Aerosol delivery system

Abstract

The present disclosure relates to an aerosol generator assembly for aerosolizing an aerosol-generating material, the aerosol generator assembly comprising: an aerosol generator comprising two elongate electrical connectors; and two barrier portions configured to at least partially define a surface defining an aerosol-generating region, the aerosol generator configured to generate an aerosol in the aerosol-generating region, each of the two barrier portions is configured to be pierced by a respective one of the two elongate electrical connectors during assembly of the aerosol generator assembly, with each of the two elongate electrical connectors extending through a respective one of the two barrier portions.

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 evaporator assembly of a vapor supply system can play an important role in the overall performance of the system, for example in helping to reduce leakage and corrosion of electrical connections. This article describes various approaches that seek to help address some of these issues. Summary of the invention

[0004] According to a first aspect of certain embodiments, an aerosol generator assembly for aerosolizing an aerosol generating material is provided, the aerosol generator assembly comprising: an aerosol generator comprising two slender electrical connectors and two barrier portions, the two barrier portions being configured to at least partially define a surface that defines an aerosol generating area, the aerosol generator being configured to generate an aerosol in the aerosol generating area, wherein each of the two barrier portions is configured to be pierced by a corresponding one of the two slender electrical connectors during assembly of the aerosol generator assembly, wherein each of the two slender electrical connectors extends through a corresponding one of the two barrier portions.

[0005] According to a second aspect of some embodiments, there is provided a cartomiser for aerosolising an aerosol generating material, the cartomiser comprising an aerosol generator assembly according to the first aspect and an aerosol generating material.

[0006] According to a third aspect of certain embodiments, an electronic aerosol supply system for aerosolizing an aerosol generating material is provided, the electronic aerosol supply system comprising an aerosol generator assembly of the first aspect or a nebulizer cartridge of the second aspect, and a control unit comprising a power source for supplying power to the aerosol generator, wherein two elongated electrical connectors form part of a circuit configured to supply power from the power source to the aerosol generator.

[0007] According to a fourth aspect of certain embodiments, a method for assembling an aerosol generator component for aerosolizing an aerosol generating material in an electronic aerosol delivery system is provided, wherein the method comprises: providing an aerosol generator comprising two slender electrical connectors; providing two barrier portions, the two barrier portions being configured to at least partially define a surface that defines an aerosol generating area, the aerosol generator being configured to generate an aerosol in the aerosol generating area; and inserting the two slender electrical connectors into the two barrier portions so that each of the two slender electrical connectors pierces and extends through a corresponding one of the two barrier portions.

[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 An aerosol delivery system including a cartridge and a control unit according to certain embodiments of the present disclosure is schematically shown in a perspective view;

[0011] Figure 2 schematically illustrates in perspective view an example aerosol generator assembly according to certain embodiments of the present disclosure; and

[0012] Figure 3 is a flow chart schematically illustrating steps in a method of forming an aerosol generator assembly for use in an aerosol delivery system according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0013] 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 apparatus and methods discussed herein that are not described in detail may be implemented according to any conventional techniques for implementing these aspects and features.

[0014] As will be explained below, the present disclosure relates to an aerosol generator assembly for aerosolizing an aerosol generating material in an electronic aerosol delivery system, the aerosol generator assembly comprising: an aerosol generator comprising two elongated electrical connectors; and two barrier portions configured to at least partially define a surface defining an aerosol generating region, the aerosol generator being configured to generate an aerosol in the aerosol generating region, wherein each of the two barrier portions is configured to be pierced by a corresponding one of the two elongated electrical connectors during assembly of the aerosol generator assembly, wherein each of the two elongated electrical connectors extends through a corresponding barrier portion of the two barrier portions. The above system prevents or inhibits (e.g., substantially reduces) liquid from moving along the elongated electrical connectors and leaving the aerosol generating region.

[0015] For example, in the absence of a barrier material or barrier portion, or in the presence of a poorly sealed barrier portion, liquid may flow out of the aerosol generating area along the elongated electrical connector or through an opening through which the elongated electrical connector extends. Therefore, the present disclosure provides an improved degree of sealing by forming an aerosol generator assembly by piercing the barrier portion with an elongated electrical connector during manufacture or assembly of the aerosol generator assembly. In particular, the opening for receiving the elongated electrical connector is formed by piercing rather than drilling or otherwise forming an opening, and the cross-section and size of the opening closely match the size and cross-section of the elongated electrical connector, thereby preventing the formation of an open space between the barrier portion and the elongated electrical connector through which liquid can flow. Preventing or inhibiting liquid from flowing through the barrier portion can, for example, prevent liquid from accumulating at the contact point between the elongated electrical connector and the electrode column, thereby preventing the conductive path between the elongated electrical connector and the electrode column from being interrupted (e.g., due to corrosion of the surface of the elongated electrical connector or the electrode column, or due to liquid forming a barrier between the elongated electrical connector and the electrode column).

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] In some embodiments, the non-flammable aerosol supply system, such as the 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.

[0025] 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.

[0026] 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.

[0027] In some embodiments, the substance to be delivered includes an active substance.

[0028] 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, cannabinoids, or components, derivatives or combinations thereof. Active substances can include one or more components, derivatives or extracts of tobacco or other plants.

[0029] In one embodiment, the active substance is a legally permitted recreational drug.

[0030] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0031] As described herein, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof.

[0032] 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, cannabis, 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 tea), thyme, cloves, cinnamon, coffee, anise (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, Flowers, lavender, lemon peel, mint, juniper, elderberry, vanilla, holly, basil plant, turmeric, turmeric root powder, sandalwood, coriander leaves, bergamot, orange blossom, myrtle, black currant, valerian, Spanish bell pepper, mace, damien, 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, heart-leaf spearmint, long-leaf mint, pineapple mint, lip calyx mint, spearmint cv, and apple mint.

[0033] 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.

[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 selected from eucalyptus, star anise, cocoa and cannabis. 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.

[0035] In some embodiments, the substance to be delivered includes a flavoring agent.

[0036] 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, cannabis, 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, yellow, grapes, durian, pitaya, cucumber, blueberries, mulberries, citrus fruits, durin brand, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, mint, lavender, aloe vera, cardamom, celery, bitter bean peel, nutmeg seeds, sandalwood, bergamot, geranium, Arabic tea, sorghum, betel leaves, coriander, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, coriander, cognac, jasmine, ylang-ylang, sage, Fennel, mustard, green pepper, ginger, coriander, 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.

[0037] In some embodiments, the flavoring agent comprises menthol, spearmint and / or peppermint. In some embodiments, the flavoring agent comprises a flavoring agent component of cucumber, blueberry, citrus fruit and / or cranberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises a flavoring agent component extracted from tobacco. In some embodiments, the flavoring agent comprises a flavoring agent component extracted from cannabis.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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 14, which provide electrical contacts on the bottom of the cartridge and corresponding elastic contact pins 16 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).

[0052] 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.

[0053] 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 includes a housing 10 (e.g., formed of plastic or metal), the housing includes a receiver wall 12, the receiver wall defining a receiver 8 for receiving the end of the cigarette cartridge as described above. In this example, the housing 10 of the control unit 2 has a generally elliptical cross-section, which is consistent with the shape and size of the cigarette 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 cigarette cartridge 4, air is inhaled through these holes toward the interface end of the cigarette cartridge part 4, where the air enters the cigarette cartridge through the opening in the base end of the cigarette cartridge. It will be understood that the interface end 6 of the cigarette cartridge 4 may not form an airtight seal with the receiver wall 12, so some of the inhaled air can also be inhaled into the cigarette cartridge through the gap between the cigarette cartridge 4 and the control unit 2.

[0054] 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 .

[0055] 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).

[0056] 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.

[0057] 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.

[0058] 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.

[0059] The cartridge 4 includes a housing portion 32, an end cap 34 including an electrode 14, an aerosol generator assembly including an aerosol generator 40, a liquid transport element 42, and a sealing member 36 including two barrier portions 38. As discussed below, the cartridge 4 is configured to contain an aerosol generating material. The cartridge 4 may be referred to as an atomizing cartridge in some instances because it includes an aerosol generator and an aerosol generating material.

[0060] In this example, the housing portion 32 includes a housing outer wall 64 and a housing inner tube 62, which are formed from a single molded piece of polypropylene in this example. The housing outer wall 64 defines the appearance of the cartridge 4, and the housing inner tube 62 defines a portion of the air passage 46 through the cartridge. The housing portion is open at the interface end 54 of the cartridge and closed at the mouthpiece end 52 of the cartridge, except for the mouthpiece opening / vapor outlet 60 in fluid communication with the housing inner tube 62.

[0061] The housing portion 32 defines a storage area or reservoir 44 between the housing outer wall 64 and the housing inner tube 62. The reservoir or storage area 44 is used to contain an aerosol-generating material (e.g., a liquid aerosol-generating material). An 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. Figure 1 In the schematically illustrated example, a reservoir 44 is provided, which is configured to store a supply of liquid aerosol-generating material. In this example, the liquid reservoir 44 has a substantially annular shape having an outer wall defined by a housing outer wall 64 and a housing inner tube 62, which defines an airflow path through the cartridge portion 4. The reservoir 44 is closed at the mouthpiece end 52 with an end wall to contain the aerosol-generating material.

[0062] The aerosol generator 40 is positioned toward the end of the reservoir 44 opposite the mouthpiece end 52. Figure 1 In some embodiments, the aerosol generator is a heater 40 (and referred to as such hereinafter) 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 other 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.

[0063] It will be understood that in e.g. Figure 1In the two-piece device shown, the aerosol generator can be in the reusable portion 2 or the cartridge portion 4. For example, in some embodiments, the aerosol generator 40 (e.g., a heater) can be included in the reusable portion 2, and when the cartridge is engaged with the reusable portion 2, the aerosol generator is brought into proximity with a portion of the aerosol generating material in the cartridge 4. In such embodiments, the cartridge can include a portion of the aerosol generating material, and when the cartridge 4 is engaged with the reusable portion 2, the aerosol generator 40 including the heater is at least partially inserted into the portion of the aerosol generating material or is at least partially disposed adjacent to or around the portion of the aerosol generating material.

[0064] exist Figure 1 In the example of the embodiment of the present invention, the liquid transport element 42 is a core 42 in contact with the heater 40. The core 42 extends transversely across the main airflow path (or first airflow path) and its end extends into a bag or recess (not shown) that is fluidly connected to a reservoir 44 of liquid aerosol generating material.

[0065] Figure 1 The sealing member 36 in the example includes silicone, and can be a single molded part of silicone. The sealing member 36 and at least one other component (such as the interface end of the inner tube 62) can be shaped to provide an orifice, and the core extends through the orifice. For example, the sealing member 36 can be shaped so that the inner wall (adjacent to the segment of the airflow path containing the aerosol generator 40) includes a pair of diametrically opposite slots. Each slot can provide a semicircular surface for accommodating the liquid transport element 42. Similarly, extending outward from the interface end 54 of the inner tube 62 (that is, in the direction away from the longitudinal axis of the cigarette cartridge) can be a corresponding (diametrically opposite) recess, which is shaped to receive a section of the liquid transport element 42 when the cigarette cartridge is assembled. The slot and the recess are aligned so that the inner tube 62 and the sealing member 36 cooperate to define the hole through which the liquid transport element 42 passes. The size of the hole through which the liquid transport element passes closely corresponds to the size and shape of the liquid transport element, but is slightly smaller, so a certain degree of compression is provided by the elasticity of the sealing member 36. 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.

[0066] In addition, in some examples, the outer edge of the sealing member 36 can be inserted into a portion of the housing portion 32 to seal the reservoir 44. For example, the sealing member 36 can be shaped to be received in an orifice at the interface end of the housing portion 32. The sealing member 36 can include one or more circumferential ridges that engage with the inner surface of the housing portion 32 and ensure a tight fit when the sealing member 36 is inserted into the housing portion 32. The connection can be configured so that the movement of the liquid along the inner surface of the housing portion 32 can be suppressed (e.g., by means of a tight fit). A similar engagement mechanism can be provided between the sealing member 36 and the housing inner tube 62.

[0067] The core 42 and the heater 40 are arranged in the airflow path of the cartridge so that the area of ​​the airflow path around the core 42 and the heater 40 actually defines the aerosol generating area (or evaporation area) of the cartridge portion 4. The aerosol generating material in the reservoir 44 penetrates into the core 42 through the end of the core adjacent to the reservoir 44 and is drawn along the core by surface tension / capillary action (i.e., wicking). In this example, the heater 40 includes a resistive wire coiled around the core 42. Figure 1 In the example of the invention, the heater 40 comprises a nickel-chromium alloy (Cr20Ni80) wire, and the core 42 comprises a glass fiber bundle, but it will be understood that the specific aerosol generator configuration is not important for the principles described herein. As an example, the core 42 may alternatively be cotton. In use, the heater 40 may be supplied with power to evaporate a certain amount of aerosol generating material (aerosol generating material) drawn to the vicinity of the heater 40 by the core 42. The evaporated aerosol generating material may then become entrained in the air drawn from the evaporation region toward the mouthpiece outlet 60 along the smoke cartridge airflow path for inhalation by the user.

[0068] As described above, the rate at which the aerosol-generating material is evaporated by the vaporizer (heater) 40 will depend on the amount (level) of power supplied to the heater 40. Therefore, power can be applied to the heater to selectively generate an aerosol from the aerosol-generating material in the cartridge portion 4. In addition, the rate of aerosol generation can be changed by changing the amount of power supplied to the heater 40 (e.g., by pulse width and / or frequency modulation techniques).

[0069] In addition to the resistance wire being wound around the capillary core 42 to provide the portion of the heater 40, the aerosol generator assembly further includes an elongated electrical connector 41, which contacts the electrode 14 mounted to the end cap 54 to allow power to be supplied to the heater 40 via the electrical interface established when the cigarette cartridge is connected to the control unit. The term elongated electrical connector 41 can be used interchangeably with the term electric wire, the usual contact wire, and the term heater wire in the embodiment where the aerosol generator is a heater. In some instances, the elongated electrical connector 41 can be provided by one or more conductive wires. In some instances, the heater wire 41 can include the same material as the resistance wire wound around the capillary core forming the heater 40. In other instances, the heater wire 41 can include a different material (e.g., a relatively low resistance material) (e.g., connected by welding) connected to the heater resistance wire 40 wound around the capillary core 42.

[0070] The sealing member 36 further includes a barrier portion 38 through which an electrical conductor 41 (e.g., a contact conductor) for the heater coil 40 passes when the cartridge is assembled. In particular, each barrier portion 38 provides a barrier for a corresponding electrical conductor 41. During assembly, the electrical conductor 41 moves into the barrier portion 38 to pierce the barrier formed by the barrier portion 38. This ensures a tight interference fit between each electrical conductor 41 and the corresponding barrier portion 38, which is also independent of the size of the electrical conductor 41 (e.g., it can vary as part of manufacturing tolerances). This allows the electrical conductor 41 to extend through the corresponding barrier portion 38 while preventing liquid (e.g., liquid aerosol generating material) from passing toward the electrode 14. This prevents or inhibits the liquid from interacting with the electrode 14, particularly the contact portion of the electrode 14 with the electrical conductor 41.

[0071] like Figure 1 , the barrier portion 38 is part of the sealing member 36. According to even other embodiments of the present invention, the barrier portion 38 can be provided by a separate and distinct component from the sealing member 36. In some embodiments, the barrier portions 38 can each include a separate disc of material configured to be received by the sealing member 36 or a different component of the surface defining the aerosol generation area (or chamber). For example, the sealing member 36 can include a recess for receiving each barrier portion 38.

[0072] Likewise Figure 1As depicted in , barrier portions 38 are provided in two different and separate areas of the surface defining the aerosol generation region (or chamber). This can help separate different pairs of electrical conductors 41 and electrodes 14 from each other, thereby reducing the risk of short circuits (e.g., by ensuring that the electrical conductor 41 cannot contact another electrical conductor or an electrode different from the intended electrode). In some other examples, the two barrier portions 38 may be provided by a single barrier surface. For example, each barrier portion 38 may be an area of ​​a single barrier surface that the electrical conductor 41 will pierce. A single barrier surface can be defined as a continuous portion of a thin or weakened material that is configured to be pierced by the electrical conductor 41.

[0073] The electrodes 14 (e.g., electrode posts) are mounted on or otherwise connected to the end cap 34. The end cap 34 is disposed at the interface end 54 of the cartridge 4. As an example, the end cap 34 may include a polypropylene molding in which a pair of gold-plated copper electrode posts 14 are mounted.

[0074] The ends of the electrode posts 14 on the bottom side of the end cap are close to being flush with the interface end 54 of the cartridge provided by the end cap 34. These are the parts of the electrodes to which the corresponding aligned resilient contacts in the control unit are connected when the cartridge is assembled and connected to the control unit. The ends of the electrode posts inside the cartridge extend away from the end cap 34. The ends of the electrodes can extend into holes in the sealing member 36 that are aligned with and extend to the barrier portion 38 through which the electrical conductors 41 pass. The electrode posts 14 are slightly larger in size than the holes and may include a chamfer at their upper ends to facilitate insertion into the holes of the sealing member 36. Due to the elastic nature of the sealing member 36, the electrode posts 14 can remain in press contact with the electrical conductors 41 for the heater 40.

[0075] The end cap 34 may also be configured to be attached to the housing portion 32. For example, the end cap 34 may include an upright wall (not shown) that is inserted into the housing portion 32. In some examples, a latch protrusion (not shown) may engage with a latch recess (not shown) in the housing portion 32 to snap fit the end cap 34 to the housing portion when the cartridge is assembled. The surface of the end cap 34 (i.e., the top or mouth end side surface) may also abut a portion of the sealing member 36 so that when the end cap 34 is attached to the housing portion 32, it presses against the sealing member 36 to hold the sealing member in a slightly compressed manner within the cartridge 4.

[0076] When the cartridge is assembled, an air passage 46 is formed extending from the air inlet in the end cap 54 through the cartridge to the vapor outlet 60. In response to a user inhalation, air can flow from the control unit air inlet 11 toward the cartridge 4 (e.g., down the passage in the control unit 2), through the end cap 34, through the passage in the sealing member 36, into the portion of the air passage adjacent to the aerosol generator 40 and at least partially defined by the sealing member 36, into the housing inner tube 62, and out through the mouthpiece outlet 60. This portion of the air passage adjacent to the aerosol generator 40 may also be referred to as an aerosol generation region or chamber, which is the primary region in which aerosol is generated during use.

[0077] As described above, when the cigarette cartridge is assembled, a reservoir for liquid is formed by the space outside the inner tube 62 of the housing and the inner surface of the outer wall 64 of the housing. This can be filled during manufacturing, for example, by a filling hole or by other means, and the filling hole is 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 is closed by a sealing member 36 at the interface end of the cigarette cartridge, which is also configured to at least partially provide an opening for receiving a liquid transport element (capillary wick) 42 of the evaporator assembly. Therefore, the end of the liquid transport element 42 extends into the reservoir, which draws the liquid from the reservoir through the opening in the air channel 46 to the heater 40 for subsequent evaporation.

[0078] In normal use, the cartridge 4 is connected to the control unit 2, and the control unit is activated to power the cartridge via the electrodes 14 in the end cap 34. The electricity then reaches the heater 40 through the connecting wire 41. The heater is thereby electrically heated, and a portion of the liquid from the liquid transport element is therefore evaporated near the heater. This generates vapor in the aerosol generation region of the air path. The liquid evaporated from the liquid transport element is replaced by more liquid drawn from the reservoir by capillary action. When the heater is activated and the user inhales on the mouthpiece end 52 of the cartridge, air is drawn into the cartridge through the air inlet in the end cap 54 and into the aerosol generation region around the heater 40. The incoming air mixes with the vapor generated from the heater 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.

[0079] Figure 2is a schematic perspective view of an exemplary aerosol generator assembly 30 according to certain embodiments of the present disclosure. The aerosol generator assembly 30 refers to an assembly of components including the aerosol generator 40, certain components that allow the aerosol generator to operate (e.g., liquid transport element 42 and electrical conductors 41), and components that define an aerosol generating chamber. In addition to the aerosol generator assembly 30, Figure 2 The electrode column 14 is depicted in contact with the electrical lead 41 (elongated electrical connector) of the aerosol generator assembly 30. Figure 1 In addition to the components, Figure 2 An upper chamber member (or portion) 70 and an upper sealing member 72 are depicted. Figure 1 The principle of component description can be widely applied to Figure 2 Those elements depicted in .

[0080] In accordance with Figure 2 In the example of , the sealing member 36 and the upper chamber member 70 are combined to form an aerosol generating chamber surrounding the aerosol generator 40. The aerosol generating chamber includes a plurality of surfaces that define an aerosol generating region of the airflow path 46 adjacent to the aerosol generator 40, where the aerosol generated by the aerosol generator 40 enters the airflow path 46. Figure 2 In the example of , the sealing member 36 provides a lower chamber portion that defines a lower or upstream surface of the chamber, while the upper chamber member 70 defines an upper or downstream surface of the chamber.

[0081] In addition, according to Figure 2 In the example of, the sealing member 36 and the upper chamber member 70 are formed to provide an orifice through which the liquid transport element 42 (e.g., core) extends. For example, the sealing member 36 can be formed to include a recessed or grooved surface 73 (adjacent to the aerosol generating chamber) for receiving the end of the liquid transport element 42; and the upper chamber member 70 can have a clamping portion 74 (e.g., a retaining, holding portion) that includes a corresponding orifice or recess that is aligned with the recessed surface 73 to create a hole through which the liquid transport element 42 passes. The hole allows liquid to travel from the liquid reservoir 44 toward the aerosol generator 40 through the liquid transport element 42 while providing an adequate seal. As described above, the sealing member 36 can be formed of an elastomeric material such as a silicone material. In contrast, the upper chamber member 70 can be a rigid material, such as a plastic material.

[0082] The upper chamber portion 70 may also define the lower portion of the reservoir 44, and in particular may be formed by the housing outer wall 64 and the inner tube 62 ( Figure 2 For example, Figure 2As shown, the upper chamber component 70 can have an annular shape, wherein the air path 46 (including the aerosol generating chamber) is partially defined by an inner channel of the upper chamber component 70, and a portion of the reservoir 44 is defined by an annular channel between the inner channel and the outer wall.

[0083] The outer wall of the upper chamber component 70 can be configured to fit within the housing outer wall 64 (not shown). In order to provide a seal that prevents liquid from moving between the outer wall of the upper chamber component 70 and the housing outer wall 64, an upper sealing component 72 is provided at the reservoir end of the upper chamber component 70 (i.e., the end of the upper chamber component 70 inserted into the open end of the reservoir 44 formed by the housing outer wall 64). The upper sealing component 72 is configured to engage with the housing outer wall 64 to form a seal that effectively closes the open end of the reservoir 44 (except via the liquid transport element 42). For example, the upper sealing component 72 may include one or more circumferentially extending (i.e., perpendicular to the insertion direction) ridges that contact the housing outer wall 64 when inserted and provide a barrier to the liquid. In some instances, the (lower or downstream) sealing component 36 may also include one or more circumferentially extending ridges that are further used to prevent liquid from moving along the housing outer wall 64.

[0084] In some examples, the inner tube 62 is configured to engage with the air passage 46 provided by the upper chamber component 70. For example, the inner tube 62 can be sized to fit within the upstream end of the upper chamber component 60. In these examples, the upper sealing component can also provide a seal with the inner tube 62, thereby preventing the movement of liquid between the inner tube 62 and the upper chamber component 70.

[0085] The upper (or downstream) sealing member 72 may be formed of the same or substantially similar material as the (lower or upstream) sealing member 36. For example, the upper sealing member 72 may be formed of an elastomeric material such as a silicone material.

[0086] and Figure 1 Consistent, Figure 2 The sealing member 36 includes two barrier portions 38, each of which is configured to be pierced by a corresponding elongated electrical connector 41 (e.g., an electrical conductor, such as a conductive wire). The barrier portions 38 are disposed in a surface of the sealing member 36 that at least partially defines a surface that defines an aerosol generation region (i.e., a surface of an aerosol generation chamber in combination with the upper chamber member 70), and the aerosol generator 40 is configured to generate an aerosol in the aerosol generation region.

[0087] In some examples where the aerosol generating material comprises a liquid aerosol generating material, the liquid aerosol generating material may travel from the aerosol generator 40 or the liquid transport element 42 via the elongated electrical connector 41 toward the barrier portion 38, or from the junction of the liquid transport element 42 with the sealing member 36 and the upper chamber portion 70 along the surface of the aerosol generating chamber. In some examples where the aerosol generating material may or may not be a liquid aerosol generating material, condensation may form in the aerosol delivery system 1. For example, condensation may form when the aerosol cools within the air path 46 (e.g., in the aerosol generating chamber or inner tube 62) before being inhaled by the user. In the above examples, it will be understood that when the aerosol delivery system 1 including the aerosol generator assembly is maintained in an upright position (i.e., with the mouthpiece outlet 60 as the uppermost component that is substantially vertical), the liquid may move under gravity in an upstream direction toward the barrier portion 38 and the connection of the cartridge 4 to the control unit 2. The barrier portion 38 serves to substantially prevent or inhibit interaction of liquid with the electrode column 14 (whether by condensation or leakage) by blocking the path between the aerosol generating chamber and the electrode column 14 (ie, providing a barrier).

[0088] The barrier portions 38 each include a segment having a reduced width compared to the thickness of the sealing member 36 away from the barrier portions 38. For example, each barrier portion 38 includes a width of up to 1 mm in a direction parallel to the insertion direction of the corresponding elongated electrical connector 41. Preferably, each barrier portion includes a width of up to 0.2 mm in a direction parallel to the insertion direction of the corresponding elongated electrical connector 41.

[0089] The barrier portions 38 are configured to be pierced by the elongated electrical connectors 41 without breaking or cracking, such that when the elongated electrical connectors 41 are inserted into their respective barrier portions 38, the only openings through the barrier portions 38 are completely filled with the elongated electrical connectors 41. In other words, each opening includes a boundary formed around the circumference of the elongated electrical connector 41 and does not include any portion extending away from the elongated electrical connector 41 (i.e., a crack or fissure in the material of the barrier portions 38).

[0090] Furthermore, because the opening is formed by piercing the barrier portion 38, rather than drilling or otherwise forming an opening for inserting the elongated electrical connector 41, the material of the barrier portion 38 is effectively displaced by inserting the elongated electrical connector 41 through the barrier portion 38, and as a result, the barrier portion 38 generates a restoring force that acts on the circumference of the elongated electrical connector 41 toward its original, non-displaced configuration. This restoring force is used to improve the seal between the barrier portion 38 and the elongated electrical connector 41, thereby preventing (or substantially inhibiting) liquid from passing through the barrier portion 38 and moving along the elongated electrical connector 41.

[0091] The barrier portion 38 may be formed of an elastomeric material such as a silicone material (e.g., consistent with the sealing member 36). Such an elastomeric material may elastically deform in response to the elongated electrical connector 41 piercing the barrier portion 38, which aids in sealing by ensuring that the barrier portion exerts a restoring force toward its original configuration. The elastomeric material also resists rupture away from the insertion point due to its elastic properties.

[0092] In some examples, the barrier portion may have a width (or diameter) that is slightly wider than the width (or diameter) of the elongated electrical connector 41 configured to pierce the barrier portion 38. For example, the width of each base may be no greater than 3 times the width of the elongated electrical connector 41, and preferably no greater than 2 times the width of the elongated electrical connector 41. In some examples, the width of each base may be up to 3 mm, and the width of each elongated electrical connector 41 may be up to 2 mm. It will be understood that in examples where the base and the elongated electrical connector 41 have circular cross-sections perpendicular to the insertion direction, the above widths are equal to the diameters of the corresponding circles; and in examples where one or both of the base and the elongated electrical connector 41 have non-circular cross-sections perpendicular to the insertion direction, the above widths refer to: the minimum width of the base and / or the maximum width of the elongated electrical connector 41 in the cross-section perpendicular to the insertion direction.

[0093] Figure 2 The sealing member 36 of the aerosol generator assembly 30 includes two guide portions 76, each of which is associated with a respective barrier portion 38. Each guide portion 76 is configured to guide the elongated electrical connector 41 toward the associated barrier portion 38 during assembly of the aerosol generator assembly. In other words, the aerosol generator assembly 30 includes two guide portions 76, wherein a respective guide portion of the two guide portions 76 is configured to guide a respective one of the elongated electrical connectors 41 to the respective barrier portion 38 during assembly. Thus, the guide portion 76 is configured to facilitate piercing of the barrier portion 38 by the elongated electrical connector 41 by guiding the elongated electrical connector 41 toward the thinner barrier portion 38.

[0094] Figure 2 The guide portion 76 of the aerosol generator assembly 30 is provided by two bowl-shaped recesses. Each bowl-shaped recess includes a base and a periphery, the base forming one of the two barrier portions 38, and the periphery forming one of the two guide portions 76. The periphery of each bowl-shaped recess surrounds the base of the bowl-shaped recess and defines a peripheral surface that is angled relative to the base of the bowl-shaped recess. Therefore, if the slender electrical connector 41 interacts with the guide portion (e.g., pushes against) during assembly of the aerosol generator assembly 30, the slender electrical connector 41 will be guided by the inclined surface toward the barrier portion 38 provided by the base of the bowl-shaped recess.

[0095] As described above, in some examples, the barrier portion (corresponding to the base) can have a width (or diameter) that is slightly wider than the width (or diameter) of the elongated electrical connector 41 configured to pierce the barrier portion 38. It will be understood that the guide portion 76 will have an inner peripheral edge corresponding to the shape of the base. In addition, the guide portion 76 has an outer peripheral edge (not adjacent to the base) that is significantly wider than the width (or diameter) of the elongated electrical connector 41 configured to pierce the associated barrier portion 38. For example, the width of each guide portion 76 (e.g., the outer diameter rather than the inner diameter defining the base) can be up to 10 times the width of the elongated electrical connector 41.

[0096] For example, the outermost width of each base may be up to 3 mm, the width of each elongated electrical connector 41 may be up to 2 mm, and the width of each guide portion may be up to 20 mm. As described above, it will be understood that in the example where the peripheral surface of the bowl-shaped recess has a circular cross-section perpendicular to the insertion direction, the above width is equal to the diameter of the corresponding circle; and in the example where the peripheral surface of the bowl-shaped recess has a non-circular cross-section perpendicular to the insertion direction, the above width refers to the minimum width of the peripheral surface in the cross-section perpendicular to the insertion direction.

[0097] It will be appreciated that the guide portion 76, e.g. Figure 2 The guiding parts disclosed in the Figure 2 In addition, in other examples ( Figure 2 In the embodiment shown in Figure 1 , the guide portion 76 may surround only a portion of the barrier portion 38. For example, the guide portion 76 may include a linear ramp or wedge extending from a portion of the barrier portion 38 and used to guide the elongated electrical connector 41 received on the surface provided by the ramp or wedge toward the barrier portion 38.

[0098] Figure 2 The sealing member 36 includes two electrode column insertion cavities or regions 78, each of which is configured to receive a corresponding electrode column 14 (or electrode). Each electrode column insertion cavity 78 extends from the barrier portion 38 to an opening in the sealing member 36, through which a corresponding electrode column 14 is received. Thus, each electrode column insertion cavity 78 is sized to receive an electrode column 14 (e.g., the electrode column insertion cavity 78 has a diameter equal to or slightly wider than the electrode column 14).

[0099] Each elongated electrical connector 41 extends through (i.e., pierces) a corresponding barrier portion 38 and enters a corresponding electrode column insertion cavity 78. The elongated electrical connector 41 and the electrode column 14 are configured to contact each other in the electrode column insertion cavity 78 and form an electrical connection capable of carrying current as part of an electrical circuit. For example, the elongated electrical connector 41 and the electrode column 14 may extend a sufficient length from opposite ends of the electrode column insertion cavity 78 to engage with each other. In some examples, the length of the elongated electrical connector 41 received in the electrode column insertion cavity 78 and the length of the electrode column 14 received in the electrode column insertion cavity 78 may be greater than the length of the electrode column insertion cavity 78, so that the elongated electrical connector 41 and the electrode column 14 are pressed against each other. In these examples, the elongated electrical connector 41 and / or the electrode column 14 may be bent or otherwise deformed to accommodate the combined length (e.g., the elongated electrical connector 41 may be deflected toward one side of the cavity when it is pressed against the electrode column 14).

[0100] Not based on Figure 2 In some other examples, the barrier portion 38 can be disposed near an outer surface of the sealing member 36 such that the elongated electrical connector 41 extends from the sealing member 36 when piercing and extending through the barrier portion 38. In these examples, the sealing member 36 does not require the electrode post to be inserted into the cavity 78, but rather the electrode post 14 is configured to contact the elongated electrical connector 41 at a location outside the sealing member 36.

[0101] Figure 2 The example of depicts an aerosol generator 40 including a resistive heater. In particular, Figure 2 The resistive heater comprises a coil heater (i.e., wherein the heater comprises a coil wound around the liquid conduit element 42). Figure 2 In some examples, the two elongated electrical connectors 41 include respective ends of the heating wire forming the coil heater. In these examples, the elongated electrical connectors 41 are formed of the same material as the coil heater. In some alternative examples, the two elongated electrical connectors 41 may be formed of a different material than the heating wire of the coil heater. For example, the elongated electrical connectors 41 may be a different wire material that is welded or otherwise connected to the heating wire of the coil heater.

[0102] It will be appreciated that other forms of aerosol generators 40 may be used in place of the resistive heater, with the barrier portion 38 and related aspects of the aerosol generator assembly 30 providing substantially similar advantageous effects. For example, even in the case where the aerosol generator 40 does not generate the aerosol from a liquid aerosol generating material, as described with respect to Figure 2 The barrier portion 38 may advantageously prevent or inhibit the movement of condensed liquid toward the electrode column 14 .

[0103] Figure 31 is a flow chart of a method 300 for assembling an aerosol generator assembly 30 for use in an aerosol generating system 1 to generate an aerosol from an aerosol generating material. The method begins at step 310 by providing an aerosol generator 40 including two elongated electrical connectors 41. The aerosol generator 40 is an electric aerosol generator configured to receive power from a power source 16 (e.g., a battery) via the two elongated electrical connectors 41. For example, the two elongated electrical connectors 41 form part of a circuit for transferring power from the power source 16 to the aerosol generator 40 (e.g., by connecting to a positive terminal and a negative terminal).

[0104] In some examples, the aerosol generator 40 can be a resistive heater. For example, the aerosol generator 40 can be a resistive coil heater including a metal wire. In some other examples, the resistive heater can be a conductive mesh or resistive track deposited on a ceramic surface. Each elongated electrical connector 41 can be welded or otherwise connected to the resistive heater (e.g., connected to a contact pad at each end of the heater). In some examples where the resistive heater is a coil heater or other form of a metal wire heater, two elongated electrical connectors 41 include corresponding ends of the heating wire forming the coil heater.

[0105] In other examples, the aerosol generator 40 may not be a resistive heater, but may be configured to generate an aerosol by other means. For example, the aerosol generator 40 may heat the aerosol generating material by different means, such as irradiation with light, or may be configured to generate an aerosol without substantially heating the aerosol generating material. For example, the aerosol generator may be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0106] Next, a second step 320 is provided, wherein two barrier portions 38 are configured to at least partially define a surface that defines an aerosol generation region. The aerosol generation region is an area or chamber in which the aerosol generator is configured to generate an aerosol. For example, an aerosol generating material and / or an aerosol generator 40 may be disposed in the aerosol generation region such that the action of the aerosol generator 40 on the aerosol generating material (e.g., heating) causes one or more volatiles to be released from the aerosol generating material to form an aerosol. By providing a barrier through which liquid cannot pass, the barrier portion 38 prevents or inhibits the movement of liquid from the aerosol generation region.

[0107] In some instances, the aerosol generating material is a liquid aerosol generating material. The liquid aerosol generating material may leak from the aerosol generator 40 (or from the liquid conducting element 42 and other associated components) in the aerosol generating region (or chamber). In some instances, in the case where the aerosol generating material may or may not be a liquid aerosol generating material (e.g., it may be a solid or gel material), condensed liquid may be formed in or around the aerosol generating region (e.g., in the shell inner tube 62). Liquid (from condensation or leakage, or other sources) may have a harmful effect on the conduction between different components. For example, the liquid may corrode the surface of the conductive element (e.g., a metal element, such as a metal wire), thereby reducing its conductivity. Therefore, it is advantageous to prevent liquid from accumulating in the region where a connection is formed between different components. This can be achieved to a certain extent by providing a barrier portion 38 to prevent or inhibit (e.g., substantially reduce) liquid from moving into the region where the connection is formed.

[0108] In some examples, the method is followed by a third step 330 of guiding the two elongated electrical connectors 41 toward the two barrier portions 38 by means of the two guide portions 76. Each of the two guide portions 76 guides a corresponding one of the two elongated electrical connectors 41 to a corresponding one of the two barrier portions 38. The guide portions 76 facilitate the formation of the aerosol generator assembly 30 by guiding the elongated electrical connectors 41 away from portions of the aerosol generator assembly 30 that are too strong or too thick to be pierced by the elongated electrical connectors 41, and toward barrier portions 38 that are configured to be pierced by the elongated electrical connectors 41 (e.g., they are segments that include a thin layer of material compared to the rest of the sealing component 36).

[0109] In addition, each guide portion 76 can be angled or inclined so that the path of least physical resistance for the corresponding elongated electrical connector 41 is toward the corresponding barrier portion 38. For example, each guide portion 76 and the barrier portion 38 can form a bowl-shaped depression in the surface of the aerosol generating chamber. Each bowl-shaped depression includes a base and a periphery, the base forming the barrier portion, and the periphery forming two guide portions. In an example, the periphery of each bowl-shaped depression surrounding the base of the bowl-shaped depression defines a peripheral surface that is angled relative to the base of the bowl-shaped depression. The peripheral surface is used to guide the elongated electrical connector 41 toward the base, rather than pushing the elongated electrical connector 41 through the peripheral surface (i.e., because the elongated electrical connector 41 moves toward the peripheral surface in a direction that is not perpendicular to the peripheral surface). It will be understood that in other examples, one or both of the guide portions 76 may extend only around a portion of the boundary defining its associated barrier portion 38.

[0110] Next, a fourth step 340 is performed to insert two elongated electrical connectors 41 into the two barrier portions 38 so that each of the two elongated electrical connectors 41 pierces and extends through a corresponding one of the two barrier portions 38. Each corresponding one of the two barrier portions 38 forms a seal around a corresponding one of the two elongated electrical connectors 41. By piercing the barrier portion 38 with the elongated electrical connector 41, the aperture or opening formed by the elongated electrical connector 41 is only large enough to accommodate the elongated electrical connector 41, and does not introduce any open space between the barrier portion 38 and the corresponding elongated electrical connector 41 through which liquid can flow. In some examples, the barrier portion 38 can be formed of an elastomeric material that elastically deforms when pierced by the elongated electrical connector 41, and in the case where the barrier portion 38 and the elongated electrical connector 41 are in contact, the elastomeric material exerts a restoring force on the surface of the elongated electrical connector 41, thereby improving the seal. The method then ends.

[0111] It will be appreciated that while the above description has focused on some 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. For example, in some implementations, according to the present reference Figure 2 A sealing member made according to the discussed principles may be implemented in an aerosol generator assembly that does not include a coil wrapped around a core to compress the core, or in which the barrier portion is provided separately from the sealing member (eg, the barrier portion may be attached to the sealing member).

[0112] Thus, a method of manufacturing or assembling an aerosol generator assembly for aerosolizing an aerosol generating material in an electronic aerosol supply system has also been described. The method comprises: providing an aerosol generator comprising two elongated electrical connectors; providing two barrier portions configured to at least partially define a surface defining an aerosol generating region, the aerosol generator being configured to generate an aerosol in the aerosol generating region; and inserting the two elongated electrical connectors into the two barrier portions such that each of the two elongated electrical connectors pierces and extends through a respective one of the two barrier portions.

[0113] An aerosol generator assembly for aerosolizing an aerosol generating material in an electronic aerosol delivery system has been described. The aerosol generator assembly includes: an aerosol generator including two elongated electrical connectors; and two barrier portions configured to at least partially define a surface defining an aerosol generating region, the aerosol generator being configured to generate an aerosol in the aerosol generating region. Each of the two barrier portions is configured to be pierced by a respective one of the two elongated electrical connectors during assembly of the aerosol generator assembly, and each of the two elongated electrical connectors extends through a respective one of the two barrier portions.

[0114] An assembly device for aerosolizing an aerosol generating material has also been described, the assembly device comprising: an aerosol generator device comprising two slender electrical connector devices; and two barrier devices configured to at least partially define a surface that defines an aerosol generating area, the aerosol generator device being configured to generate an aerosol in the aerosol generating area, wherein each of the two barrier devices is configured to be pierced by a corresponding one of the two slender electrical connector devices during assembly of the assembly device, wherein each of the two slender electrical connector devices extends through a corresponding one of the two barrier devices.

[0115] 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.

[0116] 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. An aerosol generator assembly for aerosolizing an aerosol generating material, the aerosol generator assembly comprising: an aerosol generator including two elongated electrical connectors; as well as two barrier portions configured to at least partially define a surface bounding an aerosol generation region, the aerosol generator being configured to generate an aerosol in the aerosol generation region, wherein each of the two barrier portions is configured to be pierced by a respective one of the two elongated electrical connectors during assembly of the aerosol generator assembly, Wherein, each of the two elongated electrical connectors extends through a corresponding barrier portion of the two barrier portions.

2. The aerosol generator assembly according to claim 1, wherein: The aerosol generator assembly comprises a sealing member, wherein the two barrier portions are part of the sealing member.

3. An aerosol generator assembly according to claim 1 or 2, wherein: The aerosol generator assembly comprises two guide portions, wherein a respective one of the two guide portions is configured to guide a respective one of the elongated electrical connectors to a respective barrier portion during assembly.

4. An aerosol generator assembly according to claim 3, wherein: The aerosol generator assembly includes two bowl-shaped recesses, each bowl-shaped recess includes a base and a periphery, the base forming one of the two barrier portions, the periphery forming one of the two guide portions, the periphery of each bowl-shaped recess surrounding the base of the bowl-shaped recess and defining a peripheral surface angled relative to the base of the bowl-shaped recess.

5. An aerosol generator assembly according to any one of claims 1 to 4, wherein: The aerosol generator is a resistive heater.

6. An aerosol generator assembly according to claim 5, wherein: The resistive heater comprises a coil heater and wherein the two elongated electrical connectors comprise respective ends of a heating wire forming the coil heater.

7. An aerosol generator assembly according to any one of claims 1 to 6, wherein: The two barrier portions are formed from an elastomeric material.

8. An aerosol generator assembly according to any one of claims 1 to 7, wherein: Each of the two barrier portions comprises a width parallel to an insertion direction of the respective elongated electrical connector, wherein the width is in the range of up to 1 mm.

9. An aerosol generator assembly according to any one of claims 1 to 8, wherein: The two barrier portions are provided by a single barrier surface.

10. An atomizing cartridge for aerosolizing an aerosol-generating material, the atomizing cartridge include: An aerosol generator assembly according to any one of claims 1 to 9; and Aerosol Generating Materials.

11. An electronic aerosol supply system for aerosolizing an aerosol generating material, the electronic aerosol supply system comprising: An aerosol generator assembly according to any one of claims 1 to 9 or an atomizer cartridge according to claim 10; as well as A control unit comprises a power source for supplying power to the aerosol generator, wherein the two elongated electrical connectors form part of an electrical circuit configured to supply power from the power source to the aerosol generator.

12. A method of assembling an aerosol generator assembly for aerosolizing an aerosol generating material in an electronic aerosol delivery system, wherein: The method comprises: providing an aerosol generator comprising two elongated electrical connectors; providing two barrier portions configured to at least partially define a surface bounding an aerosol generation region, the aerosol generator being configured to generate an aerosol in the aerosol generation region; and The two elongated electrical connectors are inserted into the two barrier portions such that each of the two elongated electrical connectors pierces and extends through a respective one of the two barrier portions.

13. The method according to claim 12, wherein: The method further comprises: The two elongated electrical connectors are guided toward the two barrier portions by two guide portions, wherein each of the two guide portions guides a corresponding one of the two elongated electrical connectors to a corresponding one of the two barrier portions.

14. An assembly device for aerosolizing an aerosol-generating material, the assembly device comprising: an aerosol generator device comprising two elongated electrical connector devices; as well as two barrier means configured to at least partially define a surface bounding an aerosol generation region, said aerosol generator device being configured to generate an aerosol in said aerosol generation region, wherein each of said two barrier means is configured to be pierced by a respective one of said two elongated electrical connector means during assembly of said assembly device, Wherein, each of said two elongated electrical connector means extends through a respective one of said two barrier means.

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