Aerosol delivery subsystems and methods

Abstract

An aerosol delivery subsystem, comprising: a housing comprising a cavity for receiving aerosol-generating material; and a pressure mechanism configured to, in use, displace the aerosol-generating material in the cavity to aid release of the aerosol-generating material through an outlet in the housing.

Description

[0001] AEROSOL DELIVERY SUBSYSTEMS AND METHODS

[0002] Field

[0003] The present disclosure relates to aerosol delivery systems and subsystems such as, but not exclusively, nicotine delivery systems (e.g. e-cigarettes).

[0004] Background

[0005] Aerosol delivery systems such as electronic cigarettes (e-cigarettes) generally contain an aerosol generating material, such as a chamber of a source solid or liquid, which may contain an active substance and / or a flavour, from which an aerosol or vapour is generated for inhalation by a user, for example through heat vaporisation. Thus, an aerosol delivery system will typically comprise an aerosol generation area containing an aerosol generator, e.g. a heating element, arranged to vaporise or aerosolise a portion of precursor material to generate a vapour or aerosol in the aerosol generation area. As a user inhales on the device and electrical power is supplied to the vaporiser, air is drawn into the device through an inlet hole and along an inlet air channel connecting to the aerosol generation area, where the air mixes with vaporised precursor material to form a condensation aerosol. There is an outlet channel connecting the aerosol generation area to an outlet in the mouthpiece and the air drawn into the aerosol generation area as a user inhales on the mouthpiece continues along the outlet flow path to the mouthpiece outlet, carrying the aerosol with it, for inhalation by the user. Some electronic cigarettes may also include a flavour element in the air flow path through the device to impart additional flavours. Such devices may sometimes be referred to as hybrid devices, and the flavour element may, for example, include a portion of tobacco arranged in the air flow path between the aerosol generation area and the mouthpiece such that aerosol I condensation aerosol drawn through the device passes through the portion of tobacco before exiting the mouthpiece for user inhalation.

[0006] User experiences with electronic aerosol delivery systems are continually improving as such systems become more refined in respect of the nature of the vapour they provide for user inhalation, for example in terms of deep lung delivery, mouth feel and consistency in performance. Nonetheless, approaches for improving further still on these aspects remain of interest. In particular, it is of interest to develop improvements which increase efficiency and reduce waste. Various approaches are described herein which seek to help address or mitigate at least some of the issues discussed above.

[0007] Terminology

[0008] Delivery System As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user in use, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosolgenerating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolgenerating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0009] Combustible Aerosol Provision System

[0010] According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

[0011] In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar. In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

[0012] Non-Combustible Aerosol Provision System

[0013] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

[0014] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosolgenerating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0015] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product.

[0016] Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

[0017] In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0018] In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent. In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0019] Aerosol-Free Delivery System

[0020] In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine. In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0021] Active Substance

[0022] In some embodiments, the substance to be delivered comprises an active substance. The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

[0023] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0024] As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.

[0025] Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens. In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0026] Flavours

[0027] In some embodiments, the substance to be delivered comprises a flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0028] In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis. In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

[0029] Aerosol-generating material

[0030] Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and / or flavourants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

[0031] The aerosol-generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0032] Aerosol-former material

[0033] The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0034] Functional material

[0035] The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0036] Substrate The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

[0037] Consumable

[0038] A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

[0039] Susceptor

[0040] A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

[0041] Aerosol-modifying agent

[0042] An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosolmodifying agent. The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material. Aerosol generator

[0043] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosolgenerating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0044] The present disclosure relates to aerosol delivery systems (which may also be referred to as vapour delivery systems) such as nebulisers or e-cigarettes. Throughout the following description the term “e- cigarette” or “electronic cigarette” may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol delivery system I device and electronic aerosol delivery system I device. Furthermore, and as is common in the technical field, the terms "aerosol" and "vapour", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably.

[0045] Aerosol delivery systems (e-cigarettes) often, though not always, comprise a modular assembly comprising a reusable device part and a replaceable (disposable / consumable) cartridge part. Often, the replaceable cartridge part will comprise the aerosol generating material and the vaporiser (which may collectively be called a ‘cartomizer’) and the reusable device part will comprise the power supply (e.g. rechargeable power source) and control circuitry. It will be appreciated these different parts may comprise further elements depending on functionality. For example, the reusable device part will often comprise a user interface for receiving user input and displaying operating status characteristics, and the replaceable cartridge device part in some cases comprises a temperature sensor for helping to control temperature. Cartridges are electrically and mechanically coupled to the control unit for use, for example using a screw thread, bayonet, or magnetic coupling with appropriately arranged electrical contacts. When the aerosol generating material in a cartridge is exhausted, or the user wishes to switch to a different cartridge having a different aerosol generating material, the cartridge may be removed from the reusable part and a replacement cartridge attached in its place. Systems and devices conforming to this type of two-part modular configuration may generally be referred to as two-part systems / devices.

[0046] It is common for electronic cigarettes to have a generally elongate shape. For the sake of providing a concrete example, certain embodiments of the disclosure will be taken to comprise this kind of generally elongate two-part system employing disposable cartridges. However, it will be appreciated that the underlying principles described herein may equally be adopted for different configurations, for example single-part systems or modular systems comprising more than two parts, refillable devices and single-use disposables, as well as other overall shapes, for example based on so-called box-mod high performance devices that typically have a boxier shape. More generally, it will be appreciated certain embodiments of the disclosure are based on aerosol delivery systems which are operationally configured to provide functionality in accordance with the principles described herein and the constructional aspects of systems configured to provide the functionality in accordance with certain embodiments of the disclosure is not of primary significance.

[0047] Brief summary of the invention

[0048] The present invention provides an aerosol delivery subsystem and a method as claimed. The present invention further provides additional embodiments as claimed in the dependent claims.

[0049] The claimed invention generally provides a sub-assembly or sub-system suitable for use in an aerosol delivery system, or configured for use in an aerosol delivery system. The sub-system may generally form part of an aerosol delivery system and in particular may form part of the reusable device and / or the consumable cartridge.

[0050] In particular, the claimed invention aids release of aerosol-generating material, increasing efficiency and reducing waste.

[0051] Brief description of the figures

[0052] Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0053] Figure 1 is a schematic cross-section view of an aerosol delivery system in accordance with some embodiments of the disclosure;

[0054] Figures 2a and 2b are schematic cross-section views of aerosol delivery subsystems in accordance with some embodiments of the disclosure;

[0055] Figure 2c is a schematic perspective view of the aerosol delivery subsystems of figures 2a and 2b;

[0056] Figure 2d illustrates example configurations of mixed retention materials within aerosol delivery subsystems in accordance with some embodiments of the disclosure;

[0057] Figures 3a and 3b are schematic cross-section views of aerosol delivery subsystems in accordance with some embodiments of the disclosure;

[0058] Figure 3c is a schematic perspective view of the aerosol delivery subsystems of figures 3a and 3b; and Figures 4a, 4b; 5a, 5b; and 6a, 6b are schematic cross-section views of further aerosol delivery subsystems in accordance with some embodiments of the disclosure.

[0059] Detailed description of the disclosure

[0060] 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 these are not described in detail in the interest of brevity. It will thus be appreciated that aspects and features of apparatuses and methods discussed herein which are not described in detail may be implemented in accordance with any suitable conventional techniques.

[0061] Figure 1 is a cross-sectional view through an example aerosol delivery system 1 , providing an introduction to two-part aerosol delivery systems, the components therein and their functionality.

[0062] The aerosol delivery system 1 comprises two main parts, namely a reusable part 2 and a replaceable I disposable consumable cartridge part 4. In normal use, the reusable part 2 and the cartridge part 4 are releasably coupled together at an interface 6. When the cartridge part 4 is exhausted or the user simply wishes to switch to a different cartridge part 4, the cartridge part 4 may be removed from the reusable part 2 and a replacement cartridge part 4 attached to the reusable part 2 in its place. The interface 6 provides a structural, electrical and airflow path connection between the two parts 2, 4 and may be established in accordance with conventional techniques, for example based around a screw thread, magnetic or bayonet fixing with appropriately arranged electrical contacts and openings for establishing the electrical connection and airflow path between the two parts 2, 4 as appropriate. The specific manner by which the cartridge part 4 mechanically mounts to the reusable part 2 is not significant to the principles described herein, but for the sake of a concrete example is assumed here to comprise a magnetic coupling (not represented in figure 1). It will also be appreciated the interface 6 in some implementations may not support an electrical and I or airflow path connection between the respective parts 2, 4. For example, in some implementations an aerosol generator may be provided in the reusable part 2 rather than in the cartridge part 4, or the transfer of electrical power from the reusable part 2 to the cartridge part 4 may be wireless (e.g. based on electromagnetic induction), so that an electrical connection between the reusable part 2 and the cartridge part 4 is not needed. Furthermore, in some implementations the airflow through the electronic cigarette might not go through the reusable part 2, so that an airflow path connection between the reusable part 2 and the cartridge part 4 is not needed. In some instances, a portion of the airflow path may be defined at the interface between portions of the reusable part 2 and cartridge part 4 when these are coupled together for use.

[0063] The cartridge I consumable part 4 may in accordance with certain embodiments of the disclosure be broadly conventional. In figure 1 , the cartridge part 4 comprises a cartridge housing 42 formed of a plastics material. The cartridge housing 42 supports other components of the cartridge part 4 and provides the mechanical interface 6 with the reusable part 2. The cartridge housing 42 is generally circularly symmetric about a longitudinal axis along which the cartridge part 4 couples to the reusable part 2. In this example, the cartridge part 4 has a length of around 4 cm and a diameter of around 1 .5 cm. However, it will be appreciated the specific geometry, and more generally the overall shapes and materials used, may be different in different implementations.

[0064] Within the cartridge housing 42 is a chamber or reservoir 44 that contains aerosol-generating material. In the example shown schematically in figure 1 , the reservoir 44 stores a supply of liquid aerosol generating material 43. 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 part 4. The reservoir 44 is closed at each end with end walls to contain the aerosol generating material 43. The reservoir 44 may be formed in accordance with conventional techniques, for example it may comprise a plastics material and be integrally moulded with the cartridge housing 42. The chamber or reservoir 44 may comprise a retention material 45 (liquid storage medium) for retaining aerosol generating material 43. The retention material 45 may comprise a fibrous material comprising cotton, polyethylene and / or polyester. The retention material 45 can beneficially retain the aerosol generating material 43 more effectively, providing ‘liquid lock’ to reduce leaks, but reduces the overall volume available for storing liquid and reduces liquid conductivity (rate of fluid transport through the material). Mixtures of retention materials 45 having different properties (e.g. porosity) can be used to balance liquid lock and liquid conductivity.

[0065] Embodiments of the disclosure comprise an extraction mechanism 110 configured to aid release of the aerosol-generating material to the aerosol generator 48. The extraction mechanism 110 will be described further later, with reference to the subsequent figures.

[0066] The cartridge I consumable part 4 of figure 1 further comprises an aerosol generator 48 located towards an end of the reservoir 44 opposite to a mouthpiece outlet 50. It will be appreciated that in a two-part system such as shown in figure 1 , the aerosol generator 48 may be in either of the reusable part 2 or the cartridge part 4. For example, in some embodiments, the aerosol generator 48 (e.g. a heater, which may be in the form of a wick and coil arrangement as shown, a distiller, which may be formed from a sintered metal fibre material or other porous conducting material, or any suitable alternative aerosol generator) may be comprised in the reusable part 2, and is brought into proximity with a portion of aerosol generating material in the cartridge part 4 when the cartridge part 4 is engaged with the reusable part 2. In such embodiments, the cartridge part 4 may comprise a portion of aerosol generating material, and an aerosol generator 48 comprising a heater is at least partially inserted into or at least partially surrounds the portion of aerosol generating material as the cartridge part 4 is engaged with the reusable part 2. In the example of figure 1 , a wick 46 in contact with the aerosol generator 48 extends transversely across the cartridge airflow path 52 with its ends extending into the reservoir 44 of the liquid aerosol generating material through openings in the inner wall of the reservoir 44. The openings in the inner wall of the reservoir 44 are sized to broadly match the dimensions of the wick 46 to provide a reasonable seal against leakage from the liquid reservoir 44 into the cartridge airflow path without unduly compressing the wick 46, which may be detrimental to its fluid transfer performance.

[0067] The wick 46 and aerosol generator 48 are arranged in the cartridge airflow path 52 such that a region of the cartridge airflow path 52 around the wick 46 and heater 48 in effect defines a vaporisation region for the cartridge part 4. Aerosol generating material in the reservoir 44 infiltrates the wick 46 through the ends of the wick extending into the reservoir 44 and is drawn along the wick by surface tension I capillary action (i.e. wicking). The aerosol generator 48 in this example comprises an electrically resistive wire coiled around the wick 46. In the example of figure 1 , the heater 48 comprises a nickel chrome alloy (Cr20Ni80) wire and the wick 46 comprises a glass fibre bundle, but it will be appreciated the specific aerosol generator configuration is not significant to the principles described herein. In use, electrical power may be supplied to the aerosol generator 48 to vaporise an amount of aerosol generating material (aerosol generating material) drawn to the vicinity of the aerosol generator 48 by the wick 46. Vaporised aerosol generating material may then become entrained in air drawn along the cartridge airflow path from the vaporisation region towards the mouthpiece outlet 50 for user inhalation.

[0068] As noted above, the rate at which aerosol generating material is vaporised by the aerosol generator 48 will depend on the amount (level) of power supplied to the aerosol generator 48. Thus electrical power can be applied to the aerosol generator 48 to selectively generate aerosol from the aerosol generating material in the cartridge part 4, and furthermore, the rate of aerosol generation can be changed by changing the amount of power supplied to the aerosol generator 48, for example through pulse width and / or frequency modulation techniques.

[0069] The reusable part 2 comprises an outer housing 12 having with an opening that defines an air inlet 28 for the e-cigarette, a power source 26 (for example a battery) for providing operating power for the electronic cigarette, control circuitry I 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.

[0070] The outer housing 12 may be formed, for example, from a plastics or metallic material and in this example has a circular cross section generally conforming to the shape and size of the cartridge part 4 so as to provide a smooth transition between the two parts 2, 4 at the interface 6. In this example, the reusable part 2 has a length of around 8 cm so the overall length of the e-cigarette when the cartridge part 4 and the reusable part 2 are coupled together is around 12 cm. However, and as already noted, it will be appreciated that the overall shape and scale of an electronic cigarette implementing an embodiment of the disclosure is not significant to the principles described herein.

[0071] The air inlet 28 connects to an airflow path 51 through the reusable part 2. The reusable part airflow path 51 in turn connects to the cartridge airflow path 52 across the interface 6 when the reusable part 2 and cartridge part 4 are connected together. Thus, when a user inhales on the mouthpiece opening 50, air is drawn in through the air inlet 28, along the reusable part airflow path 51 , across the interface 6, through the aerosol generation area in the vicinity of the aerosol generator 48 (where vaporised aerosol generating material becomes entrained in the air flow), along the cartridge airflow path 52, and out through the mouthpiece opening 50 for user inhalation.

[0072] The power source 26 in this example is rechargeable and may be of a conventional type, for example of the kind normally used in electronic cigarettes and other applications requiring provision of relatively high currents over relatively short periods. The power source 26 may be recharged through a charging connector in the reusable part housing 12, for example a USB connector.

[0073] First and / or second user input buttons 14, 16 may be provided, which in this example are conventional mechanical buttons, for example comprising a spring mounted component which may be pressed by a user to establish an electrical contact. In this regard, the input buttons may be considered input devices for detecting user input and the specific manner in which the buttons are implemented is not significant. The buttons may be assigned to functions such as switching the aerosol delivery system 1 on and off, and adjusting user settings such as a power to be supplied from the power source 26 to the aerosol generator 48. However, the inclusion of user input buttons is optional, and in some embodiments buttons may not be included.

[0074] A display 24 may be provided to give a user with a visual indication of various characteristics associated with the aerosol delivery system, for example current power setting information, remaining power source power, and so forth. The display may be implemented in various ways. In this example the display 24 comprises a conventional pixilated LCD screen that may be driven to display the desired information in accordance with conventional techniques. In other implementations, the display may comprise one or more discrete indicators, for example LEDs, that are arranged to display the desired information, for example through particular colours and I or flash sequences. More generally, the manner in which the display 24 is provided and information is displayed to a user using the display is not significant to the principles described herein. For example, some embodiments may not include a visual display and / or may include other means for providing a user with information relating to operating characteristics of the aerosol delivery system, for example using audio signalling, or may not include any means for providing a user with information relating to operating characteristics of the aerosol delivery system. A controller 22 is suitably configured / programmed to control the operation of the aerosol delivery system 1 to provide functionality in accordance with embodiments of the disclosure as described further herein, as well as for providing conventional operating functions of the aerosol delivery system 1 in line with the established techniques for controlling such devices. The controller (processor circuitry) 22 may be considered to logically comprise various sub-units I circuitry elements associated with different aspects of the operation of the aerosol delivery system 1 . In this example the controller 22 comprises power supply control circuitry for controlling the supply of power from the power source 26 to the aerosol generator 48 in response to user input, user programming circuitry 20 for establishing configuration settings (e.g. user-defined power settings) in response to user input, as well as other functional units I circuitry associated functionality in accordance with the principles described herein and conventional operating aspects of electronic cigarettes, such as display driving circuitry and user input detection circuitry. It will be appreciated that the functionality of the controller 22 can be provided in various different ways, for example using one or more suitably programmed programmable computer(s) and I or one or more suitably configured application-specific integrated circuit(s) I circuitry I chip(s) I chipset(s) configured to provide the desired functionality.

[0075] The functionality of the controller 22 is described further herein. For example, the controller 22 may comprise an application specific integrated circuit (ASIC) or microcontroller, for controlling the aerosol delivery device. The microcontroller or ASIC may include a CPU or micro-processor. The operations of a CPU and other electronic components are generally controlled at least in part by software programs running on the CPU (or other component). Such software programs may be stored in nonvolatile memory, such as ROM, which can be integrated into the microcontroller itself, or provided as a separate component. The CPU may access the ROM to load and execute individual software programs as and when required.

[0076] The reusable part 2 comprises an airflow sensor 30 which is electrically connected to the controller 22. In most embodiments, the airflow sensor 30 comprises a so-called “puff sensor”, in that the airflow sensor 30 is used to detect when a user is puffing on the device. In some embodiments, the airflow sensor 30 comprises a switch in an electrical path providing electrical power from the power source 26 to the aerosol generator 48. In such embodiments, the airflow sensor 30 generally comprises a pressure sensor configured to close the switch when subjected to a particular range of pressures, enabling current to flow from the power source 26 to the aerosol generator 48 once the pressure in the vicinity of the airflow sensor 30 drops below a threshold value. The threshold value can be set to a value determined by experimentation to correspond to a characteristic value associated with the initiation of a user puff. In other embodiments, the airflow sensor 30 is connected to the controller 22, and the controller distributes electrical power from the power source 26 to the aerosol generator 48 in dependence of a signal received from the airflow sensor 30 by the controller 22. The specific manner in which the signal output from the airflow sensor 30 (which may comprise a measure of capacitance, resistance or other characteristic of the airflow sensor, made by the controller 22) is used by the controller 22 to control the supply of power from the power source 26 to the aerosol generator 48 can be carried out in accordance with any approach known to the skilled person.

[0077] In the example shown in figure 1 , the airflow sensor 30 is mounted to a printed circuit board (PCB) 31 , but this is not essential. The airflow sensor 30 may comprise any sensor which is configured to determine a characteristic of airflow in an airflow path 51 disposed between air inlet 28 and mouthpiece opening 50, for example a pressure sensor or transducer (for example a membrane or solid-state pressure sensor), a combined temperature and pressure sensor, or a microphone (for example an electret-type microphone), which is sensitive to changes in air pressure, including acoustical signals. The airflow sensor 30 is situated within a sensor cavity or chamber 32, which comprises the interior space defined by one or more chamber walls 34. The sensor cavity 32 comprises a region internal to one or more chamber walls 34 in which an airflow sensor 30 can be fully or partially situated. In some embodiments, the PCB 31 comprises one of the chamber walls of a sensor housing comprising the sensor chamber I cavity 32.

[0078] A deformable membrane is disposed across an opening communicating between the sensor cavity 32 containing the sensor 30, and a portion of the airflow path disposed between air inlet 28 and mouthpiece opening 50. The deformable membrane covers the opening, and is attached to one or more of the chamber walls according to approaches described further herein.

[0079] As described further herein, the aerosol delivery system 1 comprises communication circuitry configured to enable a connection to be established with one or more further electronic devices (for example, a storage I charging case, and / or a refill I charging dock) to enable data transfer between the aerosol delivery system 1 and further electronic device(s). In some embodiments, the communication circuitry is integrated into controller 22, and in other embodiments it is implemented separately (comprising, for example, separate application-specific integrated circuit(s) I circuitry I chip(s) I chipset(s)). For example, the communication circuitry may comprise a separate module to the controller 22 which, while connected to controller 22, provides dedicated data transfer functionality for the aerosol delivery device. In some embodiments, the communication circuitry is configured to support communication between the aerosol delivery system 1 and one or more further electronic devices over a wireless interface. The communication circuitry may be configured to support wireless communications between the aerosol delivery system 1 and other electronic devices such as a case, a dock, a computing device such as a smartphone or PC, a base station supporting cellular communications, a relay node providing an onward connection to a base station, a wearable device, or any other portable or fixed device which supports wireless communications.

[0080] Wireless communications between the aerosol delivery system 1 and a further electronic device may be configured according to data transfer protocols such as Bluetooth®, ZigBee, WiFi®, Wifi Direct, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or generally any other wireless, and / or wired, network protocol or interface. The communication circuitry may comprise any suitable interface for wired data connection, such as USB-C, micro-USB or Thunderbolt interfaces, and may comprise pin or contact pad arrangements configured to engage cooperating pins or contact pads on a dock, case, cable, or other external device which can be connected to the aerosol delivery system 1 .

[0081] The controller 22 and various sub-assemblies may comprise one or more processors and data processing steps may be performed on any of these processors or on a remote processor, the data communicated by wire or wirelessly.

[0082] As outlined above, embodiments of the disclosure comprise a system 1 or subsystem 100 comprising an extraction mechanism 110 configured to aid release of the aerosol-generating material through an outlet, to minimise the residue that cannot normally be released and so is wasted. The subsystem 100 may generally comprise a (preferably replaceable / refillable) cartridge housing the aerosolgenerating material 43 and an internal extraction mechanism (within the cartridge), or the extraction mechanism 110 may be external to the cartridge, e.g. part of the device 2 or wider system 1 .

[0083] The extraction mechanism 110 may be controlled by the controller 22 and may be configured to activate in response to detecting any puff commencing (e.g. as detected by the puff sensor) or only activated selectively, for example:

[0084] • when the controller 22 estimates or detects that the aerosol-generating material 43 is becoming depleted; and / or

[0085] • when the controller 22 estimates or detects that the aerosol-generating material 43 is colder than normal (where colder temperatures may notably increase viscosity of the aerosolgenerating material 43 and hence increase residue in the cavity and / or retention material 45); and / or

[0086] • when the controller 22 detects that the user is taking a longer puff than usual (and hence supply of aerosol-generating material 43 to the aerosol generator may be limiting aerosol production); and / or

[0087] • when activated by the user, e.g. via an input such as via button 14, 16 or another Ul.

[0088] In particular, the controller 22 may activate the extraction mechanism 110 when the estimated / detected remaining quantity of aerosol-generating material 43 reaches or falls below a threshold such as 25%, 20%, 15%, 10% or 5% and / or when the ambient temperature reaches or falls below 10°C, 5°C, 0°C, -5°C or -10°C.

[0089] Depletion estimation by the controller 22 may be based on, for example:

[0090] • the number of puffs taken - e.g. if 2 ml of aerosol-generating material provides 200 ‘standard’ puffs, then the controller 22 can estimate the % of aerosol-generating material remaining based on the number of puffs taken as a fraction of the total puff capacity of the cartridge since installation; and / or • total puff duration of all puffs taken with the cartridge - e.g. compared to full puff duration capacity (e.g. compared to 200 puffs of 1s); and / or

[0091] • power consumption or charge status of the power source 26 - e.g. if a full charge of the power source 26 provides enough power for 40 standard puffs and the power source has been fully recharged three times since the cartridge was installed with a full charge (thus the power source 26 has been fully drained 3x for puffing) and currently has 50% charge left, then it can be assumed that approximately 3.5 x 40 standard puffs have been made and this can be compared to the full standard puff capacity of the cartridge.

[0092] Depletion detection by the controller 22 may be based on, for example:

[0093] • measuring the volume of aerosol-generating material remaining, e.g. using a camera to view the quantity remaining; and / or

[0094] • detecting the aerosol generator 48 reaching a higher operating temperature than normal (indicating dry-out, i.e. insufficient supply of aerosol-generating material 43); and / or

[0095] • detecting the user shaking the cartridge / system (e.g. using accelerometer data); and / or

[0096] • detecting the user taking longer puffs (which may because they are not receiving enough active ingredient).

[0097] Other techniques for estimating or detecting the quantity of aerosol-generating material remaining may be known in the art and applicable here.

[0098] In some embodiments, the controller 22 may vary a level / degree of activation of the extraction mechanism 110 in response to one or more operational or environmental parameters, such as the status of the system 1 . For example, the controller 22 may be configured to activate the extraction mechanism 110 to different power levels and / or in different regions of the cavity, e.g. depending on the amount of aerosol-generating material remaining or depending on ambient temperature. In some embodiments, the power supplied to the extraction mechanism 110 increases as the amount of aerosol-generating material remaining decreases and / or as the ambient temperature decreases. Multiple thresholds may be used for such operational parameters to provide granular control, and / or any control mechanism such as proportional, inverse proportional, PWM methods may be used.

[0099] Two core types of extraction mechanisms are detailed herein: pressure and heat mechanisms. The features outlined for one mechanism may generally be applied to the other. However, one appreciable difference is that once activated, pressure mechanisms may remain ‘active’ even after puffing stops (e.g. once the pressure is increased by the pressure extraction mechanism 110, it remains at that level until the next puff, since this can be a steady state of the pressure extraction mechanism 110, not requiring further input energy to maintain), whereas heat extraction mechanisms will ordinarily be disabled when puffing stops, to minimise power consumption. Pressure extraction mechanism

[0100] Figures 2a - 2c illustrate first pressure extraction embodiments of the disclosure. The aerosol delivery subsystems 100 of figures 2a - 2c comprise an elongate cylindrical housing 42 defining a cylindrical cavity for receiving aerosol-generating material 43 and having an outlet 47 for releasing the aerosol-generating material 43, e.g. to an aerosol generator. The outlet 47 may comprise a wick 46 configured to deliver the aerosol-generating material 43 to the aerosol generator 48.

[0101] The cavity typically has a volume in the range of 1-5 ml, such as 1 .5-4 ml or 2-3 ml, typically providing capacity for approx. 100 puffs per 1 ml. In figure 2a, the cavity is substantially filled with an optional retention material 45 for retaining liquid aerosol-generating material 43. In figure 2b, the cavity comprises a smaller volume of retention material 45 that is located at and proximal to the outlet 47, which only occupies a partial volumetric region (approximately 33%) of the cavity. The remaining volume of the cavity houses aerosol-generating material 43 freely (i.e. not in retention material 45). The term ‘volumetric region’ defines the volume of the region containing retention material, effectively the volume of the retention material as if it were solid. This is not the same as the absolute material ‘volume’, since the retention material is porous and comprises interstices / voids, thus the absolute retention material ‘volume’ is the non-porous / non-void fraction of the ‘volumetric region’.

[0102] Preferably, the retention materials) (collectively) occupy < 25%, < 20%, < 15%, < 10% or < 5% of the volumetric region of the cavity, which beneficially minimises leaks at the outlet 47 (increasing liquid lock locally at the outlet 47) without overly compromising the overall volume of the cavity for storing aerosol-generating material 43. Accordingly, this can minimise the dimensions of the overall system without compromising longevity (puff count) or risking leaks.

[0103] The subsystem 100 further comprises an extraction mechanism 110, which in figures 2a - 2c is in the form of a pressure mechanism comprising a piston 115 and an actuator 120 such as a motor, configured to displace the aerosol-generating material 43 in the cavity and / or the retention material 45, to aid release of the aerosol-generating material 43 through the outlet 47.

[0104] The pressure mechanism 110 is configured to apply pressure to the aerosol-generating material 43 to aid its release from the housing 42. The pressure applied may be applied directly or indirectly, e.g. applied to the cavity, to the aerosol-generating material 43 and / or to the retention material 45, preferably compressing the retention material 45 (where used) to release the (residual) aerosolgenerating material 43 stored therein.

[0105] In one simple embodiment (not shown), the extraction mechanism 110 comprises a solenoid configured to depress the retention material 45 when activated. Optimally, the compression direction is at least generally towards the outlet 47. The pressure differential acting on the aerosol-generating material may, for example, be > 25 kPa, > 50 kPa, > 100 kPa, > 200 kPa or > 250 kPa.

[0106] The aerosol-generating material 43 may be pre-filled in the cavity of the housing 42 or received via an optional inlet in the housing 42 (not shown), and thus the cavity may be refillable with aerosolgenerating material 43.

[0107] The subsystems 100 of figures 2a - 2c are cylindrical, but may generally be of any shape. The cavity and / or retention material 45 therein may be shaped (e.g. tapered) to direct the aerosol-generating material towards the outlet 47 in use. Similarly, the extraction mechanism 110 may be shaped to substantially match a shape of the cavity and / or retention material 45. For example, the housing 42 defining the cavity may taper towards the outlet 47 and the piston 115 may be tapered with the same profile.

[0108] Preferably, the outlet 47 is located at the lowest point of the housing 42 when in use (e.g. in an aerosol generating system), so that the aerosol-generating material 43 naturally flows (at least to some extent) to the outlet 47 under the influence of gravity in use. If the outlet 47 is located substantially at a distal end of the cavity, then the pressure mechanism 110 is preferably located substantially at the proximal end of the cavity, away from (preferably substantially opposite) the outlet 47, to be most effective.

[0109] In a further variant (not shown), the pressure mechanism may be configured to apply pressure in two or more perpendicular axes and / or be shaped to surround the retention material 45. For example, the pressure mechanism may comprise two perpendicular pistons 115 configured to compress the retention material 45 independently or co-operatively in two perpendicular directions towards the outlet 47, e.g. located in a side or corner of the housing.

[0110] As outlined above, mixtures of multiple retention materials 45 having different properties (e.g. porosity) can be used to balance liquid lock and liquid conductivity. Figure 2d illustrates some example configurations of mixed retention materials 45, including (top to bottom):

[0111] • adjacent sections

[0112] • multiple alternating or layered sections (which may be of substantially similar or varying area / volume and in any orientation); and

[0113] • inner and outer, optionally concentric sections.

[0114] Figures 3a, 3b and 3c illustrate a particular variant of the embodiment of figures 2a - 2c, where the extraction mechanism 110 comprises a threaded piston 115 driven by an electric motor 120. The threaded piston arrangement provides a variable pressure mechanism that can be controlled accurately, e.g. with a stepper motor 120, providing fine control of the pressure. Figures 3a and 3b mirror the retention material arrangements of figures 2a and 2b outlined above. As shown in figure 3a, the housing 42 comprises complementary threading for the threaded piston 115 to travel axially to compress the retention material 45. In the embodiment of figure 3b, the piston 115 compresses the fluid (air and / or aerosol-generating material 43) within the cavity, and the piston 115 may in other embodiments compress the retention material 45 as it extends further into the cavity.

[0115] The other features of figures 3a, 3b and 3c are as per figures 2a, 2b, 2c discussed above.

[0116] Figures 4a and 4b illustrate an alternative embodiment, where the extraction mechanism 110 comprises a gas-powered extraction mechanism 110, comprising a flexible membrane 118 driven by an electric pump 120. Figures 4a and 4b mirror the retention material arrangements of figures 2a and 2b outlined above.

[0117] The flexible membrane 118 is located in the cavity and operable to increase pressure on the aerosolgenerating material 43 to aid its release from the housing 42. In these embodiments, the pump 120 is configured to pump fluid (e.g. air orwater) to increase pressure on the membrane 118, which may operate as a one-way valve and permit the pumped fluid therethrough, increasing pressure on the aerosol-generating material 43 contained in the retention material 45 and / or freely in the cavity. Alternatively, the membrane 118 may deform to directly exert pressure on the aerosol-generating material 43 contained in the retention material 45 and / or freely in the cavity.

[0118] The flexible membrane 118 may be shaped to direct the aerosol-generating material 43 to the outlet 47. A relief valve (not shown) may be provided to release pressure in the event of over-pressure or simply to return the pressure to ambient.

[0119] In a further variant (not shown), the membrane 118 is omitted and the cavity is pressurised directly to displace the aerosol-generating material 43. The pressure may be increased by a pump 120 as in figures 4a - 4b, by releasing a compressed fluid (such as air) from a chamber, or releasing a weight, which is preferably shaped (e.g. tapered) to direct the aerosol-generating material 43 to the outlet 47. Such pressure mechanisms might be single use.

[0120] Heat extraction mechanism

[0121] Heat-based extraction mechanisms are now described with reference to figures 5a, 5b; and 6a, 6b, illustrating internal, integral and external heating arrangements. Key differences to the pressurebased extraction mechanisms above are outlined here - unless stated otherwise, features of pressure-based mechanisms may apply to heat-based mechanisms and vice-versa.

[0122] The heat-based extraction mechanisms depicted herein comprise a heater configured to heat the aerosol-generating material to aid its release through an outlet 47 in the housing 42, for delivery to an aerosol generator, e.g. via a wick 46. The heater is distinct to the aerosol generator and the heater may form part of a (preferably replaceable) cartridge not comprising an aerosol generator 48, for use in an aerosol delivery system 1 comprising a separate aerosol generator 48.

[0123] Heat-based extraction mechanisms are particularly beneficial when used with a retention material 45 and a liquid aerosol-generating material 43, because they lower a viscosity of the aerosol-generating material 43 to aid its release through the outlet 47. Heating the aerosol-generating material 43 may also improve flavour and reduce subsequent heating required by the aerosol generator 48, reducing time-to-aerosol and providing more consistent aerosol generation.

[0124] Figures 5a and 5b illustrate embodiments in accordance with the disclosure. The aerosol delivery subsystems 100 of figures 5a and 5b comprise a cylindrical elongate housing 42 defining a cylindrical cavity for receiving aerosol-generating material 43 and having a central outlet 47 at a distal end for releasing the aerosol-generating material 43, e.g. to an aerosol generator.

[0125] In figure 5a, the cavity is substantially filled with an optional retention material 45 for retaining liquid aerosol-generating material 43. In figure 5b, the cavity comprises a smaller volume of cylindrical retention material 45 that is located at and proximal to the distal end outlet 47, in a corner of the housing 42. The retention material 45 only occupies a partial volumetric region (approximately 60%) of the cavity. The remaining volume of the cavity houses aerosol-generating material 43 freely.

[0126] In both figures 5a and 5b, the heater 110 comprises a cylindrical coil heater element 125 having terminals extending out of the housing 42 at a proximal end, for connection to a power supply. The element 125 is internal, within the cavity of the housing 42, and integrated within the retention material 45, extending substantially around the internal perimeter of the cavity. This arrangement thus locates the element 125 within the retention element 45 and close to the internal cavity walls, which also retain aerosol-generating material 43 residue, which is releasable by heating. The heater element 125 may be shaped to at least partially surround the retention material 45, or be (at least partially) integrated therein, as shown. In other embodiments, the element 125 may be of any suitable shape, e.g. substantially the same shape as the cavity or retention material 45, shaped to substantially surround the retention material 45, or simply protrude into the cavity and / or the retention material 45.

[0127] The heater element 125 may be configured to apply heat in a single axis (e.g. using an elongate wire extending substantially only in one axis) or multiple perpendicular axes (e.g. using a wire extending in multiple axes, or a 2D element).

[0128] In figures 5a and 5b, the element 125 extends from the proximal end of the housing 42 substantially to an opposing distal end of the housing 42, where the outlet 47 is located, and is able to heat substantially the entire cavity. In other embodiments, the heater may be operable to heat only a portion of the cavity. Preferably, the heater is configured to heat at least aerosol-generating material located away from the outlet 47, to aid movement of aerosol-generating material 43 under gravity towards the outlet 47, e.g. by being located substantially at a proximal end of the cavity when the outlet 47 is located substantially at a distal end of the cavity 47, away from the heater 110.

[0129] The heater may provide substantially uniform heating, or may be configured to provide variable heating, e.g. varying with distance from the outlet 47. For example, the element 125 may have a varying thickness, providing a higher resistance configured for heating aerosol-generating material 43 away from the outlet 47, and a lower resistance for heating aerosol-generating material 43 closer to the outlet 47.

[0130] In embodiments comprising a mixture of free storage and one or more retention materials 45 for retaining aerosol-generating material 43, the heater element 125 may comprise different properties for heating the different materials. For example, the heater element 125 may have a varying thickness, providing a lower resistance for heating aerosol-generating material 43 that is stored freely, an intermediate resistance for heating aerosol-generating material 43 stored in a first retention material, and a higher resistance for heating aerosol-generating material 43 stored in a second retention material, e.g. accounting for different thermal conductivities (preferably providing higher resistance for regions having lower thermal conductivity).

[0131] Figures 6a and 6b illustrate further embodiments in accordance with the disclosure. Here, the heater 110 is external to the housing 42 rather than internal (within the cavity). As shown in figures 6a and 6b, the heater element 125 may be in the form of an annular jacket, surrounding at least a portion of the housing 42 and thus configured to heat aerosol-generating material 43 within the cavity. As in the previous sets of figures, in figure 6a, the cavity is substantially filled with an optional retention material 45 for retaining liquid aerosol-generating material 43. In figure 6b, the cavity comprises a smaller volume of retention material 45 that is located at the distal end outlet 47, in a corner of the housing 42, and only occupies a partial volumetric region (approximately 60%) of the cavity. The remaining volume of the cavity houses aerosol-generating material 43 freely.

[0132] In figures 6a and 6b, the annular jacket heater element 125 surrounds the majority of the entire housing 42, with the jacket in figure 6a being central, but not extending quite all the way to the top or bottom of the housing 42, whilst in figure 6b the jacket is located closer to the top of the housing and covering approximately half of the retention material 45 (the upper half), not surrounding the lower half of retention material 45, and hence only surrounding a portion (approx. 75%) of the cavity away from the outlet 47. In other embodiments, the element 125 may surround different portion(s) of the cavity.

[0133] In further embodiments (not shown), the heater element 125 may be at least partially integrated into the housing 42, e.g. within a wall of the housing 42. Any combination of internal, integrated and / or external heating elements 125 may be used. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. Any functions of a processor (e.g. controller) may be shared between processors on the various devices / systems in the wider system and / or a remote server. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention.

[0134] Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. Protection may also be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.

[0135] Index to reference numerals

[0136] 1 aerosol delivery system

[0137] 2 reusable part

[0138] 4 cartridge part

[0139] 6 interface between reusable part and cartridge part

[0140] 12 reusable part housing

[0141] 14, 16 user input buttons

[0142] 20 user programming circuitry

[0143] 22 controller

[0144] 24 display

[0145] 26 power source

[0146] 28 air inlet

[0147] 30 airflow sensor

[0148] 31 printed circuit board (PCB)

[0149] 32 sensor cavity or chamber

[0150] 34 chamber wall

[0151] 42 cartridge housing

[0152] 43 aerosol generating material

[0153] 44 chamber or reservoir

[0154] 45 retention material

[0155] 46 wick 47 outlet

[0156] 48 aerosol generator

[0157] 50 mouthpiece outlet

[0158] 51 airflow path through reusable part

[0159] 52 airflow path through cartridge

[0160] 100 aerosol delivery subsystem

[0161] 110 extraction mechanism

[0162] 115 piston

[0163] 118 flexible membrane

[0164] 120 actuator

[0165] 125 heater element

[0166] Particular features are set out below and may be combined, in any permutation, with any one or more features disclosed in the text and / or accompanying drawings.

[0167] Particular features 1

[0168] 1 . An aerosol delivery subsystem, comprising: a. a housing comprising a cavity for receiving aerosol-generating material; and b. a pressure mechanism configured to, in use, displace the aerosol-generating material in the cavity to aid release of the aerosol-generating material through an outlet in the housing.

[0169] 2. The subsystem of clause 1 , wherein the pressure mechanism is configured to, in use, apply pressure to the aerosol-generating material to aid the release of the aerosol-generating material through the outlet.

[0170] 3. The subsystem of any preceding clause, wherein the outlet is located substantially at a distal end of the cavity and the pressure mechanism is located substantially at a proximal end of the cavity, away from the outlet.

[0171] 4. The subsystem of any preceding clause, wherein: a. the cavity is shaped to direct the aerosol-generating material towards the outlet in use; and / or b. the pressure mechanism is shaped to substantially match a shape of the cavity.

[0172] 5. The subsystem of any preceding clause, comprising a retention material within the cavity, for retaining liquid aerosol-generating material.

[0173] 6. The subsystem of any preceding clause, comprising multiple retention materials within the cavity for retaining liquid aerosol-generating material, the multiple retention materials having different porosities.

[0174] 7. The subsystem of any of clauses 5-6, wherein the retention materials) occupy < 25%, < 20%, < 15%, < 10% or < 5% of a volumetric region of the cavity. The subsystem of any of clauses 5-7, wherein the retention material(s) is / are located only in a volumetric region of the cavity proximal to the outlet. The subsystem of any of clauses 5-8, wherein the pressure mechanism is configured to compress the retention material to aid the release of the retained aerosol-generating material. The subsystem of any of clauses 5-9, wherein: a. the pressure mechanism is configured to compress the retention material towards the outlet in use; and / or b. the pressure mechanism is shaped to substantially match a shape of the retention material; and / or c. the pressure mechanism is shaped to substantially surround the retention material. The subsystem of any preceding clause, wherein the pressure mechanism is configured to apply pressure in two or more perpendicular axes. The subsystem of any preceding clause, wherein the pressure mechanism comprises one or more of: a piston, pump, weight, flexible membrane and a chamber of compressed fluid. The subsystem of any preceding clause, wherein the pressure mechanism comprises a motor- driven threaded piston. The subsystem of any preceding clause, wherein the housing comprises an inlet for receiving the aerosol-generating material. A cartridge for an aerosol delivery system comprising the subsystem of any preceding clause. The subsystem or cartridge of any preceding clause, further comprising the aerosol-generating material. An aerosol delivery system comprising the subsystem or cartridge of any preceding clause. The cartridge of clause 15 or 16 or the aerosol delivery system of clause 17, wherein the cartridge is replaceable. The aerosol delivery system of clause 18, further comprising an aerosol generator, separate to the cartridge. A method of extracting aerosol-generating material from an aerosol delivery subsystem comprising: a. a housing having a cavity for receiving aerosol-generating material and having an outlet for releasing the aerosol-generating material; and b. a pressure mechanism configured to, in use, displace the aerosol-generating material in the cavity, the method comprising: i. applying pressure to the aerosol-generating material using the pressure mechanism, to aid release of the aerosol-generating material through the outlet. Particular features 2

[0175] 1 . A replaceable cartridge for use in an aerosol delivery system comprising an aerosol generator, the replaceable cartridge comprising: a. a housing comprising a cavity having a retention material for retaining liquid aerosolgenerating material; and b. a heater configured to, in use, heat the aerosol-generating material in the retention material to aid release of the aerosol-generating material through an outlet in the housing.

[0176] 2. The cartridge of clause 1 , wherein the cartridge does not comprise an aerosol generator.

[0177] 3. An aerosol delivery system comprising the replaceable cartridge of any preceding clause.

[0178] 4. The aerosol delivery system of clause 3, further comprising an aerosol generator, separate to the cartridge.

[0179] 5. An aerosol delivery system comprising: a. a housing comprising a cavity having a retention material for retaining liquid aerosolgenerating material; b. an aerosol generator; and c. a heater configured to, in use, heat the aerosol-generating material in the retention material to aid release of the aerosol-generating material through an outlet in the housing.

[0180] 6. The cartridge or system of any preceding clause, wherein the heater is configured to, in use, lower a viscosity of the aerosol-generating material to aid the release of the aerosol-generating material through the outlet.

[0181] 7. The cartridge or system of any preceding clause, wherein the heater is configured to, in use, heat aerosol-generating material located away from the outlet, to aid movement of aerosol-generating material under gravity towards the outlet.

[0182] 8. The cartridge or system of any preceding clause, wherein the housing is elongate and the outlet is located substantially at one end of the elongate housing.

[0183] 9. The cartridge or system of clause 8, wherein the heater is located substantially at an opposing end of the elongate housing.

[0184] 10. The cartridge or system of any preceding clause, wherein the heater: a. is configured to heat substantially the entire cavity; or b. is located substantially at a proximal end of the housing and wherein the outlet is located substantially at a distal end of the housing, away from the heater.

[0185] 11 . The cartridge or system of any preceding clause, wherein the heater: a. is located at least partially within the cavity; and / or b. is least partially integrated within a wall of the housing and / or c. is least partially integrated within the retention material; and / or d. surrounds at least a portion of the housing.

[0186] 12. The cartridge or system of any preceding clause, wherein: a. the cavity is shaped to direct the aerosol-generating material towards the outlet in use; and / or b. the heater is shaped to substantially match a shape of the cavity. The cartridge or system of any preceding clause, wherein the retention material comprises cotton. The cartridge or system of any preceding clause, comprising multiple retention materials within the cavity for retaining liquid aerosol-generating material, the multiple retention materials having different porosities. The cartridge or system of any preceding clause, wherein the retention material(s) occupy < 25%, < 20%, < 15%, < 10% or < 5% of a volumetric region of the cavity. The cartridge or system of any preceding clause, wherein the retention material(s) is / are located only in a volumetric region of the cavity proximal to the outlet. The cartridge or system of any preceding clause, wherein the heater is configured to heat the retention material to aid the release of the retained aerosol-generating material. The cartridge or system of any preceding clause, wherein: a. the heater is shaped to substantially match a shape of the retention material; and / or b. the heater is shaped to substantially surround the retention material; and / or c. the heater is shaped to substantially surround the retention material and at least a portion of the cavity not comprising the retention material . The cartridge or system of any preceding clause, wherein the heater is configured to apply heat in two or more perpendicular axes. The cartridge or system of any preceding clause, wherein the housing comprises an inlet for receiving the aerosol-generating material. The cartridge or system of any preceding clause, further comprising the aerosol-generating material. A method of extracting aerosol-generating material from a retention material located in a cavity of a housing, comprising: heating the aerosol-generating material to aid release of the aerosol-generating material through an outlet in the housing. The method of clause 22, further comprising: delivering the aerosol-generating material to an aerosol generator.

Claims

Claims1 . An aerosol delivery subsystem, comprising: a. a housing comprising a cavity for receiving aerosol-generating material; and b. a pressure mechanism configured to, in use, displace the aerosol-generating material in the cavity to aid release of the aerosol-generating material through an outlet in the housing.

2. The subsystem of claim 1 , wherein the pressure mechanism is configured to, in use, apply pressure to the aerosol-generating material to aid the release of the aerosol-generating material through the outlet.

3. The subsystem of any preceding claim, wherein the outlet is located substantially at a distal end of the cavity and the pressure mechanism is located substantially at a proximal end of the cavity, away from the outlet.

4. The subsystem of any preceding claim, wherein: a. the cavity is shaped to direct the aerosol-generating material towards the outlet in use; and / or b. the pressure mechanism is shaped to substantially match a shape of the cavity.

5. The subsystem of any preceding claim, comprising a retention material within the cavity, for retaining liquid aerosol-generating material.

6. The subsystem of any preceding claim, comprising multiple retention materials within the cavity for retaining liquid aerosol-generating material, the multiple retention materials having different porosities.

7. The subsystem of any of claims 5-6, wherein the retention material(s) occupy < 25%, < 20%, < 15%, < 10% or < 5% of a volumetric region of the cavity.

8. The subsystem of any of claims 5-7, wherein the retention material(s) is / are located only in a volumetric region of the cavity proximal to the outlet.

9. The subsystem of any of claims 5-8, wherein the pressure mechanism is configured to compress the retention material to aid the release of the retained aerosol-generating material.

10. The subsystem of any of claims 5-9, wherein: a. the pressure mechanism is configured to compress the retention material towards the outlet in use; and / or b. the pressure mechanism is shaped to substantially match a shape of the retention material; and / or c. the pressure mechanism is shaped to substantially surround the retention material.11 . The subsystem of any preceding claim, wherein the pressure mechanism is configured to apply pressure in two or more perpendicular axes.

12. The subsystem of any preceding claim, wherein the pressure mechanism comprises one or more of: a piston, pump, weight, flexible membrane and a chamber of compressed fluid.

13. The subsystem of any preceding claim, wherein the pressure mechanism comprises a motor- driven threaded piston.

14. The subsystem of any preceding claim, wherein the housing comprises an inlet for receiving the aerosol-generating material.

15. A cartridge for an aerosol delivery system comprising the subsystem of any preceding claim.

16. The subsystem or cartridge of any preceding claim, further comprising the aerosol-generating material.

17. An aerosol delivery system comprising the subsystem or cartridge of any preceding claim.

18. The cartridge of claim 15 or 16 or the aerosol delivery system of claim 17, wherein the cartridge is replaceable.

19. The aerosol delivery system of claim 18, further comprising an aerosol generator, separate to the cartridge.

20. A method of extracting aerosol-generating material from an aerosol delivery subsystem comprising: a. a housing having a cavity for receiving aerosol-generating material and having an outlet for releasing the aerosol-generating material; and b. a pressure mechanism configured to, in use, displace the aerosol-generating material in the cavity, the method comprising: i. applying pressure to the aerosol-generating material using the pressure mechanism, to aid release of the aerosol-generating material through the outlet.

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