Aerosol delivery system

Abstract

The present disclosure relates to a cartridge for an aerosol delivery system, the cartridge comprising a housing comprising a first outer wall portion partially defining an outer shape of the cartridge, and an aerosol generator for generating an aerosol for inhalation from an aerosol-generating material, the aerosol generator is disposed in a chamber defined at least in part by a first outer wall portion, where the first outer wall portion defines a first inner surface of the chamber, and where the aerosol generator is separate from the first inner surface.

Description

Technical Field

[0001] The present disclosure relates to aerosol delivery systems, such as nicotine delivery systems (eg, electronic cigarettes, etc.). Background Art

[0002] An electronic vapor supply system (e.g., an electronic cigarette (e-cigarette)) typically includes a vapor precursor material, such as a reservoir of a source liquid containing a formulation (typically including nicotine), from which vapor is generated (e.g., by thermal evaporation) for inhalation by a user. Therefore, the vapor supply system will typically include a vapor generation chamber, which includes a vaporizer assembly, and the vaporizer assembly is arranged to evaporate a portion of the precursor material to generate vapor in the vapor generation chamber. The vaporizer assembly will typically include a heater coil arranged around a liquid transport element (capillary wick), which is arranged to transfer the source liquid from the reservoir to the heater coil for evaporation. When the user inhales on the device and power is supplied to the vaporizer assembly, air is drawn into the device through the inlet hole and enters the vapor generation chamber, where the air mixes with the vaporized precursor material to form a condensed aerosol. There is an air passage connecting the vapor generation chamber and the opening in the mouthpiece so that air drawn through the vapor generation chamber when a user inhales on the mouthpiece continues along a flow path to the mouthpiece opening, carrying vapor with it for inhalation by the user.

[0003] The design of various aspects related to the vaporizer assembly of a vapor supply system can play an important role in the overall performance of the system, for example in reducing the overall size of such a delivery system (or components of the system) and managing heat transfer from the aerosol generator to the external surfaces of the delivery system. Various approaches are described herein that seek to help address some of these issues. Summary of the invention

[0004] According to a first aspect of certain embodiments, a cartridge for an aerosol delivery system is provided, the cartridge comprising: a shell comprising a first outer wall portion that partially defines the outer shape of the cartridge; and an aerosol generator for generating an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is disposed in a chamber at least partially defined by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface.

[0005] According to a second aspect of some embodiments, there is provided an aerosol delivery system for aerosolising an aerosol generating material, the aerosol delivery system comprising a cartridge according to the first aspect.

[0006] According to a third aspect of certain embodiments, a cartridge device for an aerosol delivery system is provided, the cartridge device comprising: a shell device comprising a first outer wall portion that partially defines the external shape of the cartridge device; and an aerosol generator device for generating an aerosol for inhalation from an aerosol generating material device, wherein the aerosol generator device is disposed in a chamber at least partially defined by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator device is separated from the first inner surface.

[0007] According to a fourth aspect of certain embodiments, a method for providing a cartridge for an aerosol delivery system is provided, the method comprising: providing a shell comprising a first outer wall portion that partially defines an external shape of the cartridge and a first inner surface of a chamber; and providing an aerosol generator in a chamber at least partially defined by the first outer wall portion, for generating an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is separated from the first inner surface.

[0008] It will be understood that the features and aspects of the invention described herein in relation to various aspects of the present disclosure are also applicable to, and may be appropriately combined with, embodiments of the present disclosure according to other aspects, rather than just the specific combinations described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0010] Figure 1 Schematically illustrates an aerosol delivery system including a cartridge and a control unit according to certain embodiments of the present disclosure;

[0011] Figure 2 schematically illustrates a cross-sectional view through an example cartridge according to certain embodiments of the present disclosure;

[0012] Figure 3 schematically illustrates another cross-sectional view through an example cartridge according to certain embodiments of the present disclosure; and

[0013] Figure 4 is a flow chart schematically illustrating steps in a method of providing a cartridge for use in an aerosol delivery system according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0014] Various aspects and features of certain examples and embodiments are discussed / described herein. Some aspects and features of certain examples and embodiments may be conventionally implemented, and for the sake of brevity, these aspects and features are not discussed / described in detail. Therefore, it will be understood that various aspects and features of the devices and methods discussed herein that are not described in detail may be implemented according to any conventional techniques for implementing these aspects and features.

[0015] As will be explained below, the present disclosure relates to a cartridge for an aerosol delivery system, the cartridge comprising: a housing including a first outer wall portion that partially defines an outer shape of the cartridge; and an aerosol generator for generating an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is disposed in a chamber at least partially defined by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface. The above system ensures that a suitable separation is maintained between the aerosol generator and the chamber surface to avoid excessive heating of the outer surface of the cartridge while reducing the overall size of the cartridge.

[0016] For example, the first outer wall portion defines the outer shape of the chamber and the cartridge, thereby avoiding the need for a separate chamber wall component that would affect the width of the cartridge. In particular, by using the outer wall to provide the surface of the chamber, the aerosol generator can be kept separate from the surface of the chamber (to avoid excessive heating of the surface) while reducing the size of the components surrounding the chamber (by removing the chamber wall). Therefore, the present disclosure allows for a reduced size cartridge (e.g., having a reduced thickness near the chamber) without substantially increasing the transfer of thermal energy to the outside of the device. The thermal energy can be generated by a resistive heater providing an aerosol generator, or by heat accumulation associated with the operation of a non-heater type aerosol generator (e.g., electrical power flow in a component of the aerosol generator causes a temperature increase).

[0017] The present disclosure relates to an aerosol delivery system, which may also be referred to as an aerosol or vapor supply system, such as an electronic cigarette. In the following description, the term "electronic cigarette" or "electronic cigarette" may sometimes be used, but it will be understood that this term can be used interchangeably with aerosol delivery system / device, electronic aerosol delivery system / device, vapor supply system / device, and electronic vapor supply system / device. In addition, as is common in the art, the terms "vapor" and "aerosol" and related terms such as "evaporation", "volatization" and "aerosolization" are often used interchangeably.

[0018] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user and includes non-flammable aerosol supply systems that release compounds from an aerosol generating material without burning the aerosol generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol generating materials to generate an aerosol.

[0019] According to the present disclosure, a "non-flammable" aerosol supply system is an aerosol supply system in which constituent aerosol generating materials of the aerosol supply system (or components thereof) do not burn or ignite in order to facilitate delivery of at least one substance to a user.

[0020] In some embodiments, the delivery system is a non-flammable aerosol supply system, for example, a powered non-flammable aerosol supply system. In some embodiments, the non-flammable aerosol supply system is an electronic cigarette, also known as a vapor cigarette device or an electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

[0021] In some embodiments, the non-flammable aerosol supply 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.

[0022] In some embodiments, the non-flammable aerosol supply system is a hybrid system that uses a combination of aerosol generating materials to generate an aerosol, wherein one or more of the aerosol generating materials can be heated. Each aerosol generating material can 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 includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material can include, for example, tobacco or non-tobacco products.

[0023] Generally, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0024] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-flammable aerosol supply device. These consumables are sometimes referred to as articles of manufacture in the present disclosure.

[0025] In some embodiments, the non-flammable aerosol supply system, such as a non-flammable aerosol supply device thereof, may include a power source and a controller. The power source may be, for example, an electrical power source.

[0026] In some embodiments, a non-flammable aerosol supply system may include an area for receiving a consumable product, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0027] In some embodiments, consumables for use with a non-flammable aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a shell, a wrapping paper, a filter, a mouthpiece, and / or an aerosol modifier.

[0028] In some embodiments, the substance to be delivered includes an active substance.

[0029] Active substances as used herein can be physiologically active materials, which are materials intended to achieve or enhance physiological responses. Active substances can be, for example, selected from nutrients, nootropics, psychoactive substances. Active substances can be naturally occurring or synthetically obtained. Active substances can include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6 or B12 or C), melatonin, or components, derivatives or combinations thereof. Active substances can include one or more components, derivatives or extracts of tobacco or other plants.

[0030] In one embodiment, the active substance is a legally permitted recreational drug.

[0031] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0032] The active substance may be CBD or a derivative thereof.

[0033] As described herein, the active substance may include or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, husks, etc. Alternatively, the material may include active compounds naturally present in the plant, obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, etc. Examples of plants are tobacco, eucalyptus, star anise, hemp, cocoa, fennel, lemongrass, mint, spearmint, tea tree, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (licorice root), matcha, mate, orange peel, papaya, rose, sage, tea (e.g. green or black), thyme, cloves, cinnamon, coffee, anise (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron , lavender, lemon peel, mint, juniper, elderberry, vanilla, holly, basil, turmeric, turmeric root powder, sandalwood, coriander leaves, bergamot, orange blossom, myrtle, black currant, valerian, Spanish bell pepper, mace, damion, marjoram, olive, lemon balm, lemon basil, northern onion, parsley, verbena, tarragon, geranium, mulberry, ginseng, theanine, tetramethyluric acid, maca, Indian ginseng, damson, Guanna tea, chlorophyll, baobab or any combination thereof. Mint can be selected from the following mint varieties: wild mint, mint cv, Egyptian mint, peppermint, basil mint cv, peppermint cv, spearmint, heartleaf spearmint, longleaf mint, pineapple mint, lip calyx mint, spearmint cv, and apple mint.

[0034] In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives, or extracts thereof, and the plant is tobacco.

[0035] In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is selected from eucalyptus, star anise, cocoa. In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is selected from black leaf tea tree and fennel.

[0036] In some embodiments, the substance to be delivered includes a flavoring agent.

[0037] As used herein, the terms "flavoring" and "flavor" refer to materials that can be used to produce a taste, aroma or other physical sensation desired by adult consumers in a product, where permitted by local regulations. They can include naturally occurring flavoring materials, plants, extracts of plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (licorice root), hydrangea, eugenol, Japanese magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise (fennel), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, cranberry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, Grapes, durian, pitaya, cucumber, blueberry, mulberry, citrus fruits, Durham, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, mint, lavender, aloe, cardamom, celery, bitter bean peel, nutmeg, sandalwood, bergamot, geranium, Arabic tea, sorghum, betel leaf, coriander, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, coriander, cognac, jasmine, ylang-ylang, sage, fennel incense, mustard, green pepper, ginger, cilantro, coffee, hemp, mint oil from any species of the mint family, eucalyptus, star anise, cocoa, lemongrass, red beans, flax, ginkgo biloba, hazelnuts, hibiscus, laurel, mate, orange peel, rose, tea (e.g., green or black), thyme, juniper, elderberry, basil, bay leaves, cumin, oregano, chili pepper, rosemary, saffron, lemon peel, mint, beefsteak, turmeric, coriander leaves, myrtle, black currant, valerian, Spanish bell pepper, nutmeg Peel, damson, marjoram, olive, lemon balm, lemon basil, shallot, parsley, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. They can be imitation, synthetic or natural ingredients or mixtures thereof. They can be in any suitable form, for example, liquids such as oils, solids such as powders, or gases.

[0038] In some embodiments, flavorings include menthol, spearmint and / or peppermint. In some embodiments, flavorings include flavoring components of cucumber, blueberry, citrus fruit and / or cranberry. In some embodiments, flavorings include eugenol. In some embodiments, flavorings include flavoring components extracted from tobacco.

[0039] In some embodiments, in addition to or in lieu of aroma or taste nerves, flavoring agents may include sensates that are intended to achieve somatic sensations that are typically chemically induced and sensed by stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, numbing effects. Suitable thermal effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0040] Aerosol generating materials are materials that can generate aerosols, for example, when heated, irradiated, or supplied with energy in any other way. Aerosol generating materials can be, for example, in solid, liquid, or gel form, which may or may not contain active substances and / or flavors. In some embodiments, aerosol generating materials may include "amorphous solids", which may alternatively be referred to as "integral solids" (i.e., non-fibrous). In some embodiments, amorphous solids may be dry gels. Amorphous solids are solid materials that can retain some fluid (e.g., liquid) inside them. In some embodiments, aerosol generating materials may, for example, include from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids.

[0041] The aerosol-generating material may comprise one or more active substances and / or flavouring agents, one or more aerosol-former materials, and optionally one or more other functional materials.

[0042] The aerosol forming agent material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming agent material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetyl glycerol, benzyl benzoate, benzylphenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0043] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer and / or an antioxidant.

[0044] The material may be present on or in a carrier to form a substrate. The carrier may be or include, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the carrier includes a susceptor. In some embodiments, the susceptor is embedded in the material. In some alternative embodiments, the susceptor is on one or either side of the material.

[0045] A consumable is an article comprising or consisting of an aerosol generating material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generating area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, which releases heat during use to cause the aerosol generating material to generate an aerosol. The heater may, for example, be a material that can be heated by electrical conduction.

[0046] Aerosol modifiers are substances typically located downstream of an aerosol generation region that are configured to modify the generated aerosol, for example by changing the taste, flavor, acidity or another characteristic of the aerosol. The aerosol modifier may be disposed in an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0047] For example, the aerosol modifier can be an additive or an adsorbent. For example, the aerosol modifier can include one or more of a fragrance, a colorant, water, and a carbon adsorbent. For example, the aerosol modifier can be a solid, a liquid, or a gel. The aerosol modifier can be in the form of a powder, a thread, or a granule. The aerosol modifier can be free of filter material.

[0048] An aerosol generator is an apparatus configured to cause an aerosol to be generated from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to thermal 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 can be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0049] More generally, it will be understood that certain embodiments of the present disclosure are based on methods for seeking to help optimize the performance of vaporizer components in vapor delivery systems according to the principles described herein, and that other structural and functional aspects of the electronic cigarette implementation methods according to certain embodiments of the present disclosure are not of primary importance and may be implemented, for example, according to any established method.

[0050] Figure 1is a schematic perspective view of an exemplary aerosol delivery system / device (electronic cigarette, vapor / aerosol supply system) 1 according to certain embodiments of the present disclosure. Positional terms (e.g., terms such as upper, lower, above, below, top, bottom, etc.) regarding the relative positions of various aspects of the electronic cigarette may be used herein with reference to the vertical orientation of the longitudinal axis of the electronic cigarette, with the mouthpiece (through which the user intends to inhale) at the uppermost end (unless the context indicates otherwise). However, it will be understood that this is merely for ease of explanation and is not intended to indicate that there is any required orientation of the electronic cigarette in use.

[0051] The electronic cigarette 1 comprises two main components, namely a cartridge 4 (cartridge part) and a control unit 2 (control part). The control unit 2 and the cartridge 4 are shown to be coupled together.

[0052] The cartridge 4 and the control unit 2 are coupled by establishing a mechanical and electrical connection between them. The specific manner in which the mechanical and electrical connection is established is not essential to the principles described herein and may be established according to conventional techniques, such as based on threaded, bayonet, latch or friction fit mechanical fixings, with appropriate arrangement of electrical contacts / electrodes for appropriately establishing an electrical connection between the two parts. Figure 1 In the exemplary electronic cigarette 1 shown, the cartridge includes a mouthpiece end 52 and an interface end 54, and the cartridge is connected to the control unit by inserting the interface end 6 at the interface end of the cartridge into the corresponding receiver 8 / receiving section of the control unit. The interface end 6 of the cartridge is tightly matched with the receiver 8, and may include a protrusion (not shown) that engages with a corresponding stop in the inner surface of the receiver wall 12 that defines the receiver 8 to provide a releasable mechanical engagement between the cartridge and the control unit. An electrical connection is established between the control unit and the cartridge via a pair of electrodes that provide electrical contacts on the bottom of the cartridge and corresponding elastic contact pins in the base of the receiver 8. As described above, the specific manner of establishing the electrical connection is not important for the principles described herein, and in fact some implementations may not have an electrical connection between the cartridge and the control unit at all, for example because the power transmission from the reusable part to the cartridge can be wireless (e.g., based on electromagnetic induction technology).

[0053] The electronic cigarette 1 has a generally elongated shape extending along the longitudinal axis L. When the cartridge is connected to the control unit, the total length of the electronic cigarette (along the longitudinal axis) in this example is about 12.5 cm. The total length of the control unit is about 9 cm, and the total length of the cartridge is about 5 cm (that is, when the interface end 6 of the cartridge and the receiver 8 of the control unit are connected together, there is an overlap of about 3 cm between them). The electronic cigarette has a generally elliptical cross-section, which is the largest around the middle of the electronic cigarette and tapers toward the end in a curved manner. The cross-section around the middle of the electronic cigarette has a width of about 2.5 cm and a thickness of about 1.7 cm. The end of the cartridge has a width of about 2 cm and a thickness of about 0.6 mm, while the other end of the electronic cigarette has a width of about 2 cm and a thickness of about 1.2 cm. In some examples, the shell of the electronic cigarette is formed of plastic. It will be understood that the specific size and shape of the electronic cigarette and the material of the electronic cigarette are not important for the principles described herein, and may be different in different implementations. That is, the principles described herein may be equally applicable to electronic cigarettes having different sizes, shapes and / or materials.

[0054] According to certain embodiments of the present disclosure, the control unit 2 may be broadly conventional in its functionality and general construction techniques. Figure 1 In the example of , the control unit 2 comprises a housing 10 (eg formed of plastic or metal) including a receiver wall 12 defining a receiver 8 for receiving an end of a cartridge as described above.

[0055] In this example, the housing 10 of the control unit 2 has a generally elliptical cross-section that is consistent with the shape and size of the cartridge 4 at their interface to provide a smooth transition between the two parts. The receiver wall 12 includes a control unit air inlet opening 11 (e.g., provided by one or more holes in the wall). In use, when the user inhales on the cartridge 4, air is inhaled through these holes toward the interface end of the cartridge part 4, where air enters the cartridge through an opening in the base end of the cartridge. It will be understood that the interface end 6 of the cartridge 4 may not form an airtight seal with the receiver wall 12, so some of the inhaled air may also be inhaled into the cartridge through the gap between the cartridge and the control unit 2.

[0056] The control unit further comprises a battery 16 for providing operating power to the electronic cigarette, a control circuit 18 for controlling and monitoring the operation of the electronic cigarette, a user input button 20 , and an indicator 22 .

[0057] In this example, battery 16 is rechargeable and can be of a conventional type, such as those commonly used in electronic cigarettes and other applications that require relatively high currents to be provided in relatively short periods of time. In some of these examples, battery 16 can be recharged through a charging port (not shown), which can, for example, include a USB connector; or battery 16 can be inductively recharged via suitable components for inductive charging (e.g., a susceptor assembly (not shown) configured to form part of an inductive circuit with an inductive charger).

[0058] In this example, the input button 20 is a conventional mechanical button, for example comprising a resiliently mounted component, which can be pressed by a user to establish electrical contact in an underlying circuit. In this regard, the input button can be considered to be an input device for detecting user input (e.g., to trigger vapor generation), and the specific manner in which the button is implemented is not important. For example, other forms of mechanical buttons or touch-sensitive buttons (e.g., based on capacitive or optical sensing technology) may be used in other implementations, or the button may not be present and the device may rely on a puff detector for triggering vapor generation.

[0059] Indicator 22 is provided to provide a user with a visual indication of various characteristics associated with the electronic cigarette, such as an indication of the operating state (e.g., on / off / standby), and other characteristics such as battery life or fault conditions. In some instances, indicator 22 can be provided by one or more LEDs. For example, different characteristics can be indicated by different colors and / or different flash sequences according to generally conventional techniques. In some other instances, indicator 22 can be provided by a display configured to display information to the user.

[0060] The control circuit 18 is appropriately configured / programmed to control the operation of the electronic cigarette, thereby providing conventional operating functions consistent with established technologies for controlling electronic cigarettes. The control circuit (processor circuit) 18 can be considered to logically include various subunits / circuit elements associated with different aspects of the operation of the electronic cigarette. For example, depending on the functions provided in different implementations, the control circuit 18 may include a power control circuit for controlling the power supply from the battery to the cigarette cartridge in response to user input, a user programming circuit for establishing configuration settings (e.g., user-defined power settings) in response to user input, and functions associated with other functional units / circuits according to the principles described herein and conventional operating aspects of the electronic cigarette, such as indicator light display drive circuits and user input detection circuits. It will be understood that the functions of the control circuit 18 can be provided in a variety of different ways, such as using one or more appropriately programmed programmable computers and / or one or more appropriately configured application-specific integrated circuits / circuits / chips / chip sets, which are configured to provide the desired functions.

[0061] The cartridge 4 includes a housing 32, an end cap 34, a lower (upstream) chamber portion component 36, and an upper (downstream) chamber portion 38. As discussed below, the cartridge 4 is configured to contain an aerosol-generating material (e.g., a liquid contained in a reservoir 44). The cartridge 4 may be referred to as an atomizing cartridge in some instances because it is configured to include an aerosol generator 40 and an aerosol-generating material.

[0062] The housing 32 defines the external shape (e.g., appearance) of the cartridge 4 (e.g., a portion of the aerosol delivery system 1 defined by the cartridge). In some instances, the housing 32 defines a mouthpiece configured to fit the user's mouth during smoking. For example, the housing 32 may include a mouthpiece opening / vapor outlet 60 at the downstream end of the cartridge 4 (and the system 1). The mouthpiece opening / vapor outlet 60 is in fluid communication with the aerosol generator 40 via an inner tube 62 that connects the aerosol generating chamber 50 to the mouthpiece opening 60. In some instances, the housing 32 defines an interface end 6 of the cartridge, which is configured to engage with a receiver 8 of the control unit 2, as described above.

[0063] In some instances, the housing 32 can be formed by plastic or metal materials. For example, the housing 32 can be formed by a plastic material such as polypropylene or a metal material such as aluminum. In some instances, the housing 32 can be formed as a single component. For example, the housing 32 can be formed as a single component in one piece. For example, the housing 32 can be formed by a single molded part, which defines a mouthpiece end including a mouthpiece opening 60 and an interface end 6 configured to be received by a receiver 8. In some instances, the housing 32 can further include an inner tube 62, which can also be formed as a single component in one piece with the rest of the housing 32. In some instances, the housing 32 can be an assembly of multiple components that are linked together. For example, the housing 32 can be formed by linking the upper portion defining the mouthpiece end 52 to the lower portion defining the interface end 6 of the cigarette cartridge.

[0064] Figure 1 The cartridge 4 includes a (aerosol-generating material) storage area or reservoir 44 defined between the housing 32 and the inner tube 62. The reservoir or storage area 44 is used to contain an aerosol-generating material (e.g., a liquid aerosol-generating material). The aerosol-generating material is a material that is capable of generating an aerosol when, for example, it is heated, irradiated, or energized in any other manner. In some examples, for example, according to Figure 1 In those embodiments, a reservoir 44 is provided that is configured to store a supply of liquid aerosol generating material. Figure 1 In the example of , the liquid reservoir 44 has a substantially annular shape defined by the housing 32 defining an outer annular wall and the inner tube 62 defining an inner annular wall. The reservoir 44 is closed with an end wall at the mouthpiece end 52 to contain the aerosol generating material.

[0065] exist Figure 1 In the embodiment of the present invention, the aerosol generator 40 is positioned toward the interface end 54 of the cigarette cartridge 4. The aerosol generator 40 can be a heater 40 (and hereinafter referred to as such interchangeably) configured to subject the aerosol generating material to heating so as to increase the temperature of the aerosol generating material, thereby releasing one or more volatiles from the aerosol generating material to form an aerosol. In some other examples, the aerosol generator is configured to cause an aerosol to be generated from the aerosol generating material without heating. For example, the aerosol generator can be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0066] In normal use, the cartridge 4 is connected to the control unit 2, and the control unit 2 is activated to supply power to the aerosol generator 40 via an electrical connection formed at the interface between the cartridge 4 and the control unit 2. Electricity is transferred from the interface end 54 to the heater 40 via an electrical conductor (e.g., a wire and / or a conductive electrode). The heater is therefore electrically heated, and thus a portion of the aerosol-generating material near the heater is vaporized or aerosolized. When the heater is activated and the user inhales on the mouthpiece end 52 of the cartridge, air is drawn into the cartridge 4 through the air inlet in the interface end 54 and along the air path 46. The incoming air mixes with the vapor generated from the heater 40 to form a condensed aerosol, which is then drawn along the inner tube 62 before leaving through the mouthpiece outlet / vapor outlet 60 for the user to inhale.

[0067] exist Figure 1 In the example of the present invention, the cartridge 4 includes a liquid transport element 42 for providing or transferring the liquid aerosol generating material from the reservoir 44 to the aerosol generator 40 (i.e., the heater). In some examples, the liquid transport element 42 is a core 42 (i.e., an element configured to wick the liquid aerosol generating material) disposed in contact with the heater 40. The core 42 extends transversely across the main airflow path (or the first airflow path), wherein the end of the core extends into a pocket, recess, or conduit 48, which is fluidly connected to the reservoir 44 of the liquid aerosol generating material. In some examples, the liquid transport element 42 is configured so that the liquid evaporated or aerosolized from the liquid transport element 42 is replaced by more liquid drawn from the reservoir 44 by capillary action.

[0068] Figure 1 The heater 40 in the example of FIG. 4 includes a resistive wire coiled around a core 42. Figure 1 In an example, the heater 40 may include nickel-chromium alloy (Cr20Ni80) wire, and the core 42 may include fiberglass bundles. As an example, the core 42 may alternatively be cotton, and the heater 40 may alternatively be steel.

[0069] As described above, when the cartridge 4 is assembled, a reservoir 44 for liquid is formed by the space outside the inner tube 62 and the inner surface of the housing 32. This can be filled with liquid aerosol generating material during manufacturing, for example, by filling holes or by other means, and the filling holes are then sealed. The specific properties of the liquid, for example in terms of its composition, are not of primary significance to the principles described herein, and any conventional liquid of the type commonly used in electronic cigarettes can generally be used. The reservoir 44 is closed by one or more sealing elements or components at the interface end 54 of the cartridge 4.

[0070] For example, the reservoir 44 may be closed by an upper or downstream sealing member 38 that at least partially provides an opening for receiving an end of a liquid transport element (capillary wick) 42 that extends from the air passage 46. The upper sealing member 38 is further configured to include a conduit or recess 48 that fluidly connects the reservoir 44 to the end of the liquid transport element 42. Thus, the end of the liquid transport element 42 is fluidly connected to the reservoir 44, and the end of the liquid transport element draws liquid from the reservoir through the opening in the air passage 46 to the heater 40 for subsequent evaporation.

[0071] exist Figure 1 In the example of, upper sealing member or downstream sealing member 38 and lower sealing member or upstream sealing member 36 cooperate to provide an opening for receiving the end of liquid transport element (capillary wick) 42. Upper sealing member 38 and lower sealing member 36 can be considered as a combined sealing member. In some examples, lower sealing member 36 and upper sealing member 38 can be configured to provide an orifice, and core 42 extends through these orifices. For example, lower sealing member 36 and upper sealing member 38 can be shaped so that the inner wall of each is concave (the section containing aerosol generator 40 adjacent to airflow path 46) to limit a pair of diametrically opposite slots. Each slot can provide a semicircular surface for accommodating the end of liquid transport element 42.

[0072] The corresponding slots of the upper and lower sealing members 38, 36 are aligned so that the upper and lower sealing members 38, 36 cooperate to define apertures through which the ends of the liquid transport element 42 extend. The size of the aperture through which the liquid transport element 42 passes closely corresponds to the size and shape of the liquid transport element, but is slightly smaller so that a degree of compression is provided by the sealing members 36, 38. This allows liquid to be transported along the liquid transport element by capillary action while limiting the extent to which liquid that is not transported by capillary action can pass through the openings.

[0073] Additionally, in some examples, the outer edge of the upper sealing member 38 can be inserted into a portion of the housing 32 to seal the reservoir 44. For example, the upper sealing member 38 can be shaped to be received in an aperture toward the interface end 54 of the housing portion 32. The upper sealing member 38 can include one or more circumferential ridges that engage the inner surface of the housing portion 32 and ensure a tight fit when the upper sealing member 38 is inserted into the housing portion 32.

[0074] In some examples, the upper sealing member 38 includes additional elements, such as a silicone sleeve, to facilitate the connection of the upper sealing member 38 to the housing 32 and the sealing of the reservoir 44. The connection can be configured so that the movement of liquid along the inner surface of the housing portion 32 can be inhibited (e.g., by means of a tight fit). A similar engagement mechanism can be provided between the upper sealing member 38 and the inner tube 62. The lower sealing element 36 can also be configured to be received by the housing 32 and provide a level of sealing that inhibits or prevents the movement of liquid between the lower sealing element 36 and the housing 32.

[0075] The end cap 34 of the cigarette cartridge 4 is configured to facilitate the electrical connection of the control part 2 to the aerosol generator 40. For example, the end cap 34 may include an electrode column 14 on the bottom side of the end cap 34 that is nearly flush with the interface end 54 of the cigarette cartridge 4. These are the parts of the electrodes to which the corresponding aligned elastic contacts in the control unit are connected when the cigarette cartridge is assembled and connected to the control unit. The ends of the electrode columns on the inner side of the cigarette cartridge 4 extend away from the end cap 34 (e.g., toward the heater). The ends of the electrodes can extend into the holes in the sealing member 36. Each electrode column 14 can maintain a pressed contact with an electrical conductor 41 connected to the aerosol generator 40 to facilitate the formation of an electronic circuit (in particular, an electronic circuit involving the electronic devices of the control part 2, such as the control circuit 18) between the aerosol generator 40 and the control part 2.

[0076] exist Figure 1 In the example of the end cap 34, the end cap 34 also defines an air inlet through which air is drawn into the air channel 46 of the cartridge 4. In some examples, the air inlet is configured to align with the outlet of the control portion 2, wherein the air channel 46 includes a portion of the control portion 2 (up to the outlet of the control portion 2) and a portion of the cartridge 4 (starting from the inlet of the cartridge 4).

[0077] The cartridge 4 further includes an (aerosol generating) chamber 50, which is defined by the surface of the components surrounding or close to the aerosol generator 40. In use, the aerosol generator 40 can be supplied with power to evaporate or aerosolize a certain amount of aerosol generating material in the area of ​​the airflow path 46 defined by the chamber 50. The evaporated aerosol generating material can become entrained in the air drawn through the chamber 50 along the airflow path 46. The area to which the aerosol is provided or released can also be referred to as the aerosol generating area (or evaporation area) of the airflow path 46. The chamber 50 is fluidly connected to the inlet leading to the cartridge 4 (e.g., through the passage defined by the end cap 34 and the lower sealing component 36) and is fluidly connected to the mouthpiece outlet 60 (e.g., through the inner tube 62).

[0078] As will be discussed in detail below, the chamber 50 is defined by a surface of the component that faces the aerosol generator 40 (e.g., the surface of the component has a tangential orientation and / or there is no obstruction between the component and the aerosol generator 40). In some examples, the upper sealing component 38 and the lower sealing component 36 define or otherwise bound respective portions of the chamber 50. The upper sealing component 38 and the lower sealing component 36 do not completely define the boundaries of the chamber 50.

[0079] In some examples, the upper sealing member 38 and the lower sealing member 36 may only define the following boundaries of the chamber: these boundaries are adjacent to the location where the aerosol generator 40 and / or the liquid transport element 42 interact with the chamber wall. In some examples, the upper sealing member 38 can also define the air outlet of the chamber 50 (for example, the upper sealing element can be formed to extend across the width of the chamber downstream of the aerosol generator, and the air outlet can be set in this extension range). In some examples, the lower sealing member 36 can also define the air inlet of the chamber 50 (for example, the lower sealing element can be formed to extend across the width of the chamber upstream of the aerosol generator, and the air inlet can be set in this extension range).

[0080] For example, the upper sealing member 38 and the lower sealing member 36 can be configured to define an opening or orifice (not shown) on either side of the aerosol generator 40 that exposes the airflow inner surface of the portion of the housing 32. By defining the opening or orifice, it is meant that the upper sealing member 38 and the lower sealing member 36 are shaped so that they are not fully engaged (e.g., in contact) with each other around the periphery or circumference of the outer wall of the cartridge 4. Instead, the upper sealing member 38 and the lower sealing member 36 can only contact the portion of the cartridge toward which they are engaged with the liquid transport element 42. The upper sealing member 38 and the lower sealing member 36 are separated away from these portions so that they are not in contact, thereby exposing the outer wall portion of the housing 32.

[0081] In other words, one or more outer wall portions of the housing 32 (e.g., portions defining the outer shape of the cartridge 4) include an inner surface (e.g., not defining the outer shape of the cartridge 4), which defines or otherwise delimits corresponding portions of the chamber 50 (i.e., because the upper sealing member 38 and the lower sealing member 36 are not present in these areas of the chamber). The aerosol generator 40 is disposed in a chamber 50 at least partially defined by one or more outer wall portions (e.g., defined by a first outer wall portion), wherein the one or more outer wall portions define one or more corresponding inner surfaces of the chamber 50.

[0082] The aerosol generator 40 is separated from the one or more inner surfaces, thereby creating a gap between the aerosol generator 40 and the inner surface. This provides increased space for airflow around one or more sides of the aerosol generator 40 while keeping the overall thickness of the cartridge 4 to a minimum. In addition, this allows the overall thickness of the cartridge 4 to be minimized while still maintaining a sufficient air gap between the aerosol generator 40 and the housing 32 to avoid excessive surface temperatures during use (which is particularly advantageous if the aerosol generator 40 is a heater).

[0083] Figure 2 is a schematic perspective view of an exemplary cartridge 4 according to certain embodiments of the present disclosure. Figure 1 Compared with the schematic diagram, Figure 2 A cross section extending perpendicular to the aerosol generator 40 and the liquid transport element 42 into the chamber 50 is depicted.

[0084] exist Figure 2 , the housing 32 includes a first outer wall portion 81 defining a first inner surface 91 of the chamber 50 and a second outer wall portion 82 defining a second inner surface 92 of the chamber 50 , the second inner surface 92 being opposite to the first inner surface 82 .

[0085] Figure 2 The cigarette cartridge 4 includes an interface end 6, which faces the interface end 54 of the cigarette cartridge 4 and is configured to be inserted into a corresponding receiver 8 of the control unit 2. The interface end 6 is defined by the end cap 34 and a section of the housing 32. In some examples, for example, according to Figure 2 In those examples, the first outer wall portion 81 and the second outer wall portion 91 are arranged in a section of the housing 32 providing the interface end 6, so when the cigarette cartridge 4 is attached to the control unit 2, the first outer wall portion 81 and the second outer wall portion 91 are received in the receiver 8. It will be understood that in the case of not according to Figure 2 In other examples, the first outer wall portion 81 and the second outer wall portion 91 are not in this section, so when the cigarette cartridge 4 is attached to the control unit 2, the first outer wall portion and the second outer wall portion are not received in the receiver 8.

[0086] The chamber 50 is defined at an upstream end by the lower sealing member 36, which further includes a passageway that defines a portion of the airflow path 46 connected to the inlet at the interface end 54. The chamber 50 is defined at a downstream end by the upper sealing member 38, which is connected to the inner tube 62. Although not shown, the lower sealing member 36 and the upper sealing member 38 are configured to retain the liquid transport element 42 in the chamber 50. The aerosol generator 40 is attached to the liquid transport element 42 (e.g., which includes a coil heater wrapped around a core), and thus the lower sealing member 36 and the upper sealing member 38 further retain the aerosol generator 40 in the chamber 50.

[0087] The chamber 50 is defined by a first inner surface 91 on one side of the aerosol generator 40 and by a second inner surface 92 on the opposite side of the aerosol generator 40. In some examples, the first inner surface 91 and the second inner surface 92 are exposed through an opening provided by the engagement of the lower sealing member 36 with the upper sealing member 38. For example, the lower sealing member 36 and the upper sealing member 38 can engage with each other to provide an orifice for receiving the liquid transport element 42, and not engage with each other away from these orifices (e.g., an area of ​​the chamber 50 that is tangential to the extent of the liquid transport element 42).

[0088] The aerosol generator 40 is separated from both the first inner surface 91 and the second inner surface 92. The use of the first inner surface 91 and the second inner surface 92 to define the chamber 50 provides increased space for airflow around the sides of the aerosol generator 40 while keeping the overall thickness of the cartridge 4 to a minimum. In addition, this use allows the overall thickness of the cartridge 4 to be minimized while still maintaining sufficient air gaps between the aerosol generator 40 and the housing 32 to avoid high outer surface temperatures during use; this is particularly advantageous where the aerosol generator 40 is a heater.

[0089] In some examples, an aperture 98 may be formed between the upper sealing member 36 and the lower sealing member 38 (which may be collectively considered a sealing element) to expose the first inner wall surface 91 (a similar aperture may be provided to expose the second inner wall surface 92). For example, the aperture 98 may be formed by removing (or not providing) material from one or both of the upper sealing member 36 and the lower sealing member 38 to ensure that the upper sealing member 36 and the lower sealing member 38 do not contact in the area of ​​the first inner wall surface 91. In this way, the sealing element (formed by one or both of the lower sealing member 36 and the upper sealing member 38) may be configured to define an aperture 98 that exposes the first inner wall surface 91. In some examples, the aperture 98 may extend out Figure 2 The plane shown is toward the areas of the chamber where the upper sealing member 36 and the lower sealing member 38 contact to provide a seal for the liquid transport element 42 .

[0090] Figure 3 is a schematic perspective view of an exemplary cartridge 4 according to certain embodiments of the present disclosure. Figure 1 and Figure 2 Compared with the schematic diagram, Figure 3 A cross section is depicted perpendicular to the longitudinal extension of the cartridge 4, i.e. perpendicular to the axis extending from the mouthpiece end 54 to the mouthpiece outlet 60. The cross section extends through the aerosol generator 40, the liquid transport element 42, the (aerosol generating) chamber 50 and those components defining the limits or boundaries of the chamber 50. Figure 3 The components are basically as follows Figure 1 and Figure 2 described.

[0091] like Figure 3 As depicted in FIG. 1 , chamber 50 is defined in this plane by four different components. Figure 2 As discussed, the shell 32 includes a first outer wall portion 81 defining a first inner surface 91 of the chamber 50 and a second outer wall portion 82 defining a second inner surface 92 of the chamber 50, wherein the second inner surface 92 is disposed on a side of the chamber 50 opposite to the first inner surface 91 (e.g., the aerosol generator 40 is in the middle of the chamber 50, between the first inner surface 91 and the second inner surface 92).

[0092] In some instances, for example, according to Figure 3 In an example, the first outer wall portion 81 and the second outer wall portion 82 are formed by a single wall defining the circumference of the outer shape of the cartridge 4. For example, the housing 32 may include a circular or elliptical wall (e.g., a tubular portion) providing the first outer wall portion 81 and the second outer wall portion 82. Alternatively, a single wall providing the first outer wall portion 81 and the second outer wall portion 82 may have a polygonal outer cross-section (i.e., a straight or flat side shape), or may be a combination of a flat surface and a curved surface forming the outer circumference of the cross-section of the shape.

[0093] In some examples where the first outer wall portion 81 and / or the second outer wall portion 82 define a portion (e.g., a surface) of the interface end 6 of the cartridge 4, the first outer wall portion 81 and / or the second outer wall portion 82 may be configured to be received within a receiver of the control unit 2 of the aerosol delivery system 1. For example, the first outer wall portion 81 and / or the second outer wall portion 82 may be configured to have an outer shape corresponding to the shape of the receiver 8 of the control unit 2 so as to engage with the receiver 8 when the interface end 6 is inserted into the receiver 8 (e.g., their shape may ensure that an interference fit is formed to help retain the interface end 6 in the receiver 8).

[0094] In addition to the first outer wall portion 81 and / or the second outer wall portion 82, Figure 3Also depicted is a third inner surface 93 and a fourth inner surface 94 of the upper or downstream sealing member 38 defining the chamber 50. The third inner surface 93 and the fourth inner surface 94 define, define or otherwise limit the extent of the chamber 50.

[0095] As about Figure 1 As described, the upper or downstream sealing member 38 and the lower or upstream sealing member 36 cooperate to provide an opening for receiving the ends of the liquid transport element (e.g., capillary wick) 42. These ends of the liquid transport element 42 are shown extending from the chamber 50, through the upper sealing member 38 and into a corresponding pocket or conduit 48, which is fluidly connected to a reservoir 44 of liquid aerosol generating material (not shown). The third inner surface 93 and the fourth inner surface 94 are adjacent to the opening and face the chamber 50. In the example, according to Figure 3 The third inner surface 93 and the fourth inner surface 94 each extend from the first inner surface 91 to the second inner surface 92 .

[0096] Although not shown, it will be appreciated that the lower or upstream sealing member 36 may also provide one or more surfaces that define the boundaries of the chamber 50. For example, the upper or downstream sealing member 38 may partially define the shape of the chamber 50 above (downstream) the aerosol generator 40, while the lower or upstream sealing member 36 may partially define the shape of the chamber below (upstream) the aerosol generator 40 (not shown). The respective surfaces provided by the upper and lower sealing members 36, 38 join or meet each other near the opening for receiving the liquid transport element 42.

[0097] Thus, in some examples, the lower or upstream sealing member 36 and / or the upper or downstream sealing member 38 provide sealing elements (e.g., alone or in combination) between which the aerosol generator 40 extends within the chamber 50. In some examples, the sealing element (formed by one or both of the lower or upstream sealing member 36 and / or the upper or downstream sealing member 38) is configured to suspend the aerosol generator 40 within the chamber 50. For example, the sealing element may accommodate an end of a liquid transport element 42 that forms a sub-portion of the aerosol generator 40, or otherwise position the aerosol generator 40 within the chamber 50. In some examples, the sealing element includes the lower sealing member 36 and the upper sealing member 38.

[0098] In some instances, Figure 3The gap shown as between the third inner surface 93 and the fourth inner surface 94 in which the first inner surface 91 and the second inner surface 92 are exposed can be formed by configuring one or both of the upper sealing member 36 and the lower sealing member 38 to define an aperture that exposes the first inner wall surface 91 and the second inner wall surface 92. For example, the aperture 98 can be formed by removing (or not providing) material of one or both of the upper sealing member 36 and the lower sealing member 38 in the area between the third inner surface 93 and the fourth inner surface 94. In this way, the sealing element (formed by one or both of the lower sealing member 36 and the upper sealing member 38) can be configured to define an aperture 98 that exposes the first inner wall surface 91, wherein the aperture 98 extends between the third inner surface 93 and the fourth inner surface 94.

[0099] In an example, the aerosol generator 40 is separated from the first inner surface 91 by a first separation distance D1. In other words, the surface of the aerosol generator 40 is displaced from the first inner surface 91 by the first separation distance. In some examples, the first separation distance D1 can be the minimum separation distance between the aerosol generator 40 and the first inner surface 91. In some examples, the first separation distance D1 can be the minimum, maximum, or average separation distance between the aerosol generator 40 and the first inner surface 91. In some examples, the first separation distance D1 can be the closest corresponding point between the aerosol generator 40 and the first inner surface 91 (e.g., at Figure 3 The first separation distance D1 is measured between the aerosol generator 40 at both ends of the arrow D1 in FIG. 1 and the corresponding points on the first inner surface 91. In some examples, the first separation distance D1 may be in the range of 1 mm to 3 mm.

[0100] In an example, the first outer wall portion 81 has a thickness T. The thickness T can be the minimum, maximum, or average distance between the first inner surface 91 and the outer shape (i.e., the outer surface of the first outer wall portion 81 that defines the outer shape). The thickness T can be the closest corresponding point on both sides of the first outer wall portion 81 (e.g., at Figure 3 The thickness T is measured between corresponding points on both sides of the first outer wall portion 81 at both ends of the arrow T in FIG. In some examples, the thickness T may be in the range of 0.5 mm to 2 mm.

[0101] In some examples, the ratio of thickness T to first separation distance D1 is less than 1. In other words, first separation distance D1 is greater than thickness T. In some specific examples, the ratio of thickness T to first separation distance D1 is less than 0.5. In other words, first separation distance D1 is greater than twice thickness T.

[0102] As described above, the housing 32 may include a second outer wall portion 82, which also partially defines the outer shape of the smoke cartridge 4. The second outer wall portion 82 defines a second inner surface 92 of the chamber 50, which is on the side of the chamber opposite to the first inner surface 91. The aerosol generator 40 is separated from the second inner surface 91. For example, the aerosol generator 40 may be separated from the second inner surface 91 by a second separation distance. The size of the second separation distance, the thickness of the second outer wall portion 82, and their ratios may be substantially as described above with respect to the separation of the first outer wall portion 81 from the aerosol generator 40. For example, the ratio of the thickness of the second outer wall portion 82 to the second separation distance may be less than 1, and preferably less than 0.5. In some instances, the first separation distance and the second separation distance are equal (in other words, the aerosol generator 40 is arranged to be equidistant between the first outer wall portion 81 and the second outer wall portion 82).

[0103] In some examples, the chamber 50 is defined by a lateral extension X between the outer surface of the first outer wall portion 81 and the outer surface of the second outer wall portion 82. In other words, the lateral extension X of the chamber 50 is the dimension between the two surfaces that define the size (e.g., width) of the cartridge.

[0104] In some examples, the aerosol generator 40 includes a width W that is parallel to (e.g., co-aligned with) a lateral extension X. For example, the lateral extension X can be considered to pass through the aerosol generator 40, and the width W can be equal to the portion of the lateral extension X that passes through the aerosol generator 40. The width W is generally measured through the center of the aerosol generator 40 (e.g., the center of a circumferential cross-section of a cylindrical liquid transport element 42 around which the resistive wire is wrapped to form the aerosol generator 40).

[0105] In some examples, the ratio of the width W to the lateral extension X of the cartridge is less than 0.5. In other words, the width W of the aerosol generator is less than half of the lateral extension X of the cartridge. In some examples, the lateral extension of the cartridge is in the range between 5 mm and 10 mm.

[0106] Figure 4 4 is a flow chart of a method 400 for providing a cartridge 4 for an aerosol delivery system. The method begins at step 410 by providing a housing 32 including a first outer wall portion 81 that partially defines an outer shape of the cartridge 4 and a first inner surface 91 of the chamber 50 .

[0107] In some examples, the shell 32 can be formed as a single component including the first outer wall portion 81 and other parts of the shell 32 (e.g., having the second outer wall portion 82, the mouthpiece end 52 and the inner tube 62). For example, the shell 32 can be manufactured as a single piece by injection molding or additive manufacturing. In other examples, the shell 32 can be constructed by combining two or more different parts (e.g., using a clamp, an adhesive, etc.). In these examples, the first outer wall portion 81 can be integrally combined with one or more other parts of the shell 32. For example, the first outer wall portion 81 and the second outer wall portion 82 can be provided by a single tube component (e.g., a cylindrical or elliptical tube).

[0108] The method continues at step 420 by providing an aerosol generator 40 in the chamber 50 at least partially defined by the first outer wall portion 81, wherein the aerosol generator 40 is separated from the first inner surface 91. The aerosol generator 40 is used to generate an aerosol for inhalation from an aerosol generating material.

[0109] In step 420, an aerosol generator 40 is provided so that it can be used to generate an aerosol within the chamber 50. For example, an aerosol generating material can be provided in the chamber 50 so that the aerosol generator 40 can generate an aerosol using the aerosol generating material. In some examples, the aerosol generator 40 can include or be provided in combination with a liquid transport element 42 that is configured to transfer liquid aerosol generating material from a reservoir 44 to the aerosol generator 40 for aerosolization by the aerosol generator 40 (e.g., the aerosol generator 40 can be a heater configured to heat the liquid aerosol generating material).

[0110] By providing the aerosol generator 40 separated from the first inner surface 91, it is meant that the aerosol generator 40 does not contact the first inner surface 91. There is a separation distance D1 between the aerosol generator 40 and the first inner surface 91. The separation distance describes the size of the gap or space within which air can flow (air can also flow through other areas of the chamber 50, such as the gap between the aerosol generator 40 and the second inner surface 92).

[0111] The gap provides a space in which the generated aerosol (or vapor) can be released into the air path, and also prevents or inhibits heat from being directly transferred from the aerosol generator 40 to the first inner surface 91 via conduction. The use of the first outer wall portion 81 also defines the first inner surface 91, which achieves a reduced thickness of the cartridge 4 while maximizing the size of the gap between the aerosol generator 40 and the first inner surface 91 (thereby reducing potential heat transfer by convection or radiation). In particular, instead of having an outer wall of a certain thickness (e.g., the structural minimum required for the construction of a self-supporting wall) and an aerosol generation chamber wall of a certain thickness (e.g., the structural minimum required for the construction of a self-supporting wall), the functions of different aerosol generation chamber walls can be additionally provided by the outer wall (i.e., by defining the chamber with the inner surface of the outer wall).

[0112] Method 400 then ends.

[0113] It will be appreciated that while the above description has focused on a few different aspects of an aerosol generator assembly having a number of different features, it will be appreciated that arrangements according to other embodiments of the present disclosure may include only some of these features without regard to some of the other features. Figure 2 and Figure 3 The chamber 50 defined by multiple surfaces of the discussed principles may be implemented with aerosol generators other than those formed by winding a coil around a core.

[0114] Thus, a cartridge for an aerosol delivery system has been described, the cartridge comprising a shell including a first outer wall portion that partially defines the outer shape of the cartridge, and an aerosol generator for generating an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is disposed in a chamber at least partially defined by the first outer wall portion, wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface.

[0115] An aerosol delivery system for aerosolising an aerosol generating material has also been described, the aerosol delivery system comprising a cartridge as described above.

[0116] A cartridge device for an aerosol delivery system has been further described, the cartridge device comprising: a shell device, the shell device comprising a first outer wall portion that partially defines the external shape of the cartridge device; and an aerosol generator device for generating an aerosol for inhalation from an aerosol generating material device, wherein the aerosol generator device is arranged in a chamber at least partially defined by the first outer wall portion, wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator device is separated from the first inner surface.

[0117] A method of providing a cartridge for an aerosol delivery system has been further described, the method comprising: providing a shell, the shell comprising a first outer wall portion, the first outer wall portion partially defining the outer shape of the cartridge and a first inner surface of a chamber; and providing an aerosol generator in the chamber at least partially defined by the first outer wall portion, the aerosol generator being used to generate an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is separated from the first inner surface.

[0118] Although the above embodiments focus in some aspects on some specific example aerosol delivery systems, it will be understood that the same principles can be applied to aerosol delivery systems using other technologies. That is, the specific way in which various aspects of the aerosol delivery system function, such as in terms of how the system is activated for use and the functions provided by the system, is not directly related to the basic principles of the examples described herein.

[0119] In order to solve various problems and promote technological development, the present disclosure shows various embodiments in which the claimed invention can be practiced by way of illustration. The advantages and features of the present disclosure are only representative samples of embodiments, and are not exhaustive and / or exclusive. They are presented only to help understand and teach the claimed invention. It should be understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects of the present disclosure should not be considered as limitations on the present disclosure defined by the claims or limitations on the equivalents of the claims, and other embodiments can be utilized and can be modified without departing from the scope of the claims. In addition to those specifically described herein, various embodiments may appropriately include, contain or substantially contain various combinations of disclosed elements, parts, features, parts, steps, devices, etc., so it will be understood that the features of the dependent claims can be combined with the features of the independent claims in combinations other than those explicitly set forth in the claims. The present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A cigarette cartridge for an aerosol delivery system, the cigarette cartridge comprising: A housing including a first outer wall portion partially defining an outer shape of the cartridge; as well as an aerosol generator for generating an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is disposed in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface.

2. The cigarette cartridge according to claim 1, wherein: The aerosol generator is separated from the first inner surface by a first separation distance, and wherein the first outer wall portion has a thickness between the first inner surface and the outer shape, wherein a ratio of the thickness to the first separation distance is less than 1.

3. The cigarette cartridge according to claim 2, wherein: A ratio of the thickness to the first separation distance is less than 0.

5.

4. The cigarette cartridge according to any one of claims 1 to 3, wherein: The shell includes a second outer wall portion that partially defines the outer shape of the cartridge, wherein the second outer wall portion defines a second inner surface of the chamber, the second inner surface is on a side of the chamber opposite to the first inner surface, and wherein the aerosol generator is separated from the second inner surface.

5. The cigarette cartridge according to claim 4, wherein: The chamber is defined by a lateral extension between the first inner surface and the second inner surface, and wherein the aerosol generator comprises a width parallel to the lateral extension, wherein a ratio of the width to the lateral extension of the cartridge is less than 0.

5.

6. The cigarette cartridge according to claim 5, wherein: The lateral extension range of the cigarette cartridge is between 3mm and 8mm.

7. The cigarette cartridge according to any one of claims 4 to 6, wherein: The first outer wall portion and the second outer wall portion are formed by a single wall defining a circumference of the outer shape of the cartridge.

8. The cigarette cartridge according to any one of claims 1 to 7, wherein: The first outer wall portion partially defines an interface end of the cartridge, the interface end being configured to be received within a receptacle of a control unit of an aerosol delivery system.

9. The cigarette cartridge according to any one of claims 1 to 8, wherein: The aerosol generator extends within the chamber between a third inner surface of the chamber and a fourth inner surface of the chamber, wherein the cartridge further includes a sealing element defining the third inner surface and the fourth inner surface, the sealing component being configured to suspend the aerosol generator within the chamber.

10. The cigarette cartridge according to claim 9, wherein: The sealing element is configured to define an aperture exposing the first inner wall surface, wherein the aperture extends between the third inner surface and the fourth inner surface.

11. The cigarette cartridge according to any one of claims 1 to 10, wherein: The aerosol generator includes a resistive heater.

12. The cigarette cartridge according to claim 11, wherein: The resistance heater includes a core and a coil heater.

13. An aerosol delivery system for aerosolizing an aerosol generating material, the aerosol delivery system comprising a cartridge according to any one of claims 1 to 12.

14. A cartridge device for an aerosol delivery system, the cartridge device comprising: A housing device including a first outer wall portion partially defining an outer shape of the cartridge device; as well as an aerosol generator device for generating an aerosol for inhalation from an aerosol generating material device, wherein the aerosol generator device is disposed in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator device is separate from the first inner surface.

15. A method of providing a cartridge for an aerosol delivery system, the method comprising: Providing a housing, the housing comprising a first outer wall portion, the first outer wall portion partially defining an outer shape of the cartridge and a first inner surface of the chamber; as well as An aerosol generator is provided in the chamber defined at least in part by the first outer wall portion for generating an aerosol for inhalation from an aerosol generating material, wherein the aerosol generator is separated from the first inner surface.

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