceed 0.1g.
In the example of figure 4, the openings 144a, 144b of the reservoir 144 are provided with an air-permeable barrier element 146a, 146b, such as a mesh or grid-like structure or the like, that permits air / second material to flow through the barrier element 146a, 146b but that prevents the porous substrates 246 from passing through the barrier element 146a, 146b and through the openings 144a, 144b. The barrier element may be suitably configured to prevent individual porous substrates 246 from passing therethrough. For example, if the barrier element is a mesh, the mesh size may be smaller than the smallest dimensions of the porous substrate 246. It should be appreciated that the barrier element(s) may be located along the second material flow path 52b and not necessarily at the inlet opening 144a and outlet opening 144b. Particularly in the case of the barrier element 146b, which is located downstream of the reservoir 144 during use of the second cartridge 4b, the barrier element 146b is provided to prevent the porous substrates 246 from proceeding down along the second material flow path 52b to the mouthpiece outlet 50. The barrier element 146b may therefore prevent the porous substrates 246 from being inhaled by the user and/or potentially providing a choking hazard depending on the size of the porous substrates 246.
Alternatively, or additionally, the second material flow path 52b may comprise a region or section of reduced cross-section, perpendicular to the direction of air flow along the second material flow path 52b. The section of reduced cross-section is sized to be smaller than the corresponding cross-section of an individual porous substrate 246. Figure 5, for example, schematically represents such an implementation.
Figure 5 schematically shows a part of the second cartridge 4b from figure 4, but additionally shows more of the second material flow path 52b extending from the outlet 144b of the reservoir 144. In figure 5, a first porous substrate 246a (as one of the porous substrates 246 of figure 4) is shown schematically in the second material flow path 52b downstream of the outlet 144b. As can be seen, the first porous substrate 246a is sized so as to be able to flow into the second material flow path 52b downstream of the outlet 144b. A second porous substrate 246b is schematically shown downstream of the first porous substrate 246a. However, to prevent the second porous substrate 246b from travelling further in the downstream direction of the second material flow path 52b, towards the mouthpiece outlet 50, the second material flow path 52b includes a section of reduced cross-section 152b. The section of reduced cross-section is sized such that the porous substrate 246 is unable to pass through the section of reduced cross-section 152b. For example, if the porous substrate 246 is a sphere of a certain diameter, the section of reduced cross-section 152b may be circular (in a direction perpendicular to the direction of travel of the air / second material along the second material flow path 52b) and of a diameter less than the diameter of the porous substrate 246. In this way, the section of reduced cross-section 152b prevents the porous substrate246 from passing further along the second material flow path 52b. It should be appreciated that the shape and size of the section of reduce cross-section 152b may be configured in any suitable manner depending on the size and shape of the porous substrates 246. Moreover, the shape of the section of reduce cross-section 152b need not be the same as the cross-sectional shape of the porous substrate 246.
In the described implementations, the resulting airflow A through the reservoir 144 is a function of at least the shape of the reservoir 144 and the configuration of the porous substrates 146, 246. However, in further implementations of the present disclosure, the reservoir 144 or air inlet 128 (if present) is configured to further manipulate the airflow A, for example, to provide a more turbulent airflow through the reservoir 144 to potentially generate more movement of the porous substrates 146, 246.
Figure 6 schematically shows a part of the second cartridge 4b from figure 3, but additionally shows more of the second material flow path 52b extending from the inlet 128 to the inlet 144b of the reservoir 144. Figure 6 will be understood from figure 3, and the same components are labelled with the same reference signs. Only the differences will be described herein.
In figure 6, for explaining the purposes of this implementation, the second material flow path 52b is shown in an elongated manner as compared to figure 3, for example, and is shown extending from the inlet 128 to the inlet 144b of the reservoir 144. Along the second material flow path 52b is shown a plurality of baffles 154. The baffles 154 are configured to act as a partial obstruction to the flow of air along the second material flow path 52b. The baffles 154 therefore help to generate turbulent airflow along the second material flow path 52b. For instance, in the absence of the baffles 154, the airflow through the second material flow path 52b would otherwise be substantially planar, but the baffles 154 act to disrupt the substantially planar airflow and generate turbulent airflow. When the turbulent airflow reaches the reservoir 144, containing the plurality of porous substrates 246, the turbulent airflow may help to generate more movement (or rather, a wider range or movement / directions along which the porous substrates 246 may, at least initially, travel). The turbulent airflow may therefore promote more chaotic movement of the porous substrates 246 leading to more collisions, and hence a greater release of the second material from the porous substrates 246.
The baffles 154 may take any suitable shape and be in any suitable arrangement for generating the turbulent airflow. The precise shape and arrangement of the baffles 154 may depend on the configuration of the aerosol delivery system 1 and the second material flow path 524b2, for example, as well as the desired magnitude of turbulent air desired. In addition, in some implementations, it may be desirable to provide turbulent air of a certain form or that follows a certain shape. For instance, a turbulent airflow of a swirling or corkscrew nature may be desired in order to promote collisions of the porous substrates 246 and release the second material. The baffles 154 may be arranged to help generate such an airflow; for example, by being arranged so as to mimic the desired airflow pattern (such as arranged in a spiral / corkscrew pattern). The configuration / arrangement of the baffles 154 may be found empirically or through computer simulation / modelling, for example. Broadly speaking, the number, position, shape, angle, and longitudinal extent of the baffles 154 may all be parameters that may be configured to provide turbulent airflow.
It should be appreciated that turbulent airflow may be provided in ways other than with baffles 154. For example, instead of baffles 154, or in addition to the baffles 154, the second material flow path 52b may be shaped or otherwise configured to provide turbulent airflow. For example, the section of the second material flow path 52b extending between the inlet 128 and the inlet 144b of the reservoir 144 may be shaped to provide a certain airflow. For example, if the second material flow path 52b is shaped as a spiral, relative to the reservoir 144, then airflow along the second material flow path 52b is more likely to result in a spiral airflow being produced in the reservoir 144. Alternatively, to provide turbulent airflow, the second material flow path 52b may be configured such that air flow that enters the reservoir 144 at an angle to the longitudinal axis of the reservoir 144. Thus, broadly speaking, the aerosol delivery system 1 may be configured in any suitable manner to help promote turbulent (or non-planar) airflow through the reservoir 144.
In addition, although it has been described above that the part of the second material flow path 52b upstream of the reservoir 144 may be adapted in some implementations to provide turbulent (or non-parallel) airflow, in other implementations, the part of the second material flow path downstream of the reservoir 144 may instead or alternatively be adapted to provide turbulent (or non-parallel) airflow. In addition, in other implementations, the reservoir 144 itself may additionally or alternatively be configured to provide turbulent (or non-parallel) airflow.
Figure 7 represents an example method for manufacturing an aerosol delivery system 1 according to the present disclosure.
The method starts at step S1. At step S1, the method involves providing an aerosol-generating material storage portion for storing an aerosol-generating material. For example, this may be the reservoir 44 of the first cartridge part 4a. The reservoir 44 may be provided in any suitable manner; for example, through injection moulding of a plastics material.
At step S2, the method involves providing an aerosol generator, such as a heater 48, for generating an aerosol from the aerosol-generating material stored in the aerosol-generating material storage area. It should be appreciated that step S2 may be performed before, during or after step S1 depending on how the aerosol delivery system 1 is constructed, and in particular, depending on whether the reservoir 44 is moulded around the aerosol generator 48.
At step S3, the method involves providing an air pathway, such as flow path 52, that is fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet, such as mouthpiece outlet 50, of the aerosol delivery system 1. Again, it should be appreciated that step S3 may be performed before, after or during steps S1 and/or S2 depending on how the aerosol delivery system 1 is constructed. In some implementations, the reservoir 44 and air pathway 52 may be formed simultaneously. For example, the housing of the reservoir 44 may define, at least in part, the air pathway 52.
At step S4, the method involves providing a second material storage portion for storing a second material. The second material storage portion, which may include reservoir 144 of the second cartridge part 4b, may be formed using suitable manufacturing techniques, such as injection moulding. Step S4 may be performed independently of steps S1 to S3, particularly if the second cartridge part 4b is manufactured separately to (and is connectable with) the first cartridge part 4a. The second material storage portion is arranged such that the second material is capable of being delivered to the outlet 50 of the aerosol delivery system 1 via a second material air pathway, such as second material flow path 52b. As noted above, the second material flow path 52b extends at least from the second material storage portion, but may also extend into and through the reservoir 144, and to the inlet 128 (if present).
At step S4, or as a separate step of the method, the second material storage portion is provided with one or more storage media, such as porous substrates 146, 246. The one or more storage media may be provided to the second reservoir during manufacture, e.g., sealed within the reservoir 144 when the reservoir 144 is being formed, or alternatively may be provided at a later time. For example, in the latter implementations, the reservoir 144 may be separable such that the inner volume of the reservoir 144 is accessible when the reservoir 144 is separated to thereby allow insertion and/or replacement of the one or more storage media. The one or more storage media are configured to receive and store the second material. For example, the second material may be absorbed by the one or more storage media, or otherwise be coated or have the second material disposed thereon.
In accordance with the present disclosure, the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion, in effect, by the forces generated by the user inhalation. Accordingly, the one or more storage media are configured such that the weight and/or size thereof are capable of being moved by the forces generated by a user inhalation. The user inhalation imparts kinetic energy to the one or more storage media to cause movement of the one or more storage media. By virtue of the interaction of the one or more storage media in the reservoir 144, e.g., such as collisions with the walls thereof or between other storage media, the imparted kinetic energy can be used to help aid in the release of the second material from the one or more storage media. Hence, in use, this may result in relatively more of the second material being vaporised from the one or more storage media, and in some implementations, this may also allow for second material to be vaporised from the one or more storage media at a perceptible level after a greater number of inhalations on the aerosol delivery system 1.

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, may be independently removable / replaceable, optionally with or without any associated capillary material(s) 146, or aerosol generator(s) 48, 148. Similarly, any capillary material(s) 146, or aerosol generator(s) 48, 148 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.
Although the description has focused on a first cartridge 4a that includes a liquid aerosol-generating material, it should be appreciated that the first cartridge 4a may be configured to generate aerosol from any suitable aerosol-generating material, e.g., such as tobacco or tobacco derived materials.
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.

Claims

An aerosol delivery system for providing an aerosol to a user, the aerosol delivery system comprising:
an aerosol-generating material storage portion for storing an aerosol-generating material;

an aerosol generator for generating an aerosol from the aerosol-generating material;

an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system; and

a second material storage portion for storing a second material,

wherein the second material storage portion is arranged such that the second material is capable of being delivered to the outlet of the aerosol delivery system via a second material air pathway extending at least from the second material storage portion, and

the second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material,

wherein the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
The aerosol delivery system of claim 1, wherein the size of the or each of the one or more storage media is smaller than the size of the second material storage portion.
The aerosol delivery system of claim 1 or 2, wherein the combined weight of the one or more storage media and the second material is less than a predetermined threshold.
The aerosol delivery system of any of the preceding claims, wherein the one or more storage media comprise a porous material, the porous material capable of retaining the second material in the pores of the porous material.
The aerosol delivery system of any of the preceding claims, wherein the one or more storage media comprise a plurality of spherical or approximately spherical balls, capable of holding the second material, and wherein during a user inhalation, the plurality of balls are capable of colliding with the walls of the second material storage portion and/or each other to aid in the release of the second material into the air flow through the second material storage portion.
The aerosol delivery system of any of claims 1 to 4, wherein the one or more storage media comprises a cube or cuboidal storage medium capable of holding the second material, and wherein during a user inhalation, the cube or cuboidal storage medium is capable of colliding with the walls of the second material storage portion to aid in the release of the second material into the air flow through the second material storage portion.
The aerosol delivery system of any of the preceding claims, wherein the aerosol delivery system further comprises one or more air-permeable barriers configured to permit air to flow therethrough but to prevent or restrict the passage of the one or more storage media therethrough, the one or more air-permeable barriers located so as to prevent or restrict the passage of the one or more storage media to the outlet of the aerosol delivery system.
The aerosol delivery system of any of the preceding claims, wherein the second material air pathway extending at least from the second material storage portion has at least a region where the cross-sectional size is smaller than the dimensions of the one or more storage media.
The aerosol delivery system of any of the preceding claims, wherein the aerosol delivery system further comprises a second material air pathway inlet, wherein the second material air pathway is arranged so as to be fluidly coupled with the second material air pathway inlet, such that when a user inhales on the aerosol delivery system, air is drawn into the second material storage portion via the second material air pathway inlet.
The aerosol delivery system of claim 9, when dependent on claim 7, wherein at least one of the one or more air-permeable barriers is located so as to prevent or restrict the passage of the one or more storage media to the second material air pathway inlet of the aerosol delivery system.
The aerosol delivery system of any of the preceding claims, wherein the aerosol provision system is configured to generate turbulent air flow in the second material storage portion to thereby increase the degree of motion of the one or more storage media in the second material storage portion.
An article for use with an aerosol delivery device to form an aerosol delivery system for providing an aerosol to a user, wherein the aerosol delivery system comprises an aerosol-generating material storage portion for storing an aerosol-generating material, an aerosol generator for generating an aerosol from the aerosol-generating material, and an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system, the article comprising:
a second material storage portion for storing a second material,

a second material air pathway extending at least from the second material storage portion and to an outlet of the article, wherein the outlet of the article when coupled to the aerosol delivery device, is, or is fluidly coupled to, the outlet of the aerosol delivery system, such that the second material is capable of being delivered to the outlet of the aerosol delivery system, and

the second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material,

wherein the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
An aerosol delivery device for coupling with an aerosol-generating material storage portion for storing an aerosol-generating material and a second material storage portion for storing a second material to form an aerosol delivery system for delivering an aerosol to a user, the aerosol delivery device comprising:
an air pathway capable of being fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery device; and

a second material air pathway capable of being fluidly connected to the second material storage portion, and extending at least from the second material storage portion,

wherein the aerosol delivery device is configured such that the second material storage portion is capable of being arranged such that the second material is capable of being delivered to the outlet of the aerosol delivery system via the second material air pathway, and

wherein the second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material, wherein the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.
The aerosol delivery device of claim 13, wherein the second material air pathway is configured to prevent or restrict the passage of the one or more storage media along to the second material air pathway.
A method for manufacturing an aerosol delivery system for providing an aerosol to a user, the method comprising:
providing an aerosol-generating material storage portion for storing an aerosol-generating material;

providing an aerosol generator for generating an aerosol from the aerosol-generating material;

providing an air pathway fluidly coupled to the aerosol-generating material storage portion and arranged so as to be fluidly coupled with an outlet of the aerosol delivery system; and

providing a second material storage portion for storing a second material,
wherein the second material storage portion is arranged such that the second material is capable of being delivered to the outlet of the aerosol delivery system via a second material air pathway extending at least from the second material storage portion, and
the second material storage portion comprises one or more storage media, the one or more storage media configured to receive and store the second material,

wherein the one or more storage media are configured such that, during a user inhalation, the one or more storage media are capable of moving within the second material storage portion such that the user inhalation imparts kinetic energy to the one or more storage media to aid in the release of the second material therefrom.