Aerosol delivery systems

Abstract

P126936PCT; P14623841; 82421502 31 ABSTRACT The present disclosure relates to an aerosol generator assembly for aerosolising an aerosol- generating material, the aerosol generator assembly comprising: an aerosol generator comprising two elongate electrical connectors; and two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator 5 is configured to generate aerosol, wherein each of the two barrier portions is configured to be pierced by a respective one of the two elongate electrical connectors during assembly of the aerosol generator assembly, wherein each one of the two elongate electrical connectors extends through a respective barrier portion of the two barrier portions. 10 [Accompanied by Figure 1]

Description

[0001] AEROSOL DELIVERY SYSTEMS

[0002] Field

[0003] The present disclosure relates to aerosol delivery systems such as nicotine delivery systems (e.g. electronic cigarettes and the like).

[0004] Background

[0005] Electronic vapour provision systems such as electronic cigarettes (e-cigarettes) generally contain a vapour precursor material, such as a reservoir of a source liquid containing a formulation, typically including nicotine, from which a vapour is generated for inhalation by a user, for example through heat vaporisation. Thus, a vapour provision system will typically comprise a vapour generation chamber containing a vaporiser assembly arranged to vaporise a portion of precursor material to generate a vapour in the vapour generation chamber. The vaporiser assembly will often comprise a heater coil arranged around a liquid transport element (capillary wick) that is arranged to transport source liquid from a reservoir to the heater coil for vaporisation. As a user inhales on the device and electrical power is supplied to the vaporiser assembly, air is drawn into the device through an inlet hole and into the vapour generation chamber where the air mixes with vaporised precursor material to form a condensation aerosol. There is an air channel connecting the vapour generation chamber and an opening in the mouthpiece so the air drawn through the vapour generation chamber as a user inhales on the mouthpiece continues along the flow path to the mouthpiece opening, carrying the vapour with it for inhalation by the user.

[0006] The design of aspects relating to the vaporiser assembly of a vapour provision system can play an important role in the overall performance of the system, for example in terms of helping to reduce leakage and corrosion of electrical connections. Various approaches are described herein which seek to help address some of these issues.

[0007] Summary

[0008] According to a first aspect of certain embodiments there is provided an aerosol generator assembly for aerosolising an aerosol-generating material, the aerosol generator assembly comprising: an aerosol generator comprising two elongate electrical connectors, and two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol, wherein each of the two barrier portions is configured to be pierced by a respective one of the two elongate electrical connectors during assembly of the aerosol generator assembly, wherein each one of the two elongate electrical connectors extends through a respective barrier portion of the two barrier portions. According to a second aspect of certain embodiments there is provided a cartomiser for aerosolising an aerosol-generating material, the cartomiser comprising an aerosol generator assembly in accordance with the first aspect and an aerosol-generating material.

[0009] According to a third aspect of certain embodiments there is provided an electronic aerosol provision system for aerosolising an aerosol-generating material, the electronic aerosol provision system comprising the aerosol generator assembly of the first aspect or the cartomiser of the second aspect, and a control unit comprising a power supply for supplying power to the aerosol generator, wherein the two elongate electrical connectors form part of an electrical circuit configured to supply power from the power supply to the aerosol generator.

[0010] According to a fourth aspect of certain embodiments there is provided a method of assembling an aerosol generator assembly for aerosolising an aerosol-generating material in an electronic aerosol delivery system, wherein the method comprises: providing an aerosol generator comprising two elongate electrical connectors, providing two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol, and inserting the two elongate electrical connectors into the two barrier portions such that each of the two elongate electrical connectors pierces and extends through a respective one of the two barrier portions.

[0011] It will be appreciated that features and aspects of the invention described herein in relation to the various aspects of the disclosure are equally applicable to, and may be combined with, embodiments of the disclosure according to other aspects as appropriate, and not just in the specific combinations described herein.

[0012] Brief Description of the Drawings

[0013] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0014] Figure 1 schematically represents in perspective view an aerosol delivery system comprising a cartridge and control unit in accordance with certain embodiments of the disclosure;

[0015] Figure 2 schematically represents in perspective view an example aerosol generator assembly in accordance with certain embodiments of the disclosure; and

[0016] Figure 3 is a flow diagram schematically representing steps in a method of forming an aerosol generator assembly for use in an aerosol delivery system according to an embodiment of the disclosure. Detailed Description

[0017] Aspects and features of certain examples and embodiments are discussed I described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed I described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

[0018] As will be explained below, the present disclosure relates to an aerosol generator assembly for aerosolising an aerosol-generating material in an electronic aerosol delivery system, the aerosol generator assembly comprising: an aerosol generator comprising two elongate electrical connectors; and two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol, wherein each of the two barrier portions is configured to be pierced by a respective one of the two elongate electrical connectors during assembly of the aerosol generator assembly, wherein each one of the two elongate electrical connectors extends through a respective barrier portion of the two barrier portions. The above system prevents or inhibits (e.g. substantially reduces) the movement of liquid along the elongate electrical connectors and out of the aerosol generation region.

[0019] For example, in the absence of a barrier material or portion, or in the presence of a poorly sealing barrier portion, liquid may flow out of the aerosol generating region along the elongate electrical connectors or through openings through which the elongate electrical connectors extend. As such, the present disclosure offers an improved degree of sealing by forming the aerosol generator assembly by piercing the barrier portions with the elongate electrical connectors during manufacture or assembly of the aerosol generator assembly. In particular, by piercing, rather than drilling or otherwise forming openings for receiving the elongate electrical connectors, the cross-section and size of the openings closely match the size and cross-section of the elongate electrical connectors, thereby preventing the formation of open space between the barrier portions and elongate electrical connectors through which liquid could flow. The prevention or inhibition of liquid flow through the barrier portions may, for example, prevent the accumulation of liquid at a contact point between the elongate electrical connectors and electrode posts, thereby preventing disruption of an electrically conductive pathway between the elongate electrical connectors and electrode posts (e.g. due to corrosion of the surface of either the elongate electrical connectors or electrode posts, or due to the liquid forming a barrier between the elongate electrical connectors and electrode posts). The present disclosure relates to aerosol delivery systems, which may also be referred to as aerosol or vapour provision systems, such as e-cigarettes. Throughout the following description the term “e-cigarette” or “electronic cigarette” may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol delivery system I device, electronic aerosol delivery system I device, vapour provision system I device, and electronic vapour provision system I device. Furthermore, and as is common in the technical field, the terms "vapour" and "aerosol", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably.

[0020] As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosolgenerating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

[0021] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

[0022] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0023] In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0024] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosolgenerating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

[0025] Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

[0026] In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source.

[0027] In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0028] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0029] In some embodiments, the substance to be delivered comprises an active substance.

[0030] The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, or another botanical.

[0031] In one embodiment the active substance is a legally permissible recreational drug.

[0032] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0033] As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof.

[0034] As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v..Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

[0035] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

[0036] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0037] In some embodiments, the substance to be delivered comprises a flavour.

[0038] As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0039] In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

[0040] In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

[0041] Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and / or flavourants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

[0042] The aerosol-generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material. The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3- butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0043] The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0044] The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

[0045] A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosolgenerating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, be a material heatable by electrical conduction.

[0046] An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

[0047] The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosolmodifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosolmodifying agent may be free from filtration material.

[0048] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosolgenerating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0049] More generally, it will be appreciated certain embodiments of the disclosure are based on approaches for seeking to help optimise vaporiser assembly performance in vapour delivery systems in accordance with the principles described herein, and other constructional and functional aspects of electronic cigarettes implementing approaches in accordance with certain embodiments of the disclosure are not of primary significance and may, for example, be implemented in accordance with any established approaches.

[0050] Figure 1 is a schematic perspective view of an example aerosol delivery system I device (e- cigarette, vapour I aerosol provision system) 1 in accordance with certain embodiments of the disclosure Positional terms concerning the relative location of various aspects of the electronic cigarette (e.g. terms such as upper, lower, above, below, top, bottom etc.) may be used herein with reference to a vertical orientation of a longitudinal axis of the e-cigarette with a mouthpiece (through which it is intended a user inhales) at an upper most end (unless the context indicates otherwise). However, it will be appreciated this is purely for ease of explanation and is not intended to indicate there is any required orientation for the electronic cigarette in use.

[0051] The e-cigarette 1 comprises two main components, namely a cartridge 4 (cartridge part) and a control unit 2 (control part). The control unit 2 and the cartridge 4 are shown coupled together.

[0052] The cartridge 4 and control unit 2 are coupled by establishing a mechanical and electrical connection between them. The specific manner in which the mechanical and electrical connection is established is not of primary significance to the principles described herein and may be established in accordance with conventional techniques, for example based around a screw thread, bayonet, latched or friction-fit mechanical fixing with appropriately arranged electrical contacts I electrodes for establishing the electrical connection between the two parts as appropriate. For the example electronic cigarette 1 represented in Figure 1 , the cartridge comprises a mouthpiece end 52 and an interface end 54 and is coupled to the control unit by inserting an interface end portion 6 at the interface end of the cartridge into a corresponding receptacle 81 receiving section of the control unit. The interface end portion 6 of the cartridge is a close fit to be receptacle 8 and may include includes protrusions (not shown) which engage with corresponding detents in the interior surface of a receptacle wall 12 defining the receptacle 8 to provide a releasable mechanical engagement between the cartridge and the control unit. An electrical connection is established between the control unit and the cartridge via a pair of electrodes 14 providing electrical contacts on the bottom of the cartridge and corresponding sprung contact pins 16 in the base of the receptacle 8. As noted above, the specific manner in which the electrical connection is established is not significant to the principles described herein, and indeed some implementations might not have an electrical connection between the cartridge and a control unit at all, for example because the transfer of electrical power from the reusable part to the cartridge may be wireless (e.g. based on electromagnetic induction techniques).

[0053] The electronic cigarette 1 has a generally elongate shape extending along a longitudinal axis L. When the cartridge is coupled to the control unit, the overall length of the electronic cigarette in this example (along the longitudinal axis) is around 12.5 cm. The overall length of the control unit is around 9 cm and the overall length of the cartridge is around 5 cm (i.e. there is around 3 cm of overlap between the interface end portion 6 of the cartridge and the receptacle 8 of the control unit when they are coupled together). The electronic cigarette has a cross-section which is generally oval and which is largest around the middle of the electronic cigarette and tapers in a curved manner towards the ends. The cross-section around the middle of the electronic cigarette has a width of around 2.5 cm and a thickness of around 1 .7 cm. The end of the cartridge has a width of around 2 cm and a thickness of around 0.6 mm, whereas the other end of the electronic cigarette has a width of around 2 cm and a thickness of around 1.2 cm. The outer housing of the electronic cigarette is in some examples formed from plastic. It will be appreciated the specific size and shape of the electronic cigarette and the material from which it is made is not of primary significance to the principles described herein and may be different in different implementations. That is to say, the principles described herein may equally be adopted for electronic cigarettes having different sizes, shapes and I or materials.

[0054] The control unit 2 may in accordance with certain embodiments of the disclosure be broadly conventional in terms of its functionality and general construction techniques. In the example of Figure 1 , the control unit 2 comprises outer housing 10 (formed of a plastic or metal, for example) including the receptacle wall 12 that defines the receptacle 8 for receiving the end of the cartridge as noted above. The outer housing 10 of the control unit 2 in this example has a generally oval cross section conforming to the shape and size of the cartridge 4 at their interface to provide a smooth transition between the two parts. The receptacle wall 12 includes a control unit air inlet opening 11 (e.g. provided by one or more holes in the wall). In use, when a user inhales on the cartridge 4, air is drawn in through these holes, towards the interface end of the cartridge part 4 where the air enters the cartridge through an opening in the base end of the cartridge. It will be appreciated that the interface end portion 6 of the cartridge 4 may not form an airtight seal with the receptacle wall 12 so some air drawn may also be drawn into the cartridge through gaps between the cartridge 4 and the control unit 2.

[0055] The control unit further comprises a battery 16 for providing operating power for the electronic cigarette, control circuitry 18 for controlling and monitoring the operation of the electronic cigarette, a user input button 20, an indicator 22.

[0056] The battery 16 in this example is rechargeable and may be of a conventional type, for example of the kind normally used in electronic cigarettes and other applications requiring provision of relatively high currents over relatively short periods. In some of these examples, the battery 16 may be recharged through a charging port (not shown), which may, for example, comprise a USB connector; or the battery 16 may be recharged inductively via suitable components for inductive charging (e.g. a susceptor assembly (not shown) configured to form part of an induction circuit with an inductive charger).

[0057] The input button 20 in this example is a conventional mechanical button, for example comprising a sprung mounted component which may be pressed by a user to establish an electrical contact in underlying circuitry. In this regard, the input button may be considered an input device for detecting user input, e.g. to trigger vapour generation, and the specific manner in which the button is implemented is not significant. For example, other forms of mechanical button or touch-sensitive button (e.g. based on capacitive or optical sensing techniques) may be used in other implementations, or there may be no button and the device may rely on a puff detector for triggering vapour generation.

[0058] The indicator 22 is provided to give a user with a visual indication of various characteristics associated with the electronic cigarette, for example, an indication of an operating state (e.g. on I off I standby), and other characteristics, such as battery life or fault conditions. In some examples, the indicator 22 may be provided by one or more LEDs. Different characteristics may, for example, be indicated through different colours and I or different flash sequences in accordance with generally conventional techniques. In some other examples, the indicator 22 may be provided by a display, configured to display information to a user.

[0059] The control circuitry 18 is suitably configured I programmed to control the operation of the electronic cigarette to provide conventional operating functions in line with the established techniques for controlling electronic cigarettes. The control circuitry (processor circuitry) 18 may be considered to logically comprise various sub-units I circuitry elements associated with different aspects of the electronic cigarette's operation. For example, depending on the functionality provided in different implementations, the control circuitry 18 may comprises power supply control circuitry for controlling the supply of power from the battery to the cartridge in response to user input, user programming circuitry for establishing configuration settings (e.g. user-defined power settings) in response to user input, as well as other functional units I circuitry associated functionality in accordance with the principles described herein and conventional operating aspects of electronic cigarettes, such as indicator light display driving circuitry and user input detection circuitry. It will be appreciated the functionality of the control circuitry 18 can be provided in various different ways, for example using one or more suitably programmed programmable computer(s) and I or one or more suitably configured applicationspecific integrated circuit(s) I circuitry I chip(s) I chipset(s) configured to provide the desired functionality.

[0060] The cartridge 4 comprises a housing part 32, an end cap 34 containing the electrodes 14, an aerosol generator assembly comprising an aerosol generator 40, a liquid transport element 42, and a sealing component 36 comprising two barrier portions 38. As discussed below, the cartridge 4 is configured to contain an aerosol generating material. The cartridge 4 may in some examples be termed a cartomiser in that it comprises an aerosol generator and an aerosol-generating material.

[0061] The housing part 32 in this example comprises a housing outer wall 64 and a housing inner tube 62 which in this example are formed from a single moulding of polypropylene. The housing outer wall 64 defines the external appearance of the cartridge 4 and the housing inner tube 62 defines a part of the air channel 46 through the cartridge. The housing part is open at the interface end 54 of the cartridge and closed at the mouthpiece end 52 of the cartridge except for a mouthpiece opening I vapour outlet 60 in fluid communication with the housing inner tube 62.

[0062] The housing part 32 defines a storage area or reservoir 44 between the housing outer wall 64 and the housing inner tube 62. The reservoir or storage area 44 is for containing aerosol generating material (e.g. liquid aerosol generating material). Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. In the example shown schematically in Figure 1 , a reservoir 44 is provided configured to store a supply of liquid aerosol generating material. In this example, the liquid reservoir 44 has a substantially annular shape with an outer wall defined by the housing outer wall 64 and the housing inner tube 62 that defines an airflow path through the cartridge part 4. The reservoir 44 is closed at mouthpiece end 52 with an end wall to contain the aerosol generating material.

[0063] The aerosol generator 40 is located towards an end of the reservoir 44 opposite to the mouthpiece end 52. In Figure 1 , the aerosol generator is a heater 40 (and is referred to as such below) which is configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some other embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0064] It will be appreciated that in a two-part device such as shown in Figure 1 , the aerosol generator may be in either of the reusable part 2 or the cartridge part 4. For example, in some embodiments, the aerosol generator 40 (e.g. a heater) may be comprised in the reusable part 2, and is brought into proximity with a portion of aerosol generating material in the cartridge 4 when the cartridge is engaged with the reusable part 2. In such embodiments, the cartridge may comprise a portion of aerosol generating material, and an aerosol generator 40 comprising a heater is at least partially inserted into or is provided at least partially adjacent or surrounding the portion of aerosol generating material as the cartridge 4 is engaged with the reusable part 2.

[0065] In the example of Figure 1 , the liquid transport element 42 is a wick 42 in contact with a heater 40. The wick 42 extends transversely across the primary (or first) airflow path with its ends extending into a pocket or recess (not shown) fluidly connected to a reservoir 44 of a liquid aerosol generating material.

[0066] The sealing component 36 in the example of Figure 1 comprises silicone and may be a single moulding of silicone. The sealing component 36 and at least one other component (e.g. an interface end of the inner tube 62) may be shaped to provide apertures through which the wick is extended. For example, the sealing component 36 may be shaped such that an inner wall (adjacent to the section of the airflow path containing the aerosol generator 40) includes a pair of diametrically opposing slots. Each slot may provide a semi-circular surface for accommodating the liquid transport element 42. Similarly, extended outwardly (i.e. in a direction away from the longitudinal axis of the cartridge) from the interface end 54 of the inner tube 62 may be respective (diametrically opposed) recesses shaped to receive a section of the liquid transport element 42 when the cartridge is assembled. The slots and recesses are aligned so that the inner tube 62 and sealing component 36 cooperate to define holes through which the liquid transport element 42 passes. The size of the holes through which the liquid transport element passes correspond closely to the size and shape of the liquid transport element, but are slightly smaller so a degree of compression is provided by the resilience of the sealing component 36. This allows liquid to be transported along the liquid transport element by capillary action while restricting the extent to which liquid which is not transported by capillary action can pass through the openings. Additionally, in some examples, an outer edge of the sealing component 36 may be inserted into a part of the housing part 32 to seal the reservoir 44. For example, the sealing component 36 may be shaped to be received in an aperture at the interface end of the housing part 32. The sealing component 36 may include one or more circumferential ridges which engage with an inner surface of the housing part 32 and ensure a tight fit, when the sealing component 36 is inserted into the housing part 32. The connection may be configured such that the movement of liquid along the inner surface of the housing part 32 may be inhibited (e.g. by virtue of the tight fit). A similar, engagement mechanism could be provided between the sealing component 36 and the housing inner tube 62.

[0067] The wick 42 and heater 40 are arranged in the cartridge airflow path such that a region of the airflow path around the wick 42 and heater 40 in effect defines an aerosol generation region (or vaporisation region) for the cartridge part 4. Aerosol generating material in the reservoir 44 infiltrates the wick 42 through the ends of the wick adjacent to the reservoir 44 and is drawn along the wick by surface tension I capillary action (i.e. wicking). The heater 40 in this example comprises an electrically resistive wire coiled around the wick 42. In the example of Figure 1 , the heater 40 comprises a nickel chrome alloy (Cr20Ni80) wire and the wick 42 comprises a glass fibre bundle, but it will be appreciated the specific aerosol generator configuration is not significant to the principles described herein. As an example, the wick 42 could instead be cotton. In use electrical power may be supplied to the heater 40 to vaporise an amount of aerosol generating material (aerosol generating material) drawn to the vicinity of the heater 40 by the wick 42. Vaporised aerosol generating material may then become entrained in air drawn along the cartridge airflow path from the vaporisation region towards the mouthpiece outlet 60 for user inhalation.

[0068] As noted above, the rate at which aerosol generating material is vaporised by the vaporiser (heater) 40 will depend on the amount (level) of power supplied to the heater 40. Thus electrical power can be applied to the heater to selectively generate aerosol from the aerosol generating material in the cartridge part 4, and furthermore, the rate of aerosol generation can be changed by changing the amount of power supplied to the heater 40, for example through pulse width and / or frequency modulation techniques.

[0069] In addition to the portion of the resistance wire wound around the capillary wick 42 to provide the heater 40, the aerosol generator assembly further comprises elongate electrical connectors 41 which contact electrodes 14 mounted to the end cap 54 to allow power to be supplied to the heater 40 via the electrical interface established when the cartridge is connected to a control unit. The term elongate electrical connections 41 may be used interchangeably with the terms electrical leads, contact leads generally, and also the term heater leads in embodiment where the aerosol generator is a heater. In some examples, the elongate electrical connections 41 may be provides by one or more electrically conductive wires. In some examples, the heater leads 41 may comprise the same material as the resistance wire wound around the capillary wick forming the heater 40. In other examples, the heater leads 41 may comprise a different material ( e.g. a comparatively lower-resistance material) connected to the heater resistance wire 40 wound around the capillary wick 42 (e.g. by soldered connections).

[0070] The sealing component 36 further includes barrier portions 38 through which the electrical leads 41 (e.g. contact leads) for the heater coil 40 pass when the cartridge is assembled. In particular, each of the barrier portions 38 provides a barrier to a respective one of the electrical leads 41. During assembly, the electrical leads 41 are moved into the barrier portions 38 to pierce the barriers formed by the barrier portions 38. This ensures a tight interference fit between each electrical lead 41 and respective barrier portion 38, which additionally is independent of the size of the electrical leads 41 (e.g. which may vary as part of manufacturing tolerances). This allows the electrical leads 41 to extend through the respective barrier portions 38, while impeding the passage of liquid (e.g. liquid aerosol generating material) towards the electrodes 14. This prevents or inhibits liquid from interacting with the electrodes 14 and in particular the contact portion of the electrodes 14 with the electrical leads 41.

[0071] As depicted in figure 1 , the barrier portions 38 are part of the sealing component 36. Even other examples in accordance with the present invention the barrier portions 38 may be provided by components separate and distinct from the sealing component 36. In some examples, the barrier portions 38 may each comprise a separate disc of material configured to be received by the sealing component 36 or a different component defining a surface of an aerosol generation region (or chamber). For example, the sealing component 36 may comprise recesses for receiving each barrier portion 38.

[0072] As also depicted in figure 1 , the barrier portions 38 are provided in two distinct and separate regions of the surface defining the aerosol generation region (or chamber). This may aid in separating the different pairs of electrical leads 41 and electrodes 14 separate from each other, thereby reducing the risk of short circuits (e.g. by ensuring that an electrical lead 41 cannot touch another electrical lead or an electrode other than the intended one). In some other examples, the two barrier portions 38 may be provided by a single barrier surface. For example, each barrier portion 38 may be a region of the single barrier surface which it is intended the electrical lead 41 will pierce. The single barrier surface may be defined as a continuous portion of thin or weakened material which is configured to be pierced by the electrical leads 41. The electrodes 14 (e.g. electrode posts) are mounted on or otherwise connected to an end cap 34. The end cap 34 is provided at the interface end 54 of the cartridge 4. As an example the end cap 34 may comprise a polypropylene moulding with a pair of gold-plated copper electrode posts 14 mounted therein.

[0073] The ends of the electrode posts 14 on the bottom side of the end cap are close to flush with the interface end 54 of the cartridge provided by the end cap 34. These are the parts of the electrodes to which correspondingly aligned sprung contacts in the control unit connect when the cartridge is assembled and connected to the control unit. The ends of the electrode posts on the inside of the cartridge extend away from the end cap 34. The ends of the electrode may extend into holes in the sealing component 36 which are aligned with and extend to the barrier portions 38 through which the electrical leads 41 pass. The electrode posts 14 are slightly oversized relative to the holes and may include a chamfer at their upper ends to facilitate insertion into the holes in the sealing component 36. The electrode posts 14 may be maintained in pressed contact with the electrical leads 41 for the heater 40 by virtue of the resilient nature of the sealing component 36.

[0074] The end cap 34 may also be configured to attach to an the housing part 32. For example, the end cap 34 may include an upstanding wall (not shown) which is inserted into the housing part 32. In some examples, latch projections (not shown) may engage with the latch recesses (not shown) in the housing part 32 to snap-fit the end cap 34 to the housing part when the cartridge is assembled. A surface of the end cap 34 (i.e. the top or mouth end side surface) may also abut a part of the sealing component 36 so that when the end cap 34 is attached to the housing part 32 it presses against the sealing component 36 to maintain it within the cartridge 4 in slight compression.

[0075] When the cartridge is assembled an air channel 46 extending from the air inlet in the end cap 54 to the vapour outlet 60 through the cartridge is formed. In response to a user inhalation, air may flow from the control unit air inlet 11 towards the cartridge 4 (e.g. down a channel in the control unit 2), through the end cap 34, through a passage in the sealing component 36, into a portion of the air channel adjacent to the aerosol generator 40 and defined at least partially by the sealing component 36, into the housing inner tube 62, and out through the mouthpiece outlet 60. This portion of the air channel adjacent to the aerosol generator 40 may also be referred to as an aerosol generation region or chamber, it being the primary region in which aerosol is generated during use.

[0076] As noted above, when the cartridge is assembled a reservoir for liquid is formed by the space outside the housing inner tube 62 and an inner surface of the housing outer wall 64. This may be filled during manufacture, for example through a filling hole which is then sealed, or by other means. The specific nature of the liquid, for example in terms of its composition, is not of primary significance to the principles described herein, and in general any conventional liquid of the type normally used in electronic cigarettes may be used. The reservoir is closed at the interface end of the cartridge by the sealing component 36 which is also configured to at least partly provide openings for receiving the liquid transport element (capillary wick) 42 of the vaporiser assembly. Thus, the ends of the liquid transport element 42 extend into the reservoir from which they draw liquid through the openings in the air channel 46 to the heater 40 for subsequent vaporisation.

[0077] In normal use, the cartridge 4 is coupled to the control unit 2 and the control unit activated to supply power to the cartridge via the electrodes 14 in the end cap 34. Power then passes through the connection leads 41 to the heater 40. The heater is thus electrically heated and so vaporises a portion of the liquid from the liquid transport element in the vicinity of the heater. This generates vapour in the aerosol generation region of the air path. Liquid that is vaporised from the liquid transport element is replaced by more liquid drawn from the reservoir by capillary action. While the heater is activated and a user inhales on the mouthpiece end 52 of the cartridge, air is drawn into the cartridge through the air inlet in the end cap 54 and into the aerosol generation region surrounding the heater 40. The incoming air mixes with vapour generated from the heater to form a condensation aerosol, which is then drawn along the inner tube 62 before exiting through the mouthpiece outlet / vapour outlet 60 for user inhalation.

[0078] Figure 2 is a schematic perspective view of an example aerosol generator assembly 30 in accordance with certain embodiments of the disclosure. By an aerosol generator assembly 30 it is meant an assembly of components including the aerosol generator 40, certain components allowing the aerosol generator to operate (e.g. liquid transport element 42 and electrical leads 41), and components defining the aerosol generation chamber. In addition to the aerosol generator assembly 30, figure 2 depicts electrode posts 14 in contact with the electrical leads 41 (elongate electrical connectors) of the aerosol generator assembly 30. In addition to the components of figure 1 , figure 2 depicts an upper chamber component (or part) 70, and an upper sealing component 72. The principles described above in relation to the elements of figure 1 are broadly applicable to those depicted in figure 2.

[0079] In examples in accordance with figure 2, the sealing component 36 and the upper chamber component 70 combine to form an aerosol generation chamber around the aerosol generator 40. The aerosol generation chamber comprises a number of surfaces defining the aerosol generation region of the airflow path 46 adjacent to the aerosol generator 40, in which aerosol generated by the aerosol generator 40 enters the airflow path 46. In the example of figure 2, the sealing component 36 provides a lower chamber part defining a lower or upstream surface of the chamber, while the upper chamber component 70 defines an upper or downstream surface of the chamber.

[0080] Additionally, in examples in accordance with figure 2, the sealing component 36 and upper chamber component 70 are shaped to provide apertures through which a liquid transport element 42 (e.g. a wick) is extended. For example, the sealing component 36 may be shaped to contain recessed or slotted surfaces 73 (adjacent to the aerosol generation chamber) for receiving ends of the liquid transport element 42; while the upper chamber component 70 may have a clamping part 74 (e.g. retaining, holding part) comprising a corresponding aperture or recess for which aligns with the recessed surfaces 73 to create a hole through which the liquid transport element 42 passes. The hole allows liquid to travel through the liquid transport element 42 from the liquid reservoir 44, towards the aerosol generator 40, whilst providing adequate sealing. As noted above, the sealing component 36 may be formed of a elastomeric material such as a silicone material. In contrast the upper chamber component 70 may be a rigid material such as a plastic material.

[0081] The upper chamber part 70 may also define a lower portion of a reservoir 44, and in particular may extend the reservoir formed by the housing outer wall 64 and the inner tube 62 (not shown in figure 2). For example, as shown in figure 2 the upper chamber component 70 may have an annular shape in which the air pathway 46 (including the aerosol generation chamber) is defined in part by an inner channel of the upper chamber component 70, and a portion of a reservoir 44 is defined by an annular channel between the inner channel and an outer wall.

[0082] The outer wall of the upper chamber component 70 may be configured to fit within the housing outer wall 64 (not shown). In order to provide a seal preventing the movement of liquid between the outer wall of the upper chamber component 70 and the housing outer wall 64, an upper sealing component 72 is provided at the reservoir end of the upper chamber component 70 (i.e. the end of the upper chamber component 70 which is inserted into the open end of the reservoir 44 formed by the housing outer wall 64). The upper sealing component 72 is configured to engage with the housing outer wall 64 to form a seal which effectively closes off the open end of the reservoir 44 (except for via the liquid transport element 42). For example, the upper sealing component 72 may include one or more circumferentially extending (i.e. perpendicular to the insertion direction) ridges which contact the housing outer wall 64 upon insertion and provide a barrier to liquid. In some examples, the (lower or downstream) sealing component 36 may also include one or more circumferentially extending ridges which further act to prevent the movement of liquid along the housing outer wall 64.

[0083] In some examples, the inner tube 62 is configured to engage with the air channel 46 provided by the upper chamber component 70. For example, the inner tube 62 may be sized to fit within an upstream end of the upper chamber component 60. In these example, the upper sealing component may also provide a seal with the inner tube 62, thereby preventing the movement of liquid between the inner tube 62 and the upper chamber component 70.

[0084] The upper (or downstream) sealing component 72 may be formed from the same or a substantially similar material to the (lower or upstream) sealing component 36. For example, the upper sealing component 72 may be formed from an elastomeric material such as a silicone material.

[0085] In line with figure 1 , the sealing component 36 of figure 2 includes two barrier portions 38, each of which is configured to be pierceable by a respective elongate electrical connector 41 (e.g. an electrical lead such as an electrically conductive wire). The barrier portions 38 are provided in a surface of the sealing component 36 which at least partly defines a surface bounding an aerosol generation region in which the aerosol generator 40 is configured to generate aerosol (i.e. a surface of the aerosol generation chamber in combination with the upper chamber component 70).

[0086] In some examples where an aerosol-generating material comprises a liquid aerosolgenerating material, the liquid aerosol-generating material may travel from the aerosol generator 40 or liquid transport element 42 towards the barrier portions 38 via the elongate electrical connectors 41 or along a surface of the aerosol generating chamber from the junction of the liquid transport element 42 and the sealing component 36 and upper chamber part 70. In some examples, where the aerosol-generating material may or may not be a liquid aerosolgenerating material, condensation may form in the aerosol delivery system 1. For example, condensation may form when an aerosol cools within the air pathway 46 prior to inhalation by the user (e.g. in the aerosol generation chamber or the inner tube 62). In the examples above, it will be appreciated that when the aerosol delivery system 1 containing the aerosol generator assembly is retained in an upright position (i.e. with the mouthpiece outlet 60 as substantially the vertically upper most component), liquid may move under the force of gravity in a upstream direction towards the barrier portions 38 and the connection of the cartridge 4 to the control unit 2. The barrier portions 38 act to substantially prevent or inhibit the interaction of liquid (whether from condensation or leakage) with the electrode posts 14 by obstructing the pathway (i.e. providing a barrier) between the aerosol generation chamber and the electrode posts 14.

[0087] The barrier portions 38 each comprise a section of reduced width in comparison to the thickness of the sealing component 36 away from the barrier portions 38. For example, each barrier portion 38 comprises a width of up to 1 mm in a direction parallel to the direction of insertion of the respective elongate electrical connectors 41. Preferably, each barrier portion comprises a width of up to 0.2 mm in a direction parallel to the direction of insertion of the respective elongate electrical connectors 41 .

[0088] The barrier portions 38 are configured to be pierced by the elongate electrical connectors 41 without fracturing or cracking such that when the elongate electrical connectors 41 are inserted into their respective barrier portions 38, the only openings through the barrier portions 38 are completely filled by the elongate electrical connectors 41. In other words, each opening comprises a boundary formed around a circumference of an elongate electrical connector 41 , and does not include any portion that extends away from the elongate electrical connector 41 (i.e. a crack or split in the material of the barrier portion 38).

[0089] Furthermore, because the openings are formed by piercing the barrier portions 38, rather than drilling or otherwise forming openings for the insertion of the elongate electrical connectors 41 ; the material of the barrier portions 38 is effectively displaced by the insertion of the elongate electrical connectors 41 through the barrier portions 38 and as a result the barrier portions 38 produce restoring forces acting on the circumference of the elongate electrical connectors 41 towards their original non-displaced configuration. This restoring force acts to improve the sealing of the barrier portions 38 to the elongate electrical connectors 41 , thereby preventing (or substantially inhibiting) the movement of liquid through the barrier portions 38 and along the elongate electrical connectors 41.

[0090] The barrier portions 38 may be formed from an elastomeric material such as a silicone material (e.g. in line with the sealing component 36). Such an elastomeric material is elastically deformable in response to the piercing of the barrier portions 38 by the elongate electrical connectors 41 , which aids sealing by ensuring the barrier portions exert a restoring force towards their original configuration. Elastomeric materials are also resistant to cracking away from the point of insertion due to their resilient elastic nature.

[0091] In some examples, the barrier portion may have a width (or diameter) that is slightly wider than the width (or diameter) of an elongate electrical connector 41 configured to pierce the barrier portion 38. For example, the width of each base may be no more than 3 times the width of a elongate electrical connector 41 , and preferably no more than 2 times the width of a elongate electrical connector 41. In some examples, the width of each base may be up to 3 mm, and the width of each elongate electrical connector 41 may be up to 2 mm. It will be appreciated that in examples where a base and an elongate electrical connector 41 have circular crosssections perpendicular to the insertion direction, the widths above are equivalent to diameters of the respective circles; whereas in examples where one or both of the base and the elongate electrical connector 41 have non-circular cross-sections perpendicular to the insertion direction, the widths above refer to a minimum width of the base and / or a maximum width of the elongate electrical connector 41 in the cross-section perpendicular to the insertion direction.

[0092] The sealing component 36 of the aerosol generator assembly 30 of figure 2 includes two guide portions 76 each of which is associated with a respective barrier portion 38. Each guide portion 76 is configured to guide an elongate electrical connector 41 towards the associated barrier portion 38 during the assembly of the aerosol generator assembly. In other words, the aerosol generator assembly 30 comprises two guide portions 76, wherein a respective guide portion of the two guide portions 76 is configured to guide the respective one of the elongate electrical connectors 41 to the respective barrier portion 38 during assembly. The guide portions 76 therefore are configured to facilitate the piercing of the barrier portions 38 by the elongate electrical connectors 41 by directing the elongate electrical connectors 41 towards the thinner barrier portions 38.

[0093] The guide portions 76 of the aerosol generator assembly 30 of figure 2 are provided by two bowl-shaped depressions. Each bowl-shaped depression comprises a base forming one of the two barrier portions 38 and a periphery forming one of the two guide portions 76. The periphery of each bowl-shaped depression surrounds the base of the bowl-shaped depression and defines a peripheral surface angled with respect to the base of the bowl-shaped depression. Hence, if an elongate electrical connector 41 is interacts with (e.g. pushes against) the guide portion during assembly of the aerosol generator assembly 30, the elongate electrical connector 41 will be directed by the angled surface towards the barrier portion 38 provided by the base of the bowl shaped depression.

[0094] As noted above in some examples, the barrier portion (corresponding to the base) may have a width (or diameter) that is slightly wider than the width (or diameter) of an elongate electrical connector 41 configured to pierce the barrier portion 38. It will be appreciated that the guide portions 76 will have an inner peripheral edge corresponding to the shape of the base. Additionally, the guide portions 76 have an outer peripheral edge (not adjacent to the base) which may have a width that is significantly wider than the width (or diameter) of an elongate electrical connector 41 configured to pierce the associated barrier portion 38. For example, each guide portion 76 may have a width (e.g. an outer diameter rather than the inner diameter defining the base) that is up to 10 times the width of an elongate electrical connector 41 .

[0095] For example, the outermost width of each base may be up to 3 mm, the width of each elongate electrical connector 41 may be up to 2 mm, and the width of each guide portion may be up to 20 mm. As noted above, it will be appreciated that in examples where the peripheral surface of the bowl shaped depression has a circular cross section perpendicular to the insertion direction, the widths above are equivalent to diameters of the respective circles; whereas in examples where the peripheral surface of the bowl shaped depression has a non-circular cross-sections perpendicular to the insertion direction, the widths above refer to a minimum width of the peripheral surface in the cross-section perpendicular to the insertion direction.

[0096] It will be appreciated that guide portions 76 such as those disclosed in figure 2 could also be used in combination with other example aerosol generator assemblies not in accordance with figure 2. Furthermore, in other examples (not shown in figure 2), the guide portions 76 may be surround only a portion of a barrier portion 38. For example, the guide portions 76 may comprise a linear slope or wedge extending from one part of a barrier portion 38 and acting to direct an elongate electrical connector 41 received on a surface provided by the slope or wedge towards the barrier portion 38.

[0097] The sealing component 36 of figure 2 comprises two electrode post insertion cavities or regions 78, each of which is configured to receive a respective electrode post 14 (or electrode). Each electrode post insertion cavity 78 extends from the barrier portion 38 to an opening in the sealing component 36 through which the respective electrode post 14 is received. Each electrode post insertion cavity 78 is therefore sized to receive an electrode post 14 (e.g. the electrode post insertion cavities 78 have diameters equivalent to or slightly wider than the electrode posts 14).

[0098] Each elongate electrical connector 41 extends through (i.e. pierce) a respective barrier portions 38 and into a respective electrode post insertion cavities 78. The elongate electrical connectors 41 and the electrode posts 14 are configured to contact each other in the electrode post insertion cavities 78 and form an electric connection capable of carrying a current as part of a circuit. For example, the elongate electrical connectors 41 and the electrode posts 14 may extend from opposite ends of the electrode post insertion cavities 78 sufficient lengths in order to engage with each other. In some examples the length of a elongate electrical connector 41 received in an electrode post insertion cavity 78 and the length of an electrode post 14 received in the electrode post insertion cavity 78 may be greater than the length of the electrode post insertion cavity 78, such that the elongate electrical connector 41 and electrode post 14 are pressed against each other. In these example, the elongate electrical connector 41 and / or the electrode post 14 may bend or otherwise deform in order to accommodate the combined lengths (e.g. the elongate electrical connector 41 may be deflected towards a side of the cavity when it is pressed against the electrode post 14).

[0099] In some other examples, not in accordance with figure 2, the barrier portions 38 may be provided adjacent to an external surface of the sealing component 36 such that the elongate electrical connectors 41 extend from the sealing component 36 when they pierce and extend through the barrier portions 38. In these examples, the sealing component 36 do not require electrode post insertion cavities 78, and instead the electrode posts 14 are configured to contact the elongate electrical connectors 41 at a location outside of the sealing component 36.

[0100] The example of figure 2 depicts an aerosol generator 40 comprising a resistive heater. In particular, the resistive heater of figure 2 comprises a coil heater (i.e. in which the heater comprises a coil of wire wound around the liquid conduit element 42). In some examples in accordance with figure 2, the two elongate electrical connectors 41 comprise respective ends of a heating wire forming the coil heater. In these examples, the elongate electrical connectors 41 are formed of the same material as the coil heater. In some alternative examples the two elongate electrical connectors 41 may be formed of a different material to the heating wire of the coil heater. For example, the elongate electrical connectors 41 may be a different wire material that is soldered or otherwise connected to the heating wire of the coil heater.

[0101] It will be appreciated that other forms of aerosol generator 40 could be used in place of a resistive heater, with the barrier portions 38 and related aspects of the aerosol generator assembly 30 providing substantially similar advantageous effects. For example, even where the aerosol generator 40 does not generate aerosol from a liquid aerosol-generating material, a barrier portion 38 as described in relation to figure 2 may advantageously prevent or inhibit the movement of a condensation liquid towards the electrode posts 14.

[0102] Figure 3 is a flow chart of a method 300 for assembling an aerosol generator assembly 30 for use in an aerosol generating system 1 to generate an aerosol from an aerosol-generating material. The method begins at step 310 with providing an aerosol generator 40 comprising two elongate electrical connectors 41 . The aerosol generator 40 is an electrically powered aerosol generator which is configured to receive power from a power source 16 (e.g. battery) via the two elongate electrical connectors 41. For example, the two elongate electrical connectors 41 form part of an electric circuit for transferring power from the power source 16 to the aerosol generator 40 (e.g. by connecting to positive and negative terminals).

[0103] In some examples, the aerosol generator 40 may be a resistive heater. For example, the aerosol generator 40 may be a resistive coil heater comprising a wire. In some other examples, the resistive heater may be a conductive mesh or resistive track deposited on a ceramic surface. Each elongate electrical connector 41 may be soldered to or otherwise connected to the resistive heater (e.g. to contact pads at each end of the heater). In some examples, where the resistive heater is a coil heater, or other form of wire heater, the two elongate electrical connectors 41 comprise respective ends of a heating wire forming the coil heater. In other examples, the aerosol generator 40 may not be a resistive heater, and instead may be configured to generate an aerosol by other means. For example, the aerosol generator 40 may heat an aerosol-generating material by different means, such as irradiation with light, or may be configured to generate an aerosol without substantially heating the aerosol-generating material. For example, the aerosol generator may be configured to subject the aerosolgenerating material to one or more of vibration, increased pressure, or electrostatic energy.

[0104] The second step 320 continues with providing two barrier portions 38 configured to at least partly define a surface bounding an aerosol generation region. The aerosol generation region is the region or chamber in which the aerosol generator is configured to generate aerosol. For example, the aerosol-generating material and I or the aerosol generator 40 may be provided in the aerosol generation region such that the action of the aerosol generator 40 on the aerosol-generating material (e.g. heating) causes the release of one or more volatiles from the aerosol-generating material to form an aerosol. The barrier portions 38 prevent or inhibit the movement of liquid from the aerosol generation region by presenting barriers through which the liquid is not able to pass.

[0105] In some examples, the aerosol-generation material is a liquid aerosol-generation material. A liquid aerosol-generation material may leak in the aerosol generation region (or chamber) from the aerosol generator 40 (or from the liquid conducting element 42 and other associated components). In some examples, where the aerosol-generation material may or may not be a liquid aerosol-generation material (e.g. it may be a solid or gel material), condensation liquids may form in or around the aerosol generation region (e.g. in the housing inner tube 62). Liquids (either from condensation or leakage, or another source) may have a detrimental effect on the conduction between different components. For example, liquids may corrode the surface of conductive elements (e.g. metallic elements such as wires) thereby reducing their conductivity. As such, it is advantageous to prevent liquids from accumulating in regions in which connections between different components form. This can be achieved to some extent by providing the barrier portions 38 to prevent or inhibit (e.g. substantially reduce) the movement of liquid into regions in which connections are formed.

[0106] In some examples, the method continues with a third step 330 of guiding, by two guide portions 76, the two elongate electrical connectors 41 towards the two barrier portions 38. Each guide portion of the two guide portions 76 guides a respective one of the two elongate electrical connectors 41 to a respective one of the two barrier portions 38. The guide portions 76 facilitate the formation of the aerosol generator assembly 30 by directing the elongate electrical connectors 41 away from portions of the aerosol generator assembly 30 that are too strong or thick to be pierced by the elongate electrical connectors 41 , and towards the barrier portions 38 which are configured to be pierced by the elongate electrical connectors 41 (e.g. they are segments comprising a thin layer of material in comparison to the remainder of a sealing component 36).

[0107] Additionally, each guide portions 76 may be angled or sloped so that the path of least physical resistance for a respective elongate electrical connector 41 is towards a respective barrier portion 38. For example, each guide portion 76 and barrier portion 38 may form a bowl-shaped depression in the surface of the aerosol generation chamber. Each bowl-shaped depression comprising a base forming the barrier portion and a periphery forming the two guide portion. In the examples, the periphery of each bowl-shaped depression surrounding the base of the bowl-shaped depression defines a peripheral surface angled with respect to the base of the bowl-shaped depression. The peripheral surface acting to guide the elongate electrical connector 41 towards the base, rather than the elongate electrical connector 41 being pushed through the peripheral surface (i.e. because the elongate electrical connector 41 moves towards the peripheral surface in a direction that is not perpendicular to the peripheral surface). It will be appreciated that in other examples, one or both of the guide portions 76 may only extend around a portion of a boundary defining their associated barrier portion 38.

[0108] The fourth step 340 continues with inserting the two elongate electrical connectors 41 into the two barrier portions 38 such that each of the two elongate electrical connectors 41 pierces and extends through a respective one of the two barrier portions 38. Each of the respective one of the two barrier portions 38 forms a seal around the respective one of the two elongate electrical connectors 41 . By piercing the barrier portions 38 by the elongate electrical connectors 41 , the apertures or openings formed by the elongate electrical connectors 41 are only large enough to accommodate the elongate electrical connectors 41 , and do not introduce any open space between the barrier portions 38 and respective elongate electrical connectors 41 through which liquid can flow. In some examples, the barrier portions 38 may be formed of elastomeric materials which elastically deform when pierced by the elongate electrical connectors 41 , and which exert a restoring force on the surface of elongate electrical connectors 41 , where the barrier portions 38 and elongate electrical connectors 41 are in contact, thereby improving sealing. The method then ends.

[0109] It will be appreciated that while the above description has focused on some different aspects of an aerosol generator assembly having a number of different features, it will be appreciated that arrangements in accordance with other embodiments of the disclosure may include only some of these features independently of some of the other features. For example, in some implementations a sealing component made in accordance with the principles discussed herein with reference to Figure 2 may be implemented in an aerosol generator assembly that does not include a coil wound around the wick to compress the wick, or in which the barrier portions are provided separately to the sealing component (e.g. they may be attached to the sealing component).

[0110] Thus, there has also been described a method of manufacturing or assembling an aerosol generator assembly for aerosolising an aerosol-generating material in an electronic aerosol provision system. The method comprises providing an aerosol generator comprising two elongate electrical connectors, providing two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol, and inserting the two elongate electrical connectors into the two barrier portions such that each of the two elongate electrical connectors pierces and extends through a respective one of the two barrier portions.

[0111] There has been described an aerosol generator assembly for aerosolising an aerosolgenerating material in an electronic aerosol delivery system. The aerosol generator assembly comprising an aerosol generator comprising two elongate electrical connectors; and two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol. Each of the two barrier portions is configured to be pierced by a respective one of the two elongate electrical connectors during assembly of the aerosol generator assembly, and each one of the two elongate electrical connectors extends through a respective barrier portion of the two barrier portions.

[0112] There has also been described assembly means for aerosolising an aerosol-generating material, the assembly means comprising: aerosol generator means comprising two elongate electrical connector means; and two barrier means configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator means is configured to generate aerosol, wherein each of the two barrier means is configured to be pierced by a respective one of the two elongate electrical connector means during assembly of the assembly means, wherein each one of the two elongate electrical connector means extends through a respective barrier means of the two barrier means.

[0113] While the above described embodiments have in some respects focussed on some specific example aerosol delivery systems, it will be appreciated the same principles can be applied for aerosol delivery systems using other technologies. That is to say, the specific manner in which various aspects of the aerosol delivery system function, for example in terms of how the system is activated for use and the functionality provided by the system, are not directly relevant to the principles underlying the examples described herein. In order to address various issues and advance the art, this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and / or exclusive. They are presented only to assist in understanding and to teach the claimed invention(s). It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claims. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein, and it will thus be appreciated that features of the dependent claims may be combined with features of the independent claims in combinations other than those explicitly set out in the claims. The disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

CLAIMS1. An aerosol generator assembly for aerosolising an aerosol-generating material, the aerosol generator assembly comprising: an aerosol generator comprising two elongate electrical connectors; and two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol, wherein each of the two barrier portions is configured to be pierced by a respective one of the two elongate electrical connectors during assembly of the aerosol generator assembly, wherein each one of the two elongate electrical connectors extends through a respective barrier portion of the two barrier portions.

2. The aerosol generator assembly of claim 1, wherein the aerosol generator assembly comprises a sealing component, wherein the two barrier portions are part of the sealing component.

3. The aerosol generator assembly of claim 1 or 2, wherein the aerosol generator assembly comprises two guide portions, wherein a respective guide portion of the two guide portions is configured to guide the respective one of the elongate electrical connectors to the respective barrier portion during assembly.

4. The aerosol generator assembly of claim 3, wherein the aerosol generator assembly comprises two bowl-shaped depressions, each bowl-shaped depression comprising a base forming one of the two barrier portions and a periphery forming one of the two guide portions, the periphery of each bowl-shaped depression surrounding the base of the bowl-shaped depression and defining a peripheral surface angled with respect to the base of the bowlshaped depression.

5. The aerosol generator assembly of any of claims 1 to 4, wherein the aerosol generator is a resistive heater.

6. The aerosol generator assembly of claim 5, wherein the resistive heater comprises a coil heater, and wherein the two elongate electrical connectors comprise respective ends of a heating wire forming the coil heater.

7. The aerosol generator assembly of any of claims 1 to 6, wherein the two barrier portions are formed of an elastomeric material.

8. The aerosol generator assembly of any of claims 1 to 7, wherein each barrier portion of the two barrier portions comprise a width parallel to the direction of insertion of the respective elongate electrical connectors, wherein the width is in the range of up to 1 mm.

9. The aerosol generator assembly of any of claims 1 to 8, wherein the two barrier portions are provided by a single barrier surface.

10. A cartomiser for aerosolising an aerosol-generating material, the cartomiser comprising: the aerosol generator assembly of any of claims 1 to 9; and an aerosol-generating material.

11. An electronic aerosol provision system for aerosolising an aerosol-generating material, the electronic aerosol provision system comprising: the aerosol generator assembly of any of claims 1 to 9 or the cartomiser of claim 10; and a control unit comprising a power supply for supplying power to the aerosol generator, wherein the two elongate electrical connectors form part of an electrical circuit configured to supply power from the power supply to the aerosol generator.

12. A method of assembling an aerosol generator assembly for aerosolising an aerosolgenerating material in an electronic aerosol delivery system, wherein the method comprises: providing an aerosol generator comprising two elongate electrical connectors; providing two barrier portions configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator is configured to generate aerosol; andinserting the two elongate electrical connectors into the two barrier portions such that each of the two elongate electrical connectors pierces and extends through a respective one of the two barrier portions.

13. The method of claim 12, wherein the method further comprises:Guiding, by two guide portions, the two elongate electrical connectors towards the two barrier portions, wherein each guide portion of the two guide portions guides a respective one of the two elongate electrical connectors to a respective one of the two barrier portions.

14. Assembly means for aerosolising an aerosol-generating material, the assembly means comprising: aerosol generator means comprising two elongate electrical connector means; and two barrier means configured to at least partly define a surface bounding an aerosol generation region in which the aerosol generator means is configured to generate aerosol, wherein each of the two barrier means is configured to be pierced by a respective one of the two elongate electrical connector means during assembly of the assembly means, wherein each one of the two elongate electrical connector means extends through a respective barrier means of the two barrier means.

Images