Aerosol Delivery Subsystem

Abstract

An aerosol delivery subsystem comprising: a puff sensor at one end configured to detect airflow through the air inlet in use; and an elongated power supply extending away from the puff sensor and having an electrode at a distal end away from the puff sensor for connection to the puff sensor.

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery systems, such as nicotine delivery systems, including, but not limited to, e-cigarettes, tobacco heating products (THPs), and hybrid systems. More particularly, the present disclosure relates, in part, to a component mounting bracket for an aerosol delivery subsystem. [Background technology]

[0002] Aerosol delivery systems, such as electronic cigarettes (e-cigarettes), generally include an aerosol-generating material, such as a chamber of a source solid or liquid that may contain an active substance and / or flavor, from which an aerosol or vapor is generated, e.g., by thermal vaporization, for inhalation by a user. Thus, aerosol delivery systems typically include an aerosol-generation area that includes an aerosol generator, e.g., a heating element, configured to vaporize or aerosolize a portion of a precursor material to generate a vapor or aerosol within the aerosol-generation area. When a user inhales on the device and power is supplied to the vaporizer, air is drawn into the device through an inlet hole and along an inlet air channel connecting to the aerosol-generation area, where it mixes with the vaporized precursor material to form a condensed aerosol. An outlet air channel connects the aerosol-generation area to an outlet at the mouthpiece; when a user inhales on the mouthpiece, air drawn into the aerosol-generation area continues along the outlet flow path to the mouthpiece outlet, carrying, along with the air, an aerosol for inhalation by the user. Some e-cigarettes may also include flavoring elements within the air flow path through the device to impart additional flavor. Such devices are sometimes referred to as hybrid devices, and the flavoring elements may include, for example, a portion of tobacco positioned in the air flow path between the aerosol-generation area and the mouthpiece so that the aerosol / condensation aerosol drawn through the device passes through the portion of tobacco before exiting the mouthpiece for user inhalation.

[0003] It is of interest to develop techniques that allow aerosol delivery systems to be more easily assembled, repaired, and / or recycled to increase production efficiency, improve sustainability, and reduce waste. Various techniques that attempt to help address or mitigate at least some of these problems are described herein.

[0004] term Delivery System As used herein, the term "delivery system" is intended to encompass a system that, upon use, delivers at least one substance to a user; Combustion aerosol delivery systems (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials), such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or homemade cigarettes; Non-combustion aerosol delivery systems that release compounds from aerosol-forming materials without burning the aerosol-forming materials, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials; and An aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snus or moist snuff, wherein the at least one substance may or may not include nicotine. Includes:

[0005] Combustion-type aerosol supply system According to the present disclosure, a "combustion-based" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0006] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0007] In some embodiments, the present disclosure relates to aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper, for use in combustion-based aerosol delivery systems.

[0008] Non-combustion aerosol delivery system According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0009] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0010] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0011] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0012] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0013] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0014] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0015] In some embodiments, a non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0016] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0017] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol generators, aerosol-generating areas, housings, packaging, filters, mouthpieces, and / or aerosol modifiers.

[0018] Aerosol-Free Delivery System In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snus or moist snuff, where the at least one substance may or may not contain nicotine.

[0019] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavors, one or more aerosol-former materials, and / or one or more other functional materials.

[0020] active substance In some embodiments, the substance to be delivered includes an active substance. As used herein, an active substance can be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance can be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance can be naturally occurring or synthetically obtained. The active substance can include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance can include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0021] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0022] As described herein, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0023] As described herein, the active substance may comprise or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise a synthetically derived active compound naturally occurring in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc.

[0024] Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. The active ingredient in the active ingredient is citric acid, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv and Mentha suaveolens.

[0025] In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, wherein the botanical substance is tobacco. In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, wherein the botanical substance is selected from eucalyptus, star anise, cocoa, and hemp.

[0026] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0027] Flavor In some embodiments, the substance delivered comprises a flavor. As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in products intended for adult consumers.These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime). , tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascara, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine ylang-ylang, sage, fennel, wasabi, pimenta, ginger, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damiento, maize The additives may include other additives such as joram, olive, lemon balm, lemon basil, chives, caraway seeds, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be imitation, synthetic, or natural raw materials, or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0028] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0029] In some embodiments, the flavor may include a sensation eliciting agent intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and may include agents that produce heating, cooling, tingling, or numbing effects. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0030] Aerosol-Generating Materials An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-generating material can be in the form of a solid, liquid, or gel, which may or may not contain an active substance and / or flavoring. In some embodiments, the aerosol-generating material can include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material can include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0031] The aerosol-generating materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0032] Aerosol-forming materials The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0033] functional materials The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0034] Base material The material can be on or in a support to form a substrate. The support can be or comprise, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0035] consumables A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0036] Susceptor The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0037] Aerosol Modifiers An aerosol modifier is a substance typically located downstream of the aerosol-generation area and configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier. The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, thread, or granules. The aerosol modifier may not include a filtration material.

[0038] Aerosol Generator An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, elevated pressure, or electrostatic energy.

[0039] The present disclosure relates to aerosol delivery systems (sometimes referred to as vapor delivery systems), such as nebulizers or e-cigarettes. Throughout the following description, the terms "e-cigarette" or "electronic cigarette" may sometimes be used, but it will be understood that this term may be used interchangeably with aerosol delivery systems / devices and electronic aerosol delivery systems / devices. Furthermore, as is common in the art, the terms "aerosol" and "vapor," as well as related terms such as "vaporize," "volatilize," and "aerosolize," may generally be used interchangeably.

[0040] Aerosol delivery systems (e-cigarettes) often, but not always, comprise a modular assembly comprising a reusable device portion and a replaceable (disposable / consumable) cartridge portion. Often, the replaceable cartridge portion comprises the aerosol-generating material and vaporizer (sometimes collectively referred to as a "cartomizer"), while the reusable portion comprises a power source (e.g., a rechargeable power source) and control circuitry. It will be appreciated that these various portions may comprise additional elements depending on their functionality. For example, the reusable device portion often comprises a user interface for receiving user input and displaying operational status characteristics, and the replaceable cartridge device portion may optionally comprise a temperature sensor to help control temperature. The cartridge is electrically and mechanically coupled to a control unit for use, for example, using a thread, bayonet, or magnetic coupling with appropriately positioned electrical contacts. When the aerosol-generating material in the cartridge is depleted, or when a user desires to switch to a different cartridge having a different aerosol-generating material, the cartridge may be removed from the reusable portion and a replacement cartridge installed in its place. Systems and devices that conform to this type of two-part modular configuration may be commonly referred to as "two-part" systems / devices.

[0041] It is common for electronic cigarettes to have a substantially elongated shape. To provide a concrete example, certain embodiments of the present disclosure will be construed as comprising this type of substantially elongated, two-part system employing a disposable cartridge. However, it will be understood that the basic principles described herein may equally be employed in different configurations, such as single-part systems or modular systems comprising three or more parts, refillable devices and single-use disposables, as well as other overall shapes, for example, based on so-called box-mod smart devices, which typically have a more box-like shape. More generally, certain embodiments of the present disclosure are based on aerosol delivery systems operatively configured to provide functionality according to the principles described herein, and it will be understood that the structural aspects of the systems configured to provide functionality according to certain embodiments of the present disclosure are not of primary importance. Summary of the Invention

[0042] The present invention provides aerosol delivery subsystems, systems and methods, as claimed.

[0043] The claimed invention generally provides a subassembly or subsystem 100 suitable for or configured for use in an aerosol delivery system 1 .

[0044] In some embodiments, subsystem 100 comprises bracket 110 and may form part of aerosol delivery system 1 generally, and in particular, may form part of reusable device portion 2 and / or consumable cartridge portion 4 in a two-part system, or may form part of disposable aerosol delivery system 1. The bracket may include several functional features, including, but not limited to, an integral end cap for sealing the liquid in the reservoir, a retaining portion for receiving an electrical contact pin, a seal between the pod / reservoir and the battery compartment, secure support of the battery within the housing, and one or more through holes for airflow.

[0045] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0046] [Figure 1] 1 is a schematic cross-sectional view of an aerosol delivery system 1 including a bracket 110, according to some embodiments of the present disclosure. [Figure 2] 1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing bracket 110 in greater detail. [Figure 3] 1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing bracket 110 in greater detail. [Figure 4] 1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing bracket 110 in greater detail. [Figure 5] 5 is a side cross-sectional view of the aerosol delivery subsystem 100 of FIG. 4. [Figure 6] FIG. 1 is a schematic side view of a modular power supply for an aerosol delivery subsystem 100, according to some embodiments of the present disclosure. [Figure 7] FIG. 1 is an exploded perspective view of an aerosol delivery system 1 according to some embodiments of the present disclosure. [Figure 8] FIG. 1 is a schematic side view of an assembled aerosol delivery system 1, according to some embodiments of the present disclosure. [Figure 9] 1 is a schematic diagram of an assembly process for an aerosol delivery system 1 according to some embodiments of the present disclosure. [Figure 10] 1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a second bracket 110. FIG. [Figure 11] 1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a second bracket 110. FIG. [Figure 12]1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a second bracket 110. FIG. [Figure 13] 1 is a schematic perspective view of an aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing a second bracket 110. FIG. [Figure 14] FIG. 14 is a cross-sectional view of the aerosol delivery system including the second bracket of FIGS. DETAILED DESCRIPTION OF THE INVENTION

[0047] Aspects and features of particular examples and embodiments are described herein. Some aspects and features of particular examples and embodiments may be implemented in conventional manners, and these will not be described in detail for the sake of brevity. Accordingly, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented in accordance with any suitable conventional techniques.

[0048] 1 is a cross-sectional view of an exemplary aerosol delivery system 1 according to certain embodiments of the present disclosure, providing an introduction to a two-part aerosol delivery system, the components therein, and their functions. System 1 includes a bracket 110 according to some embodiments of the present disclosure. Bracket 110 is described in detail below with reference to subsequent figures.

[0049] The aerosol delivery system 1 comprises two main parts: a reusable part 2 and a replaceable / disposable consumable cartridge part 4. In normal use, the reusable part 2 and the cartridge part 4 are detachably coupled to one another at an interface 6. When the cartridge part 4 is depleted, or when the user simply desires to switch to a different cartridge part 4, the cartridge part 4 may be removed from the reusable part 2 and a replacement cartridge part 4 attached to the reusable part 2 in its place. The interface 6 provides structural, electrical, and airflow connections between the two parts 2, 4 and may be based, for example, around a threaded, magnetic, or bayonet fastener, in accordance with conventional techniques, with appropriately positioned electrical contacts and openings for providing electrical connection and airflow between the two parts 2, 4. The particular manner in which the cartridge part 4 is mechanically attached to the reusable part 2 is not important to the principles described herein, but for purposes of illustration, it is assumed herein to comprise a magnetic coupling (not shown in FIG. 1 ). It will also be understood that interface 6 may not support an electrical and / or airflow path connection between the respective portions 2, 4 in some implementations. For example, in some implementations, the aerosol generator may be provided in the reusable portion 2 rather than in the cartridge portion 4, or the transfer of power from the reusable portion 2 to the cartridge portion 4 may be wireless (e.g., based on electromagnetic induction), such that an electrical connection between the reusable portion 2 and the cartridge portion 4 is not required. Further, in some implementations, airflow through the electronic cigarette may not pass through the reusable portion 2, such that an airflow path connection between the reusable portion 2 and the cartridge portion 4 is not required. In some cases, a portion of the airflow path may be defined at the interface between a portion of the reusable portion 2 and a portion of the cartridge portion 4 when the reusable portion 2 and the cartridge portion 4 are coupled together for use.

[0050] The cartridge / consumable portion 4, according to certain embodiments of the present disclosure, may be broadly conventional. In FIG. 1 , the cartridge portion 4 comprises a cartridge housing 42 formed of a plastic material. The cartridge housing 42 supports the other components of the cartridge portion 4 and provides a mechanical interface 6 with the reusable portion 2. The cartridge housing 42 is substantially circularly symmetric about a longitudinal axis along which the cartridge portion 4 couples to the reusable portion 2. In this example, the cartridge portion 4 has a length of about 4 cm and a diameter of about 1.5 cm. However, it will be understood that the specific geometry, and more generally, the overall shape and materials used, may vary in different implementations.

[0051] Within cartridge housing 42 is a chamber or reservoir 44 containing aerosol-generating material. In the example shown schematically in FIG. 1 , reservoir 44 stores a supply of liquid aerosol-generating material. In this example, liquid reservoir 44 has an annular shape with an outer wall defined by cartridge housing 42 and an inner wall defining air flow passage 52 through cartridge portion 4. Reservoir 44 is closed at each end by end walls to contain the aerosol-generating material. Reservoir 44 may be formed in accordance with conventional techniques, for example, comprise a plastic material, and may be integrally molded with cartridge housing 42.

[0052] The cartridge / consumable portion 4 further includes an aerosol generator 48 located against the end of the reservoir 44 opposite the mouthpiece outlet 50. It will be appreciated that in a two-part system such as that shown in FIG. 1 , the aerosol generator 48 may be in either the reusable portion 2 or the cartridge portion 4. For example, in some embodiments, the aerosol generator 48 (e.g., a heater, which may be in the form of a wick-and-coil configuration as shown, a still, which may be formed from a sintered metal fiber material or other porous, electrically conductive material, or any suitable alternative aerosol generator) may be included in the reusable portion 2 and be proximate to a portion of the aerosol-generating material within the cartridge portion 4 when the cartridge portion 4 is engaged with the reusable portion 2. In such embodiments, the cartridge portion 4 may contain a portion of the aerosol-generating material, and the aerosol generator 48, including the heater, is at least partially inserted into or at least partially surrounds a portion of the aerosol-generating material when the cartridge portion 4 is engaged with the reusable portion 2.

[0053] 1, the wick 46 in contact with the aerosol generator 48 extends laterally across the cartridge air flow path 52, with the end of the wick 46 extending into the reservoir 44 of liquid aerosol-generating material through an opening in the interior wall of the reservoir 44. The opening in the interior wall of the reservoir 44 is sized to broadly match the dimensions of the wick 46 to provide a reasonable seal against leakage from the liquid reservoir 44 into the cartridge air flow path without undue compression of the wick 46, which could be detrimental to its fluid transfer performance.

[0054] The wick 46 and aerosol generator 48 are positioned within the cartridge air flow passage 52 such that the area of ​​the cartridge air flow passage 52 around the wick 46 and heater 48 effectively defines the vaporization region for the cartridge portion 4. The aerosol-generating material in the reservoir 44 penetrates the wick 46 through the end of the wick that extends into the reservoir 44 and is drawn along the wick by surface tension / capillary action (i.e., wicking). The aerosol generator 48, in this example, comprises an electrically resistive wire wrapped around the wick 46. In the example of FIG. 1 , the heater 48 comprises a nickel-chromium alloy (Cr20Ni80) wire and the wick 46 comprises a glass fiber bundle, although it will be understood that the particular aerosol generator configuration is not critical to the principles described herein. In use, power is supplied to the aerosol generator 48 to vaporize a quantity of aerosol-generating material drawn by the wick 46 to the vicinity of the aerosol generator 48. The vaporized aerosol-forming material may then be entrained in air drawn along the cartridge air flow path from the vaporization region toward mouthpiece outlet 50 for user inhalation.

[0055] As discussed above, the rate at which the aerosol-generating material is vaporized by the aerosol generator 48 depends on the amount (level) of power supplied to the aerosol generator 48. Accordingly, power can be applied to the aerosol generator 48 to selectively generate an aerosol from the aerosol-generating material in the cartridge portion 4, and further, the rate of aerosol generation can be varied by varying the amount of power supplied to the aerosol generator 48, for example, by pulse width and / or frequency modulation techniques.

[0056] The reusable part 2 comprises an outer housing 12 having an opening defining an air inlet 28 for the e-cigarette, a power source 26 (e.g., a battery) for providing operating power for the electronic cigarette, control circuitry / controller 22 for controlling and monitoring operation of the electronic cigarette, a first user input button 14, a second user input button 16, and a visual display 24.

[0057] The device portion 2 also includes a mounting bracket 110 (not shown in FIG. 1) configured to receive a power source 26, which will be described in more detail below with reference to subsequent figures.

[0058] The outer housing 12 may be formed, for example, from a plastic or metal material and, in this example, has a circular cross-section that substantially matches the shape and size of the cartridge portion 4 so as to provide a smooth transition between the two portions 2, 4 at the interface 6. In this example, the reusable portion 2 has a length of approximately 8 cm, such that the overall length of the e-cigarette when the cartridge portion 4 and the reusable portion 2 are coupled together is approximately 12 cm. However, as previously stated, it will be understood that the overall shape and scale of an electronic cigarette implementing an embodiment of the present disclosure is not critical to the principles described herein.

[0059] Air inlet 28 connects to air flow path 51 through reusable part 2. Reusable part air flow path 51 then connects to cartridge air flow path 52 across interface 6 when reusable part 2 and cartridge part 4 are connected to one another. Thus, when a user inhales on mouthpiece opening 50, air is drawn through air inlet 28, along reusable part air flow path 51, across interface 6, through the aerosol-generation area near aerosol generator 48 (causing vaporized aerosol-generating material to be entrained in the airflow), along cartridge air flow path 52, and out through mouthpiece opening 50 for the user to inhale.

[0060] Power source or supply 26, in this example, is rechargeable and may be of a conventional type, such as the type typically used in e-cigarettes and other applications requiring the supply of relatively high current for relatively short periods of time. Power source 26 may be recharged via a charging connector, such as a USB connector, within reusable portion housing 12. In an embodiment, power source 26 has a body with a pair of electrodes extending therefrom, as shown, for example, in FIG. 6 .

[0061] A first user input button 14 and / or a second user input button 16 may be provided, which in this example are conventional mechanical buttons with spring-mounted components that can be depressed by a user, for example, to form electrical contact. In this regard, the input buttons may be considered input devices for detecting user input, and the particular manner in which the buttons are implemented is not important. The buttons may be assigned functions such as turning the aerosol delivery system 1 on and off and adjusting user settings such as the power supplied from the power source 26 to the aerosol generator 48. However, the inclusion of user input buttons is optional, and in some embodiments, buttons may not be included.

[0062] A display 24 may be provided to provide a user with visual indications of various characteristics associated with the aerosol delivery system, such as current power setting information, remaining power source power, etc. The display may be implemented in a variety of ways. In this example, the display 24 comprises a conventional pixelated LCD screen that can be driven to display desired information in accordance with conventional techniques. In other implementations, the display may comprise one or more discrete indicators, such as LEDs, configured to display desired information, for example, via particular colors and / or flashing sequences. More generally, the manner in which the display 24 is provided and information is displayed to the user using the display is not important to the principles described herein. For example, some embodiments may not include a visual display and / or may include other means for providing the user with information regarding the operating characteristics of the aerosol delivery system, for example, using audio signaling, or may not include any means for providing the user with information regarding the operating characteristics of the aerosol delivery system.

[0063] The controller 22 is suitably configured / programmed to control the operation of the aerosol delivery system 1 to provide functionality according to embodiments of the present disclosure described further herein, as well as conventional operational functions of the aerosol delivery system 1 in line with established techniques for controlling such devices. The controller (processor circuitry) 22 may be considered to logically comprise various subunits / circuit components associated with different aspects of the operation of the aerosol delivery system 1. In this example, the controller 22 comprises power supply control circuitry for controlling the supply of power from the power source 26 to the aerosol generator 48 in response to user input, user programming circuitry 20 for establishing configuration settings (e.g., user-defined power settings) in response to user input, and other functional unit / circuitry-related functions according to the principles described herein and conventional operational aspects of e-cigarettes, such as display driver circuitry and user input detection circuitry. It will be appreciated that the functionality of the controller 22 may be provided in a variety of different ways, for example, using one or more suitably programmed programmable computers and / or one or more suitably configured application-specific integrated circuits / circuitry / chips / chipsets configured to provide the desired functionality.

[0064] The functionality of the controller 22 is described further herein. For example, the controller 22 may comprise an application-specific integrated circuit (ASIC) or microcontroller for controlling the aerosol delivery device. The microcontroller or ASIC may include a CPU or microprocessor. The operation of the CPU and other electronic components is generally controlled at least in part by a software program running on the CPU (or other component). Such software programs may be stored in non-volatile memory, such as ROM, which may be integrated into the microcontroller itself or provided as a separate component. The CPU may access the ROM to load and execute individual software programs as and when needed.

[0065] The reusable part 2 includes an airflow sensor 30 electrically connected to the controller 22. In most embodiments, the airflow sensor 30 includes a so-called "puff sensor," in that the airflow sensor 30 is used to detect when a user is puffing on the device. In some embodiments, the airflow sensor 30 includes a switch in the electrical path that provides power from the power source 26 to the aerosol generator 48. In such embodiments, the airflow sensor 30 generally includes a pressure sensor configured to close the switch when exposed to a specific pressure range, allowing current to flow from the power source 26 to the aerosol generator 48 when the pressure in the vicinity of the airflow sensor 30 falls below a threshold. The threshold may be set to a value determined experimentally to correspond to a characteristic value associated with the initiation of a user puff. In other embodiments, the airflow sensor 30 is connected to the controller 22, which allocates power from the power source 26 to the aerosol generator 48 in response to a signal received by the controller 22 from the airflow sensor 30. The particular manner in which the signal output from the airflow sensor 30 (which may include a measurement of the capacitance, resistance, or other property of the airflow sensor made by the controller 22) is used by the controller 22 to control the supply of power from the power source 26 to the aerosol generator 48 may be done according to techniques known to those skilled in the art.

[0066] In the example shown in FIG. 1 , the airflow sensor 30 is mounted on a printed circuit board (PCB) 31, although this is not required. The airflow sensor 30 may comprise any sensor configured to determine characteristics of airflow within the airflow passage 51 disposed between the air inlet 28 and the mouthpiece opening 50, such as a pressure sensor or transducer (e.g., a membrane or solid-state pressure sensor), a combined temperature and pressure sensor, or a microphone sensitive to changes in air pressure, including acoustic signals (e.g., an electret-type microphone). The airflow sensor 30 is located within a sensor cavity or chamber 32 comprising an interior space defined by one or more chamber walls 34. The sensor cavity 32 comprises an area within the one or more chamber walls 34 within which the airflow sensor 30 may be fully or partially located. In some embodiments, the PCB 31 comprises one of the chamber walls of a sensor housing comprising the sensor chamber / cavity 32.

[0067] A deformable membrane is positioned across an opening communicating between the sensor cavity 32 containing the sensor 30 and a portion of the air flow path disposed between the air inlet 28 and the mouthpiece opening 50. The deformable membrane covers the opening and is attached to one or more of the chamber walls according to techniques described further herein.

[0068] As further described herein, the aerosol delivery system 1 comprises communication circuitry configured to enable a connection to be established with one or more additional electronic devices (e.g., a storage / charging case and / or a refill / charging dock) to enable data transfer between the aerosol delivery system 1 and the additional electronic devices. In some embodiments, the communication circuitry is integrated into the controller 22, while in other embodiments, the communication circuitry is implemented separately (e.g., comprising a separate application-specific integrated circuit / circuitry / chip / chipset). For example, the communication circuitry may comprise a separate module to the controller 22 that provides dedicated data transfer functionality for the aerosol delivery device while connected to the controller 22. In some embodiments, the communication circuitry is configured to support communication between the aerosol delivery system 1 and one or more additional electronic devices via a wireless interface. The communication circuitry may be configured to support wireless communication between the aerosol delivery system 1 and other electronic devices, such as a case, a dock, a computing device such as a smartphone or PC, a base station supporting cellular communication, a relay node providing a forward connection to a base station, a wearable device, or any other portable or fixed device supporting wireless communication.

[0069] Wireless communication between the aerosol delivery system 1 and the additional electronic device may be configured according to a data transfer protocol such as Bluetooth®, ZigBee, WiFi®, Wifi Direct, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or generally any other wireless and / or wired network protocol or interface. The communication circuitry may include any suitable interface for a wired data connection, such as a USB-C, micro USB, or Thunderbolt interface, and may include a pin or contact pad arrangement configured to engage with cooperating pins or contact pads on a dock, case, cable, or other external device that may be connected to the aerosol delivery system 1.

[0070] 2, 3, and 4 are schematic top-down, bottom-up, and side perspective views (respectively) of aerosol delivery subsystem 100 according to some embodiments of the present disclosure, showing bracket 110 in more detail.

[0071] As shown in FIGS. 2-4, bracket 110 is a generally tubular or cylindrical mounting bracket 110 configured to receive power supply 26, power supply 26 having a body with a pair of electrodes 27 extending therefrom (shown separately in FIG. 6). Bracket 110 includes a first (upper) portion 110a having a pair of openings 120 configured to receive the pair of electrodes 27 and present the pair of electrodes 27 for connection at an end of bracket 110, and a second portion 110b having a cavity 130 configured to receive the power supply body. In the exemplary embodiment of FIGS. 2-4, pair of openings 120 extend substantially axially and are configured to receive the pair of electrodes 27 and present the pair of electrodes 27 for connection at an axial end of bracket 110 proximal to first portion 110a. Additionally, in the embodiment of Figures 2-4, the bracket 110 further includes a third lower portion 110c having an opening for providing an air inlet 28 into the subsystem 100 having a flow path therethrough for delivering air to the aerosol generator 48 (not shown).

[0072] The first (upper) portion 110a generally comprises a truncated tube (or cylinder) having an open upper end for connection to the cartridge portion 4 (as shown in FIG. 7). The first portion 110a comprises a surface 140 having a platform 142 with a pair of openings 120 therethrough. In the exemplary embodiment of FIG. 3, the surface 140 is planar and extends substantially radially, and the platform 142 comprises two upstanding truncated cylinders 142a, 142b, each extending substantially axially (and thus substantially perpendicular to the radial surface 140) and each having an opening 120 therethrough (thereby forming a tube). The platform 142 axially spaces at least the conductive portion of the electrode 27 from the surface 140 in use. The surface 140 further comprises a peripheral wall 144, the (walled) surface 140 forming a collection area for condensate in use. The platform 142 thereby axially spaces at least the conductive portion of the electrode 27 from the water collection area in use, preferably minimising the risk of shorting out the power supply 26 in use.

[0073] First portion 110a, second portion 110b, and / or third portion 110c may generally include one or more protrusions and / or recesses configured to receive, connect to, interfere with, or mate with additional components. As shown in FIG. 2, first portion 110a includes multiple internal protrusions 145 and recesses 146 extending from wall 144 for engaging or mating with complementary protrusions 245 and / or recesses 246 on cartridge portion 4 (as shown in FIG. 7) to ensure and / or prevent rotation of portions 2, 4 relative to one another when joined. In some embodiments not shown in FIGS. 2-4, outer sidewall 150a of first portion 110a includes one or more external protrusions or recesses for engaging with other components, such as outer shell 200, during use. Such components may optionally include complementary protrusions or recesses.

[0074] In some embodiments (not shown), any of portions 110a-110c, particularly first (upper) portion 110a, may be asymmetric in cross section and / or when viewed from the proximal end perpendicular to the axial axis of its extent. Preferably, this allows for one-way mating for that portion to engage with other components (such as upper portion 110a engaging cartridge portion 4), which is detectable by a camera to automate assembly; i.e., a camera assembly can uniquely detect the orientation of first portion 110a, and then a robotic arm can position / rotate first portion 110a as needed to mate with other components during assembly. The orientation of first portion 110a may be uniquely identifiable by its asymmetry in cross section, particularly by the asymmetric or otherwise orientation-specific arrangement of visible features, i.e., opening 120, peripheral wall 144, platform 142, surface 140, and / or protrusions 145 and recesses 146. For example, each of the openings 120, the platforms 142a, 142b and / or the protrusions 145 and recesses 146 may be different shapes and / or sizes from one another.

[0075] 2-4, second portion 110b forms an intermediate portion between first (upper) portion 110a and third (lower) portion 110c. Second portion 110b generally includes opposed tubular sidewalls 150b that extend around only a portion of the circumference of generally tubular or cylindrical bracket 110, which provides power supply cavity 130 configured to receive a power supply body in use.

[0076] 2-4, the third (lower) portion 110c generally comprises a truncated tube or cylinder having an opening for providing the air inlet 28 into the subsystem 100. The third portion 110c also comprises an optional sensor cavity 32 for receiving a fluid flow sensor 30, surrounded by a fluid flow sensor seal 33. The third portion 110c further comprises a flange 164 for abutting the outer shell 200 received when assembling the system 1 (as shown in FIG. 9), and a protrusion in the form of a shoulder 162 on the outer wall 150c of the third portion 110c for engaging the outer shell 200 and achieving an interference fit therewith, which secures the outer shell 200 over the subsystem 100. Similarly, the other portions 110 a , 110 b may include protrusions, recesses, flanges and / or shoulders for engaging or abutting other components, such as the outer shell 200 .

[0077] FIG. 3 further shows a baffle cavity 135 for receiving a user-operable baffle 138 (not shown, see FIG. 5) that is slidable to adjust the airflow into the device through the inlet 28.

[0078] FIG. 4 shows subsystem 100 in use, further comprising power supply 26 and electrode 27 for connection at the axially proximal end of bracket 110, extending axially and projecting beyond the axial extent of first portion 110a. Bracket 110 in FIG. 4 also comprises additional recesses for receiving flexible, resilient, and / or absorbent inserts 170a and 170c. In FIG. 4, these comprise two radially extending recesses, one above and one below power supply cavity 130, for receiving inserts 170a and 170c, respectively, above and below the power supply body. Subsystem 100 also comprises insert 170b along the power supply body. While a recess is not necessarily required in bracket 110 because insert 170b is attached to the power supply body, in further embodiments, subsystem 100 may comprise a recess extending axially along power supply cavity 130 for receiving insert 170b along the power supply body. Inserts 170a-170c may be used to provide padding between components to achieve a secure attachment (e.g., to aid in an interference fit) and to reduce / prevent leaks when used with a liquid cartridge system. In some embodiments, inserts 170a-170c comprise ethylene vinyl acetate (EVA).

[0079] Figure 5 is a side cross-sectional view of the aerosol delivery subsystem 100 of Figure 4. In addition to the features shown in Figure 4, Figure 5 shows an optional fluid flow sensor 30 in the air flow path from the air inlet 28 and a fluid flow sensor seal 33 for sealing around the fluid flow sensor 30. In some embodiments, the sensor 30 comprises a microphone or a pressure sensor. Figure 5 also shows a baffle 38 and a baffle seal 39 for sealing around the baffle 38. In some embodiments, the seals 33, 39 comprise silicone.

[0080] Figure 6 is a schematic side view of a modular power supply for aerosol delivery subsystem 100, according to some embodiments of the present disclosure. Figure 6 shows power supply 26 comprising a body with a pair of electrodes 27 extending therefrom, positionable in a pair of openings 120 for connection to aerosol generator 48. This configuration therefore provides both an electrical connection to secure power supply 26 within system 1 and a non-permanent (easily reversible) mechanical connection. In some embodiments not shown in Figure 6, the electrodes comprising pair of electrodes 27 are different shapes and / or sizes from one another to facilitate assembly, i.e., each electrode may fit in only one of openings 120.

[0081] 7 is an exploded perspective view of an aerosol delivery system 1 according to some embodiments of the present disclosure. As described above, the device portion 2 is itself a modular subsystem 100 and includes a component mounting bracket 110. The cartridge portion 4 includes a cartridge housing 42 that contains an aerosol-generating material, such as tobacco (in the case of a THP system) or a liquid containing nicotine (in the case of an e-cigarette), and includes complementary conductive pins 227 for electrically connecting to electrodes 27 of a power supply 26 to power an aerosol generator 48 therein. The cartridge portion 4 also includes a mouthpiece shell 60 having a mouthpiece outlet 50. As shown in FIG. 9, the mouthpiece shell 60 may be separable from the cartridge housing 42.

[0082] In the exemplary embodiment of Figure 7, both the device portion 2 and the cartridge portion 4 are operable to engage with the outer shell 200 (shown in Figure 8) by an interference fit, with both the device portion 2 and the cartridge portion 4 including protrusions 162, 262, 362. Specifically, in this example, the device portion 2 includes protrusion 162 on the distal portion 110c of the bracket 110, the cartridge housing 42 of the cartridge portion 4 includes protrusion 262, and the mouthpiece shell 60 of the cartridge portion 4 includes protrusion 362. The protrusions 162, 262, 362 extend radially to engage the shell 200 by an interference fit.

[0083] As outlined above with reference to FIG. 2, cartridge portion 4 also includes protrusions 245 and recesses 246 for engaging or mating with complementary protrusions 145 and recesses 146 extending from wall 144 of first portion 110a to ensure and / or prevent rotation of portions 2, 4 relative to one another when joined.

[0084] FIG. 8 is a schematic side view of an aerosol delivery system 1 according to some embodiments of the present disclosure. FIG. 8 illustrates a generally tubular or cylindrical example of an elongated disposable or reusable e-cigarette or THP system 1, including a collar 210 that secures an outer shell 200 surrounding the aerosol delivery system 1. In a two-part system, such as the system of FIG. 7, the outer shell 200 is secured over both the device portion 2 and the cartridge 4 portion. Thus, the entire system 1 can be easily disassembled without tools by removing the push-fit end collar 210 and then pulling the bracket 110 from the shell 200, thereby removing all of the interconnected subsystem components. The cartridge portion 4 can be similarly removed from the other end of the outer shell 200.

[0085] 9 is a schematic diagram of an assembly process for an aerosol delivery system 1 according to some embodiments of the present disclosure. Subsystem 100 includes a bracket 110 that stores components of device portion 2, allowing them to be installed and removed from system 1 together so that the overall system 1 can be easily assembled and disassembled. In some embodiments, the various components and / or portions are held together by an interference fit to achieve tool-less assembly.

[0086] 9, subsystem 100 receives cartridge housing 42 at its proximal axial end and connects electrode 27 to aerosol generator 48 within cartridge housing 42. Outer shell 200 is then secured to subsystem 100 by an interference fit at bracket protrusion 162 and is pressed axially against bracket flange 164 at the end of bracket 110. Mouthpiece shell 60 is similarly secured to outer shell 200 by an interference fit at mouthpiece shell protrusion 362, thereby securing outer shell 200 between bracket flange 164 and mouthpiece shell 60.

[0087] Figures 10-14 show further examples of the present disclosure that will now be described in more detail. Like reference numerals from the previous examples of Figures 1-9 have been used for convenience, but any features of those examples may be combined, and are particularly contemplated in combination, although detailed discussion of multiple permutations has been omitted for the sake of brevity.

[0088] 10-13 are schematic perspective views of the aerosol delivery subsystem 100 according to some embodiments of the present disclosure, particularly showing the second bracket 110 in more detail.

[0089] In this second example, bracket 110 comprises a first tubular portion 110a having a pair of openings 120 configured to receive a pair of power supply terminals / electrodes 27 and present the pair of power supply terminals / electrodes 27 for connection at the ends of bracket 110, and a second portion 110b having a tubular sidewall 150b extending around only a portion of the circumference of bracket 110 and having a cavity 130 configured to receive a power supply body. Cavity 130 in second portion 110b is formed by tubular sidewall 150b extending axially away from first portion 110a, best shown in FIG. 12. Opening 120 extends through a surface spanning the sidewall of first portion 110a.

[0090] Compared to the first example, the overall shape of the bracket 110 is different, with the second example being shaped generally like a premolar or molar, with the first portion 110a resembling a crown portion and the second portion 110b resembling a root or pedicle. This second example also does not require the third portion 110c or the peripheral wall 144, although these may still be provided.

[0091] The bracket 110 of Figures 10-14 includes one or more openings 121 configured to provide an air flow path therethrough, as will be described in more detail below.

[0092] Figure 11 shows bracket 110 with a protrusion in the form of a flange 154 configured to receive or engage with aerosol generator 48 or cartridge / cartomizer. Flange 154 also includes external protrusion 145. Figure 14 shows flange 154 (circled) which, in use, engages with cartridge housing 42, which will be described in more detail below.

[0093] FIG. 12 shows a side view of bracket 110, showing that second portion 110b includes bridge supports 115 that space the end of the power supply body from first portion 110a and allow airflow through openings 121.

[0094] 13 shows subassembly 100 further comprising flexible, resilient and / or absorbent inserts 170a and 170c as in the previous example, and elongated power supply 26 having wires 29 running from electrodes 27 around the sides of the power supply body to end cap 160. In this second example, instead of bracket 110 with third portion 110c, a separate end cap 160 having flange 164 is provided.

[0095] In some configurations, the airflow sensor 30, configured to detect airflow through the air inlet 28 during use, is beneficially located substantially at one end of the system 1, away from the cartridge and mouthpiece 50, where it is less likely to come into contact with e-liquid or condensation. In FIGS. 13-14 , the end cap 160 includes the air inlet 28 at the proximal inlet end of the subsystem (shown in FIG. 14 ), and the airflow sensor 30 is located in the airflow path from the air inlet 28 to detect puffs as air enters the system 1 (shown in FIG. 14 ). The same advantage accrues from the first example shown in FIG. 5 , where the third portion 110 c of the bracket also includes the air inlet 28 and stores the sensor 30. In contrast, the configuration of FIG. 1 positions the sensor 30 at the side air inlet 28, proximal to the aerosol generator 48, simplifying the air inlet path and power wiring.

[0096] 13 , the sensor 30 is connected to an electrode of the elongated power supply 26 that extends longitudinally away from the sensor 30 by a wire 29 that extends along the battery compartment to an electrode 27 at the distal / downstream (axial) end of the power supply 26, with the electrode 27 facing / extending away from the sensor 30 (and inlet 28). In FIG. 13 , the wire 29 extends along the right side of the power supply body, between the power supply body and the bracket 110, and is thus held by the bracket 110. Alternatively, the wire 29 may extend along the power supply aligned with the midpoint of the electrode 27, and thus the wire 29 can have the same length for both terminals at the farthest axial end of the power supply 26 away from the sensor 30. The bracket 110 may include additional features, such as a third leg for securing the wire 29. The same terminal / electrode 27 also powers, in use, an aerosol generator 48, shown in Figure 14 at the distal / downstream end of the subsystem further away from the puff sensor 30 and the inlet 28. The subsystem may comprise a reusable device portion 2 of the aerosol delivery system 1 for use with a removable / replaceable cartridge portion 4.

[0097] As best shown in FIG. 13, the wiring 29 is preferably longer than the shortest path from the electrode 27 to the sensor 30, i.e., has excess length so that the puff sensor 30 is axially separable from the power supply 26 when connected; this aids in assembly, for example, allowing for insertion / removal of the end cap 160 without damaging the connection, allowing this subassembly to be assembled outside of the housing / shell 200 before the end cap 160 is pressed into place.

[0098] Typically, power supply 26 may have a length (extending away from sensor 30) of 25-35 mm, 35-45 mm, or 45-55 mm. Assuming a typical minimum length of 15 mm to reliably connect sensor 30 to electrodes / terminals 27 at the distal / downstream axial end of power supply 26 (note that the shortest path may have slightly different lengths for different + / - terminals), the corresponding minimum wire length is 40-50 mm, 50-60 mm, or 60-70 mm. Preferably, the wire has an excess length of 20-30 mm, 30-40 mm, or 40-50 mm greater than this minimum "shortest path" length to allow for easy installation / removal, thus having a length of 60-70 mm, 70-80 mm, 80-90 mm, 90-100 mm, 100-110 mm, or 110-120 mm. Any excess length of wire 29 may be accommodated within space 166 between end cap 160 and power supply 26 (as best seen in FIG. 14, excess length of wire 29 may be accommodated by being wound within space 166). Space 166 may also accommodate absorbent material 170c to capture any aerosol-generating material or condensation that may have leaked.

[0099] Figure 14 is a cross-sectional view of an aerosol delivery system 1 according to some embodiments of the present disclosure, including the second bracket 110 of Figures 10-13. As shown, the aerosol delivery system 1 of Figure 14 includes the subsystem of Figure 13 and additional components that form the system 1.

[0100] In addition to the components shown in FIG. 13 , system 1 of FIG. 14 further includes an outer shell 200 around end cap 160, bracket 110, and cartridge housing 42. Internally, system 1 also includes a sealing element 133 that engages bracket first portion 110 a and aerosol generator 48, providing a seal therebetween and, therefore, between aerosol generator 48 and power supply 26 during use. As noted above, flange 154 of bracket 110 engages cartridge housing 42 (circled) to secure the cartridge to bracket 110. Bracket 110 provides separation between the cartridge and power supply 26, reducing the risk of leaks affecting power supply 26 and sensor 30. System 1 further includes a manifold 58 at the distal downstream end of system 1 opposite end cap 160 for directing aerosol from aerosol generator 48 to mouthpiece 50.

[0101] As shown in FIG. 14 , air inlet 28 to end cap 160 provides airflow into system 1 at its proximal inlet end. The airflow may be adjustable by a slidable baffle 38 to regulate airflow into system 1 through inlet 28, as discussed above with reference to FIG. 5 . System 1 provides an airflow path therethrough, passing through power supply 26 and on to aerosol generator 48 for capturing vapor and generating aerosol. In some examples, bracket 110 provides an airflow path around power supply 26, for example, by providing space between power supply 26 and second portion 110 b and / or by providing space between power supply 26, bracket 110, and the inner wall of shell 200. Such spacing may be achieved, for example, by achieving a relatively loose fit radially and relying primarily on axial retention, optionally with padding to prevent vibration, or by using an interference fit (e.g., with padding) between respective elements around only a portion of the circumference, for example, at alternating sections. In some examples, the bracket 110 includes one or more openings 121 to provide an air flow path therethrough from the second portion 110b to the first portion 110a.

[0102] Thus, as detailed herein, the bracket 110 may provide several functions, which may include: Holds the electrodes / terminals 27 of the power supply 26 Present or extend the electrodes / terminals 27 of the power supply 26 Holds the power supply 26 itself Fix the cartridge Provide a seal between the cartridge and the power supply 26 Provide an air flow path to the aerosol generator / cartridge By integrating several functions into one-piece components, the total component count for the device is reduced, which helps reduce costs and simplify the manufacturing / assembly process.

[0103] Beneficially, aspects of the configuration disclosed herein (particularly the separation between the cartridge and power supply 26) allow the cartridge to contain freely stored liquid in a reservoir, which can maximize storage volume without the need for a storage medium such as cotton, which is often used to help reduce leakage, but which itself occupies volume and absorbs some of the liquid that cannot be released, thus reducing the effective capacity. The use of freely stored liquid allows for a smaller reservoir for the same volume of aerosol-generating material, which results in a more compact device. This space savings within the cartridge can provide room to accommodate any excess length of wire 29 connecting to airflow sensor 30, which avoids impacting the overall size of system 1.

[0104] In some examples, as shown in FIGS. 1-9, the bracket 110 also serves the function of an end cap 160.

[0105] The modular nature of the overall system 1, and particularly the subsystem 100, therefore allows for easy installation and removal of individual components, such as the power supply body and electrodes 27. In conventional configurations, these connections are typically soldered and fixed one-to-one directly into place within the subsystem 100, making assembly and disassembly more time-consuming and tedious, and increasing the likelihood of damage during assembly / disassembly. By providing the mounting bracket 110, the various components can be connected to each other as modular subsystems 100, which are then collectively assembled into the entire system 1, resulting in a faster, more convenient, and less damaging assembly process. Furthermore, the process is reversible, thus enhancing recyclability, which is particularly important for disposable devices that are typically single-use and discarded (and therefore not recycled) as a complete unit. Thus, the present invention significantly enhances recyclability, as the various components can be easily removed and sent to an appropriate recycling center.

[0106] In the embodiment of FIG. 1, various components (such as aerosol generator 48) are shown as components of cartridge portion 4, but in some embodiments, these may instead be components of device portion 2 or subsystem 100, and bracket 110 may include additional features, such as protrusions, recesses, shelves and / or cavities, for storing these components.

[0107] The steps of the disclosed methods may be performed in any suitable order.

[0108] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention.

[0109] Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Moreover, the present disclosure may include other inventions not currently claimed but which may be claimed in the future. Protection may be sought for any feature disclosed in any one or more of the published documents referenced herein in combination with the present disclosure.

[0110] Specific feature A 1. An aerosol delivery subsystem comprising a generally tubular or cylindrical mounting bracket, the bracket configured to receive a power supply having a body with a pair of electrodes extending therefrom, the bracket comprising: a. a first portion having a pair of openings configured to receive a pair of electrodes and present the pair of electrodes for connection at an end of a bracket; b. a second portion having a cavity configured to receive a power supply body; an aerosol delivery subsystem comprising:

[0111] 2.A pair of openings, a. extend substantially axially; and / or b. configured to receive a pair of electrodes and present the pair of electrodes for connection at the axial ends of the bracket; and / or c. An aerosol delivery subsystem as described in clause 1, configured to present a pair of electrodes for connection at an end of the bracket proximal to the first portion.

[0112] 3. a. An opening for providing air inlet into the subsystem; and / or b. a cavity for receiving a fluid flow sensor 3. The aerosol delivery subsystem of clause 1 or 2, further comprising a third portion having:

[0113] 4. The bracket is a. a first upper portion having a pair of openings configured to receive a pair of electrodes and present the pair of electrodes for connection at an end of a bracket; b. a second intermediate portion having a cavity configured to receive the power supply body; c. a third lower portion; 4. The aerosol delivery subsystem of any one of clauses 1 to 3, comprising:

[0114] 5. The first part, the second part, and / or the third part are a. Truncated cylinders or tubes, and / or b. Opposing side walls that extend around only a portion of the circumference of a generally tubular or cylindrical bracket; and / or c. a flange or shoulder for abutting an outer shell or another component, and / or d. Protrusions and / or recesses for engaging an outer shell or another component 5. The aerosol delivery subsystem of any one of clauses 1 to 4, comprising:

[0115] 6. a. the first upper section and the third lower section both comprise a truncated cylinder or tube; b. the second intermediate portion comprises opposed tubular sidewalls extending around only a portion of the circumference of the tube; c. the third lower portion includes a flange and a protrusion or recess for removably receiving and engaging the outer shell; 6. The aerosol delivery subsystem of any one of clauses 1 to 5.

[0116] 7. An aerosol delivery subsystem described in any one of clauses 1 to 6, wherein the first part comprises a surface having a platform through which a pair of openings pass, the platform axially spacing at least the conductive portion of the electrode from the surface in use.

[0117] 8. a. the surface has a peripheral wall to form a collection area for condensate during use; b. the platform, in use, axially spaces at least a conductive portion of the electrode from the water collection area; 8. The aerosol delivery subsystem of clause 7.

[0118] 9. The aerosol delivery subsystem of clause 7 or 8, wherein the surface extends substantially radially and the platform extends substantially axially, substantially perpendicular to the radial surface, away from the collection area.

[0119] 10. The aerosol delivery subsystem of any one of clauses 1-9, wherein the first portion, the second portion, and / or the third portion are asymmetric in cross section.

[0120] 11. An aerosol delivery subsystem described in any one of clauses 1 to 10, wherein the first portion, second portion, and / or third portion are asymmetric when viewed from the proximal end perpendicular to the axial axis of their extent.

[0121] 12. An aerosol delivery subsystem described in any one of clauses 1 to 11, wherein the first part, the second part, and / or the third part have a plurality of protrusions and / or recesses configured to receive, connect to, interfere with, or engage with an additional component, and the configuration of the plurality of protrusions and / or recesses is asymmetric in cross section.

[0122] 13. An aerosol delivery subsystem described in any one of clauses 1-12, wherein the openings of a pair of openings are different shapes and / or sizes from each other.

[0123] 14. An aerosol delivery subsystem described in any one of clauses 1 to 13, wherein the outer wall of the bracket has one or more protrusions or recesses at one or more ends thereof for engaging with complementary protrusions or recesses.

[0124] 15. An aerosol delivery subsystem described in any one of clauses 1-14, further comprising one or more recesses for receiving a flexible, elastic and / or absorbent insert.

[0125] 16. a. radially extending recesses above and / or below the cavity configured to receive the power source body for receiving a flexible, resilient, and / or absorbent insert above and / or below the power source body; and / or b. an axially extending recess along the cavity configured to receive the power supply body for receiving a flexible, resilient, and / or absorbent insert along the power supply body; 16. The aerosol delivery subsystem of any one of clauses 1 to 15, comprising:

[0126] 17. a. a power supply having a body and electrodes extending therefrom; and / or b. fluid flow sensors, and / or c. a seal to seal around the fluid flow sensor; and / or d. flexible, elastic and / or absorbent inserts, and / or e. an outer shell for storing the bracket; and / or f. Baffles to regulate airflow through the subsystem; and / or g. Aerosol generators, and / or h. a cartridge or cartomizer for storing aerosol- or smoke-generating materials to produce an aerosol or smoke for inhalation by a user; and / or i. Mouthpiece, and / or j. Controller 17. The aerosol delivery subsystem of any one of clauses 1-16, further comprising:

[0127] 18. The aerosol delivery subsystem of clause 17, wherein the subsystem is configured to accept a power supply, a fluid flow sensor, a seal, an insert, an outer shell, a baffle, an aerosol generator, a cartridge or cartomizer, a mouthpiece, and / or a controller having an interference fit.

[0128] 19. An aerosol delivery subsystem according to clause 17 or 18, comprising a power supply, wherein the pair of electrodes comprises a positive electrode and a negative electrode of different shapes and / or sizes.

[0129] 20. A generally tubular or cylindrical aerosol delivery system comprising a generally tubular or cylindrical mounting bracket according to any one of clauses 1 to 19.

[0130] 21. A set of instructions for a 3D printer configured to print the aerosol delivery subsystem of any one of clauses 1-20.

[0131] 22. A method of assembling an aerosol delivery subsystem comprising a generally tubular or cylindrical mounting bracket and a power supply having a body with a pair of electrodes extending therefrom, comprising: a. mounting a power supply body in a cavity of a bracket; b. attaching a pair of electrodes to a pair of openings in the bracket, the pair of electrodes presenting for connection at the ends of the bracket; A method comprising:

[0132] 23. An aerosol delivery subsystem comprising a generally tubular or cylindrical mounting means, the mounting means configured to receive a power supply having a body with a pair of electrodes extending therefrom, and a bracket: a. a first means having a pair of openings configured to receive a pair of electrodes and present the pair of electrodes for connection at an end of a bracket; b. a second means having a cavity configured to receive a power supply body; an aerosol delivery subsystem comprising:

[0133] Specific feature B 1. An aerosol delivery subsystem comprising a mounting bracket configured to receive a power supply having a body with a pair of electrodes extending therefrom, the bracket comprising: a. a first tubular or cylindrical portion having a pair of openings configured to receive a pair of electrodes and present the pair of electrodes for connection at an end of a bracket; b. a second portion having a tubular sidewall extending around only a portion of the circumference of the bracket and having a cavity configured to receive the power supply body; an aerosol delivery subsystem comprising:

[0134] 2.A pair of openings, a. extend substantially axially; and / or b. extending through a surface spanning the sidewall of the first tubular or cylindrical portion; and / or c. configured to receive a pair of electrodes and present the pair of electrodes for connection at the axial ends of the bracket; and / or d. An aerosol delivery subsystem as described in clause 1, configured to present a pair of electrodes for connection at an end of the bracket proximal to the first portion.

[0135] 3. The aerosol delivery subsystem described in clause 1 or 2, wherein the bracket further comprises one or more openings configured to provide an air flow path therethrough.

[0136] 4. An aerosol delivery subsystem described in any one of clauses 1 to 3, wherein the tubular side wall of the second portion forms a leg extending axially away from the first portion.

[0137] 5. An aerosol delivery subsystem described in any one of clauses 1 to 4, wherein the second portion comprises a bridge support between the tubular side walls.

[0138] 6. An aerosol delivery subsystem described in any one of clauses 1 to 5, further comprising a sealing element for sealing between the first portion of the bracket and the aerosol generator, or a reservoir, cartridge or cartomizer for storing aerosol-generating or smoke-generating material.

[0139] 7. An aerosol delivery subsystem described in any one of clauses 1 to 6, wherein the first part comprises a flange or protrusion configured to receive or engage with an aerosol generator, or a reservoir, cartridge or cartomizer that stores aerosol-generating or smoke-generating material.

[0140] 8. An aerosol delivery subsystem described in any one of clauses 1 to 7, wherein in use, when connected to the power supply and the aerosol generator, reservoir, cartridge or cartomizer, the bracket comprises or provides an air flow path for air flow through the power supply and to the aerosol generator, reservoir, cartridge or cartomizer.

[0141] 9. a. the first portion comprises a truncated cylinder or tube; and / or b. the second portion comprises opposing side walls that extend around only a portion of the perimeter of the bracket; and / or c. the bracket further comprises a flange or shoulder for abutting against the outer shell or another component; and / or d. the bracket further comprises one or more protrusions and / or recesses for engaging the outer shell or another component; 9. The aerosol delivery subsystem of any one of clauses 1 to 8.

[0142] 10. An aerosol delivery subsystem described in any one of clauses 1 to 9, wherein the first part comprises a surface having a platform through which a pair of openings pass, the platform axially spacing at least the conductive portion of the electrode from the surface in use.

[0143] 11. a. the surface has a peripheral wall to form a collection area for condensate during use; b. the platform, in use, axially spaces at least a conductive portion of the electrode from the water collection area; 11. The aerosol delivery subsystem of clause 10.

[0144] 12. The aerosol delivery subsystem of clause 10, wherein the surface extends substantially radially and the platform extends substantially axially, substantially perpendicular to the radial surface, away from the collection area.

[0145] 13. The aerosol delivery subsystem of any one of clauses 1-12, wherein the first portion and / or the second portion are asymmetric in cross section.

[0146] 14. An aerosol delivery subsystem described in any one of clauses 1 to 13, wherein the first portion and / or the second portion are asymmetric when viewed from the proximal end perpendicular to the axial axis of their extent.

[0147] 15. An aerosol delivery subsystem described in any one of clauses 1 to 14, wherein the first part and / or the second part have a plurality of protrusions and / or recesses configured to receive, connect to, interfere with, or engage with an additional component, and the configuration of the plurality of protrusions and / or recesses is asymmetric in cross section.

[0148] 16. An aerosol delivery subsystem described in any one of clauses 1-15, wherein the openings of a pair of openings are different shapes and / or sizes from each other.

[0149] 17. An aerosol delivery subsystem described in any one of clauses 1 to 16, wherein the outer wall of the bracket has one or more protrusions or recesses at one or more ends thereof for engaging with complementary protrusions or recesses.

[0150] 18. An aerosol delivery subsystem described in any one of clauses 1-17, further comprising one or more recesses for receiving a flexible, elastic and / or absorbent insert.

[0151] 19. a. radially extending recesses above and / or below the cavity configured to receive the power source body for receiving a flexible, resilient, and / or absorbent insert above and / or below the power source body; and / or b. an axially extending recess along the cavity configured to receive the power supply body for receiving a flexible, resilient, and / or absorbent insert along the power supply body; 19. The aerosol delivery subsystem of any one of clauses 1-18, comprising:

[0152] 20. a. a power supply having a body and electrodes extending therefrom; and / or b. fluid flow sensors, and / or c. a seal to seal around the fluid flow sensor; and / or d. flexible, elastic and / or absorbent inserts, and / or e. an outer shell for storing the bracket; and / or f. Baffles to regulate airflow through the subsystem; and / or g. Aerosol generators, and / or h. a reservoir, cartridge, or cartomizer for storing aerosol- or smoke-generating materials to produce an aerosol or smoke for inhalation by a user; and / or i. Mouthpiece, and / or j. Controller 20. The aerosol delivery subsystem of any one of clauses 1-19, further comprising:

[0153] 21. The aerosol delivery subsystem of clause 20, wherein the subsystem is configured to accept a power supply, a fluid flow sensor, a seal, an insert, an outer shell, a baffle, an aerosol generator, a reservoir, a cartridge or cartomizer, a mouthpiece, and / or a controller having an interference fit.

[0154] 22. An aerosol delivery subsystem according to clause 20 or 21, comprising a sealing element and an aerosol generator, reservoir, cartridge or cartomizer according to clause 6.

[0155] 23. Equipped with a power supply; a. the pair of electrodes comprises a positive electrode and a negative electrode of different shapes and / or sizes; and / or b. the subsystem includes an air flow path around the power supply through one or more openings in the bracket; and / or c. The aerosol delivery subsystem of clause 20 or 21, wherein the power source is held in a bracket or brackets around a portion of the circumference of the power source.

[0156] 24. An aerosol delivery subsystem as described in clause 20, comprising a reservoir, cartridge or cartomizer containing a freely stored liquid therein.

[0157] 25. A set of instructions for a 3D printer configured to print the aerosol delivery subsystem described in any one of clauses 1-24.

[0158] 26. An aerosol delivery system comprising an aerosol delivery subsystem according to any one of clauses 1 to 25.

[0159] 27. The aerosol delivery system of clause 26, wherein the bracket provides an air flow path around the power source.

Claims

1. a. a puff sensor at one end configured to detect airflow through the air inlet in use; b. an elongated power supply extending away from said puff sensor and having an electrode at a distal end remote from said puff sensor for connection to said puff sensor; an aerosol delivery subsystem comprising:

2. 10. The aerosol delivery subsystem of claim 1, further comprising wiring for connecting the puff sensor to the distal end electrode of the power supply, the wiring having excess length such that when connected, the puff sensor is axially detachable from the power supply to facilitate assembly.

3. 3. The aerosol delivery subsystem of claim 1, wherein the power source has a length extending away from the puff sensor of 25 to 35 mm, 35 to 45 mm, or 45 to 55 mm.

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

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

6. 6. The aerosol delivery subsystem of claim 1, wherein the air inlet is located at the end of the subsystem and the puff sensor is located in the airflow path from the air inlet into the subsystem.

7. 7. The aerosol delivery subsystem of claim 1, further comprising a mounting bracket for the power supply, the bracket providing electrodes for connection at ends of the bracket.

8. The aerosol delivery subsystem of any one of claims 1 to 7, further comprising a baffle across the air inlet for regulating air flow through the air inlet.

9. The aerosol delivery subsystem of any one of claims 1 to 8, wherein the baffle is slidable to adjust the air flow through the air inlet.

10. 10. The aerosol delivery subsystem of claim 1, wherein the air inlet is located at a proximal end of the subsystem, and the subsystem further comprises an aerosol generator at a distal end of the subsystem remote from the puff sensor.

11. 11. The aerosol delivery subsystem of claim 1, wherein the puff sensor, the power supply, and the aerosol generator are substantially axially aligned in the order puff sensor-power supply-aerosol generator.

12. 12. An aerosol delivery subsystem according to any preceding claim, comprising a cartridge or reservoir for storing aerosol-generating material.

13. 13. The aerosol delivery subsystem of claim 12, wherein the puff sensor, the power supply, the aerosol generator, and the cartridge or reservoir are substantially axially aligned in the order of puff sensor-power supply-aerosol generator-cartridge or reservoir.

14. 14. The aerosol delivery subsystem of claim 12 or 13, comprising a liquid freely stored within the cartridge or reservoir.

15. the mounting bracket for the power supply; b) an end cap containing the puff sensor and the air inlet; c. a shell configured to receive the end cap, the mounting bracket, and the power supply; 15. The aerosol delivery subsystem of any one of claims 1 to 14, comprising:

16. 16. The aerosol delivery subsystem of claim 15, wherein the shell provides a space between the end cap and the power supply to receive the wiring.

17. An aerosol delivery system comprising the aerosol delivery subsystem of any one of claims 1 to 16.

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

19. 19. The aerosol delivery system of claim 17 or 18, comprising a mouthpiece, the puff sensor being located substantially at a proximal end of the system, away from the mouthpiece located at the opposite distal end of the system.

20. 1. A method of assembling an aerosol delivery subsystem, the subsystem comprising: a. a puff sensor configured to detect airflow through the air inlet in use; b. an elongate power supply that, in use, extends away from said puff sensor and has an electrode at a distal end remote from said puff sensor; c. a mounting bracket for said power supply, said bracket providing electrodes for connection at ends of said bracket; d. Wiring for connecting the puff sensor to the electrode, the wiring extending along the length of the power supply body in use and having excess length to aid in assembly; wherein the method comprises: mounting the power supply at the bracket; wiring the puff sensor to the electrode; mounting the puff sensor in an end cap comprising the air inlet; positioning the bracket and the power supply within an outer shell; securing the end cap to the shell to form a proximal end of the system, the shell providing a space between the end cap and the power source to accommodate the excess length of wiring; A method comprising:

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