Aerosol delivery subsystem

Abstract

An aerosol delivery subsystem includes: a smoke sensor at one end configured to detect, in use, an airflow through an air inlet; and an elongate power source extending away from the smoke sensor and having an electrode at a distal end away from the smoke sensor for connection to the smoke sensor.

Description

Technical Field

[0001] The present disclosure relates to aerosol delivery systems, such as, but not limited to, nicotine delivery systems including electronic cigarettes, tobacco heating products (THPs), and hybrid systems. More particularly, the present disclosure relates in part to component mounting brackets for aerosol delivery subsystems. Background Art

[0002] Aerosol delivery systems (such as electronic cigarettes (e-cigarettes)) typically contain a chamber of aerosol-forming material, such as a source solid or source liquid, which may contain an active substance and / or flavor, and generate an aerosol or vapor from the active substance and / or flavor, for example by thermal evaporation for a user to inhale. Thus, an aerosol delivery system will generally include an aerosol-generating region containing an aerosol generator (such as a heating element), the aerosol generator being arranged to evaporate or aerosolize a portion of a precursor material to generate a vapor or aerosol in the aerosol-generating region. When a user inhales on the device and power is supplied to the evaporator, air is drawn through an inlet aperture and along an inlet air passage connecting to the aerosol-generating region into the device, where the air is mixed with the evaporated precursor material to form a condensed aerosol. There is an outlet passage connecting the aerosol-generating region to an outlet in the mouthpiece, and when the user inhales on the mouthpiece, the air drawn into the aerosol-generating region continues along an outlet flow path to the mouthpiece outlet, carrying the aerosol with the air, for inhalation by the user. Some e-cigarettes may also include a flavor element in the airflow path through the device to impart additional flavor. Such devices may sometimes be referred to as hybrid devices, and the flavor element may include, for example, a portion of tobacco arranged in the airflow path between the aerosol-generating region and the mouthpiece such that the aerosol / condensed aerosol drawn through the device passes through this portion of tobacco before leaving the mouthpiece for inhalation by the user.

[0003] There is interest in developing methods that enable aerosol delivery systems to be more easily assembled, repaired, and / or recycled to increase production efficiency, improve sustainability, and reduce waste. Various methods are described herein that seek to help solve or mitigate at least some of these problems.

[0004] Terminology

[0005] Delivery System

[0006] As used herein, the term "delivery system" is intended to cover systems that deliver at least one substance to a user in use, and includes:

[0007] Combustible aerosol supply systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for self-rolling or for self-making cigarettes (based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials);

[0008] Incombustible aerosol supply systems that release compounds from aerosol - forming materials without burning the aerosol - forming materials to deliver the at least one substance to a user, such as electronic cigarettes, tobacco - heating products, and hybrid systems, to generate an aerosol using a combination of aerosol - forming materials; and

[0009] Non - aerosol delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including but not limited to lozenges, chewing gums, patches, articles including inhalable powders, and oral products, such as oral tobacco including snuff or moist snuff, where the at least one substance may or may not include nicotine.

[0010] Combustible aerosol supply systems

[0011] According to the present disclosure, a “combustible” aerosol supply system is an aerosol supply system in which the constituent aerosol - forming material of the aerosol supply system (or its components) burns or ignites during use to facilitate delivery of at least one substance to a user.

[0012] In some embodiments, the delivery system is a combustible aerosol supply system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0013] In some embodiments, the present disclosure relates to a component for use in a combustible aerosol supply system, such as a filter, filter rod, filter segment, tobacco rod, spill, aerosol modifier release component, such as a capsule, wire, or bead, or paper, such as tipping paper, mouth - piece paper, or cigarette paper.

[0014] Incombustible aerosol supply systems

[0015] According to the present disclosure, an “incombustible” aerosol supply system is an aerosol supply system in which the constituent aerosol - forming material of the aerosol supply system (or its components) does not burn or ignite while delivering at least one substance to a user.

[0016] In some embodiments, the delivery system is an incombustible aerosol supply system, such as a powered incombustible aerosol supply system.

[0017] In some embodiments, the incombustible aerosol supply system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (ENDS), but it should be noted that the presence of nicotine in the aerosol - forming material is not required.

[0018] In some embodiments, the incombustible aerosol supply system is an aerosol - forming material heating system, also known as a heat - not - burn system. An example of such a system is a tobacco - heating system.

[0019] 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, where one or more of the aerosol-generating materials can be heated. Each aerosol-generating material can be in the form of, for example, a solid, liquid, or gel, and can contain or can be free of 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.

[0020] Generally, the non-flammable aerosol supply system can include a non-flammable aerosol supply device and a consumable for use with the non-flammable aerosol supply device.

[0021] In some embodiments, the present disclosure relates to a consumable that includes an aerosol-generating material and is configured to be used with a non-flammable aerosol supply device. These consumables are sometimes referred to as articles in the present disclosure.

[0022] In some embodiments, the non-flammable aerosol supply system, such as its non-flammable aerosol supply device, can include a power source and a controller. The power source can be, for example, a power supply or a heat source. In some embodiments, the heat source includes a carbon matrix that can be energized to distribute power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat source.

[0023] In some embodiments, the non-flammable aerosol supply system can include a region for receiving a consumable, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0024] In some embodiments, a consumable for use with a non-flammable aerosol supply device can include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material delivery component, an aerosol generator, an aerosol generation region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0025] Non-aerosol delivery system

[0026] In some embodiments, the delivery system is a non-aerosol delivery system that delivers at least one substance to a user orally, nasally, transdermally, or in another manner without forming an aerosol, including but not limited to lozenges, chewing gum, patches, articles including inhalable powders, and oral products such as oral tobacco including snuff or moist snuff, where the at least one substance can include or can be free of nicotine.

[0027] In some embodiments, the material to be delivered can be an aerosol - forming material or a material not intended to be aerosolized. Optionally, either material can include one or more active components, one or more flavorants, one or more aerosol - forming agent materials, and / or one or more other functional materials.

[0028] Active substance

[0029] In some embodiments, the material to be delivered includes an active substance. As used herein, an active substance can be a physiologically active material, which is a material intended to effect or enhance a physiological response. The active substance can be selected, for example, from nutraceuticals, nootropics, psychoactive substances. The active substance can be naturally occurring or synthetically obtained. The active substance can include, for example, nicotine, caffeine, taurine, theobromine, vitamins (such as B6 or B12 or C), melatonin, or a component, derivative, or combination thereof. The active substance can include one or more components, derivatives, or extracts of tobacco or other plants.

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

[0031] As described herein, the active substance can include or be derived from one or more plants or their components, derivatives, or extracts. 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, hulls, husks, etc. Alternatively, the material can include an active compound naturally present in a plant, obtained synthetically. The material can be in the form of a liquid, gas, solid, powder, dust, crushed particles, fines, pellets, fragments, strips, sheets, etc.

[0032] Examples of plants are tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, mint, spearmint, red leaf tea tree, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (such as green tea or black tea), thyme, clove, cinnamon, coffee, anise (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elderflower, vanilla, holly, perilla plant, turmeric, turmeric powder, sandalwood, coriander leaf, bergamot, neroli, myrtle, blackcurrant, valerian, bell pepper, mace, damarane, marjoram, olive, lemon balm, lemon basil, chive, parsley, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, kanna, chlorophyll, baobab, or any combination thereof. The mint can be selected from the following mint varieties: wild mint, mint, Egyptian mint, peppermint, basil mint, peppermint c.v., spearmint, heartleaf spearmint, longleaf mint, pineapple mint, calamintha, spearmint c.v., and apple mint.

[0033] In some embodiments, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plant is tobacco. In some embodiments, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plants are selected from eucalyptus, star anise and cocoa.

[0034] In some embodiments, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plants are selected from red leaf tea tree and fennel.

[0035] Flavoring agent

[0036] In some embodiments, the substance to be delivered includes a flavorant. As used herein, the terms "flavorant" and "spice" refer to materials that, where permitted by local regulations, can be used to create the desired taste, aroma, or other somatic sensations in a product for adult consumers. It can include naturally occurring flavorant materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, Japanese magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise (star anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, pitaya, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, mint, lavender, aloe vera, cardamom, celery, bitter melon peel, nutmeg, sandalwood, bergamot, geranium, khat, 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, mustard, green pepper, ginger, cilantro, coffee, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, adzuki bean, flax, ginkgo leaf, hazelnut, hibiscus, bay, yerba mate, orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, chili pepper, rosemary, saffron, lemon peel, mint, costmary, turmeric, coriander, myrtle, blackcurrant, valerian, Spanish sweet pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, wild leek, parsley, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, 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. It can be a mimetic, synthetic, or natural ingredient or a mixture thereof. It can be in any suitable form, e.g., a liquid such as an oil, a solid such as a powder, or a gas.

[0037] In some embodiments, the flavorant includes menthol, spearmint, and / or peppermint. In some embodiments, the flavorant includes flavorant components of cucumber, blueberry, citrus fruits, and / or cranberry. In some embodiments, the flavorant includes eugenol. In some embodiments, the flavorant includes flavorant components extracted from tobacco.

[0038] In some embodiments, in addition to or instead of aromatic or taste nerves, flavorants may include sensates, which are intended to achieve somatosensory sensations typically induced and perceived by chemical stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, numbing effects. Suitable heat-effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable coolants may be, but are not limited to, cineole, WS-3.

[0039] Aerosol-forming material

[0040] An aerosol-forming material is a material that is capable of generating an aerosol when heated, irradiated, or electrified in any other way, for example. The aerosol-forming material may be in solid, liquid, or gel form, for example, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-forming material may include "amorphous solids", which may alternatively be referred to as "monolithic solids" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that can retain some fluid (such as a liquid) within it. In some embodiments, the aerosol-forming material may include, for example, from about 50 wt%, 60 wt%, or 70 wt% amorphous solids to about 90 wt%, 95 wt%, or 100 wt% amorphous solids.

[0041] The aerosol-forming material may include one or more active substances and / or flavorants, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0042] Aerosol-forming agent material

[0043] 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-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, glycerol diacetate mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0044] Functional material

[0045] The one or more other functional materials may include one or more of pH regulators, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0046] Matrix

[0047] The material may be present on or in a carrier to form a substrate. The carrier may be or include, for example, paper, card, cardboard, chipboard, 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 within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

[0048] Consumable

[0049] A consumable is an article that includes or consists of an aerosol - generating material, with some or all of the aerosol - generating material intended to be consumed by a user during use. The 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. The 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 include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0050] Susceptor

[0051] A susceptor is a material that can be heated by penetration with a varying magnetic field (such as an alternating magnetic field). The susceptor may be a conductive material such that penetration by the varying magnetic field causes inductive heating of the material. The heating material may be a magnetic material such that penetration by the varying magnetic field causes hysteresis heating of the material. The susceptor may be both conductive and magnetic such that the susceptor can be heated by both heating mechanisms. In this document, a device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0052] Aerosol modifier

[0053] An aerosol modifier is a substance that is typically located downstream of the aerosol - generating area and is configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be provided in an aerosol - modifier release component that is operable to selectively release the aerosol modifier. For example, the aerosol modifier may be an additive or an adsorbent. For example, the aerosol modifier may include one or more of a flavoring, a coloring agent, water, and a carbon adsorbent. For example, the aerosol modifier may be a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a wire, or a granule. The aerosol modifier may be free of filter material.

[0054] Aerosol generator

[0055] An aerosol generator is a device configured to cause aerosol to be generated from an aerosol - forming material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol - forming material to thermal energy in order to release one or more volatiles from the aerosol - forming material to form an aerosol. In some embodiments, the aerosol generator is configured to cause aerosol to be generated from the aerosol - forming material without heating. For example, the aerosol generator can be configured to subject the aerosol - forming material to one or more of vibration, increased pressure, or electrostatic energy.

[0056] This disclosure relates to an aerosol delivery system (which may also be referred to as a vapor delivery system), such as an atomizer or an electronic cigarette. In the following description, the term "electronic cigarette" or "e - cigarette" may sometimes be used, but it will be understood that this term may be used interchangeably with aerosol delivery system / device and electronic aerosol delivery system / device. Additionally, as is common in the art, the terms "aerosol" and "vapor" and related terms such as "evaporation", "volatilization", and "aerosolization" are generally used interchangeably.

[0057] An aerosol delivery system (e - cigarette) typically (although not always) includes modular components, which include a reusable device portion and a replaceable (disposable / consumable) cartridge component. Generally, the replaceable cartridge component will include an aerosol - forming material and an evaporator (which may be collectively referred to as an "atomizer"), and the reusable device portion will include a power source (e.g., a rechargeable power source) and a control circuit. It will be understood that these different portions may include additional elements depending on their functions. For example, the reusable device portion will typically include a user interface for receiving user input and displaying operating - state characteristics, and the replaceable cartridge device portion includes a temperature sensor for helping to control the temperature in some cases. The cartridge is electrically and mechanically coupled to the control unit, for example, using a thread, a bayonet, or a magnetic coupling with appropriately arranged electrical contacts, for use. When the aerosol - forming material in the cartridge is depleted, or when the user wishes to switch to a different cartridge with a different aerosol - forming material, the cartridge can be removed from the reusable component, and a replacement cartridge can be attached in its place. Systems and devices that conform to this type of two - piece modular configuration are generally referred to as two - piece systems / devices.

[0058] Electronic cigarettes generally have a generally elongated shape. To provide a specific example, certain embodiments of the present disclosure will be considered to include such a generally elongated two-piece system employing a disposable cartridge. However, it will be understood that the basic principles described herein can equally apply to different configurations, such as a single-piece system or a modular system including more than two components, a refillable device and a single-use disposable article, as well as other overall shapes, such as a so-called box-modular high-performance device that generally has a box-like shape. More generally, it will be understood that certain embodiments of the present disclosure are based on an aerosol delivery system that is operationally configured to provide functions in accordance with the principles described herein, and the construction of the system configured to provide the functions of certain embodiments of the present disclosure is not of primary importance. Summary of the Invention

[0059] The present invention provides an aerosol delivery subsystem, system, and method as claimed.

[0060] The claimed invention generally provides a subassembly or subsystem 100 suitable for use in or configured to be used in an aerosol delivery system 1.

[0061] In some embodiments, the subsystem 100 includes a holder 110 and can generally form part of the aerosol delivery system 1, particularly can form part of the reusable device component 2 and / or the consumable cartridge component 4 in a two-piece system, or form part of a disposable aerosol delivery system 1. The holder can include a number of functional features, including but not limited to: an integral end cap for sealing the liquid in the reservoir; a retaining member for receiving electrical contact pins; a seal between the container / reservoir and the battery compartment; firmly supporting the battery within the housing; and one or more through-holes for air flow. Brief Description of the Drawings

[0062] Embodiments of the present disclosure will now be described by way of example only with reference to the drawings, in which:

[0063] Figure 1 is a schematic cross-sectional view of an aerosol delivery system 1 including a holder 110 according to some embodiments of the present disclosure.

[0064] Figure 2 , Figure 3 and Figure 4 are schematic perspective views of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing the holder 110 in more detail.

[0065] Figure 5 is Figure 4 a vertical cross-sectional view of the aerosol delivery subsystem 100.

[0066] Figure 6 Is a schematic side view of a modular power supply for an aerosol delivery subsystem 100 according to some embodiments of the present disclosure.

[0067] Figure 7 Is an exploded perspective view of an aerosol delivery system 1 according to some embodiments of the present disclosure.

[0068] Figure 8 Is a schematic side view of an assembled aerosol delivery system 1 according to some embodiments of the present disclosure.

[0069] Figure 9 Is a schematic diagram of the assembly process for an aerosol delivery system 1 according to some embodiments of the present disclosure.

[0070] Figure 10 、 Figure 11 、 Figure 12 and Figure 13 Are schematic perspective views of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing the second bracket 110.

[0071] Figure 14 Is a cross-sectional view of an aerosol delivery system including Figures 10 to 13 The second bracket. Detailed Description

[0072] Aspects and features of certain examples and embodiments are described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally, and for the sake of brevity, these aspects and features are not described in detail. Accordingly, it will be understood that aspects and features of the devices and methods discussed herein that are not described in detail may be implemented according to any suitable conventional techniques.

[0073] Figure 1 Is a cross-sectional view of an example aerosol delivery system 1 according to certain embodiments of the present disclosure, which provides an introduction to a two-piece aerosol delivery system, its components, and their functions. System 1 includes a bracket 110 according to some embodiments of the present disclosure. The bracket 110 will be described in detail with reference to the subsequent figures.

[0074] The aerosol delivery system 1 includes two main components, namely a reusable component 2 and a replaceable / disposable consumable cartridge component 4. In normal use, the reusable component 2 and the cartridge component 4 are releasably coupled together at an interface 6. When the cartridge component 4 is depleted or the user simply wishes to switch to a different cartridge component 4, the cartridge component 4 can be removed from the reusable component 2 and a replacement cartridge component 4 is attached to the reusable component 2 in the appropriate position. The interface 6 provides structural, electrical, and airflow path connections between the two components 2, 4 and can be established according to conventional techniques, such as based on screw threads, magnetism, or bayonet fixation, with appropriately arranged electrical contacts and openings for properly establishing the electrical connection and airflow path between the two components 2, 4. The specific manner in which the cartridge component 4 is mechanically mounted to the reusable component 2 is not important for the principles described herein, but for a specific example, it is assumed here to include a magnetic coupler ( Figure 1 not shown in). It will also be understood that the interface 6 may not support electrical connection and / or airflow path connection between the corresponding components 2, 4 in some implementations. For example, in some implementations, the aerosol generator may be provided in the reusable component 2 instead of in the cartridge component 4, or the power transmission from the reusable component 2 to the cartridge component 4 may be wireless (e.g., based on electromagnetic induction), such that no electrical connection between the reusable component 2 and the cartridge component 4 is required. Additionally, in some implementations, the airflow through the electronic cigarette may not pass through the reusable component 2, such that no airflow path connection between the reusable component 2 and the cartridge component 4 is required. In some cases, when the reusable component 2 and the cartridge component 4 are coupled together for use, a portion of the airflow path may be defined at the interface between these portions.

[0075] According to certain embodiments of the present disclosure, the cartridge / consumable component 4 can be widely conventional. In Figure 1 one, the cartridge component 4 includes a cartridge housing 42 formed of a plastic material. The cartridge housing 42 supports the other components of the cartridge component 4 and provides a mechanical interface 6 with the reusable component 2. The cartridge housing 42 is generally circularly symmetric about a longitudinal axis along which the cartridge component 4 is coupled to the reusable component 2. In this example, the cartridge component 4 has a length of approximately 4 cm and a diameter of approximately 1.5 cm. However, it will be understood that the specific geometry, and more generally, the overall shape and materials used, can be different in different implementations.

[0076] Within the cartridge housing 42 is a chamber or reservoir 44 containing the aerosol-generating material. In Figure 1In the schematically illustrated example, the reservoir 44 stores a supply of liquid aerosol - forming material. In this example, the liquid reservoir 44 has an annular shape with an outer wall defined by the cartridge housing 42 and an inner wall that defines an airflow path 52 through the cartridge member 4. The reservoir 44 is closed at each end with end walls to contain the aerosol - forming material. The reservoir 44 can be formed according to conventional techniques, for example, it can include a plastic material and be integrally molded with the cartridge housing 42.

[0077] The cartridge / consumable member 4 also includes an aerosol generator 48 positioned towards the end of the reservoir 44 opposite the mouthpiece outlet 50. It will be understood that in, for example, Figure 1 the two - piece system shown, the aerosol generator 48 can be in either the reusable member 2 or the cartridge member 4. For example, in some embodiments, the aerosol generator 48 (e.g., a heater, which can be in the form of a core and coil arrangement as shown, a distiller, which can be formed from sintered metal fiber material or other porous conductive material, or any suitable alternative aerosol generator) can be included in the reusable member 2 and when the cartridge member 4 is engaged with the reusable member 2, brought into proximity with a portion of the aerosol - forming material in the cartridge member 4. In such an embodiment, the cartridge member 4 can include a portion of the aerosol - forming material and when the cartridge member 4 is engaged with the reusable member 2, the aerosol generator 48 including the heater is at least partially inserted into or at least partially surrounds that portion of the aerosol - forming material.

[0078] In Figure 1 the example, the core 46 in contact with the aerosol generator 48 extends transversely across the cartridge airflow path 52 and its end extends through an opening in the inner wall of the reservoir 44 into the reservoir 44 of the liquid aerosol - forming material. The size of the opening in the inner wall of the reservoir 44 is designed to broadly match the size of the core 46 to provide a reasonable seal to prevent leakage from the liquid reservoir 44 into the cartridge airflow path without unduly compressing the core 46, which could impair its fluid transfer performance.

[0079] The core 46 and the aerosol generator 48 are arranged in the cartridge airflow path 52 such that the region of the cartridge airflow path 52 around the core 46 and the heater 48 effectively defines the evaporation region of the cartridge member 4. The aerosol - forming material in the reservoir 44 penetrates into the core 46 through the end of the core extending into the reservoir 44 and is drawn along the core by surface tension / capillary action (i.e., wicking). In this example, the aerosol generator 48 includes a resistance wire coiled around the core 46. In Figure 1In an example, the heater 48 includes a Nichrome (Cr20Ni80) wire, and the core 46 includes a bundle of fiberglass, but it will be understood that the specific aerosol generator configuration is not important for the principles described herein. In use, electrical power can be supplied to the aerosol generator 48 to cause a quantity of aerosol-forming material (aerosol-forming material) drawn through the core 46 and near the aerosol generator 48 to vaporize. The vaporized aerosol-forming material can then become entrained in the air drawn along the cartridge airflow path from the vaporization zone towards the mouthpiece outlet 50 for inhalation by the user.

[0080] As described above, the rate at which the aerosol-forming material is vaporized by the aerosol generator 48 will depend on the amount (level) of electrical power supplied to the aerosol generator 48, and thus, electrical power can be applied to the aerosol generator 48 to selectively generate an aerosol from the aerosol-forming material in the cartridge component 4. Additionally, the rate of aerosol generation can be varied by changing the amount of electrical power supplied to the aerosol generator 48, for example, by pulse width and / or frequency modulation techniques.

[0081] The reusable component 2 includes a housing 12 having an opening that defines an air inlet 28 for the electronic cigarette; a power source 26 (e.g., a battery) for providing operating power to the electronic cigarette; a control circuit / controller 22 for controlling and monitoring the operation of the electronic cigarette; a first user input button 14; a second user input button 16; and a visual display 24. The device component 2 also includes a mounting bracket 110 configured to receive the power source 26 ( Figure 1 not shown in ) and will be described in more detail later with reference to the subsequent figures.

[0082] The housing 12 can be formed, for example, from a plastic or metal material and in this example has a generally circular cross-section that generally conforms to the shape and dimensions of the cartridge component 4 to provide a smooth transition between the two components 2, 4 at the interface 6. In this example, the reusable component 2 has a length of approximately 8 cm, so that the overall length of the electronic cigarette when the cartridge component 4 and the reusable component 2 are coupled together is approximately 12 cm. However, as has been noted, it will be understood that the overall shape and scale of the electronic cigarette implementing the embodiments of the present disclosure are not important for the principles described herein.

[0083] The air inlet 28 is connected to the airflow path 51 through the reusable component 2. When the reusable component 2 and the cartridge component 4 are connected together, the airflow path 51 of the reusable component is further connected to the cartridge airflow path 52 through the interface 6. Thus, when the user inhales on the mouthpiece opening 50, air is drawn in through the air inlet 28, along the airflow path 51 of the reusable component, through the interface 6, through the aerosol generation region near the aerosol generator 48 (where the evaporated aerosol-generating material is entrained in the airflow), along the cartridge airflow path 52, and exits through the mouthpiece opening 50 for the user to inhale.

[0084] In this example, the power source or supply 26 is rechargeable and can be of a conventional type, such as the type commonly used in electronic cigarettes and other applications that require relatively high current to be provided over a relatively short period of time. The power source 26 can be recharged through a charging connector (such as a USB connector) in the reusable component housing 12. In an embodiment, the power source 26 has a body with a pair of electrodes extending therefrom, such as as Figure 6 shown.

[0085] A first user input button 14 and / or a second user input button 16 can be provided. In this example, they are conventional mechanical buttons, such as including spring-loaded components that can be pressed by the user to establish electrical contact. In this regard, the input buttons can be considered input devices for detecting user input, and the specific manner of implementing the buttons is not important. The buttons can be assigned functions such as turning on and off the aerosol delivery system 1 and adjusting user settings (such as the power supplied from the power source 26 to the aerosol generator 48). However, including user input buttons is optional and may not be included in some embodiments.

[0086] A display 24 can be provided to give the user a visual indication of various characteristics associated with the aerosol delivery system, such as current power setting information, remaining power source power, and so on. The display can be implemented in various ways. In this example, the display 24 includes a conventional pixelated LCD screen, which can be driven to display the desired information according to conventional techniques. In other implementations, the display can include one or more discrete indicators, such as LEDs, arranged to display the desired information, for example, through a specific color and / or flash sequence. More generally, the manner of providing the display 24 and using the display to show information to the user is not important for the principles described herein. For example, some embodiments may not include a visual display and / or may include other means for providing information related to the operating characteristics of the aerosol delivery system to the user, such as using audio signals, or may not include any means for providing information related to the operating characteristics of the aerosol delivery system to the user.

[0087] The controller 22 is suitably configured / programmed to control the operation of the aerosol delivery system 1 to provide functions in accordance with embodiments of the present disclosure as further described herein, as well as for providing conventional operating functions of the aerosol delivery system 1 that conform to established techniques for controlling such devices. The controller (processor circuitry) 22 can be considered to logically include various sub-units / circuit elements associated with different aspects of the operation of the aerosol delivery system 1. In this example, the controller 22 includes a power control circuit for controlling the power supply from the power source 26 to the aerosol generator 48 in response to user input, a user programming circuit 20 for establishing configuration settings (e.g., user-defined power settings) in response to user input, and other functional units / circuits associated with functions in accordance with the principles described herein and aspects of the conventional operation of electronic cigarettes, such as a display driver circuit and a user input detection circuit. It will be understood that the functions of the controller 22 can be provided in a variety of different ways, such as using one or more suitably programmed programmable computers and / or one or more suitably configured application specific integrated circuits / circuits / chips / chip sets that are configured to provide the desired functions.

[0088] The functions of the controller 22 are further described herein. For example, the controller 22 can include an application specific integrated circuit (ASIC) or a microcontroller for controlling the aerosol delivery device. The microcontroller or ASIC can include a CPU or a microprocessor. The operation of the CPU and other electronic components is generally at least partially controlled by software programs running on the CPU (or other components). Such software programs can be stored in non-volatile memory, such as ROM, which can be integrated into the microcontroller itself or provided as a separate component. The CPU can access the ROM to load and execute the respective software programs when needed.

[0089] The reusable component 2 includes an airflow sensor 30 electrically connected to the controller 22. In most embodiments, the airflow sensor 30 includes a so-called "puff sensor" as the airflow sensor 30 is used to detect when a user puffs on the device. In some embodiments, the airflow sensor 30 includes a switch in the electrical path that supplies power from the power source 26 to the aerosol generator 48. In such an embodiment, the airflow sensor 30 typically includes a pressure sensor configured to close the switch when subjected to a particular range of pressures such that once the pressure near the airflow sensor 30 drops below a threshold, current can flow from the power source 26 to the aerosol generator 48. The threshold can be set to a value determined experimentally to correspond to a characteristic value associated with the start of a user puff. In other embodiments, the airflow sensor 30 is connected to the controller 22 and the controller distributes power from the power source 26 to the aerosol generator 48 based on signals received by the controller 22 from the airflow sensor 30. The manner in which the signals output from the airflow sensor 30 (which can include measurements of the capacitance, resistance, or other characteristics of the airflow sensor by the controller 22) are used by the controller 22 to control the power supply from the power source 26 to the aerosol generator 48 can be performed according to any method known to those skilled in the art.

[0090] In Figure 1 In the illustrated example, the airflow sensor 30 is mounted to a printed circuit board (PCB) 31, but this is not required. The airflow sensor 30 can include any sensor configured to determine the characteristics of the airflow in the airflow path 51 disposed between the air inlet 28 and the mouthpiece opening 50, such as a pressure sensor or transducer (e.g., a diaphragm or solid-state pressure sensor), a combined temperature and pressure sensor, or a microphone sensitive to changes in air pressure including acoustic signals (e.g., an electret microphone). The airflow sensor 30 is located within a sensor cavity or chamber 32 that includes an internal space defined by one or more chamber walls 34. The sensor cavity 32 includes an area within one or more of the chamber walls 34 in which the airflow sensor 30 can be located, in whole or in part. In some embodiments, the PCB 31 includes one of the chamber walls of the sensor housing that includes the sensor cavity / chamber 32.

[0091] A deformable membrane is disposed across an opening that provides communication between the sensor cavity 32 containing the sensor 30 and a portion of the airflow path disposed between the air inlet 28 and the mouthpiece opening 50. The deformable membrane covers the opening and is attached to one or more of the chamber walls according to the methods further described herein.

[0092] As further described herein, the aerosol delivery system 1 includes a communication circuit configured to enable connection with one or more additional electronic devices (e.g., a storage / charging housing, and / or a refill / charging dock) to enable data transfer between the aerosol delivery system 1 and the additional electronic devices. In some embodiments, the communication circuit is integrated into the controller 22, and in other embodiments, it is implemented separately (including, for example, a separate application specific integrated circuit / circuit / chip / chipset). For example, the communication circuit may include a module separate from the controller 22 that provides dedicated data transfer functionality for the aerosol delivery device while being connected to the controller 22. In some embodiments, the communication circuit is configured to support communication between the aerosol delivery system 1 and one or more additional electronic devices via a wireless interface. The communication circuit may be configured to support wireless communication between the aerosol delivery system 1 and other electronic devices such as a housing, a dock, a computing device such as a smart phone or a PC, a cellular communication supported base station, a relay node providing a forward link to the base station, a wearable device, or any other portable or fixed device that supports wireless communication.

[0093] The wireless communication between the aerosol delivery system 1 and the additional electronic devices may be configured according to a data transfer protocol such as Bluetooth, ZigBee, Wifi Direct, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or substantially any other wireless and / or wired network protocol or interface. The communication circuit may include any suitable interface for a wired data connection such as a USB-C, micro USB, or Thunderbolt interface, and may include a pin or contact pad arrangement configured to engage mating pins or contact pads on a dock, a housing, a cable, or other external device connectable to the aerosol delivery system 1.

[0094] Figure 2 、 Figure 3 and Figure 4 (respectively) are a schematic top perspective view, a bottom perspective view, and a side perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, more particularly showing the bracket 110.

[0095] As Figures 2 to 4 shown, the bracket 110 is a substantially tubular or columnar mounting bracket 110 and is configured to receive a power source 26 having a body with a pair of electrodes 27 extending therefrom (in Figure 6(shown separately). The bracket 110 includes a first part (upper part) 110a having a pair of holes 120 configured to receive the pair of electrodes 27 and present them at the end of the bracket 110 for connection, and a second part 110b having a cavity 130 configured to receive the power supply body. In Figures 2 to 4 In an exemplary embodiment, the pair of holes 120 extend substantially axially, are configured to receive the pair of electrodes 27, and connect them at the axial end of the bracket 110 near the first part 110a. Further, in Figures 2 to 4 In an embodiment, the bracket 110 further includes a third lower part 110c having a hole for providing an air inlet 28 to the subsystem 100, having a flow path therethrough to convey air to the aerosol generator 48 (not shown).

[0096] The first part (upper part) 110a generally includes a truncated tube (or column) having an open upper end for connection to the cartridge member 4 ( Figure 7 as shown). The first part 110a includes a surface 140 having a platform 142 with the pair of holes 120 therethrough. In Figure 3 In an exemplary embodiment, the surface 140 is planar and extends substantially radially, and the platform 142 includes two upright truncated cylinders 142a, 142b, each cylinder extending substantially axially (thus substantially perpendicular to the radial surface 140) and each cylinder having a hole 120 therethrough (thus forming a tube). In use, the platform 142 axially spaces at least the conductive portion of the electrode 27 from the surface 140. The surface 140 further includes a peripheral wall 144, and the (walled) surface 140 forms a trapping area for condensate in use. Thus, in use, the platform 142 at least axially spaces the conductive portion of the electrode 27 from the trapping area, thereby advantageously minimizing the risk of short - circuiting the power supply 26 in use.

[0097] The first part 110a, the second part 110b, and / or the third part 110c may generally include one or more protrusions and / or recesses arranged to receive, connect to, interfere with additional components or interlock with interlocking additional components. As Figure 2 shown, the first part 110a includes a plurality of internal protrusions 145 and recesses 146 extending from the wall 144 for engaging or interlocking with complementary protrusions 245 and / or recesses 246 on the cartridge member 4 (as Figure 7 shown) to fix and / or prevent relative rotation of the components 2, 4 with respect to each other upon connection. In Figures 2 to 4 In some embodiments not shown, the outer wall 150a of the first part 110a includes one or more external protrusions or recesses for engaging with other components such as the housing 200 in use. Such components may optionally include complementary protrusions or recesses.

[0098] In some embodiments (not shown), any of portions 110a - 110c, but particularly the first portion (upper) 110a, may be asymmetrical in cross - section and / or when viewed from the proximal end perpendicular to its axial extension axis. Advantageously, this can provide a one - way fit for this portion to engage with other components (e.g., upper portion 110a engages with cartridge component 4), which can be detected by a camera to automate assembly, i.e., the camera assembly can uniquely detect the orientation of the first portion 110a, and the robotic arm can then position / rotate it as necessary for assembly with other components during assembly. The orientation of the first portion 110a can be uniquely identified by the asymmetry of the cross - section, particularly the arrangement of visible features having asymmetry or otherwise unique orientation, such visible features being holes 120, circumferential wall 144, platforms 142, surface 140, and / or protrusions and recesses 145, 146. For example, each of holes 120, platforms 142a, 142b, and / or protrusions and recesses 145, 146 can have different shapes and / or sizes from each other.

[0099] In Figures 2 to 4 , the second portion 110b forms an intermediate portion between the first portion (upper) 110a and the third portion (lower) 110c. The second portion 110b generally includes opposing tubular sidewalls 150b that extend only around a partial periphery of the substantially tubular or cylindrical support 110, thereby providing a power cavity 130 configured to receive a power body in use.

[0100] As Figures 2 to 4 illustrated by the example of, the third portion (lower) 110c generally includes a truncated tube or cylinder having a hole for providing an air inlet 28 to the subsystem 100. The third portion 110c also includes an optional sensor cavity 32 for receiving a fluid flow sensor 30, which is surrounded by a fluid flow sensor seal 33. The third portion 110c additionally includes a flange 164 for abutting the housing 200, which is received when assembling the system 1 (as Figure 9 illustrated), and a protrusion in the form of a shoulder 162 on the outer wall 150c of the third portion 110c, the shoulder protrusion 162 for engaging with the housing 200 and providing an interference fit therewith to secure the housing 200 above the subsystem 100. Similarly, the other portions 110a, 110b can include protrusions, recesses, flanges, and / or shoulders for engaging or abutting other components such as the housing 200.

[0101] Figure 3 Also shown is a baffle cavity 135 for receiving a user - operable baffle 138 (not shown, see Figure 5 ), which is slidable to adjust the airflow entering the device through the inlet 28.

[0102] Figure 4 Shows subsystem 100 in use, which further includes a power source 26 and electrodes 27 that axially extend and protrude beyond the axial extent of the first portion 110a for connection at the axial proximal end of the stent 110. Figure 4 The stent 110 in also includes additional recesses for receiving flexible, resilient, and / or absorbent inserts 170a and 170c. In Figure 4 these include two radially extending recesses, one above and one below the power source cavity 130, for receiving inserts 170a, 170c above and below the power source body, respectively. Subsystem 100 further includes an insert 170b beside the power source body. Since insert 170b is attached to the power source body, a recess is not necessarily required in the stent 110, but in additional embodiments, subsystem 100 may include a recess that axially extends beside the power source cavity 130 for receiving insert 170b beside the power source body. Inserts 170a to 170c provide padding between components to provide a secure fit (e.g., to help with interference fit) and, when used with a liquid cartridge system, can be used to reduce / prevent leakage. In some embodiments, inserts 170a to 170c include ethylene vinyl acetate (EVA).

[0103] Figure 5 is Figure 4 a vertical cross-sectional view of the aerosol delivery subsystem 100 of. In addition to Figure 4 the features shown, Figure 5 shows an optional fluid flow sensor 30 in the air flow path starting from the air inlet 28, and a fluid flow sensor seal 33 for sealing around the fluid flow sensor 30. In some embodiments, sensor 30 includes a microphone or a pressure sensor. Figure 5 Also shown is a baffle 38 and a baffle seal 39 for sealing around the baffle 38. In some embodiments, seals 33, 39 include silicone.

[0104] Figure 6 is a schematic side view of a modular power source for an aerosol delivery subsystem 100 according to some embodiments of the present disclosure. Figure 6 Shows a power source 26 that includes a body having a pair of electrodes 27 extending therefrom, the pair of electrodes being located in the pair of holes 120 for connection to the aerosol generator 48. Thus, this arrangement provides an electrical and non-permanent (easily reversible) mechanical connection for securing the power source 26 within the system 1. In some embodiments, Figure 6Not shown in the figure, the electrodes comprising the pair of electrodes 27 have different shapes and / or sizes from each other to facilitate assembly, ie, each electrode can be fitted in only one hole 120 .

[0105] Figure 7 is an exploded perspective view of an aerosol delivery system 1 according to some embodiments of the present disclosure. As described above, the device component 2 itself is a modular subsystem 100 and includes a component mounting bracket 110. The cartridge component 4 includes a cartridge housing 42, which contains an aerosol generating material such as tobacco (for THP systems) or a liquid containing nicotine (for electronic cigarettes), and includes complementary conductive pins 227 for electrically connecting to electrodes 27 of a power source 26 to provide power to an aerosol generator 48 therein. The cartridge component 4 also includes a mouthpiece housing 60 having a mouthpiece outlet 50. As shown Figure 9 As shown, the mouthpiece housing 60 can be separated from the cartridge housing 42.

[0106] exist Figure 7 In the example embodiment, by the device component 2 and the cartridge component 4 including the protrusions 162, 262, 362, the device component 2 and the cartridge component 4 are both operable to engage the housing 200 ( Figure 8 ). Specifically, in this example, device component 2 includes protrusion 162 on distal portion 110c of support 110, while cartridge housing 42 of cartridge component 4 includes protrusion 262, and mouthpiece housing 60 of cartridge component 4 includes protrusion 362. Protrusions 162, 262, 362 extend radially to engage housing 200 by an interference fit.

[0107] As mentioned above Figure 2 As described, the cartridge component 4 further comprises a protrusion 245 and a recess 246 for engaging or interlocking with a complementary protrusion 145 and recess 146 extending from the wall 144 of the first portion 110a to fix and / or prevent the components 2, 4 from rotating relative to each other when coupled.

[0108] Figure 8 is a schematic side view of an aerosol delivery system 1 according to some embodiments of the present disclosure. Figure 8 An example of a substantially tubular or cylindrical shape of an elongated disposable or reusable electronic cigarette or THP system 1 is shown, which includes a collar 210 that secures a housing 200 surrounding the aerosol delivery system 1. Figure 7 In a two-piece system of the system, the housing 200 is fixed over both the device component 2 and the cartridge component 4. Thus, the entire system 1 can be easily disassembled without the need for tools by removing the push-fit end collar 210 and then extracting the bracket 110 from the housing 200 (which removes all interconnected subsystem components). The cartridge component 4 can be similarly removed from the other end of the housing 200.

[0109] Figure 9 is a schematic diagram of the assembly process for an aerosol delivery system 1 according to some embodiments of the present disclosure. The entire system 1 can be easily assembled and disassembled because the subsystem 100 includes a bracket 110 that houses the components of the device component 2, enabling these components to be commonly mounted into / removed from the system 1. In some embodiments, the various components and / or parts are held by an interference fit to provide tool-free assembly.

[0110] As Figure 9 shown, the subsystem 100 receives the cartridge housing 42 at the axially proximal end of the subsystem 100 and connects the electrode 27 to the aerosol generator 48 within the cartridge housing 42. Then the outer housing 200 is fixed to the subsystem 100 by an interference fit at the bracket protrusion 162 and axially pressed to abut against the bracket flange 164 at the end of the bracket 110. The mouthpiece housing 60 is similarly fixed to the outer housing 200 by an interference fit at the mouthpiece housing protrusion 362, thereby fixing the outer housing 200 between the bracket flange 164 and the mouthpiece housing 60.

[0111] Figures 10 to 14 Another example of the present disclosure is shown and will now be described in more detail. For convenience, the same reference numerals from Figures 1 to 9 the previous example are used, and although any features of the examples can be combined and specifically considered in combination, the detailed discussion of multiple permutations is omitted for brevity.

[0112] Figures 10 to 13 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, particularly showing the second bracket 110 in more detail.

[0113] In this second example, the bracket 110 includes a tubular first portion 110a and a second portion 110b. The first portion has a pair of holes 120 configured to receive the pair of power terminals / electrodes 27 and present them for connection at the end of the bracket 110. The second portion includes a tubular sidewall 150b that extends only around a portion of the periphery of the bracket 110 and has a cavity 130 configured to receive the power supply body. The cavity 130 of the second portion 110b is formed by the tubular sidewall 150b, which axially extends away from the first portion 110a, as Figure 12 best shown. The holes 120 extend through the surface of the sidewall across the first portion 110a.

[0114] Compared with the first example, the overall shape of the bracket 110 is different. The shape of the second example is generally similar to that of a premolar or molar, where the first part 110a is similar to the crown part and the second part 110b is similar to the root or shank of the tooth. This second example does not require either the third part 110c or the circumferential wall 144, although these can still be provided.

[0115] Figures 10 to 14 The bracket 110 includes one or more holes 121 configured to provide an air flow path therethrough, which will be described in more detail later.

[0116] Figure 11 The bracket 110 is shown including a protrusion in the form of a flange 154 configured to receive or engage the aerosol generator 48 or the cartridge / atomizer. The flange 154 also includes an external protrusion 145. Figure 14 The flange 154 is shown engaging the cartridge housing 42 (circled) in use, which will be described in more detail later.

[0117] Figure 12 A side view of the bracket 110 is shown, and the second part 110b is shown including a bridge support 115 that spaces the end of the power supply body from the first part 110a and allows air to flow through the holes 121.

[0118] Figure 13 The subassembly 100 is shown, which additionally includes flexible, elastic, and / or absorbent inserts 170a and 170c as in the previous example, and an elongate power supply 26 having wiring 29 that extends from electrodes 27 around the side of the power supply body down to an end cap 160. In this second example, a separate end cap 160 having a flange 164 is provided instead of the bracket 110 including the third part 110c.

[0119] In some arrangements, an air flow sensor 30 configured to detect air flow through the air inlet 28 in use is advantageously disposed substantially at one end of the system 1, away from the cartridge and the mouthpiece 50, where the air flow sensor is less likely to come into contact with the e-liquid or condensate. In Figures 13 to 14 the end cap 160 includes an air inlet 28 (as Figure 14 shown) at the proximal inlet end of the subsystem, and the air flow sensor 30 is located in the air flow path starting from the air inlet 28 for detecting puffing when air flows into the system 1 (as Figure 14 shown). The same benefit is derived from Figure 5 the first example shown, where the third part 110c of the bracket similarly includes an air inlet 28 and houses the sensor 30. In contrast, Figure 1The arrangement positions the sensor 30 at the side of the air inlet 28, which is proximal to the aerosol generator 48, simplifying the air inlet path and the electrical wiring.

[0120] In Figure 13 the sensor 30 is connected to the electrode of the elongate power source 26 by wiring 29 of an electrode 27 that extends to the distal / downstream (axial) end of the power source 26 beside the battery compartment. The elongate power source extends longitudinally away from the sensor 30, and the electrode 27 extends towards / away from the sensor 30 (and the inlet 28). In Figure 13 the wiring 29 extends between the power source body and the bracket 110 along the right hand side of the power source body and is thus held by the bracket 110. Alternatively, the wiring 29 can extend beside the power source aligned with the midpoint of the electrode 27, so the wiring 29 can have the same length for two terminals that are away from the sensor 30 at the furthest axial ends of the power source 26. The bracket 110 can include additional features such as a third leg to secure the wiring 29. The same terminal / electrode 27 also supplies power to the aerosol generator 48 in use, which is shown in Figure 14 at the distal / downstream end of the subsystem, further away from the puff sensor 30 and the inlet 28. The subsystem can include a reusable device portion 2 of the aerosol delivery system 1 for use with a removable / replaceable cartomizer component 4.

[0121] As Figure 13 best shown in, the wiring 29 is preferably longer than the shortest path from the electrode 27 to the sensor 30, i.e., has an excess length, such that when connected, the puff sensor 30 can be axially separated from the power source 26 to assist assembly, for example to allow the insertion / removal of the end cap 160 without damaging this connection, thus allowing this subassembly to be assembled outside the housing / casing 200 before the end cap 160 is pushed into place.

[0122] Typically, the power source 26 can have a length of 25 - 35 mm, 35 - 45 mm, or 45 - 55 mm (extending away from the sensor 30). Assuming a typical minimum length of 15 mm to reliably connect the sensor 30 to the electrode / terminal 27 at the distal / downstream axial end of the power source 26 (note that the shortest path may have slightly different lengths for different + / − terminals), the corresponding minimum wiring length is 40 - 50 mm, 50 - 60 mm, or 60 - 70 mm. Preferably, the wiring has an excess length that is 20 - 30 mm, 30 - 40 mm, or 40 - 50 mm greater than this minimum “shortest path” length to allow for easy installation / removal, and thus has a length of 60 - 70 mm, 70 - 80 mm, 80 - 90 mm, 90 - 100 mm, 100 - 110 mm, or 110 - 120 mm. Any excess length of the wiring 29 can be accommodated in the space 166 between the end cap 160 and the power source 26 (inFigure 14 (best seen by coiling in space 166 to accommodate the excess length of the wiring 29). Space 166 can also accommodate absorbent material 170c to capture any aerosol - generating material or condensate that may have leaked.

[0123] Figure 14 is a cross - sectional view of an aerosol delivery system 1 according to some embodiments of the present disclosure, which includes Figures 10 to 13 a second bracket 110. As shown, Figure 14 the aerosol delivery system 1 of Figure 13 includes subsystems and additional components that form the system 1.

[0124] In addition to Figure 13 the components shown, Figure 14 the system 1 of

[0125] also includes a housing 200 that surrounds the end cap 160, the bracket 110, and the cartridge housing 42. Internally, the system 1 also includes a sealing element 133 that engages a first portion 110a of the bracket and the aerosol generator 48, thereby providing a seal therebetween and thus providing a seal between the aerosol generator 48 and the power source 26 in use. As described above, the flange 154 of the bracket 110 engages the cartridge housing 42 (circled), thereby fixing the cartridge to the bracket 110. The bracket 110 provides separation between the cartridge and the power source 26, reducing the risk of leakage affecting the power source 26 and the sensor 30. The system 1 also includes a manifold 58 for directing aerosol from the aerosol generator 48 to the mouthpiece 50 at the distal downstream end of the system 1 opposite the end cap 160. Figure 14 As Figure 5 shown, an air inlet 28 to the end cap 160 provides an airflow into the system 1 at its proximal inlet end. The airflow can be adjusted by a baffle 38, which is slidable to adjust the airflow into the system 1 through the inlet 28, as discussed above with reference to

[0126] As detailed herein, the holder 110 can thus provide several functions, which can include:

[0127] · Holding the electrodes / terminals 27 of the power source 26

[0128] · Presenting or extending the electrodes / terminals 27 of the power source 26

[0129] · Holding the power source 26 itself

[0130] · Securing the cartridge

[0131] ● Providing a seal between the cartridge and the power source 26

[0132] · Providing an airflow path to the aerosol generator / cartridge

[0133] Combining several functions into a single-piece component reduces the total number of components of the device, thus helping to reduce costs and simplify the manufacturing / assembly process.

[0134] Advantageously, aspects of the arrangement disclosed herein (notably the separation between the cartridge and the power source 26) can allow the cartridge to include a liquid freely stored in a reservoir, maximizing the storage volume without the need for a storage medium such as cotton, which is commonly used to help reduce leakage but which itself occupies volume and absorbs a portion of the liquid that cannot be released, thus reducing the effective capacity. Using freely stored liquid allows the reservoir to be smaller for the same volume of aerosol-generating material, thus providing a more compact device. This space saving in the cartridge can provide space for accommodating any excess length of the wire 29 connected to the airflow sensor 30, thus avoiding any impact on the overall size of the system 1.

[0135] In some instances, as Figures 1 to 9 shown, the holder 110 additionally provides the function of the end cap 160.

[0136] The modular nature of the entire system 1, and in particular the modular nature of the subsystem 100, thus allows for the easy installation and removal of individual components, such as the power source body and the electrodes 27. In existing arrangements, these connections would typically be directly welded and fixed one by one in place within the subsystem 100, and thus assembly and disassembly are more time-consuming and precise, increasing the likelihood of damage during assembly / disassembly. By providing the mounting holder 110, the various components can be connected together as a modular subsystem 100, which can then be jointly assembled into the entire system 1, providing a faster, more convenient and less damaging assembly process. Additionally, the method is reversible and thus improves recyclability, which is particularly important for disposable devices that are typically single-use and discarded as a complete unit (and thus not recycled). Thus, the present invention significantly improves recyclability as the various components can be easily removed and transported to an appropriate recycling center.

[0137] Although in Figure 1 the embodiments, various components (such as the aerosol generator 48) are shown as components of the cartridge component 4, in some embodiments, these can alternatively be components of the device component 2 or the subsystem 100, and the bracket 110 can include additional features for accommodating these components, such as protrusions, recesses, shelves, and / or cavities.

[0138] The steps of the disclosed method can be performed in any suitable order.

[0139] The various embodiments described herein are only used to assist in understanding and teaching the claimed features. These embodiments are provided only as representative samples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not considered to be limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and other embodiments can be used and modifications can be made without departing from the scope of the claimed invention.

[0140] In addition to those specifically described herein, the various embodiments of the present invention can suitably include, contain, or substantially contain a suitable combination of the disclosed elements, components, features, parts, steps, methods, etc. Additionally, the present disclosure can include other inventions that are not currently claimed but may be claimed in the future. Protection can be sought for any features disclosed in any one or more of the publications cited herein in connection with the present disclosure.

[0141] Specific feature A

[0142] 1. An aerosol delivery subsystem, comprising a substantially tubular or cylindrical mounting bracket configured to receive a power source having a body with a pair of electrodes extending therefrom, the bracket comprising:

[0143] a. A first portion having a pair of holes configured to receive the pair of electrodes and present the pair of electrodes for connection at an end of the bracket; and

[0144] b. A second portion having a cavity configured to receive the body of the power source.

[0145] 2. The subsystem according to clause 1, wherein the pair of holes:

[0146] a. Extend substantially axially; and / or

[0147] b. Are configured to receive the pair of electrodes and present the pair of electrodes for connection at an axial end of the bracket; and / or

[0148] c. Constructed such that the pair of electrodes are connected at the end of the support near the first part.

[0149] 3. The subsystem according to any one of the preceding clauses further includes a third part having:

[0150] a. A hole for providing an air inlet to the subsystem; and / or

[0151] b. A cavity for receiving a fluid flow sensor.

[0152] 4. The subsystem according to any one of the preceding clauses, wherein the support includes:

[0153] a. A first upper part having a pair of holes configured to receive the pair of electrodes and presenting the pair of electrodes for connection at the end of the support;

[0154] b. A second intermediate part having a cavity configured to receive the power supply body; and

[0155] c. A third lower part.

[0156] 5. The subsystem according to any one of the preceding clauses, wherein the first part, the second part, and / or the third part include:

[0157] a. A truncated cylinder or tube; and / or

[0158] b. Opposite side walls that extend only around a partial periphery of the substantially tubular or cylindrical support; and / or

[0159] c. A flange or shoulder for abutting against the housing or another component; and / or

[0160] d. Protrusions and / or recesses for engaging with the housing or another component.

[0161] 6. The subsystem according to any one of the preceding clauses, wherein:

[0162] a. Both the first upper part and the third lower part include a truncated cylinder or tube; and

[0163] b. The second intermediate part includes opposite tubular sides that extend only around a partial periphery of the tube; and

[0164] c. The third lower part includes a flange and protrusions or recesses for removably receiving and engaging the housing.

[0165] 7. The subsystem according to any one of the preceding clauses, wherein the first part includes a surface having a platform with the pair of holes therethrough, the platform axially spacing at least the conductive part of the electrode from the surface in use.

[0166] 8. The subsystem according to clause 7, wherein:

[0167] a. The surface includes a circumferential wall and forms a trapping area for condensate in use; and

[0168] b. The platform axially spaces at least the conductive portion of the electrode from the trapping area in use.

[0169] 9. The subsystem according to clause 7 or 8, wherein the surface extends substantially radially, and the platform extends substantially axially, substantially perpendicular to the radial surface and away from the trapping area.

[0170] 10. The subsystem according to any one of the preceding clauses, wherein the first part, the second part, and / or the third part are asymmetric in cross-section.

[0171] 11. The subsystem according to any one of the preceding clauses, wherein the first part, the second part, and / or the third part are asymmetric when viewed from the proximal end perpendicular to the axial extension axis.

[0172] 12. The subsystem according to any one of the preceding clauses, wherein the first part, the second part, and / or the third part include a plurality of protrusions and / or recesses arranged to receive, connect to, interfere with, or interlock with additional components, and wherein the plurality of protrusions and / or recesses are arranged to be asymmetric in cross-section.

[0173] 13. The subsystem according to any one of the preceding clauses, wherein the holes in the pair of holes have different shapes and / or sizes from each other.

[0174] 14. The subsystem according to any one of the preceding clauses, wherein the outer wall of the bracket includes one or more protrusions or recesses at one or more of its ends for engaging with complementary protrusions or recesses.

[0175] 15. The subsystem according to any one of the preceding clauses, further comprising one or more recesses for receiving flexible, elastic, and / or absorbent inserts.

[0176] 16. The subsystem according to any one of the preceding clauses, comprising:

[0177] a. Recesses extending radially above and / or below the cavity configured to receive the power supply body for receiving flexible, elastic, and / or absorbent inserts above and / or below the power supply body; and / or

[0178] b. Recesses extending axially beside the cavity configured to receive the power supply body for receiving flexible, elastic, and / or absorbent inserts beside the power supply body.

[0179] 17. The subsystem according to any one of the preceding clauses further comprises:

[0180] a. A power source having a body and electrodes extending therefrom; and / or

[0181] b. A fluid flow sensor; and / or

[0182] c. A seal for sealing around the fluid flow sensor; and / or

[0183] d. A flexible, elastic and / or absorbent insert; and / or

[0184] e. A housing for accommodating the bracket; and / or

[0185] f. A baffle for regulating the air flow through the subsystem; and / or

[0186] g. An aerosol generator; and / or

[0187] h. A cartridge or atomizer containing aerosol - generating material or smoke - generating material for generating an aerosol or smoke for user inhalation; and / or

[0188] i. A mouthpiece; and / or

[0189] j. A controller.

[0190] 18. The subsystem according to clause 17, wherein the subsystem is configured to receive the power source, the fluid flow sensor, the seal, the insert, the housing, the baffle, the aerosol generator, the cartridge or atomizer, the mouthpiece and / or the controller in an interference - fit manner.

[0191] 19. The subsystem according to clause 17 or 18, comprising a power source, wherein the pair of electrodes comprises a positive electrode and a negative electrode that are different from each other in shape and / or size.

[0192] 20. A substantially tubular or cylindrical aerosol delivery system comprising a substantially tubular or cylindrical mounting bracket according to any one of the preceding clauses.

[0193] 21. An instruction set for a 3D printer, configured to print an aerosol delivery subsystem according to any one of the preceding clauses.

[0194] 22. A method of assembling an aerosol delivery subsystem, the aerosol delivery subsystem comprising a substantially tubular or cylindrical mounting bracket and a power source having a body with a pair of electrodes extending therefrom, the method comprising:

[0195] a. Mounting the power - source body in the cavity of the bracket; and

[0196] b. Mount the pair of electrodes in a pair of holes in the bracket, presenting the pair of electrodes for connection at the end of the bracket.

[0197] 23. An aerosol delivery subsystem comprising a substantially tubular or cylindrical mounting device configured to receive a power source having a body from which a pair of electrodes extend, the bracket comprising:

[0198] a. A first device having a pair of holes configured to receive the pair of electrodes and to present the pair of electrodes for connection at the end of the bracket; and

[0199] b. A second device having a cavity configured to receive the body of the power source.

[0200] Specific feature B

[0201] 1. An aerosol delivery subsystem comprising a mounting bracket configured to receive a power source, the power source having a body from which a pair of electrodes extend, the bracket comprising:

[0202] a. A tubular or cylindrical first portion having a pair of holes configured to receive the pair of electrodes and to present the pair of electrodes for connection at the end of the bracket; and

[0203] b. A second portion including a tubular sidewall extending only around a partial periphery of the bracket and having a cavity configured to receive the body of the power source.

[0204] 2. The subsystem according to clause 1, wherein the pair of holes:

[0205] a. Extend substantially axially; and / or

[0206] b. Extend through a surface across the sidewall of the tubular or cylindrical first portion; and / or

[0207] c. Are configured to receive the pair of electrodes and to present the pair of electrodes for connection at the axial end of the bracket; and / or

[0208] d. Are configured to connect the pair of electrodes at an end of the bracket adjacent to the first portion.

[0209] 3. The subsystem according to any of the preceding clauses, wherein the bracket further comprises one or more holes configured to provide an airflow path therethrough.

[0210] 4. The subsystem according to any of the preceding clauses, wherein the tubular sidewall of the second portion forms a leg extending axially away from the first portion.

[0211] 5. The subsystem according to any one of the preceding clauses, wherein the second part includes a bridge support between the tubular sidewalls.

[0212] 6. The subsystem according to any one of the preceding clauses, further comprising: a sealing element for sealing between the first part of the holder and an aerosol generator or a reservoir, cartridge or atomizer containing aerosol-forming material or smoke-forming material.

[0213] 7. The subsystem according to any one of the preceding clauses, wherein the first part includes a flange or projection configured to receive or engage an aerosol generator or a reservoir, cartridge or atomizer containing aerosol-forming material or smoke-forming material.

[0214] 8. The subsystem according to any one of the preceding clauses, wherein in use, when connected to a power source and an aerosol generator, reservoir, cartridge or atomizer, the holder includes or provides an airflow path for allowing airflow to pass through the power source to the aerosol generator, reservoir, cartridge or atomizer.

[0215] 9. The subsystem according to any one of the preceding clauses, wherein:

[0216] a. The first part includes a truncated cylinder or tube; and / or

[0217] b. The second part includes opposing sidewalls that extend only around a portion of the circumference of the holder; and / or

[0218] c. The holder further includes a flange or shoulder for abutting against a housing or another component; and / or

[0219] d. The holder further includes one or more protrusions and / or recesses for engaging with a housing or another component.

[0220] 10. The subsystem according to any one of the preceding clauses, wherein the first part includes a surface having a platform with the pair of holes therethrough, the platform axially spacing at least the conductive part of the electrode from the surface in use.

[0221] 11. The subsystem according to clause 10, wherein:

[0222] a. The surface includes a circumferential wall and forms a trapping area for condensate in use; and

[0223] b. In use, the platform axially spaces at least the conductive part of the electrode from the trapping area.

[0224] 12. The subsystem according to clause 10, wherein the surface extends substantially radially, and the platform extends substantially axially, substantially perpendicular to the radial surface and away from the trapping area.

[0225] 13. The subsystem according to any one of the preceding clauses, wherein the first part and / or the second part is asymmetric in cross-section.

[0226] 14. The subsystem according to any one of the preceding clauses, wherein the first part and / or the second part is asymmetric when viewed from the proximal end perpendicular to the axial extension axis.

[0227] 15. The subsystem according to any one of the preceding clauses, wherein the first part and / or the second part includes a plurality of protrusions and / or recesses arranged to receive, connect to, interfere with or interlock with additional components, and wherein the plurality of protrusions and / or recesses are arranged to be asymmetric in cross-section.

[0228] 16. The subsystem according to any one of the preceding clauses, wherein the holes in the pair of holes have different shapes and / or sizes from each other.

[0229] 17. The subsystem according to any one of the preceding clauses, wherein the outer wall of the bracket includes one or more protrusions or recesses at one or more of its ends for engaging with complementary protrusions or recesses.

[0230] 18. The subsystem according to any one of the preceding clauses, further comprising one or more recesses for receiving a flexible, elastic and / or absorbent insert.

[0231] 19. The subsystem according to any one of the preceding clauses, comprising:

[0232] a. A recess extending radially above and / or below a cavity of a body configured to receive a power source for receiving a flexible, elastic and / or absorbent insert above and / or below the body of the power source; and / or

[0233] b. A recess extending axially beside a cavity of a body configured to receive a power source for receiving a flexible, elastic and / or absorbent insert beside the body of the power source.

[0234] 20. The subsystem according to any one of the preceding clauses, further comprising:

[0235] a. A power source having a body and an electrode extending therefrom; and / or

[0236] b. A fluid flow sensor; and / or

[0237] c. A seal for sealing around the fluid flow sensor; and / or

[0238] d. A flexible, elastic and / or absorbent insert; and / or

[0239] e a housing for accommodating the holder; and / or

[0240] f. a baffle for regulating the airflow through the subsystem; and / or

[0241] g. an aerosol generator; and / or

[0242] h. a reservoir, a cartridge or an atomizer containing an aerosol-forming material or a smoke-forming material for generating an aerosol or smoke for inhalation by a user; and / or

[0243] i. a mouthpiece; and / or

[0244] j. a controller.

[0245] 21. The subsystem according to clause 20, wherein the subsystem is configured to receive a power source, a fluid flow sensor, a seal, an insert, a housing, a baffle, an aerosol generator, a reservoir, a cartridge or an atomizer, a mouthpiece and / or a controller in an interference fit manner.

[0246] 22. The subsystem according to clause 20 or 21, comprising a sealing element according to clause 6 and an aerosol generator, a reservoir, a cartridge or an atomizer.

[0247] 23. The subsystem according to clause 20 or 21, comprising a power source, wherein:

[0248] a. the pair of electrodes comprises a positive electrode and a negative electrode having different shapes and / or sizes from each other; and / or

[0249] b. the subsystem comprises an airflow path around the power source and through one or more holes in the holder; and / or

[0250] c. the power source is held in the holder around the holder or a partial periphery of the power source.

[0251] 24. The subsystem according to clause 20, comprising a reservoir, a cartridge or an atomizer, the reservoir, the cartridge or the atomizer containing a liquid freely stored therein.

[0252] 25. An instruction set for a 3D printer, configured to print an aerosol delivery subsystem according to any one of the preceding clauses.

[0253] 26. An aerosol delivery system comprising a subsystem according to any one of the preceding clauses.

[0254] 27. The aerosol delivery system according to clause 26, wherein the holder provides an airflow path around the power source.

Claims

1. An aerosol delivery subsystem, comprising: a. A puff sensor at one end, configured to detect an air flow through an air inlet during use; and b. An elongated power source extending away from the puff sensor and having an electrode at a distal end away from the puff sensor for connection to the puff sensor.

2. The subsystem according to claim 1 further comprises: Wiring for the electrode at the distal end of the power source to connect the puff sensor to the power source, wherein the wiring has an excess length such that the puff sensor and the power source can be axially separated when the wiring is connected to assist in assembly.

3. The subsystem according to any one of the preceding claims, wherein, The power source has a length extending away from the puff sensor of 25 - 35 mm, 35 - 45 mm, or 45 - 55 mm.

4. The subsystem according to claim 2 or 3, wherein, The wiring has an excess length of 20 - 30 mm, 30 - 40 mm, or 40 - 50 mm.

5. The subsystem according to claim 2, 3 or 4, wherein The wiring has a length of 60 - 70 mm, 70 - 80 mm, 80 - 90 mm, 90 - 100 mm, 100 - 110 mm, or 110 - 120 mm.

6. The subsystem according to any one of the preceding claims, wherein, The air inlet is at the end of the subsystem, and the puff sensor is in the air flow path from the air inlet into the subsystem.

7. The subsystem according to any one of the preceding claims, further comprising a mounting bracket for the power source, the bracket presenting the electrode for connection at an end of the bracket.

8. The subsystem according to any one of the preceding claims, further comprising a baffle across the air inlet for regulating the air flow through the air inlet.

9. The subsystem according to any one of the preceding claims, wherein, The baffle is slidable to regulate the air flow through the air inlet.

10. The subsystem according to any one of the preceding claims, wherein, The air inlet is at the proximal end of the subsystem, and the subsystem further comprises an aerosol generator at the distal end of the subsystem away from the puff sensor.

11. The subsystem according to any one of the preceding claims, wherein, The puff sensor, the power source, and the aerosol generator are substantially axially aligned in the following order: puff sensor - power source - aerosol generator.

12. The subsystem according to any one of the preceding claims, comprising a cartridge or reservoir containing aerosol - forming material.

13. The subsystem according to claim 12, wherein, The puff sensor, the power source, the aerosol generator, and the cartridge or the reservoir are substantially axially aligned in the following order: puff sensor - power source - aerosol generator - cartridge or reservoir.

14. The subsystem according to claim 12 or 13, comprising a liquid freely stored in the cartridge or the reservoir.

15. The subsystem according to any one of the preceding claims, comprising: a. A mounting bracket for the power source; b. An end cap including the puff sensor and the air inlet; and c. A housing configured to receive the end cap, the mounting bracket, and the power source.

16. The subsystem according to claim 15, wherein, The housing provides a space for receiving the wiring between the end cap and the power source.

17. An aerosol delivery system comprising the subsystem according to any one of the preceding claims.

18. The aerosol delivery system according to claim 17, comprising a mounting bracket for the power source, the bracket providing an air flow path around the power source.

19. The aerosol delivery system according to claim 17 or 18, comprising a mouthpiece, wherein, The puff sensor is located substantially at a proximal end of the aerosol delivery system, remote from the mouthpiece located at an opposite distal end of the aerosol delivery system.

20. A method of assembling an aerosol delivery subsystem, the subsystem comprising: a. A puff sensor configured to detect an airflow through an air inlet in use; b. An elongate power source extending remote from the puff sensor in use and having an electrode at a distal end remote from the puff sensor; c. A mounting bracket for the power source presenting an electrode for connection at an end of the bracket; and d. A wiring for connecting the puff sensor to the electrode, the wiring passing along a length of the body of the power source in use and having an excess length to assist assembly, the method comprising: · Mounting the power source in the bracket; · Wiring the puff sensor to the electrode; · Mounting the puff sensor in an end cap including the air inlet; · Positioning the bracket and the power source in a housing; and ● Securing the end cap to the housing to form a proximal end of the system, the housing providing a space between the end cap and the power source to accommodate the excess length of the wiring.

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