WO2023046503A1

WO2023046503A1 - Aerosol delivery component

Info

Publication number: WO2023046503A1
Application number: PCT/EP2022/075184
Authority: WO
Inventors: John Williams; Jill JONES; Jeroen DE VROOMEN; Ian Stuart
Original assignee: Nerudia Limited
Priority date: 2021-09-27
Filing date: 2022-09-09
Publication date: 2023-03-30

Abstract

Disclosed is an aerosol-delivery component comprising: a vaporiser including an elongate wick and a heating element, wherein the heating element includes a coiled portion wound around the wick with a pitch of 0.6mm or more, and wherein the coiled portion extends over 40% or more of the axial length of the wick.

Description

AEROSOL DELIVERY COMPONENT

Technical field

The present disclosure relates to an aerosol-delivery component (e.g. a smoking substitute component), which may be a consumable for receipt in an aerosol-delivery device to form an aerosoldelivery system (e.g. a smoking substitute system).

Background

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute systems in order to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute systems, which may also be known as electronic nicotine delivery systems, may comprise electronic systems that permit a user to simulate the act of smoking by producing an aerosol, also referred to as a “vapour”, which is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour and health risks associated with traditional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and tobacco products.

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories. Some smoking substitute systems are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute systems do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form).

There are a number of different categories of smoking substitute systems, each utilising a different smoking substitute approach. A smoking substitute approach corresponds to the manner in which the substitute system operates for a user. One approach for a smoking substitute system is the so-called “vaping” approach, in which a vaporisable liquid, typically referred to (and referred to herein) as “e-liquid”, is heated by a heater to produce an aerosol vapour which is inhaled by a user. An e-liquid typically includes a base liquid as well as nicotine and/or flavourings. The resulting vapour therefore typically contains nicotine and/or flavourings. The base liquid may include propylene glycol and/or vegetable glycerine.

A typical vaping smoking substitute system includes a mouthpiece, a power source (typically a battery), a tank or liquid reservoir for containing e-liquid, as well as a heater. In use, electrical energy is supplied from the power source to the heater, which heats the e-liquid to produce an aerosol (or “vapour”) which is inhaled by a user through the mouthpiece.

Vaping smoking substitute systems can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute systems which typically have a heater and a sealed tank which is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute systems include a device which includes the power source, wherein the device is configured to be physically and electrically coupled to a consumable component including the tank and the heater. In this way, when the tank of the consumable component has been emptied, the device can be reused by connecting it to a new consumable component. Another subset of closed system vaping smoking substitute systems are completely disposable, and intended for one-use only.

There are also “open system” vaping smoking substitute systems which typically have a tank that is configured to be refilled by a user, so the system can be used multiple times.

An example vaping smoking substitute system is the myblu™ e-cigarette. The myblu™ e cigarette is a closed system which includes a device and a consumable component. The device and consumable component are physically and electrically coupled together by pushing the consumable component into the device. The device includes a rechargeable battery. The consumable component includes a mouthpiece, a sealed tank which contains e-liquid, as well as a vaporiser, which for this system is a heating filament coiled around a portion of a wick which is partially immersed in the e-liquid. The system is activated when a microprocessor on board the device detects a user inhaling through the mouthpiece. When the system is activated, electrical energy is supplied from the power source to the vaporiser, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.

Another example vaping smoking substitute system is the blu PRO™ e-cigarette. The blu PRO™ e cigarette is an open system which includes a device, a (refillable) tank, and a mouthpiece. The device and tank are physically and electrically coupled together by screwing one to the other. The mouthpiece and refillable tank are physically coupled together by screwing one into the other, and detaching the mouthpiece from the refillable tank allows the tank to be refilled with e-liquid. The system is activated by a button on the device. When the system is activated, electrical energy is supplied from the power source to a vaporiser, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece. As the vapour passes through the consumable (entrained in the airflow) from the location of vaporization to an outlet of the consumable (e.g. a mouthpiece), the vapour cools and condenses to form an aerosol for inhalation by the user. The aerosol may contain nicotine and/or flavour compounds.

The known vaporisers typically comprise a heating filament or wire wrapped around an absorbent cylindrical wick which is in fluid communication with the e-liquid. The heating wire heats and vaporises the e-liquid within the wick. It has been found that sugars leaching from the e-liquid may be caramelised by the high temperatures generated within the wick by the heating wire resulting in undesirable vapour components that may raise health concerns.

The present disclosure is directed towards ameliorating this problem.

Summary

According to a first aspect there is a provided an aerosol delivery component (e.g. a smoking substitute component), comprising a vaporiser including an elongate wick and a heating element, wherein the heating element includes a coiled portion wound around the wick with a pitch of 0.6mm or more, and wherein the coiled portion extends over 40% or more of the axial length of the wick.

By providing a coiled heating filament having an increased pitch of 1 mm or more spread over 40% or more of the axial length of the wick, heating of the wick by the filament is extended over a greater area and thus hot spots within the wick which may lead to caramelisation of sugars and undesirable vapour components are reduced or eliminated. The novel arrangement of the wick leads to a more even heating of the wick and prevent concentration of heat at an axially central portion of the wick

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The component may comprise a component housing having an upstream mouthpiece portion and a downstream base portion. The mouthpiece portion and base portion may be integrally formed.

The component comprises an airflow path that extends from an air inlet to an outlet. The outlet is preferably provided in the mouthpiece portion. In this respect, a user may draw fluid (e.g. air) into and along the airflow path by inhaling at the outlet (i.e. using the mouthpiece portion).

The air flow path passes the vaporiser between the air inlet and the outlet. The vaporiser may be housed in a vaporising chamber.

The airflow path may comprise a first portion extending from the air inlet towards the vaporiser. A second portion of the airflow path passes through the vaporising chamber to a conduit that extends to the outlet. The conduit may extend along the axial centre of the component.

References to “downstream” in relation to the airflow path are intended to refer to the direction towards the outlet/mouth piece portion. Thus the second portion of the airflow path is downstream of the first portion of the airflow path. Conversely, references to “upstream” are intended to refer to the direction towards the air inlet. Thus the first portion of the airflow path (and the air inlet) is upstream of the second portion of the airflow path (and the outlet/mouthpiece portion).

References to “upper”, “lower”, “above” or “below” are intended to refer to the component when in an upright/vertical orientation i.e. with elongate (longitudinal/length) axis of the component vertically aligned and with the mouthpiece vertically uppermost.

References to “downstream” in relation to the air flow path are intended to refer to the direction towards the outlet/mouthpiece portion. Thus the second and third portions of the air flow path are downstream of the first portion of the air flow path. Conversely, references to “upstream” are intended to referto the direction towards the air inlet. Thus the first portion of the air flow path (and the air inlet) is upstream of the second/third portions of the air flow path (and the outlet/mouthpiece portion).

The component may comprise a tank for housing an aerosol precursor (e.g. a liquid aerosol precursor). The aerosol precursor may comprise an e-liquid, for example, comprising a base liquid and e.g. nicotine. The base liquid may include propylene glycol and/or vegetable glycerine.

The conduit may extend through the tank with the conduit walls defining an inner region of the tank. In this respect, the tank may surround the conduit e.g. the tank may be annular.

The tank may be defined by one or more side walls (e.g. laterally opposed first and second side walls) extending longitudinally from the mouthpiece portion.

The tank may further comprise opposing front and rear walls spaced by the laterally opposed first and second side walls.

At least a portion of one of the walls defining the tank may be translucent or transparent.

The distance between the first and second side walls may define a width of the tank. The distance between the front and rear walls may define a depth of the tank. The width of the tank may be greater than the depth of the tank.

The length of the tank/component housing may be greater than the width of the tank/component housing. The depth of the tank/component housing may be smaller than each of the width and the length.

The tank walls may be integrally formed and may additionally be integrally formed with the mouthpiece portion. In that way, the component may be easily manufactured using injection moulding.

As discussed above, the air flow path passes the vaporiser between the air inlet and the outlet. The vaporiser comprises a coiled heating element e.g. a coiled heating filament for heating the wick.

The wick may be oriented so as to extend in the direction of the width dimension of the component (perpendicular to the longitudinal axis of the component). Thus the wick may extend in a direction perpendicular to the direction of airflow in the airflow path. The vaporiser may be disposed in the vaporising chamber. The vaporising chamber may form part of the airflow path.

The vaporising chamber may be defined by one or more chamber walls. The wick is elongate and may extend between first and second opposing chamber walls. The first and second chamber walls may separate (i.e. partially separate) the vaporising chamber from the tank. The first and second chamber walls may each comprise a respective opening through which a respective end of the wick projects such that the wick is fluid communication with aerosol precursor/e-liquid in the tank i.e. opposing axial ends of the wick are both inserted into the tank. In this way a central portion of the wick may be exposed to air in the airflow path and end portions of the wick may be in contact with aerosol precursor/e-liquid stored in the tank. The wick may comprise a porous material. Thus, aerosol precursor may be drawn (e.g. by capillary action) along the wick, from the tank to the exposed portion of the wick.

A transverse chamber wall (e.g. a third wall) may separate the vaporising chamber from aerosol precursor in the tank. In this respect, the transverse chamber wall may partly define the (base of the) tank. A vent may be provided in the transverse chamber wall for the flow of air into the aerosol precursor tank (i.e. so as to allow for pressure equalisation in the tank).

The vaporising chamber may be defined by an insert base assembly (e.g. an insert base assembly at least partially formed of silicone) received into an open (e.g. lower) end of the housing. The chamber walls may be walls of the insert base assembly.

The wick has an elongate shape. The wick may be cylindrical.

The heating element may be in the form of a filament or wire wound about the wick (e.g. the filament may extend helically about the wick). The filament may have a diameter of between 0.1 and 0.3mm e.g. it may have a diameter of around 0.2mm.

The wick may have an axial length (which may extend perpendicularly to the axis of the component as discussed above) of between 8 and 14 mm, e.g. between 9 and 13mm or between 10 and 12mm such as around 11 mm.

The heating element/filament is wound around the wick to form the coiled portion which extends over 40% or greater, e.g. 45% or greater such as 50% or greater or 55% or greater such as around 56% to 58% or greater of the axial length of the wick.

The axial centre of the heating element/filament may be coincident with the axial centre of the wick.

The coiled portion may comprise between 4 and 8 revolutions e.g. between 5 and 7 revolutions. For example, the coiled portion may have 6 revolutions.

The pitch of the coiled portion i.e. the spacing between adjacent revolutions is 0.6mm or more, such as 0.7, 0.8 or 0.9mm or more. In some embodiment, the pitch of the coiled portion is 1 mm or more.

The heating element may be electrically connectable (or connected) to a power source. The consumable component may comprise an electrical interface which may include one or more electrical contacts. The heating element/filament may further comprise at least one connecting portion for connection to a respective electrical contact. The or each connecting portion may extend parallel to the axis of the wick in a direction towards the axial centre of the coiled portion. It/they may (each) extend 20-30% e.g. 25% of the axial length of the coiled portion (e.g. by 1.5 revolutions of a 6 revolution coil). In this way, extra axial extension of the heating element/filament compared to known heating elements/filaments may be accommodated as the heating element/filament effectively doubles back on itself with the or each connecting portion running alongside the coiled portion to access the electrical contacts.

Thus, in operation, the power source may supply electricity to (i.e. apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e. drawn from the tank) to be heated so as to form a vapour and become entrained in fluid flowing along the airflow path. This vapour may subsequently cool to form an aerosol in the airflow path (e.g. the third portion of the airflow path).

In a second aspect there is provided an aerosol-delivery system (e.g. a smoking substitute system) comprising a component according to the first aspect and an aerosol-delivery (e.g. smoking substitute) device.

The component may be an aerosol-delivery (e.g. a smoking substitute) consumable i.e. in some embodiments the component may be a consumable component for engagement with the aerosoldelivery (e.g. a smoking substitute) device to form the aerosol-delivery (e.g. s smoking substitute) system.

The device may be configured to receive the consumable component. For example the device and the consumable component may be configured to be physically coupled together. For example, the consumable component may be at least partially received in a recess of the device, such that there is snap engagement between the device and the consumable component. Alternatively, the device and the consumable component may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable component may comprise one or more engagement portions for engaging with the device.

The consumable component may comprise an electrical interface for interfacing with a corresponding electrical interface of the device. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the device is engaged with the consumable component, the electrical interface may be configured to transfer electrical power from the power source to a heating element of the consumable component. The electrical interface may also be used to identify the consumable component from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable component is connected to the device. The device may alternatively or additionally be able to detect information about the consumable component via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of the consumable. In this respect, the consumable component may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

In other embodiments, the component may be integrally formed with the aerosol-delivery (e.g. a smoking substitute) device to form the aerosol-delivery (e.g. s smoking substitute) system.

In such embodiments, the aerosol former (e.g. e-liquid) may be replenished by re-filling a tank that is integral with the device (rather than replacing the consumable). Access to the tank (for re-filling of the e-liquid) may be provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap).

Further features of the device are described below. These are applicable to both the device for receiving a consumable component and to the device integral with the component.

The device may comprise a power source e.g. a rechargeable battery. The device may comprise a controller.

A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method. The device may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

An airflow (i.e. puff) sensor may be provided that is configured to detect a puff (i.e. inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e. puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to a heating element in response to airflow detection by the sensor. The control may be in the form of activation of the heating element in response to a detected airflow. The airflow sensor may form part of the device.

In a third aspect there is provided a method of using the aerosol-delivery (e.g. smoking substitute) consumable component according to the first aspect, the method comprising engaging the consumable component with an aerosol-delivery (e.g. smoking substitute) device (as described above) having a power source so as to electrically connect the power source to the consumable component (i.e. to the vaporiser of the consumable component).

This disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided. BRIEF DESCRIPTION OF THE DRAWINGS

So that further aspects and features thereof may be appreciated, embodiments will now be discussed in further detail with reference to the accompanying figures, in which:

• Fig. 1 A is a front schematic view of a smoking substitute system;

• Fig. 1 B is a front schematic view of a device of the system;

• Fig. 1 C is a front schematic view of a consumable of the system;

• Fig. 2A is a schematic of the components of the device;

• Fig. 2B is a schematic of the components of the consumable;

• Fig. 3 is a front section view of the consumable;

• Fig. 4 is a perspective view of an insert base assembly showing the coiled heating filament; and

• Fig. 5 is a plan view of the coiled heating filament.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Fig. 1A shows a first embodiment of a smoking substitute system 100. In this example, the smoking substitute system 100 includes a device 102 and a component 104. The component 104 may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e. open systems), the device may be integral with the component. In such systems, a tank of the aerosol delivery system may be accessible for refilling the device.

In this example, the smoking substitute system 100 is a closed system vaping system, wherein the component 104 includes a sealed tank 106 and is intended for single-use only. The component 104 is removably engageable with the device 102 (i.e. for removal and replacement). Fig. 1A shows the smoking substitute system 100 with the device 102 physically coupled to the component 104, Fig. 1 B shows the device 102 of the smoking substitute system 100 without the component 104, and Fig. 1 C shows the component 104 of the smoking substitute system 100 without the device 102.

The device 102 and the component 104 are configured to be physically coupled together by pushing the component 104 into a cavity at an upper end 108 of the device 102, such that there is an interference fit between the device 102 and the component 104. In other examples, the device 102 and the component may be coupled by screwing one onto the other, or through a bayonet fitting.

The component 104 includes a mouthpiece portion at an upper end 109 of the component 104, and one or more air inlets (not shown) in fluid communication with the mouthpiece portion such that air can be drawn into and through the component 104 when a user inhales through the mouthpiece portion.

The tank 106 containing e-liquid is located at the lower end 1 11 of the component 104.

The tank 106 includes a window 112, which allows the amount of e-liquid in the tank 106 to be visually assessed. The device 102 includes a slot 114 so that the window 112 of the component 104 can be seen whilst the rest of the tank 106 is obscured from view when the component 104 is inserted into the cavity at the upper end 108 of the device 102.

The lower end 110 of the device 102 also includes a light 116 (e.g. an LED) located behind a small translucent cover. The light 116 may be configured to illuminate when the smoking substitute system 100 is activated. Whilst not shown, the component 104 may identify itself to the device 102, via an electrical interface, RFID chip, or barcode.

The lower end 110 of the device 102 also includes a charging connection 115, which is usable to charge a battery within the device 102. The charging connection 115 can also be used to transfer data to and from the device, for example to update firmware thereon.

Figs. 2A and 2B are schematic drawings of the device 102 and component 104. As is apparent from Fig. 2A, the device 102 includes a power source 118, a controller 120, a memory 122, a wireless interface 124, an electrical interface 126, and, optionally, one or more additional components 128.

The power source 1 18 is preferably a battery, more preferably a rechargeable battery. The controller 120 may include a microprocessor, for example. The memory 122 preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 to perform certain tasks or steps of a method.

The wireless interface 124 is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface 124 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface 124 may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 of the device 102 may include one or more electrical contacts. The electrical interface 126 may be located in a base of the aperture in the upper end 108 of the device 102. When the device 102 is physically coupled to the component 104, the electrical interface 126 is configured to transfer electrical power from the power source 118 to the component 104 (i.e. upon activation of the smoking substitute system 100). The electrical interface 126 may also be used to identify the component 104 from a list of known components. For example, the component 104 may be a particular flavour and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126). This can be indicated to the controller 120 of the device 102 when the component 104 is connected to the device 102. Additionally, or alternatively, there may be a separate communication interface provided in the device 102 and a corresponding communication interface in the component 104 such that, when connected, the component 104 can identify itself to the device 102.

The additional components 128 of the device 102 may comprise the light 116 discussed above.

The additional components 128 of the device 102 also comprises the charging connection 115 configured to receive power from the charging station (i.e. when the power source 118 is a rechargeable battery). This may be located at the lower end 110 of the device 102.

The additional components 128 of the device 102 may, if the power source 118 is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in a charging station (if present).

The additional components 128 of the device 102 may include a sensor, such as an airflow (i.e. puff) sensor for detecting airflow in the smoking substitute system 100, e.g. caused by a user inhaling through a mouthpiece portion 136 of the component 104. The smoking substitute system 100 may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the component 104. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 of the device 102 may include a user input, e.g. a button. The smoking substitute system 100 may be configured to be activated when a user interacts with the user input (e.g. presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100.

As shown in Fig. 2B, the component 104 includes the tank 106, an electrical interface 130, a vaporiser 132, one or more air inlets 134, a mouthpiece portion 136, and one or more additional components 138.

The electrical interface 130 of the component 104 may include one or more electrical contacts. The electrical interface 126 of the device 102 and an electrical interface 130 of the component 104 are configured to contact each other and thereby electrically couple the device 102 to the component 104 when the lower end 111 of the component 104 is inserted into the upper end 108 of the device 102 (as shown in Fig. 1 A). In this way, electrical energy (e.g. in the form of an electrical current) is able to be supplied from the power source 118 in the device 102 to the vaporiser 132 in the component 104.

The vaporiser 132 is configured to heat and vaporise e-liquid contained in the tank 106 using electrical energy supplied from the power source 118. As will be described further below, the vaporiser 132 includes a heating filament and a wick. The wick draws e-liquid from the tank 106 and the heating filament heats the e-liquid to vaporise the e-liquid.

The one or more air inlets 134 are preferably configured to allow air to be drawn into the smoking substitute system 100, when a user inhales through the mouthpiece portion 136. When the component 104 is physically coupled to the device 102, the air inlets 134 receive air, which flows to the air inlets 134 along a gap between the device 102 and the lower end 111 of the component 104.

In operation, a user activates the smoking substitute system 100, e.g. through interaction with a user input forming part of the device 102 or by inhaling through the mouthpiece portion 136 as described above. Upon activation, the controller 120 may supply electrical energy from the power source 118 to the vaporiser 132 (via electrical interfaces 126, 130), which may cause the vaporiser 132 to heat e- liquid drawn from the tank 106 to produce a vapour which is inhaled by a user through the mouthpiece portion 136.

An example of one of the one or more additional components 138 of the component 104 is an interface for obtaining an identifier of the component 104. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the component. The component 104 may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the device 102.

It should be appreciated that the smoking substitute system 100 shown in figures 1 A to 2B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

Fig. 3 is a section view of an example of the component 104 described above. The component 104 comprises a tank 106 for storing e-liquid, a mouthpiece portion 136 and a conduit 140 extending along a longitudinal axis of the component 104. In the illustrated embodiment the conduit 140 is in the form of a tube having a substantially circular transverse cross-section (i.e. transverse to the longitudinal axis). The tank 106 surrounds the conduit 140, such that the conduit 140 extends centrally through the tank

106.

A tank housing 142 of the tank 106 defines an outer casing of the component 104, whilst a conduit wall 144 defines the conduit 140. The tank housing 142 extends from the lower end 11 1 of the component 104 to the mouthpiece portion 136 at the upper end 109 of the component 104. At the junction between the mouthpiece portion 136 and the tank housing 142, the mouthpiece portion 136 is wider than the tank housing 142, so as to define a lip 146 that overhangs the tank housing 142. This lip 146 acts as a stop feature when the component 104 is inserted into the device 102 (i.e. by contact with an upper edge of the device 102).

The tank 106, the conduit 140 and the mouthpiece portion 136 are integrally formed with each other so as to form a single unitary component and may e.g. be formed by way of an injection moulding process. Such a component may be formed of a thermoplastic material such as polypropylene.

The mouthpiece portion 136 comprises a mouthpiece aperture 148 defining an outlet of the conduit 140. The vaporiser 132 is fluidly connected to the mouthpiece aperture 148 and is located in a vaporising chamber 156 of the component 104. The vaporising chamber 156 is downstream of the inlet 134 of the component 104 and is fluidly connected to the mouthpiece aperture 148 (i.e. outlet) by the conduit 140.

The vaporiser 132 comprises a porous wick 150 and a heating filament 152 coiled around the porous wick 150. The wick 150 extends transversely across the chamber vaporising 156 between sidewalls of the chamber 156 which are partly formed by an insert base assembly 158 that defines the lower end 111 of the component 104 that connects with the device 102. The insert base assembly 158 is inserted into an open lower end of the tank 106 so as to seal against the tank housing 142.

An inner sleeve 154 projects into the tank 106 and seals with the conduit 140 (around the conduit wall 144) so as to separate the vaporising chamber 156 from the e-liquid in the tank 106. Ends of the wick 150 project through apertures defined by the inner sleeve 154/insert base assembly 158 and into the tank 106 so as to be in contact with the e-liquid in the tank 106. In this way, e-liquid is transported along the wick 150 (e.g. by capillary action) to a central portion of the wick 150 that is exposed to airflow through the vaporising chamber 156. The transported e-liquid is heated by the heating filament 152 (when activated e.g. by detection of inhalation), which causes the e-liquid to be vaporised and to be entrained in air flowing past the wick 150. This vaporised liquid may cool to form an aerosol in the conduit 140, which may then be inhaled by a user. The heating filament 152 (which is clearly shown in Figures 4 and 5) has a diameter of 0.2mm and coils helically around the wick 150 to form a coiled portion 160 having 6 revolutions. The pitch P of the coiled portion 160 (i.e. the spacing between adjacent coils) is around 1 mm.

The wick 150 has an axial length of around 11 mm and the coiled portion 160 has an axial length of around 6.2mm. This the coiled portion160 extends over around 56% of the axial length of the wick 150. The axial centre of the coiled portion 160 is coincident with the axial centre of the wick 150.

The insert base assembly 158 also accommodates the electrical interface 119 of the consumable component 102 comprising two electrical contacts 136a, 136b that are electrically connected to the heating filament 152.

The heating filament 152 comprises two connecting portions 161 a, 161 b at opposing ends for connection with tabs 162a, 162b which extend from the contacts 136a, 136b.

The connecting portions 161 a, 161 b extend parallel to the axis of the wick 150/coiled portion 160 in a direction towards the axial centre of the coiled portion 160. In this way, the heating filament 152 effectively doubles back on itself with the connecting portions 161 a, 161 b running alongside the coiled portion 150 to access the tabs 162a, 162b.

In this way, when the consumable component 104 is engaged with the device 102, power can be supplied from the power source 1 18 of the device to the heating filament 152.

While exemplary embodiments have been described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments set forth above are considered to be illustrative and not limiting.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/- 10%.

The words "preferred" and "preferably" are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

Claims

1 . An aerosol-delivery component comprising: a vaporiser including an elongate wick and a heating element, wherein the heating element includes a coiled portion wound around the wick with a pitch of 0.6mm or more, and wherein the coiled portion extends over 40% or more of the axial length of the wick.

2. A component according to claim 1 wherein the pitch of the coiled portion is 0.8mm or more.

3. A component according to claim 3 wherein the pitch of the coiled portion is 1 mm or more.

4. A component according to any one of the preceding claims wherein the coiled portion extends over 50% or greater of the axial length of the wick.

5. A component according to claim 4 wherein the coiled portion extends over 55% or greater of the axial length of the wick.

6. A component according to any one of the preceding claims wherein the coiled portion comprises between 5, 6 or 7 revolutions.

7. A component according to any one of the preceding claims wherein the heating element comprises a filament or wire having a diameter of between 0.1 and 0.3mm.

8. A component according to any one of the preceding claims wherein the wick has an axial length of between 8 and 14 mm.

9. A component according to any one of the preceding claims wherein the heating element is electrically connectable to one or more electrical contacts and wherein the heating element further comprises at least one connecting portion for connection to a respective electrical contact, the or each connecting portion extending parallel to the axis of the wick in a direction towards the axial centre of the coiled portion.

10. A component according to any one of the preceding claims further comprising a tank for housing an aerosol precursor wherein opposing axial ends of the wick are both inserted into the tank.

11. A component according to any one of the preceding claims which is a consumable component for receipt in a smoking substitute device.

12. An aerosol-delivery system comprising a component according to any one of the preceding claims and a device comprising a power source.