Device and method

Abstract

To provide an aerosol delivery device capable of generating flavored aerosol while preventing contamination of a flavoring reservoir by aerosol particles and / or liquid condensate from the aerosol.SOLUTION: An aerosol delivery device comprises: an air inlet 5; a flavoring reservoir 36 arranged to release a flavoring material to air passing therethrough; an aerosol chamber 6 arranged to provide an aerosol to air passing therethrough; and an aerosol outlet 7; where the air inlet, the flavoring reservoir, the aerosol chamber and the aerosol outlet are arranged in fluid communication in that order.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to aerosol delivery devices and methods, and more particularly but not exclusively to aerosol delivery devices and methods that utilize flavor reservoirs. [Background technology]

[0002] The aerosol delivery device can be used to generate a nicotine-containing condensation aerosol.

[0003] An example of an inhalation device is described in the following patent document 1, which relates to an inhalation device component for generating a nicotine-containing steam / air mixture and / or a nicotine-containing condensation aerosol by vaporizing a nicotine solution highly diluted with ethanol and / or water. The inhalation device comprises the following components: a housing, a chamber arranged in the housing, an air intake opening for supplying air from the surroundings to the chamber, and a vaporizer for vaporizing a part of the highly diluted nicotine solution, the vaporizer comprising a vaporizing or steam emission surface arranged in the chamber, from which steam generated passes over the chamber, where it mixes with the air supplied through the air intake opening, thereby finally generating a nicotine-containing steam / air mixture and / or a condensation aerosol. In order to maximally remove the highly diluted solvent in the formed steam / air mixture or condensation aerosol, the inhalation device comprises a two-stage solvent removal device, which consists of a condensate discharge and storage device in communication with the chamber and a condenser through which the formed steam / air mixture and / or condensation aerosol flows.

[0004] Another example of an inhalation part is described in Patent Document 2 below, which has a housing with a housing jacket, a mouthpiece with a mouthpiece opening for delivering an inhalable medium into the user's oral cavity, and a perfume container that contains perfume and releases the perfume to the outside, capable of communicating with the outside by diffusion, and allows the user to smell the perfume, wherein a) the housing includes housing parts, b) the mouthpiece is removably connected to the housing parts, c) the housing jacket includes a first jacket part and a second jacket part, d) the housing parts form the first jacket part, e) the mouthpiece forms the second jacket part, and f) the perfume container is structurally combined with the mouthpiece, has a planar structure, is arranged flat on the second jacket part, or itself forms the second jacket part.

[0005] A non-heating tobacco flavored inhaler is described in the following Patent Document 3. According to this document, the non-heating tobacco flavored inhaler is provided with an inhalation holder having an inhalation route defined therein, and further provided with a filler disposed in the inhalation route. The filler is made of tobacco particles, and the inhalation route and the filler provide an airflow resistance in the range of about 40 to about 80 mmAq.

[0006] Another non-heating flavor inhaler is described in the following Patent Document 3. According to this document, the non-heating flavor inhaler is provided with a suction holder, an upstream region and a downstream region defined in the suction holder, the downstream region extending from the tip of the suction holder to the mouthpiece end except for the upstream region and having a forward flow path extending along the upstream region, an outer air introduction opening formed in the peripheral wall of the suction holder and connecting the upstream region with the outside, and a pouch attached to the boundary between the upstream region and the downstream region, extending along the longitudinal axis of the suction holder, and releasing tobacco flavor. Summary of the Invention

[0007] In view of the first aspect, there is provided an aerosol delivery device, the device including an air inlet, a flavor reservoir arranged to release flavor material into the air passing therethrough, an aerosol chamber arranged to provide an aerosol to the air passing therethrough, and an aerosol outlet, the air inlet, the flavor reservoir, the aerosol chamber and the aerosol outlet being arranged in fluid communication in that order, such that flavored aerosol can be generated in a manner that prevents the flavor reservoir from being contaminated with aerosol particles and / or liquid condensation from the aerosol, while at the same time subjecting the entire air volume to both flavoring and aerosol generation.

[0008] In accordance with another aspect, there is provided an apparatus configured to impart flavor to an air stream entering the apparatus before the air stream reaches an aerosol generator of the apparatus, the apparatus being operable to deliver a flavored aerosol from an outlet thereby, the apparatus being capable of producing flavored aerosol by passing an entire volume of air through the flavoring and aerosol generation section without contaminating the flavor source with aerosol particles and condensate.

[0009] In view of yet another aspect, a method for generating a flavored aerosol is provided, the method comprising: passing an airflow through a flavor reservoir such that flavor molecules and / or particles are carried by the airflow to impart flavor to the airflow; generating an aerosol by passing the airflow carrying the flavor molecules and / or particles through an aerosol generator that vaporizes a liquid into the airflow to produce a flavored aerosol; and delivering the flavored aerosol to a mouthpiece. Thus, the flavored aerosol can be generated in a manner that prevents contamination of the flavor reservoir with aerosol particles and / or condensation of the liquid from the aerosol, while at the same time subjecting the entire air volume to both flavoring and aerosol generation. [Brief description of the drawings]

[0010] The present disclosure will now be described, by way of example only, with reference to the accompanying drawings in which like reference numbers refer to similar elements and in which: [Figure 1] 1 is a cross-sectional view of an aerosol delivery device including an aerosol forming member according to a first example. [Diagram 2] 2 is a cross-sectional view of the aerosol delivery portion of the aerosol delivery device shown in FIG. 1. [Diagram 3] 1 shows examples of aerosol-forming members. [Figure 4] 1 shows examples of aerosol-forming members. [Diagram 5] 1 shows examples of aerosol-forming members. [Figure 6] 1 shows examples of aerosol-forming members. [Figure 7] 1 shows examples of aerosol-forming members. [Figure 8] 1 shows an example of an aerosol forming member located in the aerosol chamber. [Figure 9a] 4 shows an example of a control circuit. [Figure 9b] 4 shows an example of a control circuit. [Figure 10] 1 is a cross-sectional view of an aerosol delivery device including an aerosol forming member according to another example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Because the methods described herein may be subject to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and will herein be described in detail, but it will be understood that the drawings and their detailed description are not intended to limit the scope to the particular forms disclosed, but rather to cover all modifications, equivalents and alternative forms falling within the spirit and scope defined by the following claims.

[0012] Referring to FIG. 1, a first example of an aerosol delivery device is shown. The aerosol delivery device 1 includes an aerosol delivery portion 1′ and a power supply portion 1″. In this example, the aerosol delivery portion 1′ and the power supply portion 1″ are arranged as separate regions of one unitary aerosol delivery device 1 with a single housing 2 that contains both portions. In other examples, the aerosol delivery portion 1′ and the power supply portion 1″ may be removably connected such that a given power supply portion 1″ can receive many different aerosol delivery portions 1′ and / or such that a given aerosol delivery portion 1′ can receive many different power supply portions 1″. In such other examples, the housing 2 may be operable to be interchangeable or may be divided corresponding to the division of these portions such that each portion includes its own corresponding housing portion.

[0013] The aerosol delivery device 1 may be configured to be reusable or disposable. In examples where the aerosol delivery portion 1' and the power supply portion 1" are separable, either or both of the aerosol delivery portion 1' and the power supply portion 1" may be configured to be reusable or disposable.

[0014] The power supply portion 1'' provides a power source for powering one or more components in the aerosol delivery portion 1'. In this example, the power supply portion 1'' includes a battery 30 together with a housing. The supply of power from the battery 30 to the aerosol delivery portion 1' is controlled by an electrical circuit 34. In other examples, the battery may be replaced by another portable power source, such as a capacitive power storage unit such as a supercapacitor or ultracapacitor, a mechanical power source such as a spring or dynamo, or a chemical energy source such as a fuel cell.

[0015] Figure 2 shows the aerosol delivery portion 1' in more detail. As can be seen in Figure 2, the aerosol delivery portion 1' is contained within a housing 2 and has a mouthpiece 3 at one end and an attachment member at the other end. The attachment member is configured to connect (permanently or releasably) to a power supply portion 1''. As shown in Figure 2, the attachment member has a connecting member 35 for providing an electrical connection between the power supply portion 1'' of the aerosol delivery portion 1' and any powered elements.

[0016] The aerosol delivery portion 1' shown in Figure 2 defines a gas pathway therethrough having an inlet 5, a flavour reservoir 36, a plenum chamber 4, an aerosol chamber 6 (also referred to as annular passage 18), a purifying member 32 and an exit opening 7 extending through the mouthpiece 3. Air flow through the gas pathway is promoted by drawing on the mouthpiece 3. Such drawing is provided by a user who draws air through the aerosol delivery device 1 when inhaling to receive a supply of aerosol. In summary, air first drawn therein through the inlet 5 and passing through the gas pathway picks up flavour material from the flavour reservoir 36 before an aerosol is formed in the aerosol chamber 6 for delivery to the exit opening 7. This process is described in more detail below.

[0017] As shown in Figure 2, the flavour reservoir 36 provides an inlet passage or pathway between the inlet opening 5 and the plenum chamber 4. In some instances there may be a single inlet 5, while in other instances there may be multiple inlets 5 at different locations around the circumference of the housing 2. The inlet passage or pathway provided by the flavour reservoir has an annular cross-section and surrounds the aerosol chamber 6 and associated aerosol forming member 10. In this example configuration, the air inside the inlet passage and the aerosol inside the tubular passage (aerosol chamber 6) flow in opposite directions.

[0018] As fresh air moves through the inlet passage, it passes over or through the flavor reservoir 36, causing the reservoir to release flavor. The flavor dispersed in the air is drawn downstream with the air. The flavor-enriched / flavored air is then collected in the plenum chamber 4, which acts to ensure that the air flows evenly into the aerosol chamber 6 / tubular passage 18. Air enters the aerosol chamber 6 through the air inlet 31'.

[0019] As will be described in more detail below, the aerosol forming member 10 has a chamber wall 25 surrounding an aerosol chamber 6 with a liquid storage matrix 26 disposed on the exterior of the chamber wall, the aerosol chamber 6 having an aerosol chamber inlet 31' and an aerosol chamber outlet 31''. The inlet passage / flavor reservoir 36 and the liquid storage matrix 26 are separated by a support member 37 located between the liquid storage matrix 26 and the flavor reservoir 36. The aerosol forming member 10 uses heat provided by an electric current to facilitate the generation of an aerosol.

[0020] In this example, the flavour reservoir 36 is located around the aerosol-forming member 10. While the heat generated by the heating element of the aerosol-forming member 10 is primarily used to vaporize the liquid provided from the liquid storage matrix 26, a portion of the heat may be used to heat the flavour reservoir 36 to increase its temperature. This secondary or waste heat may be transferred to the flavour reservoir by thermal conduction through components of the aerosol-forming member 10 and the support member 37. For example, heat may be transferred through the chamber wall 25, through the liquid storage matrix 26 and through the tubular support member 37 that holds the aerosol-forming member 10 and the liquid storage matrix 26, thereby providing heat to the flavour reservoir 36 and the flavours contained therein.

[0021] This conductive heat transfer allows the flavor reservoir 36 to be brought to a temperature that will allow for a good increase in flavor therein. Because flavor release to the interior of the reservoir is primarily by diffusion, and diffusion is highly dependent on the temperature at which it is operated, the amount of temperature rise in the flavor reservoir due to conductive heat transfer need not be large to result in increased flavor release. In addition to the thermal conductivity of the conductive heat transfer path and the heated structure of the reservoir, the amount of temperature rise will depend on many factors related to the use of the device. For example, the length of a given puff or puff through the device will affect the time that the heating element is activated, and therefore the total amount of heat generated during the puff or puff. Also, the time interval between puffs or puffs will affect the total temperature rise if that interval is so short that at least some parts of the device do not cool completely between puffs or puffs. In practice, a temperature rise in the range of 5°C to 30°C is expected to be suitable, with an increase of 1°C or less expected to provide some increase in flavor release. The expected temperature rise for a given run of the device can be calculated and measured, and in some cases it may be preferable to match the flavor of the flavor reservoir to the expected temperature rise.

[0022] The configuration of this example provides that the only gas entering the flavor reservoir is air introduced into the device through inlet opening 5. Because flavor reservoir 36 does not receive vapors or aerosols generated within aerosol chamber 6, the surfaces of the flavor-delivering members within the flavor reservoir do not attract and become clogged with condensate or aerosol particles generated in aerosol chamber 6.

[0023] Of course, the entire volume of air inhaled by the user when inhaling to receive the aerosol supply (typically the volume is in the range of 30-80 ml) is provided to the aerosol chamber 6 and is used up completely to generate the aerosol, thereby efficiently forming the aerosol.

[0024] The flavor reservoir 36 includes a flavor carrier and a flavoring material. The flavor carrier may include a permeable highly porous wadding or filler material. In this example, the filler material completely fills or extends across the cross section of the inlet passage or channel in which the flavor reservoir 36 is disposed. In other examples, the flavor reservoir 36 may extend across less than the entire cross section. The flavor reservoir 36 may comprise a prefabricated pack or cartridge. In some examples, the flavor reservoir may include or consist of tobacco or tobacco extract as a flavoring material. Suitable tobaccos are, among others, dry fermented tobacco, reconstituted tobacco, expanded tobacco or mixtures thereof. The tobacco may be present as cut tobacco, such as finely cut tobacco, or as fine granules or tobacco powder. Such a form provides a relatively large surface area that facilitates the release of flavors contained in the tobacco. In other examples, the flavor reservoir 36 may include an inert wadding or filler material as a flavor carrier, or may comprise another open-pored inert substrate having a surface coated with a flavoring material. The coating may comprise a fraction, such as an extract, concentrate or distillate of tobacco or tobacco smoke, or a volatile, aromatic or flavourful fraction of such an extract, concentrate or distillate, or tobacco powder. Flavour materials such as the above examples extracted from or based on at least a portion of tobacco are sometimes referred to as tobacco derivatives. The coating may alternatively or additionally comprise menthol or essential oils.

[0025] The flavoring substance or material may be a substance that is insoluble in water and / or glycerol. Insoluble in this context refers to a solubility of less than 1% by weight at 20° C. and 1 atm. Thus, flavorings that are not soluble in water or glycerol can be effectively included in the aerosol provided by the aerosol delivery device by dispersing the flavoring in the air stream within the flavor reservoir.

[0026] This allows the air entering through the inlet 5 to be flavored. As discussed above, the release of flavor into the passing air may be facilitated or enhanced by heating the flavor reservoir 36, for example, by using a method to transfer excess heat from the aerosol-forming device 10 to the flavor reservoir 36.

[0027] In this example, the flavor reservoir 36 is further configured as a flow resistor 33. The flow resistor 33 acts as an element that resists the flow of air and is the main pressure drop when the user inhales air (also referred to as inhaling through the device, or drawing on the device, or puffing on the device). The flow resistor can be configured to provide a pressure drop suitable for a particular application. In one example, the pressure drop can be configured to correspond to or approximate the pressure drop expected in a conventional (i.e., lit cigarette type) cigarette. The relatively large volume flavor reservoir 36 can provide flow characteristics that substantially correspond to the flow characteristics of a cigarette. In other examples, where the device is configured to deliver flavorants and / or liquid suspensions to an aerosol of material other than that associated with tobacco smoke, a different pressure drop may be configured as required for that use. The flow characteristic of the configuration shown in FIG. 2 is substantially linear, i.e. the pressure drop across the flavor reservoir 36 is directly proportional to the flow rate through the flavor reservoir 36.

[0028] Figure 3 shows the aerosol-forming member in more detail. As shown in Figure 3, the aerosol-forming member 10a comprises a material configured to wick and heat a solution, such that a sheet of the material can absorb a solution and then be heated to vaporize it to form a vapor. The material used in this example is substantially sheet-like and comprises two major opposing surfaces 20, 21. The sheet material may comprise an open pore structure, a foam structure or an interconnected network of pores, all of which form a capillary structure. The capillary structure allows the aerosol-forming member 10a to wick or absorb a solution. The term "capillary structure" as used herein is to be understood as a structure through which a liquid or solution can move as a result of capillary action.

[0029] The aerosol-forming member 10a in this example may be made of porous, granular, fibrous or flocculent sintered metal to form a capillary structure. For example, Bekipor™ sintered fibrous material from Bekaert (www.bekaert.com) falls into this category of materials. In other examples, the aerosol-forming member 10a includes an open-pore metal foam or a group of wire mesh or layers of calendared wire mesh, which also form a capillary structure. The aerosol-forming member 10a may be made of stainless steel. Additionally, the aerosol-forming member 10a may be formed with a capillary structure that extends through the entire aerosol-forming member 10a such that the capillary structure is exposed on the two major faces 20, 21 of the sheet material. In some examples, one of the major faces 20, 21 may be sealed with a metal foil or cover that is sintered or glued to it. Alternatively, one or both areas of the major faces 20, 21 may be sealed. In other examples, the aerosol-forming member 10a is configured such that the capillary structure does not extend through the entire aerosol-forming member. In another example, a thin support layer may be fired onto one or both of the major surfaces 20, 21. Such a support layer may be formed from stainless steel mesh.

[0030] The material used to form the aerosol-forming member 10a is heatable in that it comprises sufficient electrical resistivity such that when an electric current is passed through it, the aerosol-forming member 10a heats up to a temperature sufficient to evaporate or vaporize the liquid held in the capillary structure. Thus, in this example, the aerosol-forming member 10a can be said to comprise a heating element formed with the capillary structure such that the heating element and the capillary structure are integrated to form a single object or unit.

[0031] In the examples above where the sheet material includes a single layer configured to wick and heat the solution, the sheet material can be described as including a heating element and a wick disposed on the same surface.

[0032] Additionally, the aerosol-forming member 10a may combine any of the above mentioned structures and materials, for example by providing multiple layers of different structures / materials, which are bonded together, for example by sintering.

[0033] In one such example, the aerosol forming member is substantially sheet-like and includes a sheet material formed from multiple layers. For example, the aerosol forming member 10a may include a first heatable layer acting as a heating element. The first layer is formed from a material configured to be heated. The first layer may be formed from a metal such as stainless steel. The aerosol forming member 10a may further include a second layer formed from an open pore structure, a foam structure, or an interconnected network of pores, all of which form a capillary structure. The capillary structure allows the aerosol forming member 10a to soak up or absorb a solution. The second layer may be made of a porous, granular, fibrous, or furry material to form a capillary structure. Alternatively, the second layer may include a cloth of open pore foam or a mesh layer forming a group of capillary structures. The second layer may be made of a non-conductive material such as glass, carbon, or ceramic. The second layer acts as a wick. The first layer (the heating element) and the second layer (the wick formed with the capillary structure) are layered together to form a sheet material having two opposing major surfaces, with the capillary structure exposed on one or both of the major surfaces. In this example, the sheet material may be described as including the heating element and the wick arranged in parallel planes. In one example, the first layer may be formed of a metal wire mesh or metal foil and the second layer may be formed of a fiberglass structure or fabric fritted or glued onto the first layer.

[0034] In another example, the first layer may also include a capillary structure as described with reference to the second layer to allow both heating and wicking of the solution. In this example, the sheets of material are arranged parallel to the same plane. The heater may be described as including a heating element and a wick disposed thereon.

[0035] In another example, the sheet material includes a third layer that is similar to the second layer in that it includes a capillary structure. The second and third layers sandwich the first layer such that the capillary structure is exposed on both major surfaces of the sheet.

[0036] The sheet material according to any of the above examples has a thickness or depth which typically falls within the range of 20 to 500 μm. In some cases the thickness falls within the range of 50 to 200 μm. The thickness or depth should be understood to mean the distance between the two main faces 20, 21 of the sheet material.

[0037] Figures 3 and 4 show the aerosol-forming member 10a in an unfolded state or position, while Figure 6 shows the aerosol-forming member 10a in a folded state or position. The sheet material has a first or central section 11 and second and third sections 12, 13 on either side of the central section 11. The dashed lines in Figure 3 indicate the boundaries between the sections 11, 12, 13. The second and third sections 12, 13 are formed with slots or notches 14 that extend from opposing long edges 12a, 13a of the aerosol-forming member 10a towards and into the first section 11. In the configuration shown in Figure 3, the second section 12 is formed with five slots 14 and the third section 13 is formed with four slots 14, although other numbers of slots are possible. The slots 14 are generally parallel to one another as illustrated in Figure 3 and are spaced apart across the second and third sections 12, 13.

[0038] The opposing free ends of the first section 11 act as electrical terminals 15, 16. The electrical terminals 15, 16 are configured to be electrically connected to a power source, such as a battery 30, for example, via an electrical circuit 34, such that an electrical current can be passed across the aerosol-forming member 10a. The electrical terminals 15, 16 may extend from the first section such that they enter into connection holes (not shown) of the aerosol delivery device, as shown in FIG. 2, which are electrically connected to a power source. Alternatively, conductive wires may be clipped, soldered or welded to each electrical terminal 15, 16 to allow electrical current to be passed through the aerosol-forming member 10a. In some cases, the electrical terminals are flush with adjacent edges of the second and third sections 12, 13 to prevent the terminals from protruding. The terminals may be connected to the conductive wires via clips and / or the wires may be soldered or welded to the terminals. Of course, the electrical terminals may be of any other shape, and other suitable means for connecting the electrical terminals to the power source are envisioned.

[0039] When a current passes through the aerosol-forming member 10a, the slots 14 compress the electric field 17 so that the current is substantially contained within the first section 11 as illustrated in FIG. 4. The dashed lines in FIG. 4 indicate the boundaries between the first, second and third sections 11, 12, 13. As a result, the first section 11 is primarily or directly heated, and the second and third sections 12, 13 remain relatively unheated, although it is expected that the heat generated by the current passing through the first section will heat the second and third sections 12, 13 to some extent. The heat generated in or transferred to the second and third sections is then transferred outwardly as described above, slightly heating the flavour reservoir 36. Additionally or alternatively, heat is transferred to the flavour reservoir by one or more of the following: radiant heat originating from the heated first section 11 and absorbed by the chamber walls and heat released from vapor condensing on the chamber walls 25. The heat transferred to the flavour reservoir may be considered as secondary or waste heat, since it is not directly used to generate the aerosol.

[0040] However, the present teachings are not limited to the aerosol-forming member 10a including slots to store heat in the first section 11. An example of a configuration in which the sheet material includes discontinuous sections having different material properties is shown in FIG. 5. The first section 11 is made of a material with low electrical resistivity, and the second or third section 12, 13 is formed of a material with high electrical resistivity such that when a potential difference is applied between the terminals 15, 16, the current passes mainly through the first section. Of course, the first section may be formed with a capillary structure extending throughout the aerosol-forming member. The difference in electrical resistivity causes the first section 11 to heat up compared to the second and third sections 12, 13.

[0041] In one such embodiment, the sheet material includes a non-conductive fibrous web or fabric made of glass or carbon fibers, glass or carbon fiber yarns, or other non-conductive and inert fibrous materials. The fibrous web or fabric provides a capillary structure and extends through all sections of the sheet material. Conductive fibers or wires are incorporated into the fibrous web or fabric in a first or central section of the sheet material to enable heating of said first or central section. The conductive fibers or wires may be made of stainless steel or a heating wire alloy such as chrome nickel. Alternatively, the conductive fibers may be replaced with non-conductive fibers and the conductive wires (heating wires) replaced with non-conductive yarns.

[0042] Thus, it will be appreciated that various configurations consistent with the present teachings can primarily heat the first section 11 to promote aerosol generation, with secondary heating provided by conduction of heat from the aerosol-forming member to the flavor reservoir.

[0043] 6, there is shown the aerosol-forming member 10a in a folded state or position. The second and third sections 12, 13 are folded about the first section 11 such that the second and third sections 12, 13 surround the first section 11 and form a passageway 18. Regions 19a, 19b of the second and third sections 12, 13 overlap such that the passageway 18 is completely enclosed in a direction about the first section 11. The first section 11 is substantially planar or flat and is suspended in the passageway 18 such that it extends across the passageway 18.

[0044] Of course, the second and third sections 12, 13 need not form a tubular passageway 18. In alternative embodiments, the second and third sections 12, 13 are folded about the first section 11 such that they form a passageway having an oval, square, rectangular, or any other type of polygonal cross-section.

[0045] It should also be understood that the first section 11 is not limited to being planar or flat. In another example, the first section 11 includes pleats having ridges and grooves such that it follows a serpentine or oscillatory path or a sinusoidal curved surface. The ridges and grooves may extend in a direction parallel to the opposing long edges 12a, 13a of the sheet material.

[0046] In another example shown in Figure 7, the third section 13 is omitted such that the aerosol-forming member 10c has a first section 11 and a second section 12. The second section 12 extends from the first section 11 and is folded around the first section 11 such that the second section 12 forms a passageway 18 and the first section 11 is suspended across the passageway 18. Alternatively, the second section 12 partially surrounds the first section 11. For example, the second section 12 may extend around a single surface of the first section such that the cross-section of the aerosol-forming member is semicircular.

[0047] Referring now to FIG. 8, the aerosol-forming member 10a is located in the aerosol chamber 6. The aerosol-forming member is therefore adjacent or proximate to the liquid storage matrix, defining a chamber wall 25. The chamber wall is therefore located at the boundary edge of the structure that constitutes the storage matrix. The liquid storage matrix 26 includes a capillary structure, such as an interconnected porous or open-pore structure, so that it can hold a solution or liquid. The liquid storage matrix 26 may be formed from a fibrous material, such as polyethylene or polyester fibers. In instances where heat is conducted to the flavour reservoir 35 by secondary heat from the aerosol-forming member, the liquid reservoir may be configured to conduct secondary heat. This may be provided by the storage matrix being itself thermally conductive, or by providing a thermally conductive member passing through or around the storage matrix.

[0048] The shape of the aerosol chamber 6 defined by the chamber wall 25 corresponds to the shape of the aerosol-forming member 10a. In the configuration shown in FIG. 8, the second and third sections 12, 13 are in contact with the liquid storage matrix 26. In another embodiment, only one of the second and third sections 12, 13 is in contact with the liquid storage matrix 26. Alternatively, if the aerosol-forming member comprises only the second section 12 as shown in FIG. 7, only the second section is in contact with the liquid storage matrix 26. It is understood that the entire second and / or third sections 12, 13 do not have to be in contact with the liquid storage matrix 26. For example, only a part of the second and / or third sections may be in contact with the liquid storage matrix 26. In such an embodiment, the surface section of the liquid storage matrix 26 (not in contact with the sections 12, 13) effectively forms a section of the chamber wall 25. In another embodiment, the aerosol-forming member 10a may be in contact with the liquid storage matrix 26 only via the outer edge of the sections 12, 13. In this embodiment, the chamber wall 25 is formed entirely by the liquid storage matrix 26.

[0049] Of course, the aerosol-forming chamber and the aerosol-forming member may be configured in any suitable manner that results in the formation of an aerosol as air passes through the chamber, thus, as another example, a so-called atomizer may be used that is based on the use of a heating coil wound around a fiber core.

[0050] As illustrated in FIG. 8, the first section 11 is positioned across the aerosol chamber 6 .

[0051] Advantageously, the liquid storage matrix 26 does not need to be made of a heat resistant material because it is shielded from the heat of the first section 11 by the second and / or third sections 12, 13, which are not substantially heated during operation of the aerosol delivery device 1. The secondary heat transferred through or across the storage matrix is ​​low enough that no special heat resistance is required.

[0052] The liquid storage matrix 26 holds the solution which is formed into an aerosol by the aerosol-forming member 10a. The solution is drawn or absorbed into the aerosol-forming member 10a by capillary action through the capillary structure of the second and third sections 12, 13. The solution spreads through the capillary structure of the aerosol-forming member 10a, i.e. the first, second and third sections 11, 12, 13. When the first section is heated, the solution evaporates from the first section 11, forming a vapor which, when condensed, forms an inhalable aerosol. Thereafter and even during heating, the first section 11 is replenished with solution by capillary action which moves the solution from the liquid storage matrix 26 through the second and third sections 12, 13 to the first section 11. This is explained in more detail below.

[0053] The capillarity of the aerosol-forming member 10a is greater than that of the liquid storage matrix 26 to induce the flow of the solution from the liquid storage matrix 26 towards the aerosol-forming member 10a. The capillarity is determined by the pore size and wetting condition of the corresponding capillary structure.

[0054] As mentioned above, the power source for heating the aerosol-forming member 10a may be a battery 30. The battery 30 includes a controller and is regulated by an electrical circuit 34 mounted on a printed circuit board (PCB). An exemplary circuit configuration is shown in Figures 9a and 9b.

[0055] As shown in FIG. 9a, the electrical terminals 15, 16 of the aerosol-forming member 10a are electrically connected to the positive and negative terminals of the battery 30, respectively, as described above. The electrical current to the terminals 15, 16 is controlled by an electrical circuit 34. The circuit in this example includes a pressure-activated switch 40 that is actuated in response to a signal from a pressure sensor 41. The pressure sensor 41 is positioned to detect pressure fluctuations when a user begins to inhale through the aerosol delivery device. The pressure sensor may be placed in fluid communication with the plenum chamber 4, for example, to detect pressure changes. Although the pressure sensor 41 is shown in FIG. 9 as being connected to the electrical circuit 34 via a connecting member 35, it is also possible to place the pressure sensor 41 in the electrical circuit 34 and have the plenum chamber 4 and the pressure sensor 41 in fluid communication via a path extending through the connecting member 35. The signal from the pressure sensor 41 then actuates the switch 40 (either directly or via a controller) to allow electrical current to flow from the battery 30 to the terminals 15, 16. The switch 40 may be an electrical switch, such as a power MOS field effect transistor switching circuit, which is actuable in response to a signal from the pressure sensor. The switch and any control circuitry may thus be provided on the PCB of the electrical circuit 34.

[0056] As shown in the example of Figure 9b, the supply of current from the battery 30 to the terminals 15, 16 may be controlled via a switch 42 which is actuated in response to a user actuated switch 43. The user actuated switch may be in a accessible location on the housing 2 or may be within a recess in the housing. The switch 42 may be actuated directly by the user actuated switch 43. Alternatively, control circuitry may be provided for controlling the switch 42 in response to actuation of the user actuated switch 43. The switch 42 may be an electrical switch, such as a power MOS field effect transistor switching circuit which is actuable in response to a signal from the user actuated switch 43. The switch and any control circuitry may thus be provided on the PCB of the electrical circuitry 34.

[0057] Further, the switch circuitry may automatically control the temperature, for example by using a temperature sensor which may terminate the supply of current once a threshold temperature is reached. Additionally or alternatively, the switch circuitry may automatically control the activation time such that the supply of current may terminate once a threshold activation time is reached.

[0058] In some cases, circuitry 34 may be configured to require very low or zero power other than when the switch is actuated to indicate that power is required to be supplied to terminals 15, 16.

[0059] As electrical current is drawn from the battery 30 through the sheet material, the electrical resistance of the sheet material increases the temperature of the first section 11 of the sheet material. In embodiments where the sheet material includes several layers, the resistance of the conductive layer acting as a heating element increases the temperature of the first section 11, which in turn heats adjacent non-conductive second and / or third layers of the first section 11.

[0060] The operation of the aerosol delivery device 1 will now be described with reference to Figures 1 and 8. In use, a user may manually activate the aerosol delivery device 1 when the user begins inhaling through the aerosol delivery device 1 (see, for example, the configuration of Figure 9b) or the aerosol delivery device 1 may be activated automatically (see, for example, Figure 9a). In either case, the battery 30 provides a potential difference between the electrical terminals 15, 16 of the aerosol-forming member 10a upon actuating the aerosol delivery device, causing an electrical current to flow between the electrical terminals 15, 16, thereby increasing the temperature of the first section 11 of the sheet material. The heat is contained within the first section 11 substantially by the presence of the slots 14, although it will be appreciated that heat may be contained within the first section by other means as discussed above. It will also be appreciated that secondary heat may be delivered to the flavour reservoir 35 as discussed above. This increase in temperature in the first section 11 causes the solution held in the capillary structures of the first section 11 of the sheet material to evaporate to form a vapour. The vapor mixes with air that is drawn into aerosol delivery device 1 through inlet 5, flavor reservoir 35, plenum chamber 4, and chamber inlet 31' by suction caused by the user inhaling through the device. The vapor mixes with the air in aerosol chamber 6, and as this occurs the vapor condenses and forms droplets, creating an inhalable aerosol.

[0061] The aerosol-forming member 10a according to any of the above-mentioned embodiments is positioned in the housing such that the plane of the major surfaces 20, 21 are parallel or substantially aligned with the direction of airflow through the aerosol chamber 6. Thus, when a solution is held in the aerosol-forming member 10a and heated to vaporize, the solution vaporizes transversely to the direction of airflow. In embodiments where the capillary structures are exposed on both sides of the sheet material, the solution is vaporized in opposite directions from both sides as shown by the arrows in FIG. 8. The vapor mixes with the air and forms an aerosol within the passageway 18 formed by the second and / or third sections 12, 13. The passageway 18 directs the flow of aerosol through the aerosol delivery device towards the user.

[0062] When the aerosol-forming device is started, excess vapor is generated on the chamber walls 6 formed by the second and / or third sections 12, 13 of the aerosol-forming member 10a and is prone to condensation. The released heat of condensation is therefore available for transport to the flavour reservoir, where the condensate is reabsorbed into the capillary structures of the sections 12, 13 and resupplied by capillary action to the section 11 of the aerosol-forming member 10a as described above. In addition to any such heat of condensation, secondary or waste heat may be supplied to the flavour reservoir by conductive heat transfer within the aerosol-forming member from the hotter section 11 to the adjacent colder section 12, 13. Secondary or waste heat may also be supplied to the flavour reservoir by radiative heat transfer from the hotter section 11 to the adjacent colder section 12, 13. Heat rays may traverse the aerosol chamber 6 and are then absorbed by the chamber walls 25 formed by the sections 12, 13. All three heat sources are active to some degree, their relative proportions depending on the exact design of the device. Both of these mechanisms provide secondary or waste heat that passes through or around the liquid storage matrix 36 and reaches the flavor reservoir 36 to heat the flavorants contained therein.

[0063] After the aerosol forming member 10a is activated and an aerosol is formed in the passageway 18, the aerosol is drawn through the passageway 18 as the user continues to inhale. The aerosol exits the aerosol chamber 6 through the chamber outlet 31'', as shown in Figure 2. The aerosol then passes through an optional aerosol refining member 32 provided in the housing 2, which cools the aerosol. The refining member 32 may further include a flavouring agent such as menthol, which is released into the aerosol stream before entering the user's mouth through the outlet opening 7 provided in the mouthpiece 3. Meanwhile, the solution evaporated from the capillary structure of the first section 11 of the sheet material is replaced with fresh solution from the liquid storage matrix 26 due to the capillary effect of the capillary structure described above and the second and / or third sections coming into contact with the liquid storage matrix 26. Fresh air enters the passageway 18 through the inlet opening 5, the flavour reservoir 36, the plenum chamber 4 and the chamber inlet 31'. In some examples, a pressure drop member or flow resistor 33 is provided to control the flow of air through the aerosol chamber 6. The flow resistor 33 may consist of a simple opening or hole, and may be identical to the inlet opening 5 of the housing 2. Alternatively, the flow resistor 33 may consist of a porous body similar to a cigarette filter that provides the flow resistance of a conventional cigarette. In some instances, the flow resistor 33 may be provided by a material, as described above, that provides structure to retain or provide flavour within the flavour reservoir. In such instances, the material thus serves the dual function of flavour transport and flow restriction.

[0064] Thus, described herein are examples of the operation and structure of an aerosol delivery device that utilizes secondary heat from an aerosol generating structure to warm a flavor source to facilitate the delivery of flavor from the flavor source to the inhaled air before the inhaled air reaches the aerosol generating structure.

[0065] FIG. 10 shows another example of an aerosol delivery device. The aerosol delivery device 1 includes an aerosol delivery portion 1′ and a power supply portion 1″. In this example, the aerosol delivery portion 1′ and the power supply portion 1″ are arranged as separate regions of one unitary aerosol delivery device 1 with a single housing 2 that contains both portions. In other examples, the aerosol delivery portion 1′ and the power supply portion 1″ can be removably connected such that a given power supply portion 1″ can receive many different aerosol delivery portions 1′ and / or such that a given aerosol delivery portion 1′ can receive many different power supply portions 1″. In such other examples, the housing 2 can be operable to allow replacement of a portion or member (such as the power source 30) or can be divided corresponding to the division of these portions such that each portion includes its own corresponding housing portion.

[0066] The aerosol delivery device 1 may be configured to be reusable or disposable. In examples where the aerosol delivery portion 1' and the power supply portion 1" are separable or openable, either or both of the aerosol delivery portion 1' and the power supply portion 1" may be configured to be reusable or disposable.

[0067] In this example, the portable power source 30 (which may be a battery, or other portable power source as described with reference to Figure 1 above) does not use the entire diameter of the housing 2, but has a gas passage around it (either entirely surrounding or partially adjacent to) from the inlet 5 to the plenum chamber 4. As in the previous example, this gas path is located in a flavour reservoir 36. The flavour reservoir 36 operates in the same manner as described with reference to Figures 1 and 2, with the provision for heating the flavour reservoir 36 being omitted.

[0068] As fresh air moves through the inlet passage as in the example above, it passes through the flavor reservoir 36, which causes the container to release flavor. The flavor dispersed in the air is drawn downstream with the air. The flavor enriched / flavored air is then collected in the plenum chamber 4. The plenum chamber 4 allows the air to flow evenly to the aerosol chamber 6 / tubular passage 18. In this example configuration, the air inside the inlet passage and the aerosol inside the tubular passage 18 (aerosol chamber 6) flow in the same direction but are separated by the axial offset between the center of flow through the inlet passage and the tubular passage and the plenum chamber 4.

[0069] In the example of FIG. 10, two options for delivering heat to flavor reservoir 36 can be employed independently or in combination.

[0070] The first option takes advantage of the property of many batteries to heat up slightly when they provide electrical current. Thus, if the portable power source 30 is a battery or other power source that tends to heat up when it provides electrical current, the heat generated by the power source 30 may be used to provide heat to a flavor reservoir 36 located around or adjacent to the power source 30.

[0071] A second option is to utilize a separate heat generating means that provides heat to the flavour reservoir 36 other than by conducting secondary heat from the aerosol forming member 10. Such a separate heat generating means can be provided by providing a control circuit 34 that provides a low current through one or more conductive structures in or adjacent to the flavour reservoir 36 simultaneously with the supply of electrical current to the aerosol forming member 10.

[0072] As in the previous example, this conductive heat transfer allows the flavor reservoir 36 to reach a temperature that can enhance the release of flavor therein.

[0073] Thus, there is described herein an example of the operation and construction of an aerosol delivery device that utilizes secondary heat from an aerosol-generating structure or another heat source to heat a flavorant source to facilitate the delivery of flavor from the flavorant source to the inhaled air before the inhaled air reaches the aerosol-generating structure. It is apparent that the example provided herein provides a compact construction.

[0074] Of course, in some implementations the flavor source may not be heated, and instead the flavor reservoir may not be heated and the inhaled air may be passed through the flavor reservoir before it reaches the aerosol-generating structure.

[0075] The above-mentioned embodiment of the aerosol-forming member 10 of the aerosol delivery device 1 has been described as using a solution. This solution may of course contain certain ingredients or substances that have an irritating effect on the user. These ingredients or substances may be of any type suitable for delivery via inhalation. The solution in which these ingredients or substances are held or dissolved may consist mainly of water, ethanol, glycerol, propylene glycol or a mixture of the above-mentioned solvents. By a sufficiently high degree of dilution with a readily volatile solvent such as ethanol and / or water, even substances that are otherwise difficult to evaporate can be evaporated substantially without residue, and thermal decomposition of the liquid material can be avoided or significantly reduced.

[0076] It will be understood that the term "passage" is not limited to a particular cross-section, and further, a passage may be completely enclosed about its longitudinal axis, but it will also be understood that a passage may not be enclosed but may be open along a section parallel to its longitudinal axis.

[0077] It is envisioned that the aerosol-forming member 10 according to any of the above-described embodiments may be oxidized or coated with a non-conductive material to prevent short circuits. The entire disclosure exemplarily illustrates various embodiments in which the claimed invention may be practiced. The advantages and features of the disclosure are merely representative examples of embodiments and are not exhaustive or exclusive. They are provided merely to aid in the understanding and teaching of the claimed features. It is to be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the disclosure should not be construed as limiting the disclosure to the exact scope of the claims or to the equivalents of the claims, but that other embodiments may be utilized or modified without departing from the scope and / or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed elements, components, features, parts, steps, means, or other combinations. The disclosure also includes other inventions that are not currently claimed but may be claimed in the future. [Prior art documents] [Patent documents]

[0078] [Patent Document 1] U.S. Patent Application No. 2011 / 0226236 [Patent Document 2] International Application Publication No. 2011 / 109848 Brochure [Patent Document 3] International Application Publication No. 2010 / 095659 Brochure

Claims

1. An air inlet; a flavor reservoir arranged to release flavor material into air passing therethrough; an aerosol chamber arranged to provide an aerosol to air passing therethrough; an aerosol outlet; An aerosol delivery device in which an air inlet, a flavor reservoir, an aerosol chamber, and an aerosol outlet are disposed in fluid communication, in that order.

2. 10. The aerosol delivery device of claim 1, wherein the aerosol outlet is in fluid communication with a mouthpiece outlet for delivering the aerosol therethrough upon inhalation on the mouthpiece.

3. 3. The aerosol delivery device of claim 1, further comprising an aerosol forming member arranged to generate an aerosol in air passing through the aerosol chamber.

4. 4. The aerosol delivery device of claim 1, 2 or 3, wherein the aerosol forming member includes a heating element arranged to generate a condensed aerosol.

5. 5. The aerosol delivery device of claim 4, further comprising a liquid reservoir in fluid communication with the heating element and arranged to deliver liquid to the heating element, the heating element arranged to generate an aerosol by vaporizing liquid therefrom.

6. 6. The aerosol delivery device of claim 4 or 5, wherein the flavour reservoir is in conductive thermal communication with the heating element.

7. 7. The aerosol delivery device of claim 3, further comprising a switch for actuating the aerosol forming member in response to a flow of air from the air inlet to the aerosol outlet.

8. 8. The aerosol delivery device of any one of claims 1 to 7, wherein the flavour reservoir is in conductive thermal communication with a heat source.

9. 9. The aerosol delivery device of any one of claims 1 to 8, wherein the flavour reservoir comprises a flavour carrier and a flavour material.

10. 10. The aerosol delivery device of claim 9, wherein the flavoring material is insoluble in one or more selected from the group consisting of water and glycerol.

11. 11. The aerosol delivery device of any one of claims 1 to 10, wherein the flavour reservoir comprises tobacco or a tobacco derivative.

12. 12. An aerosol delivery device according to claim 9, 10 or 11 when dependent on claim 6 or 8, wherein the flavourant carrier is in conductive thermal communication with a heating element or source.

13. 13. The aerosol delivery device according to claim 1, further comprising a flow resistor as an element for resisting air flow downstream of the inlet and upstream of the aerosol forming member.

14. 14. An aerosol member according to claim 13 when dependent on claim 9, wherein the flow resistor comprises a flavourant carrier.

15. 15. The aerosol delivery device of any one of claims 1 to 14, wherein the flavor reservoir is disposed at least partially around the periphery of the aerosol chamber.

16. 16. The aerosol delivery device of any one of claims 1 to 15, wherein the flavor reservoir is disposed at least partially surrounding the aerosol chamber.

17. 17. The aerosol delivery device of any one of claims 13 to 16, wherein the flow resistance provides a pressure drop proportional to the amount of flow through the flow resistance.

18. 1. An apparatus configured to impart flavor to an airflow entering the apparatus before the airflow reaches an aerosol generator of the apparatus, the apparatus being operable to thereby deliver a flavored aerosol from an outlet.

19. 20. The device of claim 18, comprising an inlet configured to admit air flow into the device.

20. 20. Apparatus according to claim 18 or 19, characterized in that it includes a power source for heating an aerosol generator for generating an aerosol in the airflow.

21. 21. A device according to claim 18, 19 or 20, including a flavouring material held in an airflow path through the device.

22. 22. The apparatus of claim 21 including a heat source for heating the flavoring material.

23. 23. The apparatus of claim 22, wherein the heat source is an aerosol generator.

24. 24. The device of any one of claims 18 to 23, configured to cause airflow during flavoring to flow in a first direction and through the aerosol generator in a second direction substantially opposite the first direction.

25. 25. An apparatus according to any one of claims 18 to 24, comprising a flavourant carrier configured to store a flavourant for application to the air stream.

26. 26. The device of claim 25, wherein the flavorant carrier is configured to restrict air flow therethrough.

27. Passing an air stream through the flavor reservoir so as to flavor the air stream by causing flavor molecules and / or particles to become entrained in the air stream; generating an aerosol by passing an air stream carrying the flavor molecules and / or particles through an aerosol generator which evaporates a liquid into the air stream to generate a flavored aerosol; delivering the flavored aerosol to a mouthpiece.

28. 30. The method of claim 27, wherein said flavoring comprises passing an air stream through a heated flavor reservoir.

29. 29. A method according to claim 27 or 28, wherein generating the aerosol comprises passing an air stream carrying flavour molecules and / or particles through a heated aerosol generator.

30. 30. The method of claim 28 or 29, wherein the heated aerosol generator heats a heated flavor reservoir.

31. 31. The method of any one of claims 27 to 30, comprising initiating heating of at least one of the flavor reservoir and the aerosol generator in response to sensing airflow.

32. 32. A method as claimed in any one of claims 27 to 31, characterized in that the air flow is restricted before, during or after passing the air flow into the flavour reservoir and before passing the air flow into the aerosol generator.

33. 23. Apparatus substantially as herein described with reference to any of the accompanying drawings.

34. 23. A method substantially as herein described with reference to any of the accompanying drawings.

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