Vapour provision system with air flow channel

Abstract

A component for a vapour provision system comprises a chamber for housing an atomiser configured to generate vapour; a first air flow channel through the component and bypassing the chamber; and a vapour flow channel leading from the chamber to a junction with the air flow channel to deliver vapour generated in the aerosol provision chamber into the air flow channel to mix with air flowing in the air flow channel to form an aerosol.

Description

[0001] VAPOUR PROVISION SYSTEM WITH AIR FLOW CHANNEL

[0002] Technical Field

[0003] The present disclosure relates to a component for a vapour provision system having air flow channels, and a vapour provision system comprising such a component.

[0004] Background

[0005] Many electronic vapour provision systems, such as e-cigarettes and other electronic nicotine delivery systems that deliver nicotine via vaporised liquids, utilise an atomiser to generate vapour. An atomiser typically comprises a heater in the form of one or more electrical heating elements which apply heat to an aerosolisable substrate material (typically in liquid form) in order to vaporise the liquid. The resulting vapour is entrained into a flow of air through the system which is produced by the user drawing air into the system by inhalation, to create an aerosol for delivery to the user through an aerosol outlet at the mouthpiece of the system. The atomiser is located within a chamber, and the flow of air is along an air flow channel that passes through the chamber, where the air collects the vapour. The air becomes heated, in part due to combination with the high temperature vapour, and also due to flowing over and around the heater, and in some designs also through the heater. The resulting aerosol delivered for inhalation is therefore warm.

[0006] For user comfort and safety, a vapour provision system is generally designed in order that the temperature of the aerosol at the mouthpiece should be limited to around 70 degrees centigrade. However, it is common for this temperature to be exceeded, for example if the heater operating temperature increases due to a reduced amount of substrate available for vaporisation, or if the user inhales on the system in an unconventional way, or if the user has modified or adjusted the system such as by replacing the heater or changing to a substrate that vaporises at a different temperature. This increased aerosol temperature can be detrimental to safety and to the user experience.

[0007] Approaches to reducing the aerosol temperature at the mouthpiece are therefore of interest.

[0008] Summary

[0009] According to a first aspect of some embodiments described herein, there is provided a component for a vapour provision system, comprising: a chamber for housing an atomiser configured to generate vapour; a first air flow channel through the component and bypassing the chamber; and a vapour flow channel leading from the chamber to a junction with the air flow channel to deliver vapour generated in the aerosol provision chamber into the air flow channel to mix with air flowing in the air flow channel to form an aerosol.

[0010] According to a second aspect of some embodiments described herein, there is provided a vapour provision system comprising a component according to the first aspect. These and further aspects of the certain embodiments are set out in the appended independent and dependent claims. It will be appreciated that features of the dependent claims may be combined with each other and features of the independent claims in combinations other than those explicitly set out in the claims. Furthermore, the approach described herein is not restricted to specific embodiments such as set out below, but includes and contemplates any appropriate combinations of features presented herein. For example, a component or a vapour provision system comprising a component may be provided in accordance with approaches described herein which includes any one or more of the various features described below as appropriate.

[0011] Brief Description of the Drawings

[0012] Various embodiments of the invention will now be described in detail by way of example only with reference to the following drawings in which:

[0013] Figure 1 shows a simplified schematic longitudinal cross-section through an example vapour provision system to which aspects of the disclosure can be applied;

[0014] Figure 2 shows a simplified schematic longitudinal cross-section through a cartridge for a vapour provision system according to the prior art;

[0015] Figure 3 shows a simplified schematic longitudinal cross-section through a first example component according to an aspect of the disclosure;

[0016] Figure 4 shows a simplified schematic longitudinal cross-section through a second example component according to an aspect of the disclosure;

[0017] Figure 5 shows a simplified schematic longitudinal cross-section through a third example component according to an aspect of the disclosure;

[0018] Figure 6A shows a simplified schematic longitudinal cross-section through a fourth example component according to an aspect of the disclosure; and

[0019] Figure 6B shows a simplified schematic longitudinal cross-section through a fifth example component according to an aspect of the disclosure.

[0020] Detailed Description

[0021] Aspects and features of certain examples and embodiments are discussed I described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed I described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

[0022] As described above, the present disclosure relates to electronic aerosol or vapour provision systems, such as e-cigarettes. Throughout the following description the terms “e- cigarette” and “electronic cigarette” may sometimes be used; however, it will be appreciated these terms may be used interchangeably with aerosol (vapour) provision system or device. The systems are intended to generate an inhalable aerosol by vaporisation of an aerosolforming substrate in the form of a liquid or gel which may or may not contain nicotine. Additionally, hybrid systems may comprise a liquid or gel substrate plus a solid substrate which is also heated. The solid substrate may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. The term “aerosolisable substrate material” as used herein is intended to refer to substrate materials which can form an aerosol, either through the application of heat or some other means. The term “aerosol” may be used interchangeably with “vapour”.

[0023] As used herein, the term “component” is used to refer to a part, section, unit, module, assembly or similar of an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an exterior housing or wall. An electronic cigarette may be formed or built from one or more such components, and the components may be removably or separably connectable to one another, or may be permanently joined together during manufacture to define the whole electronic cigarette. The present disclosure is applicable to (but not limited to) systems comprising two components separably connectable to one another and configured, for example, as an aerosolisable substrate material carrying component holding liquid or another aerosolisable substrate material (a cartridge, cartomiser or consumable), and a control unit or device component having a battery for providing electrical power to operate an element for generating vapour from the substrate material. For the sake of providing a concrete example, in the present disclosure, a cartridge or cartomiser is described as an example of the aerosolisable substrate material carrying portion or component, but the disclosure is not limited in this regard and is applicable to any configuration of aerosolisable substrate material carrying portion or component. Also, such a component may include more or fewer parts than those included in the examples.

[0024] The present disclosure is relevant to vapour provision systems and components thereof that utilise aerosolisable substrate material in the form of a liquid or a gel which is held in a reservoir, tank, container or other receptacle comprised in the system. An arrangement for delivering the substrate material from the reservoir for the purpose of providing it for vapour I aerosol generation is included. The terms “liquid”, “gel”, “fluid”, “source liquid”, “source gel”, “source fluid” and the like may be used interchangeably with “aerosolisable substrate material” and “substrate material” to refer to aerosolisable substrate material that has a form capable of being stored and delivered in accordance with examples of the present disclosure.

[0025] Figure 1 is a highly schematic diagram (not to scale) of a generic example aerosol / vapour provision system such as an e-cigarette 10, presented for the purpose of showing the relationship between the various parts of a typical system and explaining the general principles of operation. The e-cigarette 10 has a generally elongate shape in this example, extending along a longitudinal axis indicated by a dashed line, and comprises two main components, namely a control or power component, section or unit 20, and a cartridge assembly or section 30 (sometimes referred to as a cartomiser or clearomiser) carrying aerosolisable substrate material and operating as a vapour-generating component.

[0026] The cartomiser 30 includes a reservoir 3 containing a source liquid or other aerosolisable substrate material comprising a formulation such as liquid or gel from which an aerosol is to be generated, for example containing nicotine. As an example, the source liquid may comprise around 1 to 3% nicotine and 50% glycerol, with the remainder comprising roughly equal measures of water and propylene glycol, and possibly also comprising other components, such as flavourings. Nicotine-free source liquid may also be used, such as to deliver flavouring. A solid substrate (not illustrated), such as a portion of tobacco or other flavour element through which vapour generated from the liquid is passed, may also be included. The reservoir 3 has the form of a storage tank, being a container or receptacle in which source liquid can be stored such that the liquid is free to move and flow within the confines of the tank. For a consumable cartomiser, the reservoir 3 may be sealed after filling during manufacture so as to be disposable after the source liquid is consumed, otherwise, it may have an inlet port or other opening through which new source liquid can be added by the user. The cartomiser 30 also comprises an electrically powered heating element or heater 4 located externally of the reservoir tank 3 for generating the aerosol by vaporisation of the source liquid by heating. A liquid transfer or delivery arrangement (liquid transport element) such as a wick or other porous element 6 may be provided to deliver source liquid from the reservoir 3 to the heater 4. A wick 6 may have one or more parts located inside the reservoir 3, or otherwise be in fluid communication with the liquid in the reservoir 3, so as to be able to absorb source liquid and transfer it by wicking or capillary action to other parts of the wick 6 that are adjacent or in contact with the heater 4. This liquid is thereby heated and vaporised, to be replaced by new source liquid from the reservoir for transfer to the heater 4 by the wick 6. The wick may be thought of as a bridge, path or conduit between the reservoir 3 and the heater 4 that delivers or transfers liquid from the reservoir to the heater. Terms including conduit, liquid conduit, liquid transfer path, liquid delivery path, liquid transfer mechanism or element, and liquid delivery mechanism or element may all be used interchangeably herein to refer to a wick or corresponding component or structure.

[0027] A heater and wick (or similar) combination is sometimes referred to as an atomiser or atomiser assembly, and the reservoir with its source liquid plus the atomiser may be collectively referred to as an aerosol source. Other terminology may include a liquid delivery assembly or a liquid transfer assembly, where in the present context these terms may be used interchangeably to refer to a vapour-generating element (vapour generator) plus a wicking or similar component or structure (liquid transport element) that delivers or transfers liquid obtained from a reservoir to the vapour generator for vapour I aerosol generation. Various designs are possible, in which the parts may be differently arranged compared with the highly schematic representation of Figure 1. For example, the wick 6 may be an entirely separate element from the heater 4, or the heater 4 may be configured to be porous and able to perform at least part of the wicking function directly (a conductive mesh, such as a metallic mesh, for example). In an electrical or electronic device, the vapour generating element may be an electrical heating element that operates by ohmic / resistive (Joule) heating or by inductive heating. In general, therefore, an atomiser can be considered as one or more elements that implement the functionality of a vapour-generating or vaporising element able to generate vapour from source liquid delivered to it, and a liquid transport or delivery element able to deliver or transport liquid from a reservoir or similar liquid store to the vapour generator by a wicking action I capillary force. An atomiser is typically housed in a cartomiser component of a vapour generating system. In some designs, liquid may be dispensed from a reservoir directly onto a vapour generator with no need for a distinct wicking or capillary element. Embodiments of the disclosure are applicable to all and any such configurations which are consistent with the examples and description herein.

[0028] Returning to Figure 1 , the cartomiser 30 also includes a mouthpiece or mouthpiece portion 35 having an opening or aerosol outlet through which a user may inhale the aerosol generated by the atomiser 4.

[0029] The power component or control unit or, simply, device or device component 20 includes a cell or battery 5 (referred to herein after as a battery, and which may be rechargeable) to provide power for electrical components of the e-cigarette 10, in particular to operate the heater 4. Additionally, there is a controller 28 such as a printed circuit board and / or other electronics or circuitry for generally controlling the e-cigarette. The control electronics / circuitry 28 operates the heater 4 using power from the battery 5 when vapour is required, for example in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects an inhalation on the system 10 during which air enters through one or more air inlets 26 in the wall of the control unit 20. When the heating element 4 is operated, the heating element 4 vaporises source liquid delivered from the reservoir 3 by the liquid delivery element 6 to generate the aerosol, and this is then inhaled by a user through the opening in the mouthpiece 35. The aerosol is carried from the aerosol source to the mouthpiece 35 along one or more air flow channels (not shown) that connect the air inlet(s) 26 to the aerosol source to the aerosol outlet when a user inhales on the mouthpiece 35. Since in this example the air inlets 26 to the system are located in the device component 20, the cartomiser 30 has its own air inlet(s) in air flow communication with the device component 20 so that air drawn in through the device air inlet(s) 26 can reach the interior of the cartomiser 30, and the atomiser. In other designs, air inlets may be located in the outer wall of the cartomiser 30 so that air enters directly into the cartomiser 30 instead of arriving there via the device component 20.

[0030] The device component (control unit) 20 and the cartomiser (cartridge assembly) 30 are, in this example, separate connectable parts detachable from one another by separation in a direction parallel to the longitudinal axis, as indicated by the solid arrows in Figure 1. The components 20, 30 are joined together when the device 10 is in use by cooperating engagement elements 21 , 31 (for example, a screw or bayonet fitting) which provide mechanical and in some cases electrical connectivity between the power section 20 and the cartridge assembly 30. Electrical connectivity is required if the heater 4 operates by ohmic heating, so that current can be passed through the heater 4 when it is connected to the battery 5. In systems that use inductive heating, electrical connectivity can be omitted if no parts requiring electrical power are located in the cartomiser 30. An inductive work coil can be housed in the power section 20 and supplied with power from the battery 5, and the cartomiser 30 and the power section 20 shaped so that when they are connected, there is an appropriate exposure of the heater 4 to flux generated by the coil for the purpose of generating current flow in the material of the heater. Also, apertures for air flow from the device component 20 to the cartomiser 30 are included at the interfacing parts of the two components 20, 30. The Figure 1 design is merely an example arrangement, and the various parts and features may be differently distributed between the power section 20 and the cartridge assembly section 30, and other components and elements may be included. The two sections may connect together end-to-end in a longitudinal configuration as in Figure 1 , or in a different configuration such as a parallel, side-by-side arrangement. The system may or may not be generally cylindrical and / or have a generally longitudinal shape. Either or both sections or components may be intended to be disposed of and replaced when exhausted (the reservoir is empty or the battery is flat, for example), or be intended for multiple uses enabled by actions such as refilling the reservoir and recharging the battery. In other examples, the system 10 may be unitary, in that the parts of the control unit 20 and the cartomiser 30 are comprised in a single housing and cannot be separated. Embodiments and examples of the present disclosure are applicable to any of these configurations and other configurations of which the skilled person will be aware.

[0031] Figure 2 shows a highly simplified schematic representation of a cartridge or a cartomiser component according to existing example designs of vapour provision systems, in particular having reference to air flow through such systems. The cartridge 20 comprises an outer housing within which is located a reservoir 3 for storing aerosolisable substrate material, which is delivered to and vaporised by an atomiser 5. In this example, the reservoir 3 has an annular shape, with a central though-hole passing along its length and oriented along the longitudinal axis of the cartridge 20. Also in this example, the atomiser 5 comprises an elongate wick or other porous element 6 and a heater 4 in the form of a wire coil electrical heating element wrapped around the wick 6. The two ends of the wick 6 are located inside the reservoir 3 so that the wick 6 spans the through-hole surrounded by the annular reservoir 3, and the wick 6 absorbs substrate material from the reservoir and carries it to the vicinity of the heater 4 for heating and vaporisation, to generate a vapour v. The atomiser is housed in a chamber 14 defined in the through-hole. An air flow channel 11 extends through the cartridge 30 from an air inlet 12 at one end of the cartridge to an aerosol outlet 13 at an opposite end of the cartridge 30, the aerosol outlet 13 being defined in a mouthpiece or mouthpiece portion 35 of the cartridge 30. An air flow direction along the air flow channel 11 is from the air inlet 12 to the aerosol outlet 13, so that the air flow inlet is upstream of the aerosol outlet 13 with respect to the direction of air flow through the cartridge 30. The chamber 14 is located at an intermediate point along the air flow channel 11 so that the interior of the chamber 14 forms part of the air flow channel 11. In this way, air a which is drawn into the cartridge 30 through the air inlet 12 when a user inhales at the mouthpiece 35 passes along a first, upstream, part of the air flow channel 11 before entering the chamber 14. Inside the chamber 14, the air a collects the vapour v produced by the atomiser 5 and the combined air a and vapour v form an aerosol A that flows out of the chamber 14 into a second, downstream part of the air flow channel 11 to reach the aerosol outlet 13. Here the aerosol A leaves the cartridge 30 and is delivered into the user’s mouth for inhalation.

[0032] The air a drawn in through the air inlet 12 is heated during its passage through the chamber 14, by mixing with the vapour v and also by interaction with the atomiser, since the air a passes over, through, around and near the heater 4. Consequently, the aerosol A delivered at the mouthpiece 35 can be considerably hotter than the incoming air a. While a vapour provision system will typically be designed with the intention of keeping the aerosol temperature at the mouthpiece to below about 70 degrees centigrade for the safety and comfort of the user, operation of the vapour provision system under various circumstances can readily lead to an increased, and potentially undesirable or unsafe, aerosol temperature at the mouthpiece.

[0033] The present disclosure proposes to address this by configuring a cartridge, cartomiser or other component of a vapour provision system in which an atomiser is located such that the air flow does not interact directly with the atomiser. The incoming air therefore does not undergo heating by the heater, and the aerosol temperature at the mouthpiece can be reduced or minimised. This is achieved by arranging an air flow channel through the component which bypasses the chamber in which the atomiser is housed. Therefore the chamber is not comprised within the air flow channel, and air passing through the component along the air flow channel does not flow through the chamber. A separate vapour flow channel is provided that connects the chamber to the air flow channel. Vapour generated in the chamber flows along the vapour flow channel and is delivered into a stream of air flowing along the air flow channel. The vapour and the air mix in the air flow channel at and downstream of the location of a junction between the vapour flow channel and the air flow channel, to form the required aerosol.

[0034] Figure 3 shows a highly simplified and schematic representation of an example component such as a cartridge 30 which is configured in accordance with this proposed approach. An air flow channel 11 extends through the component 30 from an air inlet 12 (which may or may not be the primary air intake for the vapour provision system, for example if the primary air intake is located in a device component of the system as in the Figure 1 example) to an aerosol outlet 13. Air flow direction along the air flow channel 11 channel is indicated by the arrow in Figure 3, from an upstream end II at the air inlet 12 to a downstream end D at the aerosol outlet 13. The air flow channel 11 is in air flow communication with the air inlet 12 and the aerosol outlet 13, enabling a flow or stream of air through the component 30, along the air flow channel 11. An atomiser 5 is located or housed in a chamber 14 within the component 30. The chamber 14 is separate from the air flow channel 11 , and the air inlet 12 is located outside of the chamber 14 and does not provide any air intake into the chamber 14. The atomiser 5, depicted schematically only, may be configured in any manner apparent to the skilled person for the vaporisation of aerosolisable substrate material stored in a reservoir of the system (not shown, and may or may not be located in with component 30). For example, the atomiser 5 may comprise a heater (one or more electrical heating elements) with an associated wick or other porous member that carries substrate material from the reservoir to the heater by capillary action, or may comprise a porous electrically resistive member such as a metallic mesh able to perform both heating and wicking functions. A vapour flow channel 15 is provided which extends between an outlet of the chamber 14 and the air flow channel 11 , joining the air flow channel 11 at a junction 16. The vapour flow channel 15 thereby connects the interior of the chamber 14 and the interior of the air flow channel 11 so that vapour v generated by the atomiser 5 can leave the chamber 14, flow along or through the vapour flow channel 15, and enter the air flow channel 11. In this way, vapour v can combine with air a flowing the air flow channel 11 to create aerosol A, which is drawn along the air flow channel 11 and delivered through the aerosol outlet 13.

[0035] This arrangement allows air, transformed into aerosol, to pass through the component without interacting with the heater, which is achieved by the air flow channel 11 bypassing the chamber 14 housing the atomiser 5. This is in contrast with known designs such as shown in Figure 3 in which the air flow channel passes directly through the atomiser chamber. By avoiding the heater, the air drawn through the component is not heated by any interaction with the heater, and maintains the environmental temperature at which it enters the component. The only heat which is input to the air is from the vapour. Also, the vapour flow channel 15 allows some transit time of the vapour before it reaches the stream of air in the air flow channel, during which the vapour can cool slightly, thereby producing less heating of the air when the vapour and air mix together to form the aerosol. The temperature of the aerosol is thereby reduced compared to arrangements in which the air passes by the heater. Unsafe and uncomfortable high aerosol temperatures at the mouthpiece can be obviated.

[0036] A further benefit of removing the air flow away from the heater is that the air is not able to have a cooling effect on the heater. Accordingly, the temperature of the heater can be maintained at the required operating temperature more accurately and effectively, and operation of the heater is made more efficient. Battery power in the vapour provision is therefore conserved, and battery life extended.

[0037] Vapour may simply diffuse along the vapour flow channel 15 to the air flow channel 11 , but in order to improve vapour delivery to the air stream, a narrowing or constriction of the air flow channel 11 can be provided at the location of the junction 16 where the vapour flow channel 15 meets the air flow channel 11. This constricted portion 17 of the air flow channel 11 , in which the cross-section of the air flow channel is reduced or restricted, has a smaller cross-sectional area than the adjacent parts of the air flow channel 11 located upstream and downstream of the junction 16. This reduced cross-section produces an increase in the velocity of the air flow through the constricted portion, with an associated decrease in the static pressure of the flowing air. This is in accordance with Bernoulli’s principle. Hence, a reduced air pressure is created at the junction 16, compared to air pressure in the chamber 15. This pressure differential acts to suck or draw the vapour in the chamber 14 through the vapour flow channel 15 and into the air flow channel 11.

[0038] While any reduction in the size of the air flow channel 11 at the junction 16 can assist in drawing the vapour by causing a reduction in air pressure, a more extreme narrowing will produce a greater pressure drop and a corresponding larger pressure differential, and hence aid in maintaining a steady flow of incoming vapour from the chamber 14. It is proposed that the cross-sectional area of the air flow channel at the constricted portion 17 may be one half or less of a smallest cross-sectional area of the air flow channel elsewhere in the air flow channel. For example, the cross-sectional area at the constricted portion may be 0.5, 0.4, 0.3, 0.25, 0.2, or 0.1 times the smallest cross-sectional area elsewhere. However, it may be necessary to balance the amount of narrowing with the corresponding resistance to draw which will be experienced by the user inhaling on the mouthpiece, so that the resistance to draw is not increased to a level which makes use of the vapour provision system become inconvenient. Accordingly, a more useful lower limit for the size of the constricted portion may be 0.2 times of the smallest cross-sectional area elsewhere. Hence, in some examples the constricted portion may have a cross-sectional area in the range of 0.2 - 0.5 times the next smallest cross-sectional area of the air flow channel. Ratios outside the range are not excluded, however, so in other examples the constricted portion may be less than 1 but more than 0.5 times the next smallest cross-sectional area.

[0039] As regards actual dimensions of the constructed portion of the air flow channel, this will depend to some extent on the width selected for the wider parts of the air flow channel and the ratio of the constricted portion to the wider parts which it is decided to provide for the purpose of decreasing air pressure at the junction. However, in some examples, the constricted portion of the air flow channel may have a cross-sectional area which is 5 mm2or less, such as 5, 4.5, 4, 3.5, 3, or 2.5 mm2. Usefully, though, the cross-sectional area is preferably not smaller than 0.5 mm2, although smaller values may be tolerated in some designs.

[0040] In Figure 3, the vapour flow channel 15 is depicted as sloping, in that it joins the air flow channel 11 at a non-perpendicular angle to the longitudinal extent of the air flow channel, and to the direction of air flow along the air flow channel 11. The vapour flow channel 15 is angled so as to be directed more towards the downstream end of the air flow channel 11 . This angled or sloped arrangement, although not essential, aids in keeping the resistance to draw along the air flow channel low, where in contrast a junction between the two channels 11 , 15 which forms a right angle, or where the vapour flow channel 15 is directed towards the upstream direction, will tend to increase the resistance to draw. Accordingly, it is proposed that the vapour flow channel 15 converges towards the air flow channel 11 (towards the downstream direction of air flow) at an acute angle. Usefully, the angle may be 60 degrees or less, for example (although larger degrees are not excluded). Smaller degrees reduce the resistance to draw more, so the angle may be 50 degrees or less, or 40 degrees or less, or 30 degrees or less, for example. In general, the size of the chamber 14, and relative positions and dimensions of the chamber 14 and the air flow channel 11 will contribute to the feasible size of the angle. A more acute angle might be facilitated by the outlet from the chamber 14 that leads into the vapour flow channel 15 being in an upper wall of the chamber 14 (downstream wall of the chamber, closest to the aerosol outlet 13) rather than in a side wall of the chamber 14 as depicted in Figure 3, for example. The relevant acute angle between the air flow channel 11 and the vapour flow channel 15 is shown as 0 in Figure 3, and is the angle between the air flow channel 11 and the vapour flow channel 15 on the upstream side of the junction 16.

[0041] In order to increase the amount of cooling of the aerosol before the aerosol reaches the aerosol outlet 13 , it is beneficial for the junction 16 to be located upstream of the aerosol outlet 13, rather than vapour flow channel 11 delivering vapour to the air stream directly at the aerosol outlet 13. Note that some cooling will still be available in such an arrangement since the hot vapour will still combine with the unheated air. However, more cooling can occur if the aerosol flows along the downstream part of the air flow channel 11 , after the junction 16, and this also provides more space and time for the aerosol to form. Therefore, the junction 16 may be located upstream of the aerosol outlet by a distance of at least 10 mm. Other distances are not excluded, however, and the possible value of the distance will also be determined according to the overall length of the component and the longitudinal position of the chamber 14 within the component. A position for the chamber 14 which is closer to the upstream end of the component, proximate the air inlet 12, will enable the separation of the junction 16 from the aerosol outlet 13 to be maximised. A maximum feasible distance will depend on the location of the chamber 14 and the vapour flow channel. To achieve a smoother flow of aerosol, the location of the junction 16 may be higher (more upstream) that the vapour outlet of the chamber 14, so that the vapour flow channel slopes towards the upstream direction. The distance from the junction 16 to the aerosol outlet 13 would not typically exceed 100 mm, although higher values may be possible in some designs. Overall, a useful range for the distance is therefore 10 - 100 mm.

[0042] Similarly, a downstream portion of the air flow channel 11 which is long compared to the length of the vapour flow channel 15 can also aid in providing a greater distance for formation and cooling of the aerosol before the aerosol reaches the mouthpiece. Accordingly, in some examples, the air flow channel 11 has a length between the junction 16 and the aerosol outlet 13 which is longer than the length of the vapour flow channel 15 (defined as the distance between the vapour outlet of the chamber where the vapour flow channel 15 commences and the junction 16). For example, the length of the air flow channel 11 between the junction 16 and the aerosol outlet 13 may be at least twice the length of the vapour flow channel 15. Other values are not excluded, however.

[0043] Similarly, a shorter upstream portion of the air flow channel 11 , before the junction 16, compared to the length of the vapour flow channel 15 can also aid in providing a longer downstream portion of the air flow channel 11 , to allow greater cooling for a given overall length of the air flow channel (since this is constrained by the overall size of the component and / or the vapour provision system). Therefore, in some examples, the air flow channel 11 has a length between the air inlet 12 and the junction 16 which is half the length of the vapour flow channel or less. Other values are not excluded, however.

[0044] Taking the atomiser chamber out of the air flow channel can also contribute to reduced leakage from the vapour provision system. Liquid may leave the reservoir via the porous member of the atomiser at a higher rate than the atomiser is able to vaporise the liquid, or the liquid may be forced out of the reservoir around the porous member due to air pressure changes or pressure waves within the reservoir. This may lead to excess liquid at the atomiser that may drip off the atomiser. Also, vapour which is not picked up the flowing air may condense back to liquid form. These factors can produce free liquid within the chamber. In existing configurations in which the air flow channel passes through the chamber (such as Figure 3), the free liquid can travel along the air flow channel and leak from the vapour provision system at the air inlet or the aerosol outlet, or can reach electrical connections or components leading to damage or malfunction. In the proposed configuration, however, any free liquid in the chamber cannot easily reach the air flow channel and is therefore captured within the chamber.

[0045] In some examples, the chamber 14 may itself also have a dedicated air inlet 18, separate from the air inlet 12 leading to the air flow channel 11. The chamber’s air inlet 18 is therefore not intended to contribute to the amount of air flow along the air flow channel 11 , and can be considered as a minor or secondary air inlet. The minor air inlet 18 allows a small amount of air to enter the chamber 14, which can help to maintain pressure within the chamber during vapour generation. If vapour is drawn along the vapour flow channel 15 and into the air flow channel 11 at a greater rate than new vapour is created by the atomiser, the pressure in the chamber 14 can drop. This reduced pressure can produce a pressure differential between the chamber 14 and the reservoir, causing excess liquid to be drawn into the chamber 14 from the reservoir, which may not be vaporised and will form free liquid in the chamber 14. An intake of air through the minor air inlet 18 can mitigate this, by rebalancing the pressure in the chamber 14. Air intake into the chamber 14 can also help to reduce condensation of generated vapour back to liquid. The presence of the minor air inlet 18 can therefore help to reduce leakage by minimising free liquid accumulation inside the chamber. However, any free liquid that nevertheless does form could be at risk of leaking out through the minor air inlet 18. Accordingly, it is proposed that if a minor air inlet is included, it may be configured to inhibit the egress of liquid from the chamber via the minor air inlet. This can be enabled by sizing the minor air inlet so as to be too small for liquid (under normal circumstances) to readily pass through it and out of the chamber. For example, the minor air inlet may have a width which is 4 mm or less, such as 3 mm, 2.5 mm, 2 mm, 1.5 mm, 1 mm, or less than 1 mm. Alternatively, a larger minor air inlet might be covered or spanned by a structure that itself inhibits liquid flow through the structure (and hence through the minor air inlet) but allows the inward flow of air. For example, this could be a mesh with apertures too small for the passage of liquid, or an air permeable and liquid impermeable membrane.

[0046] Figure 4 shows a highly schematic representation of another example component according to an aspect of the disclosure. In this example, the vapour flow channel 15 is reduced to a minimum length. The chamber 14 abuts the air flow channel 11, and the vapour flow channel 15 takes the form of an aperture in a wall or walls separating the chamber 14 from the air flow channel 11 , and located at the junction 16. The vapour flow channel 15 therefore has a length corresponding to the thickness of the wall or walls in which the aperture is defined. This arrangement reduces the space required in the component 30 to accommodate the vapour flow channel 15. However, the minimal length of the vapour flow channel 15 offers less opportunity for cooling of the vapour before the vapour mixes with air in the air flow channel 11. Also, there is less separation of the air flow channel from the chamber so that some advantages provided by bypassing the flow of air past the chamber as discussed above may be diminished.

[0047] In other example components, it is proposed that a second air flow channel, also bypassing the vapour chamber, can be provided. In the above description, therefore, the air channel can be alternatively designated a first air flow channel.

[0048] Figure 5 shows a highly simplified and schematic representation of an example component such as a cartridge which is configured in this way, with a second air flow channel. The component 30 has a chamber 14 housing an atomiser 5 (and having an optional minor air outlet 18), a first air flow channel 11 between a first air inlet 12 and a first aerosol outlet 13, and a first vapour flow channel 15 connecting the chamber 14 with the first air flow channel 11 at a first junction 16, all as described with regard to Figure 3. Additionally, a second air flow channel 11a is provided, running through the component 30, bypassing the chamber 14, and in air flow communication with a second air inlet 12a, outside the chamber, at the upstream end of the component 30 and a second aerosol outlet 13a at the downstream end of the component 30. A second vapour flow channel 15a extends from the chamber 14 to a second junction 16a with the second air flow channel 11a, located at a constricted portion 17a of the second air flow channel 11a. The second vapour flow channel 15a leaves the chamber 14 from a second vapour outlet different from the first vapour outlet leading to the first vapour flow channel 15 in this example, but alternatively both vapour flow channels 15, 15a might share a single outlet from the chamber 14.

[0049] The component 30 operates in the same manner as the Figure 3 example, except that the vapour generated by the atomiser 5 leaves the chamber 14 via both vapour flow channels 15, 15a so that vapour is delivered into two air streams, one in each air flow channel 11 , 11a. This can increase the amount of cooler air with which the vapour is mixed, thereby increasing the cooling effect on the aerosol by the time it reaches the mouthpiece.

[0050] As depicted in Figure 5, the component 30 comprises two aerosol outlets 13, 13a, one for each air flow channel 11 , 11a. If desired, these can exist separately in or at the mouthpiece of the vapour provision system so that two aerosol streams are delivered to the user. Alternatively, the two aerosol streams can be combined before delivery to the user. Following the configuration of the Figure 5 component, an additional mouthpiece part can be connected downstream of the component which receives the aerosol streams from each aerosol outlet 13, 13a, and combines them into a single channel with a single mouthpiece outlet for the user. Alternatively, the component 30 can be configured such that the first air flow channel 13 and the second airflow channel 13a are combined or converged into a single air flow channel leading to a single aerosol outlet. The two air flow channels are combined downstream of the aerosol outlet. In any configuration, and similar for the Figure 3 and 4 example, a mouthpiece part may be integrally formed with the component, or may be a separate part coupled to the component or otherwise located downstream of the component.

[0051] In the Figure 5 example, the first air flow channel 11 and the second air flow channel 11a bypass the chamber 14 at opposite sides of the chamber. One air flow channel is situated on each side of the chamber 14, closer to the outer surface of the component 30 with the chamber 14 arranged centrally within the transverse cross-section of the component 30 (where the transverse cross-section is orthogonal to the direction of air flow alone the first and second air flow channels 11 , 11a). While this is not essential for the provision of two air flow channels in the component, it provides a symmetrical arrangement of the various parts within the component, giving a balanced component that can feel more pleasant in the user’s hand. Similarly, the first and second vapour flow channels also may have a symmetrical arrangement, as shown in Figure 5. The vapour flow channels can lead from vapour outputs disposed on opposite sides of the chamber, which can enable a more equal division of the vapour between the two air flow channels so that each air flow channel provides a similar amount of aerosol and a similar amount of cooling. As shown in Figure 5, the symmetrical configuration provides an arrangement of vapour flow channel and air flow channel which is mirrored on each side of the component.

[0052] Figure 6A shows a longitudinal cross-sectional view of an example component having two air flow channels and a single aerosol outlet. As in the Figure 5 example, the component 30 comprises two air inlets 12, 12a, each supplying an intake to air to a separate (first and second) air flow channels 11 , 11a, which each bypass the chamber 14. The chamber 14 has first and second associated vapour flow channels 14, 14a, each delivering vapour from the chamber 14 to a different one of the first and second air flow channels 11 , 11a. Downstream of the junctions (not shown) where the vapour flow channels 14, 14a join the air flow channels 11 , 11a, the air flow channels 11 , 11a combine at an air flow convergence point 40 to form a single combined air flow channel 11 b carrying aerosol from both air flow channels 11 , 11a. The combined air flow channel 11 b has an aerosol outlet 13, which is located in an integral mouthpiece portion 41 of the component 30 through which a single stream of aerosol is delivered to the user’s mouth. The air inlets 12, 12a, air flow channels 11 , 11a and vapour flow channels 14, 14a are arranged symmetrically on each side of the chamber 14, and the combined air flow channel 11 b is centrally arranged with respect to the transverse cross section of the component 30. The component is configured as a cartridge or consumable component, such that its lower (as depicted), downstream end can be connected to a device component housing a battery and electronics for powering and controlling the atomiser (not shown), in order to form a complete vapour provision system. The space within the upper part of the component 30 that surrounds the first and second air flow channels 11 , 11a and the combined air flow channel 11b and is bounded by the outer wall of the component 30 forms a reservoir 3 for aerosolisable substrate material which is supplied to the atomiser in the chamber via one or more liquid flow paths between the reservoir 3 and the chamber 14.

[0053] Figure 6B shows a longitudinal cross-sectional view of a further example component having two air flow channels. This example is similar to the example of Figure 6A, but differs in that it additionally comprises a minor air inlet 18 for the chamber 14.

[0054] In a further example (not depicted), a component may have a single air inlet into a single air flow channel which then separates into two diverging air flow channels which each bypass the chamber, and then combine, downstream of the junctions with the vapour flow channels, back into a single air flow channel leading to a single aerosol outlet. Alternatively, the two air flow channels may not combine downstream of the junctions, and instead each lead to a separate aerosol outlet.

[0055] In other examples, more than two air flow channels may be provided. Each air flow channel may have a separate air inlet, or each air flow channel may separate from a single air flow channel fed by a single air inlet. Similarly, the plural air flow channels may combine into a single air flow channel having a single aerosol outlet, or may each continue to a separate aerosol outlet.

[0056] In still other examples, the component may be a sub-component of a cartridge component or a device component, and is configured to be assembled together with other parts in order to form a complete component that can be coupled with another component to form a vapour provision system. Alternatively, the component may be a subcomponent of a vapour provision system, which is configured to be assembled together with other parts in order to form a complete unitary vapour provision system.

[0057] In conclusion, in order to address various issues and advance the art, this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and / or exclusive. They are presented only to assist in understanding and to teach the claimed invention(s). It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects of the disclosure are not to be considered limitations on the disclosure 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 claims. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. The disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

Claims1. A component for a vapour provision system, comprising: a chamber for housing an atomiser configured to generate vapour; a first air flow channel through the component and bypassing the chamber; and a vapour flow channel leading from the chamber to a junction with the air flow channel to deliver vapour generated in the aerosol provision chamber into the air flow channel to mix with air flowing in the air flow channel to form an aerosol.

2. A component according to claim 1 , wherein the junction is at a constricted portion of the first air flow channel that causes a reduced air pressure at the junction in order to draw the vapour along the vapour flow channel.

3. A component according to claim 2, wherein the first air flow channel has a cross- sectional area at the constricted portion which is one half or less of a smallest cross- sectional area elsewhere in the first air flow channel.

4. A component according to claim 2 or claim 3, wherein the constricted portion of the first air flow channel has a cross-sectional area of 5 mm2or less.

5. A component according to any preceding claim, wherein, at the junction, the vapour flow channel converges on the first air flow channel at an acute angle.

6. A component according to any preceding claim, wherein at the junction, the vapour flow channel converges on the first air flow channel at an angle of 60 degrees or less.

7. A component according to any preceding claim, further comprising a first air inlet outside the chamber through which air can enter the component and an aerosol outlet through which aerosol can be delivered for inhalation, the first air flow channel in air flow communication with the first air inlet and the aerosol outlet.

8. A component according to claim 7, wherein the junction is located upstream of the aerosol outlet by a distance in the range of 10 - 100 mm.

9. A component according to claim 7 or claim 8, wherein a length of the first air flow channel between the junction and the aerosol outlet is longer than a length of the vapour flow channel.

10. A component according to claim 9, wherein the length of the first air flow channel between the junction and the aerosol outlet is at least twice the length of the vapour flow channel.

11. A component according to any one of claims 7 to 10, wherein a length of the first air flow channel between the first air inlet and the junction is at half the length of vapour flow channel or less.

12. A component according to any one of claims 7 to 11 , further comprising a second air flow channel through the component and bypassing the chamber, and a second vapour flow channel extending from the chamber to a second junction with the second air flow channel.

13. A component according to claim 12, further comprising a second air inlet outside the chamber, the second air flow channel in air flow communication with the second air inlet and the aerosol outlet.

14. A component according to claim 12 or claim 13, wherein the first air flow channel and the second air flow channel combine upstream of the aerosol outlet.

15. A component according to any one of claims 12 to 14, wherein the first air flow channel and the second air flow channel bypass the chamber on opposite sides of the chamber.

16. A component according to any one of claims 12 to 15, wherein the first air flow channel and the second air flow channel are disposed symmetrically within the component.

17. A component according to any preceding claim, further comprising a mouthpiece, the aerosol outlet located in the mouthpiece.

18. A component according to any preceding claim, further comprising a minor air inlet into the chamber.

19. A component according to claim 18, wherein the minor air inlet is configured to inhibit the egress of liquid from the chamber.

20. A component according to any preceding claim, further comprising an atomiser housed in the chamber.

21. A component according to claim 20, wherein the atomiser comprises a heater and a porous member to carry aerosolisable substrate material to the heater.

22. A component according to claim 21 wherein the atomiser comprises a conductive mesh configured for a heating function and a wicking function.

23. A component according to any one of claims 20 to 22, further comprising a reservoir for storing aerosol forming substrate to be vaporised by the atomiser.

24. A component according to any preceding claim, wherein the component is a cartridge component configured for connection with a device component housing a battery to form the vapour provision system.

25. A vapour provision system comprising a component according to any preceding claim.

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