Article, systems and methods

Abstract

Described is an article (4) for use with an aerosol provision system (1) for generating an aerosol from an aerosol-generating material. The article includes an aerosol generator comprising a porous substrate (46) and a heating element (48), wherein the porous substrate comprises a front surface on which the heating element is disposed, a rear surface opposite the front surface, and at least one side surface connecting the front surface and the rear surface; an aerosol-generating material storage portion (44) for storing an aerosol-generating material, wherein the aerosol-generating material storage portion is provided in fluid communication with at least the rear surface of the aerosol generator such that aerosol-generating material is able to be provided to the rear surface of the aerosol generator; and an airflow path (52) extending from the aerosol generator to an air outlet (50) of the article, wherein the aerosol generator is arranged, in use, to provide vaporised aerosol-generating material to the airflow path. The aerosol generator is arranged such that the at least one side surface comprises an exposed region that is exposed to the airflow path. The exposed region is arranged such that condensed liquid present in the airflow path is capable of flowing to, and being absorbed by, the exposed region of the at least one side surface of the porous substrate. Also described is an aerosol provision system and a method.

Description

[0001] DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0002] ARTICLE, SYSTEMS AND METHODS

[0003] Field

[0004] This disclosure relates to aerosol delivery systems, which may include nicotine delivery systems, and components therefor.

[0005] Background

[0006] Aerosol delivery systems such as electronic cigarettes (e-cigarettes) generally contain an aerosol generating material, such as a chamber of a solid or liquid source, which may contain an active substance and / or a flavour, from which an aerosol or vapour is generated for inhalation by a user, e.g. through heat vaporisation. An aerosol delivery system typically comprises an aerosol generation area containing an aerosol generator, e.g. a heating element, arranged to vaporise or aerosolise a portion of precursor material to generate a vapour or aerosol in the aerosol generation area. As a user inhales on the system and electrical power is supplied to the vaporiser, air is drawn into the system through an inlet hole and along an inlet air channel connecting to the aerosol generation area, where the air mixes with vaporised precursor material to form a condensation aerosol. There is an outlet channel connecting the aerosol generation area to an outlet in a mouthpiece and the air drawn into the aerosol generation area as a user inhales on the mouthpiece continues along the outlet flow path to the mouthpiece outlet, carrying the aerosol with it, for inhalation by the user.

[0007] Some aerosol delivery devices are prone to condensation of generated aerosol that is unable to be delivered to a user by the collects on the walls of an air flow path. Such condensation can be an inconvenience to users, particularly as the condensed liquid may leak out in a user’s pocket or other container for storing the aerosol delivery system between uses. In addition, the condensed liquid represents wasted aerosol-generating material that, in effect, is unable to be delivered to a user.

[0008] Various approaches are described herein which seek to help address or mitigate some of these issues.

[0009] Brief summary of the invention

[0010] According to a first aspect of certain embodiments there is provided an article for use with an aerosol provision system for generating an aerosol from an aerosol-generating material, the article including an aerosol generator comprising a porous substrate and a heating element, wherein the porous substrate comprises a front surface on which the heating element is disposed, a rear surface opposite the front surface, and at least one side surface connecting the front surface and the rear surface; an aerosol-generating material storage portion for storing an aerosol-generating material, wherein the aerosol-generating material storage portion is provided in fluid communication with at least the rear DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 surface of the aerosol generator such that aerosol-generating material is able to be provided to the rear surface of the aerosol generator; and an airflow path extending from the aerosol generator to an air outlet of the article, wherein the aerosol generator is arranged, in use, to provide vaporised aerosol-generating material to the airflow path. The aerosol generator is arranged such that the at least one side surface comprises an exposed region that is exposed to the airflow path, and wherein the exposed region is arranged such that condensed liquid present in the airflow path is capable of flowing to, and being absorbed by, the exposed region of the at least one side surface of the porous substrate.

[0011] In some examples, the aerosol generator protrudes into the airflow path, wherein the exposed region of the at least one side surface is arranged to be perpendicular, or substantially perpendicular, to the direction of extent of the airflow path at the location of the aerosol generator.

[0012] In some examples, the airflow path extends along a straight line from the aerosol generator to the air outlet, and wherein the front surface of the aerosol generator is parallel to the straight line.

[0013] In some examples, the airflow path comprises a wall defining at least a part of the airflow path, and wherein condensed liquid that collects on the wall is capable of flowing along the wall in the direction towards the aerosol generator.

[0014] In some examples, the porous substrate of the aerosol generator comprises six surfaces, wherein the front surface and rear surface form two larger surfaces of the porous substrate with the porous substrate comprising four side surfaces, wherein at least a part of one of the side surfaces forms the exposed region.

[0015] In some examples, the airflow path comprises a first side and a second side, and wherein the aerosol generator is provided on a first side of the airflow path.

[0016] In some examples, the article comprises an aerosol generator support comprising a recessed portion sized to receive the aerosol generator.

[0017] In some examples, the recessed portion comprises a length, width and depth dimension, and wherein the length and width of the recessed portion are sized to receive at least the rear surface of the aerosol generator.

[0018] In some examples, the depth dimension is less than the distance between the front surface and the rear surface of the aerosol generator such that, when the aerosol generator is received in the aerosol generator support, at least a part of the at least one side surface protrudes from the recessed portion to form the exposed region, or wherein the article further comprises a seal element positioned between the aerosol generator and the recessed portion and wherein the depth dimension of the DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 recessed portion minus the thickness of the seal element is less than the distance between the front surface and the rear surface of the aerosol generator such that, when the aerosol generator is received in the aerosol generator support, at least a part of the at least one side surface protrudes from the recessed portion to form the exposed region.

[0019] In some examples, the recessed portion comprises an opening in fluid communication with the aerosol-generating material storage portion and configured to allow aerosol-generating material from the aerosol-generating material storage portion to be provided to the aerosol generator when the aerosol generator is located in the recessed portion.

[0020] In some examples, the article further comprises a condensation trap arranged to receive and collect at least some of the excess condensed liquid present in the airflow path that is not absorbed by the exposed region.

[0021] In some examples, the condensation trap comprises a protrusion that protrudes into the airflow path and a storage reservoir coupled to the protrusion, wherein the protrusion is configured to guide condensed liquid from the airflow path to the storage reservoir.

[0022] In some examples, the condensation trap is provided on a second side of the airflow path, opposite the aerosol generator.

[0023] According to a second aspect of certain embodiments there is provided an aerosol provision system for generating an aerosol from an aerosol-generating material, the aerosol provision system including: the article of the first aspect; and an aerosol provision device comprising a power source capable of selectively providing power to the aerosol generator of the article.

[0024] According to a third aspect of certain embodiments there is provided a method for manufacturing an article for use with an aerosol provision system for generating an aerosol from an aerosol-generating material, the method including: providing an aerosol generator comprising a porous substrate and a heating element, wherein the porous substrate comprises a front surface on which the heating element is disposed, a rear surface opposite the front surface, and at least one side surface connecting the front surface and the rear surface; providing an aerosol-generating material storage portion for storing an aerosol-generating material, wherein the aerosol-generating material storage portion is provided in fluid communication with at least the rear surface of the aerosol generator such that aerosol-generating material is able to be provided to the rear surface of the aerosol generator; and providing an airflow path extending from the aerosol generator to an air outlet of the article, wherein the aerosol generator is arranged, in use, to provide vaporised aerosol-generating material to the airflow path. The method comprises arranging the aerosol generator such that the at least one side surface comprises an exposed region that is exposed to the airflow path, and arranging the DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 exposed region such that condensed liquid present in the airflow path is capable of flowing to, and being absorbed by, the exposed region of the at least one side surface of the porous substrate.

[0025] Brief description of the figures

[0026] Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0027] Figure 1 is a schematic cross-section view of an aerosol provision system in accordance with an aspect of the present disclosure;

[0028] Figure 2 is a schematic cross-section view of the cartridge of the aerosol provision system of Figure 1 in more detail;

[0029] Figure 3 is a schematic cross-section of a part of the cartridge of Figure 2, and in particular Figure 3 shows the exposed region of a porous substrate of the aerosol generator;

[0030] Figure 4 is a schematic view of the condensation trap of the cartridges of Figures 2 and 3, shown the position of the condensation trap on one side of the flow path of the cartridge; and

[0031] Figure 5 is an example method for manufacturing a cartridge, such as the cartridge of Figures 2 and 3, according to an aspect of the present disclosure.

[0032] Detailed description of the disclosure

[0033] Aspects and features of certain examples and embodiments are discussed / 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.

[0034] 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 aerosolgenerating material without combusting the aerosol-generating material, such as electronic cigarettes, and hybrid systems to generate aerosol using a combination of aerosol-generating materials. 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.

[0035] In some embodiments, the non-combustible aerosol provision system is a powered non-combustible aerosol provision system. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0036] In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device, electronic cigarette or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. Throughout the following description the term “e-cigarette” is sometimes used but this term may be used interchangeably with aerosol (vapour) provision system.

[0037] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product.

[0038] 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.

[0039] 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.

[0040] The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free.

[0041] The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former.

[0042] Optionally, a substance to be delivered and / or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free.

[0043] The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

[0044] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0045] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0046] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

[0047] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

[0048] The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially 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 amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

[0049] The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

[0050] In some embodiments, the substance to be delivered comprises an active substance.

[0051] The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

[0052] In one embodiment the active substance is a legally permissible recreational drug.

[0053] In some implementations, the active substance comprises nicotine. In some implementations, the active substance comprises caffeine, melatonin or vitamin B12. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0054] 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.

[0055] The active substance may be CBD or a derivative thereof.

[0056] 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.

[0057] 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.

[0058] 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 selected from eucalyptus, star anise, cocoa and hemp.

[0059] 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.

[0060] As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste or aroma 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 DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 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.

[0061] 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.

[0062] 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.

[0063] 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 glycerine, 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. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0064] The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0065] An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosolmodifying agent.

[0066] The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosolmodifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

[0067] In some implementations, the aerosol provision systems comprise a modular assembly including an aerosol provision device (sometimes referred to as a reusable part) and an article comprising aerosolgenerating material (sometimes referred to as a consumable or a replaceable part). However, in other implementations, the aerosol provision systems may comprise a one-piece arrangement where the article and aerosol provision device are integrally formed.

[0068] 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.

[0069] In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source.

[0070] 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.

[0071] 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 aerosolgenerating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0072] 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 (or storage portion), an aerosolgenerating material transfer component, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

[0073] A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically- conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

[0074] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosolgenerating material. In some implementations, 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 implementations, 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.

[0075] Figure 1 is a cross-sectional view through an aerosol provision system 1 provided in accordance with certain aspects of the disclosure. The aerosol provision system 1 of Figure 1 is adapted to vaporise a liquid aerosol-generating material (sometimes referred to as a source liquid or an e-liquid). However, the principles of the present disclosure are not limited to aerosol provision system 1 adapted to vaporise liquid aerosol-generating material, and may more broadly be applied to aerosol-generating material that are capable of flowing at expected operational temperatures of the aerosol provision system.

[0076] The aerosol provision system 1 shown in Figure 1 comprises two main components, namely an aerosol provision device 2 and a replaceable / disposable cartridge 4 (which is an example of an article or consumable). The aerosol provision system 1 of Figure 1 is an example of a modular construction of an aerosol provision system 1. In this regard, the aerosol provision device 2 and the cartridge 4 are able to engage with or disengage from one another at an interface 6. However, as DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 mentioned above, the principles of the present disclosure also apply to other constructions of the aerosol provision system 1 , such as one-part or unitary constructions where the device 2 and cartridge 4 may be integrally formed (or in other words, the aerosol provision device 1 is provided with an integrally formed aerosol-generating material storage area).

[0077] The aerosol provision system 1 in this example is generally elongate and cylindrical in shape. The aerosol provision system 1 may be sized so as to approximate a conventional cigarette. However, it should be understood that the general size and shape of the aerosol provision system 1 is not significant to the principles of the present disclosure. In some other implementations, the aerosol provision system 1 may conform to different overall shapes; for example, the aerosol provision device 2 may be based on so-called box-mod high performance devices that typically have a more box-like shape.

[0078] The aerosol provision device 2 comprises components that are generally intended to have a longer lifetime than the cartridge 4. In otherwords, the device 2 is intended to be used, sequentially, with multiple cartridges 4. The cartridge 4 comprises components (such as aerosol-generating material) that are consumed when forming an aerosol for delivery to the user during use of the aerosol provision system 1 .

[0079] In the example modular configuration of Figure 1 , the device 2 and the cartridge 4 are releasably coupled together at the first interface 6. When the aerosol-generating material in the cartridge 4 is exhausted or the user simply wishes to switch to a different cartridge 4 (e.g., containing a different aerosol-generating material), the cartridge 4 may be removed from the device 2 and a replacement cartridge 4 attached to the device 2 in its place. The interface 6 provides a structural connection between the device 2 and cartridge 4 and may be established in accordance with broadly conventional techniques, for example based around a screw thread, latch mechanism, bayonet fixing or magnetic coupling. In some implementations, the interface 6 may also provide an electrical coupling between the device 2 and the cartridge 4 using suitable electrical contacts. The electrical coupling may allow for power and I or data to be supplied to I from the cartridge 4.

[0080] It should also be understood that in some implementations, the cartridge 4 may be refillable. That is, the cartridge 4 may be refilled with aerosol-generating material when the cartridge 4 is depleted, using an appropriate mechanism such as a one-way refilling valve or the like (not shown). The cartridge 4 may be removed from the device 2 in order to be refilled. In other examples, the cartridge 4 may be configured so as to be refilled while attached to the device 2.

[0081] In implementations where the aerosol provision system 1 is a one-part or unitary system, the aerosol provision system 1 may be designed to be disposable once the aerosol-generating material is exhausted. Alternatively, the aerosol provision system 1 may be provided with a suitable mechanism, DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 such as a one-way valve or the like, to enable the integrated cartridge 4 (or integrated aerosolgenerating material storage area) to be refilled with aerosol-generating material.

[0082] In Figure 1 , the cartridge part 4 is shown highly schematically. The cartridge part 4 comprises a cartridge housing 42, an aerosol-generating material storage area 44, an aerosol generator assembly, an outlet or mouthpiece opening 50, and an air path 52.

[0083] The cartridge housing 42 supports other components of the cartridge 4 and provides the mechanical interface 6 with the device 2. The cartridge housing 42 is formed from a suitable material, such as a plastics material or a metal material. In the described implementation, the cartridge housing 42 is generally circularly symmetric about a longitudinal axis along which the cartridge 4 couples to the device 2. In this example the cartridge 4 has a length of around 4 cm and a diameter of around 1 .5 cm. However, it will be appreciated the specific geometry, and more generally the overall shapes, may be different in different implementations. The cartridge 4 comprises a first end, broadly defined by the interface 6, and a second end which is opposite the first end and includes the mouthpiece opening 50. The second end including the mouthpiece opening 50 is intended to be received in / by a user’s mouth and may therefore be referred to as a mouthpiece end of the cartridge 4.

[0084] Within the cartridge housing 42 is an aerosol-generating material storage area 44 (also sometimes call a reservoir 44). In the described implementation, the cartridge 4, or more particularly the reservoir 44, of Figure 1 is configured to store a liquid aerosol-generating material, which may be referred to herein as a source liquid, e-liquid or liquid. The source liquid may be broadly conventional, and may contain nicotine and I or other active ingredients, and I or one or more flavours, as described above. In some implementations, the source liquid may contain no nicotine.

[0085] The reservoir 44 in this example has a broadly annular shape with an outer wall defined by the cartridge housing 42 and an inner wall that defines the air path 52 through the cartridge 4. The reservoir 44 is closed at each end with end walls to contain the liquid. The reservoir 44 may be formed in accordance with conventional techniques, for example it may comprise a plastics material and be integrally moulded with the cartridge housing 42.

[0086] The cartridge 4 further comprises an aerosol generator. The aerosol generator assembly comprises a heating element 48 (as an example of a component capable of generating an aerosol) and an aerosol-generating material transport element 46. The aerosol generator assembly is an apparatus that is, in use, configured to cause aerosol to be generated from the aerosol-generating material (e.g., the source liquid).

[0087] In the described implementation, the aerosol-generating material transport element 46 comprises a porous substrate 46, such as a porous ceramic, while the heating element 48 comprises an electrically conductive trace disposed on at least one surface of the porous substrate 46. The porous substrate 46 is arranged so as to transport the aerosol-generating material from the aerosol- DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 generating material storage area 44 (reservoir 44) to the heating element 48, for example via capillary action. In this regard, it should be appreciated that a part of the porous substrate 46 is provided in fluid communication with the aerosol-generating material storage area 44, as schematically shown in Figure 1 . In use, the heating element 48 is provided with electrical power, which causes the heating element 48 to generate heat and consequently subjects the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. The heating element 48 is arranged to receive electrical power from the aerosol provision device 2 (described in more detail below). However, this may broadly be either through electrical connectors that extend from the aerosol provision device 2 and contact the heating element 48 (i.e., such that an electrical current is passed between ends of the electrically conductive trace), or via exposure to an alternating magnetic field generated by the aerosol provision device 2 (such that the electrically conductive trace acts as a susceptor). In some implementations, the heating element 48 and the aerosol-generating material transport element 46 may be formed from a single component, e.g., a plurality of sintered steel fibres forming a planar structure.

[0088] In the described example, the aerosol generator is located towards an end of the reservoir 44. In this example, the aerosol generator protrudes into the both the reservoir 44 and the air path 52. Accordingly, aerosol-generating material is able to be transported to the heating element 48 via the porous substrate 46, and subsequently when the heating element 48 is activated I energised (i.e., provided with electrical current), aerosol is capable of being provided to the air path 52. The region of the cartridge air path 52 provided around the heating element 48 defines a vaporisation region for the cartridge 4. This vaporisation region is the region of the cartridge 4 where vapour is initially generated.

[0089] Aerosol is delivered to the user via the mouthpiece opening 50 provided at the mouthpiece end of the cartridge 4. During use, the user may place their lips on or around the mouthpiece end of the cartridge 4 and draw air / aerosol through the mouthpiece opening 50. More specifically, air is drawn into and along the air path 52, past the heating element 48 where aerosol is entrained into the drawn air, and the combined aerosol I air is then inhaled by the user through the mouthpiece opening 50. Although Figure 1 shows the mouthpiece end of the cartridge 4 as being an integral part of the cartridge 4, a separate mouthpiece component may be provided which releasably couples to the end of the cartridge 4.

[0090] The device part 2 comprises an outer housing 12 with an opening that defines an air inlet 28 for the aerosol provision system 1 , a power source 26 for providing operating power for the aerosol provision system 1 , a controller or control circuitry 20 for controlling and monitoring the operation of the aerosol provision system 1 , and an inhalation sensor (puff detector) 16 located in a chamber 18. The device 2 further comprises an optional indicator 14.

[0091] The outer housing 12 may be formed, for example, from a plastics or metallic material and in this example has a circular cross-section generally conforming to the shape and size of the cartridge 4 so DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 as to provide a smooth transition between the two parts at the interface 6. In this example, the device 2 has a length of around 8 cm so the overall length of the aerosol provision system 1 when the cartridge 4 and device 2 are coupled together is around 12 cm. However, and as already noted, it will be appreciated that the overall shape and scale of an aerosol provision system 1 implementing the present disclosure is not significant to the principles described herein.

[0092] The outer housing 12 further comprises an air inlet 28 which connects to an air path 30 provided through the device 2. The device air path 30 in turn connects to the cartridge air path 52 across the interface 6 when the device 2 and cartridge 4 are connected together. In this regard, the interface 6 is also arranged to provide a connection of the respective air paths 30 and 52, such that air and / or aerosol is able to pass along the coupled air paths 30, 52. In other implementations, the device 2 does not comprise an air path 30 and instead the cartridge 4 comprises the air path 52 and a suitable air inlet which permits air to enter into the air path 52 when the cartridge 4 and device 2 are coupled.

[0093] The power source 26 in this example is a battery 26. The battery 26 may be rechargeable and may be of a broadly conventional type, for example of the kind normally used in aerosol provision devices and other applications requiring provision of relatively high currents over relatively short periods. The battery 26 may be, for example, a lithium ion battery. The battery 26 may be recharged through a suitable charging connector provided at or in the outer housing 12, for example a USB connector. Additionally or alternatively, the device 2 may comprise suitable circuitry to facilitate wireless charging of the battery 26. In other examples, the power source 26 may be an alternative component suitable for storing energy such as a super capacitor.

[0094] The control circuitry or control unit 20 is suitably configured I programmed to control the operation of the aerosol provision system 1 . The control circuitry 20 may be considered to logically comprise various sub-units I circuitry elements associated with different aspects of the aerosol provision system's operation and may be implemented by provision of a (micro)controller, processor, ASIC or similar form of control chip. The control circuitry 20 may be arranged to control any functionality associated with the aerosol provision system 1. By way of non-limiting examples only, the functionality may include the charging or re-charging of the battery 26, the discharging of the battery 26 (e.g., for providing power to the heating element 48), in addition to other functionality such as controlling visual indicators (e.g., LEDs) I displays, communication functionality for communicating with external devices, etc. The control circuitry 20 may be mounted to a printed circuit board (PCB). Note also that the functionality provided by the control circuitry 20 may be split across multiple circuit boards and I or across components which are not mounted to a PCB, and these additional components and I or PCBs can be located as appropriate within the aerosol provision device 2. For example, functionality of the control circuit 20 for controlling the (re)charging functionality of the battery 26 may be provided separately (e.g. on a different PCB) from the functionality for controlling the discharge of the battery 26. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0095] As noted above, when the device 2 and the cartridge 4 are coupled together at interface 6, the interface 6 provides an electrical connection between the device 2 and the cartridge 4. More particularly, electrical contacts on the device 2, which are coupled to the power source 26, are electrically coupled to electrical contacts on the cartridge, which are coupled to the heating element 48. Accordingly, under suitable control by the control circuitry 20, electrical power from the power source 26 is able to be supplied from the power source 26 to the heater 48, thereby energising the heating element 48 and allowing the heating element 48 to vaporise liquid in the proximity of the heating element 48 held in the porous substrate 46.

[0096] In the example of Figure 1 , the aerosol provision device 2 comprises a chamber 18 containing the inhalation sensor 16, which in this example is a pressure sensor. The pressure sensor 16 is in fluid communication with the air path 30 in the device 2 (e.g. the chamber 18 branches off from the air path 30 in the device 2). When a user inhales on the aerosol provision system 1 at the mouthpiece end, and subsequently draws air into the device 2 via the air inlet 28 and along the air paths 30, 52, the pressure sensor 16 detects a change (a drop) in the pressure within chamber 18. If the drop in pressure is sufficient, the pressure sensor 16 (or control circuitry 20 coupled thereto) detects a user inhalation.

[0097] The aerosol provision system 1 is controlled to generate aerosol in response to detecting an inhalation by a user. That is, when the pressure sensor 16 detects a drop in pressure in the pressure sensor chamber 18, the control circuitry 20 responds by causing electrical power to be supplied from the battery 26 to the heating element 48 sufficient to cause vaporisation of the liquid held within the porous substrate 46. This is an example of an aerosol provision system which is said to be “puff actuated”. The pressure sensor 16 may be used to start and I or end the power supply to the heating element 48 (e.g., when the pressure sensor detects the absence of an inhalation). It should be appreciated that the inhalation sensor 16 may be any suitable sensor, such as an air flow sensor, for sensing when a user inhales on the mouthpiece end of the cartridge 4 and subsequently draws air along the air paths 30, 52. Accordingly, the presence of the chamber 18 is optional and its presence may depend on the characteristics of the selected inhalation sensor 16. For example, an air flow sensor may sit in the air flow path 30, 52.

[0098] In other implementations, the aerosol provision device 2 includes a button or other user actuatable mechanism. When the button or other user actuatable mechanism is actuated by the user, the control circuitry 20 caused power to be supplied to the heating element 48 as described above. This is an example of an aerosol provision device which is said to be “button actuated”. The button may be used to start and I or end power supply to the heating element 48 (e.g., when the button is released by the user). In some implementations, both a button (or other user actuatable mechanism) and an inhalation sensor 16 may be used to control the delivery of power to the heating element 48, e.g., by requiring both the button press and a pressure drop indicative of an inhalation to be present before supplying power to the heating element 48. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0099] The aerosol provision device 2 further comprises an optional indicator 14 (i.e. an output mechanism).

[0100] The indicator 14 may be provided for providing feedback to a user of the aerosol provision device 1 . For example, the indicator 14 may indicate information such as whether the heating element 48 is currently active, a remaining battery life (of the battery 26), total number of activations of the heating element 48, amount of liquid remaining in the reservoir 44, etc. Alternatively or additionally, the indicator 14 may display operational parameters of the aerosol provision device 2. In some implementations, the indicator 14 may be provided in conjunction with an input mechanism (such as one or more buttons or a touch screen display) which may allow operational parameters to be programmed and / or settings of the aerosol provision device 1 to be changed. The indicator 14 may be a visual indication (such as a display or one or more LEDs), an audio indicator (such as a speaker) or a haptic indictor (such as a haptic motor).

[0101] Figure 2 is a cross-sectional view of the cartridge 4 of Figure 1 in more detail in accordance with certain embodiments of the disclosure. Figure 2 shows the cartridge 4 in isolation, but it should be understood that the cartridge 4 is for use with the aerosol provision device 2 of Figure 1 .

[0102] The cartridge 4 of Figure 2 is shown comprising the components as discussed in respect of Figure 1 . That is, the cartridge 4 comprises a cartridge housing 42 which defines, in part, an annular reservoir 44 and the air path 52 which terminates at the mouthpiece opening 50. The cartridge 4 also comprises the aerosol generator, although unlike with Figure 1 , only the porous substrate 46 is visible in Figure 2.

[0103] The cartridge 4 of Figure 2 shows further constructional details of the cartridge 4 and in particular the lower end of the cartridge 4 closest to the interface 6 (that allows coupling to the aerosol provision device 2). Broadly speaking, the cartridge housing 42 is formed with a closed end of the reservoir 44 (i.e., the end closest to the mouthpiece opening 50) and an open end that is opposite the closed end of the reservoir 44. The closed end is, in effect, plugged by an arrangement that includes an inner plug sleeve 41 , a aerosol generator support 43, and a plug base 45. When the cartridge 4 is assembled, e.g., as is shown in Figure 2, the arrangement of the inner plug sleeve 41 , aerosol generator support 43, and plug base 45 closes off the open end of the reservoir 44 thereby retaining (or substantially retaining) any aerosol-generating material in the reservoir 44 and forms the base or interface 6 of the cartridge 4. For instance, the reservoir 44 may be filled with aerosol-generating material (e.g., source liquid) when the cartridge housing 42 is inverted, and then the open end of the cartridge housing 42 is plugged by the arrangement of the inner plug sleeve 41 , aerosol generator support 43, and plug base 45.

[0104] In more detail, the inner plug sleeve 41 is a U-shaped element that is sized so as to fit within the cartridge housing 42, and in particular, in a manner such that the arms of the U-shaped element abut DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 against the inner surface of the cartridge housing 42. A section of the base of the U-shaped element is also arranged to abut against the end of the cartridge housing 42 that forms the tubular air path 52, as broadly shown in Figure 2. The inner plug 41 includes a central opening in the base of the U- shaped element that permits air (and aerosol) to pass through the central opening and to the part of the air path 52 formed by the cartridge housing 42. That is to say, the U-shaped element does not obstruct (or block) the part of the air path 52 formed in the cartridge housing 42, and the central opening forms a part of the overall air path 52 through the cartridge 4.

[0105] The base of the U-shaped element generally acts to seal the open end of the reservoir 44. This is seen, for example, on the left-hand side of Figure 2 where the base of the U-shaped element extends from the tubular part of the air path 52 to the inner wall of the cartridge housing 42. The inner plug sleeve 41 therefore primarily prevents the passage of aerosol-generating material out of the reservoir 44 through the open end of the reservoir 44. However, on one side of the base of the U-shaped element, a reservoir opening 41a is provided that is provided to permit aerosol-generating material in the reservoir 44 to pass through the inner plug sleeve 41 . That is to say, generally the inner plug sleeve 41 prevents passage of aerosol-generating material from the reservoir 44 except through the reservoir opening 41a. The inner plug sleeve 41 may be provided with features that improve the ability of the inner plug sleeve to retain aerosol-generating material within the reservoir 44; for example, one or more ridges or O-rings may be provided on the outer surface of the inner plug sleeve 41 that abut the inner wall of the cartridge housing 42 (schematically shown in Figure 2).

[0106] The aerosol generator support 43 is provided within the inner plug sleeve 41 . That is, the inner plug sleeve 41 is sized so as to accommodate the aerosol generator support 43 therein. The aerosol generator support 43 may be formed from any suitable material. The aerosol generator support 43 may be formed from a flexible and / or resilient material, which may allow the aerosol generator support 43 to be held in a press-fit manner within the inner plug sleeve 41 . The aerosol generator support 43 may be formed from a material that is thermally stable at the expected operational temperatures of the heating element 48 (e.g., on the order of 180°C to 220°C). In some implementations, the aerosol generator support 43 may be formed from a silicone material.

[0107] The aerosol generator support 43 is configured to support (hold I receive) the aerosol generator. In particular, in the present implementation, the heating assembly support 43 comprises an opening or recessed portion 43a into which the porous substrate 46 of the aerosol generator is capable of being received. The recessed portion 43a is suitably sized so as to receive the porous substrate 46. The porous substrate 46 may be retained in the recessed portion 43a through a press-fit engagement between the outer surfaces of the porous substrate 46 and the inner surfaces of the recessed portion 43a.

[0108] The recessed portion 43a is provided with an opening that communicates with an aerosol-generating material channel 43b provided in the aerosol generator support 43. The aerosol-generating material DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 channel 43b extends from an outer surface of the aerosol generator support 43 to the opening of the recessed portion 43a. In particular, when the aerosol generator support 43 is positioned within the inner plug sleeve 41 , the aerosol-generating material channel 43b is arranged such that the aerosolgenerating material channel 43b communicates with the reservoir opening 41a in the inner plug sleeve 41. Accordingly, aerosol-generating material that is provided in the reservoir 44 is capable of passing from the reservoir 44 through the reservoir opening 41 a in the inner plug sleeve 41 and to the aerosol-generating material channel 43b where the aerosol-generating material is capable of being provided to the opening of the recessed portion 43a and to the porous substrate 46 located in the recessed portion 43a. Put another way, the aerosol-generating material channel 43b permits aerosolgenerating material to pass to the porous substrate 46 located in the recessed portion 43a of the aerosol generator support 43.

[0109] In some implementations, an optional sealing element 43c may be provided at the base of the recessed portion 43a, for example such as an O-ring or the like, that creates a liquid-tight seal between the recessed portion 43a and one or more surfaces of the porous substrate 46. In this way, the sealing element 43a prevents or reduces the escape of aerosol-generating material, such as liquid aerosol-generating material, along pathways between the recessed portion 43a and the porous substrate 46 held therein. In some implementations, the sealing element 43c may be omitted, particularly if the aerosol generator support 43 is formed from a flexible I resilient material such that any pathways between the porous substrate 46 and the recessed portion 43a are capable of being appropriately sealed by the aerosol generator support 43 itself.

[0110] The aerosol generator support 43 is provided so as to appropriately position the aerosol generator in the cartridge 4 such that the aerosol generator can be supplied with aerosol-generating material (from the reservoir 44) and also so as to provide aerosol to the air path 52 of the cartridge 4. In the present implementation, when the aerosol generator support 43 is positioned in the cartridge 4 (more particularly in the inner plug sleeve 41 , the aerosol generator is arranged to one side of the cartridge 4, as shown in Figure 2. The aerosol generator support 43 is provided with an opening or channel that allows air to pass by the aerosol generator (and in particular, past a surface of the porous substrate 46 that includes the heating element 48), and through the central opening of the inner plug sleeve 41 . That is to say, the aerosol generator support 43 is arranged to allow air to pass over I adjacent the aerosol generator in such a way that the air is capable of passing to the mouthpiece opening 50.

[0111] The plug base 45 is arranged so as to be inserted into the inner plug sleeve 41 and / or the cartridge housing 42. The plug base 45 helps to retain the inner plug sleeve 41 and aerosol generator support 43 within the cartridge housing 42. The plug base 45 also acts to provide the interface 6 for the cartridge 4 (or more particularly, in this implementation, a lower surface of the cartridge 4). The plug base 45 may be retained by friction fit within the cartridge housing 42 and / or through some other mechanism (such as one or more latches, or the like, as schematically shown in Figure 2). The plug base 45 therefore may be considered to apply a force to the aerosol generator support 43, pressing DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 the aerosol generator support 43 into the inner plug sleeve 41 and consequently pressing the inner plug sleeve 41 into the and against the cartridge housing 42. Accordingly, when the cartridge 4 is assembled, the reservoir 44 is substantially sealed by the inner plug sleeve 41 , aerosol generator support 43 and plug base 45.

[0112] The plug base 45 comprises a central opening. The central opening is arranged to act as an air inlet for the air path 52. That is, when the cartridge 4 is assembled, air is capable of entering the cartridge 4 via the central opening of the plug base 45, passing through the plug base 45 and past the aerosol generator held in the aerosol generator support 43, through the central opening of the inner plug sleeve 41 and along the tubular part of the cartridge housing 42. The pathway that air flows through the cartridge 4 is shown in Figure 2 by the arrows labelled A. The air path 52 of the cartridge 4 extends from the central opening of the plug base 45 to the mouthpiece opening 50 and passes through the plug base 45, aerosol generator support 43, inner plug sleeve 41 and tubular portion of the cartridge housing 42 as described above.

[0113] The plug base 45 is also provided with a plurality of electrodes 47 (only one of which is shown in Figure 2). The plurality of electrodes 47 may be integrally formed with the plug base 45 or may be inserted into corresponding recesses of the plug base 45. The plurality of electrodes 47 are configured to, at one end, electrically contact the heating element 48. In particular, a first electrode may electrically contact one end of the heating element 48, while another second electrode may electrically contact the other end of the heating element 48. The opposite ends of the plurality of electrodes 47 may extend to the surface of the plug base 45 that forms an outer surface of the cartridge 4 (e.g., the interface 6). Accordingly, in this implementation, when the cartridge 4 is coupled to the aerosol provision device 2, electrical contacts on the aerosol provision device 2 electrically couple with the plurality of electrodes 47 such that an electrical current may be provided to the heating element 48 via the plurality of electrodes 47.

[0114] It should be appreciated that the cartridge 4 as shown in Figure 2 is an example of a suitable cartridge 4 that is constructed in accordance with the principles of the present disclosure. However, other designs of the cartridge 4 may be realised. For example, the inner plug sleeve 41 , the aerosol generator support 43 and plug base 45 may be integrally formed as a single component that is inserted into the cartridge housing 42. In other implementations, the tubular part of the cartridge housing 42 may extend to the base of the cartridge 4, and the plugging arrangement may instead comprise an annular plug that is located between the inner wall of the cartridge housing 42 and the outer wall of the tubular part of the cartridge housing 42. Put more generally, the design of the cartridge 4 is not limited to that shown and other designs may be possible within the context of the present disclosure.

[0115] In aerosol provision systems 1 that vaporise an aerosol-generating material, some of the vaporised / aerosolised aerosol-generating material condenses in the air path 52 prior to exiting the cartridge 4 DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 via the mouthpiece opening 50. That is to say, this condensed liquid is not delivered to the user as an aerosol, but instead remains in the cartridge 4, and in particular in the air path 52, after use. This can be inconvenient for a user as the condensed liquid may leak out of the cartridge 4 through the mouthpiece opening 50 and / or the air inlet (e.g., the air inlet of the plug base 45), which may cause discomfort to the user or damage to the user’s clothing I baggage or the like. In addition, the condensed liquid may, in effect, be wasted as it cannot be easily re-aerosolised and delivered to the user as an aerosol despite potentially having active substances, flavours or the like that are desired to be delivered to the user.

[0116] Therefore, in accordance with the principles of the present disclosure, the aerosol generator comprises the porous substrate 46 that has a front surface on which the heating element 48 is disposed, a rear surface opposite the front surface, and at least one side surface that is arranged to connect the front surface and the rear surface. For example, the porous substrate 46 may be a cuboid, having one of the larger surfaces as the front surface and the other of the larger surfaces as the rear surface, with four side surfaces extending between the larger rectangular surfaces accordingly. That is to say, the porous substrate 46 of the aerosol generator comprises six surfaces, wherein the front surface and rear surface form two larger surfaces of the porous substrate 46 with the porous substrate 46 comprising four side surfaces. The aerosol generator is arranged in the cartridge 4 such that the at least one side surface comprises an exposed region that is exposed to the air path 52 of the cartridge 4. The exposed region is arranged such that condensed liquid present in the air path 52 (for example, on the inner wall of the tubular part of the cartridge housing 42) is capable of flowing to, and being absorbed by, the exposed region of the at least one side surface of the porous substrate 46. In this way, at least some of the condensed liquid that collects on a wall or surface of the air path 52 is capable of flowing to the exposed region of the porous substrate 46 such that it can be reabsorbed by the porous substrate 46 and consequently reheated and delivered to the user. This approach can allow for recycling of aerosolised but non-delivered aerosol-generating material as well as help reduce leakage of liquid out of the aerosol-generating system 1 .

[0117] Figure 3 schematically represents a part of the cartridge 4 of Figure 2 (more specifically, the part shown in the dashed box of Figure 2). Figure 3 is provided for explaining the principles of the present disclosure in more detail. Figure 3 will be understood from Figure 2, and like components are described with like reference signs.

[0118] Figure 3 is provided to show the path of the condensed liquid that accumulates in the air path 52 of the cartridge 4. A first path along which any condensed liquid can flow is shown with the solid arrows in Figure 3. When the cartridge 4 is orientated such that gravity acts substantially in the direction from the opening 50 towards the interface 6, any condensed liquid, under the force of gravity, flows in a direction towards the interface 6. The condensed liquid typically flows along the walls of the tubular part of the cartridge housing 42 defining a part of the air path 52. This is schematically shown in DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0119] Figure 3, where the solid arrows run down the walls of the part of the cartridge hosing 42 defining the air path 52.

[0120] As seen in Figure 3, the porous substrate 46 extends into the air path 52 from the recessed portion 43a of the aerosol generator support 43. More particularly, a part of the side surface of the porous substrate 46 is exposed to the air path 52, thereby forming an exposed region 46a of the porous substrate 46. By exposed, it is meant that the part of the side surface of the porous substrate 46 is not covered or blocked by the aerosol generator support 43. By virtue of the fact that the exposed region 46a of the porous substrate 46 is present in the air path 52, any condensed liquid that flows along the walls of the tubular part of the cartridge housing 42 defining a part of the air path 52 is capable of coming into contact with the exposed region 46a of the porous substrate 46. This is schematically shown in Figure 3. Accordingly, because the porous substrate 46 is porous, the condensed liquid is capable of being absorbed by the exposed region 46a of the porous substrate 46 and re-used as described above.

[0121] In the example of Figures 2 and 3, the aerosol generator is positioned such that the surface that comprises the heating element 48 (i.e., the front surface) is parallel with the longitudinal axis of the cartridge 4, and in particular, with the axis of extent of the air path 52 downstream of the aerosol generator. In this way, the exposed region 46a of the at least one side surface of the porous substrate 46 is arranged to be perpendicular (or in other implementations, substantially perpendicular, i.e., within the range of 70° to 90°, with respect to the direction of extent of the air path 52 downstream of the aerosol generator). Accordingly, when the condensed liquid flows along the walls of the air path 52, the condensed liquid has a greater chance of contacting and flowing into the exposed region 46a of the porous substrate 46.

[0122] In principle, the surface that comprises the heating element 48 of the aerosol generator may be arranged parallel to the direction of extent of the air path 52 only in the region of the air path 52 that is adjacent to the aerosol generator. That is, for instance, the air path 52 itself may take a different path, e.g., non-linear / not straight, through the cartridge 4, but as long as the exposed region 46a is perpendicular (or substantially perpendicular) to the air path 52 in the vicinity of the aerosol generator 46, the condensed liquid has a greater chance of being absorbed by the porous substrate 46 (as opposed to running off / flowing over the surface of the porous substrate 46). However, in some implementations, such as the one described in Figure 3, having an air path 52 that extends substantially along a straight path downstream of the aerosol generator may have benefits in that condensed liquid can flow along the walls of the air path 52 in a relatively direct manner (and therefore not get trapped in bends or kinks of the air path 52 that may otherwise be present in other implementations).

[0123] In addition, the air path 52 upstream of the aerosol generator of the presently described implementation also follows a straight line from the air inlet of the plug base 45 to the aerosol DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 generator (and hence the entire air path 52 follows a straight line from the air inlet in the plug base 45 to the mouthpiece opening 50). Such a flow path 52 that is straight from the air inlet to the mouthpiece outlet 50 has been found to have certain advantages in terms of the aerosol that is generated and delivered to the user. Without wishing to be bound by theory, a straight airflow path is thought to provide an increased air flow speed, particularly in the vicinity of the aerosol generator, which may impact the properties of the aerosol generated and delivered to the user. However, it should be appreciated that in other implementations, the flow path 52 upstream of the aerosol generator may be arranged in any suitable way such that air is capable of being delivered to the aerosol generator (or more particularly, the vaporisation region around the aerosol generator).

[0124] The aerosol generator support 43 comprises the recessed portion 43a sized to receive the aerosol generator. In particular, the recessed portion 43a comprises a length (for example, in the direction parallel to the longitudinal axis of the cartridge 4), a width (for example, in the direction perpendicular to the longitudinal axis of the cartridge 4 and into and out of the plane of Figure 3), and depth dimension (for example, in the direction perpendicular to the longitudinal axis of the cartridge 4 and to the left and right of Figure 3). Given the cuboid shape of the porous substrate 46 if the example described above, the length and width of the recessed portion 43a are sized to receive at least the rear surface of the aerosol generator / porous substrate 46. That is, the recessed portion 43a is sized to receive the rectangular shape of the rear surface of the porous substrate 46.

[0125] In respect of the depth dimension of the recessed portion 43a, this may be configured in one of two ways. In a first implementation, not shown in Figure 2 or 3, the depth of the recessed portion 43a is set to be less than the distance between the front surface and the rear surface of the porous substrate 46. Accordingly, when the aerosol generator is received in the recessed portion 43a of the aerosol generator support 43, the base of the recessed portion 43a limits the extent to which the aerosol generator / porous substrate 46 can be inserted into the recessed portion 43a. Accordingly, because of the difference in sizes, at least a part of the at least one side surface of the porous substrate 46 subsequently protrudes from the recessed portion 43a to form the exposed region 46a. In a second implementation, when the sealing element 43c is present (and positioned between the aerosol generator and the base of the recessed portion 43a), the depth dimension of the recessed portion 43a minus the thickness of the sealing element 43c is set to be less than the distance between the front surface and the rear surface of the aerosol generator. Accordingly, in a similar manner, the base of the recessed portion 43a combined with the thickness of the sealing element 43c limits the extent to which the aerosol generator / porous substrate 46 can be inserted into the recessed portion 43a, thereby meaning that at least a part of the at least one side surface of the porous substrate 46 subsequently protrudes from the recessed portion 43a to form the exposed region 46a.

[0126] The example cartridge 4 of Figures 2 and 3 is an example of an asymmetric cartridge 4. That is, in the example cartridge 4, the aerosol generator is provided on one side of the cartridge 4. In particular, the DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 flow path 52 comprises a first side and a second opposite side, where the aerosol generator is provided on a first side of the flow path 52.

[0127] Accordingly, only condensed liquid that flows along the walls of the first side of the flow path 52 is capable of contacting the exposed region 46a of the porous substrate 46. To help reduce the amount of condensed liquid that escapes the cartridge 4 (e.g., via the mouthpiece outlet 50 or the air inlet in the plug base 45), the cartridge 4 is provided with a condensation trap 49 arranged to receive and collect at least some of the excess condensed liquid present in the flow path 52 that is not absorbed by the exposed region 46a.

[0128] With reference to Figure 3, Figure 3 also shows a second path along which condensed liquid can flow shown via the dashed arrows in Figure 3. The second path is substantially the same as the first path shown by the solid arrows, but is shown on the opposite side (i.e., the second side) of the flow path 52, i.e., the side opposite the aerosol generator and the exposed region 46a. When the cartridge 4 is orientated such that gravity acts substantially in the direction from the opening 50 towards the interface 6, any condensed liquid, under the force of gravity, flows in a direction towards the interface 6, as described before. However, in this case, it is the condensation trap 49 that receives the condensed liquid. Figure 4 schematically shows the condensation trap 49 when viewed at an angle along the flow path 52.

[0129] The condensation trap 49 in the present example comprises a protrusion that protrudes into the flow path 52 and a storage reservoir coupled to the protrusion. As can be seen in Figure 3 in particular, the condensation trap 49 forms a U-shaped element that is positioned around the end of the tubular part of the cartridge housing 42 that defines a part of the flow path 52. Because the protrusion extends into the flow path 52, the protrusion is configured to guide condensed liquid from the flow path 52 to the storage reservoir (i.e., the U-shaped element), where the condensed liquid may be retained. The condensed liquid may be retained in a sponge (not shown) located in the reservoir, or alternatively the tortuous path along which any condensed liquid that is stored in the reservoir of the condensation trap 49 would have to flow to escape the reservoir may act to retain at least some of any collected condensed liquid. The condensation trap 49, although shown taking a specific form in Figures 2 and 3, may in principle take any form that is suitable for capturing and retaining, to at least some degree, condensed liquid.

[0130] In this example, the condensation trap 49 is a part of the aerosol generator support 43 and comprises the protrusion and the reservoir. However, the condensation trap 49 may be configured to be present in, and / or extend into, any of the components described above; namely, the plug base 45. For example, in some implementations, the reservoir and / or protrusion may be in fluid communication with various hollow condensation storage regions in the plug base 45, such that condensed liquid that is captured by the condensation trap 49 is capable of flowing through I into hollow regions of the plug base 45, where it may be retained / trapped and unable to (easily) escape the storage regions. The DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 condensed liquid may be retained in the hollow regions by virtue of a tortuous path that condensed liquid flows along into to reach the hollow region, or alternatively the hollow region of the plug base 45 may be provided with an absorbent material, such as a cotton pad or wadding, or otherwise formed as an absorbent region of the plug base 45 such that condensed liquid that flows to the hollow region is retained or trapped in the hollow region by virtue of the absorbent material. In some implementations, the storage regions may not be in direct communication with the condensation trap 49, but instead may be arranged as overflow storage regions that are configured to capture condensed liquid that either overflows the condensation trap 49 (when the condensation trap 49 is full), or that does not flow into the condensation trap 49 and / or to the exposed region 43a. In this way, condensed liquid is able to be collected I retained in the condensation storage regions of the plug base 45, such that condensed liquid is less likely, or prevented, from exiting the cartridge 4 and / or aerosol provision system 1 .

[0131] Therefore, broadly speaking, the present disclosure provides a cartridge 4 (or more generally an aerosol provision system 1) that is arranged such that a part of a side surface of a porous substrate 46 forming an aerosol generator is exposed to a flow path 52 (and in particular and air / aerosol flow path 52). The exposed region 46a therefore acts as a mechanism for absorbing at least some of the condensed liquid that may be present in the flow path 52 as a result of using the aerosol provision system 1 to generate and deliver aerosol to a user. In this way, not only may some of the condensed liquid be prevented from escaping the cartridge 4, but some of the condensed liquid may be re-used (recycled) thereby improving the longevity of the aerosol provision system 1 I cartridge 4.

[0132] Figure 5 represents an example method for manufacturing a cartridge 4 I aerosol provision system 1 according to the present disclosure.

[0133] The method starts at step S1 , with the step of providing an aerosol generator comprising a porous substrate 46 and a heating element 48. As described above, the porous substrate 46 comprises a front surface on which the heating element 48 is disposed, a rear surface opposite the front surface, and at least one side surface connecting the front surface and the rear surface. The aerosol generator may be provided in any suitable manner. For example, the porous substrate 46 may be provided and then a heating element 48 may be disposed (e.g., via a deposition technique) on the front surface of the porous substrate 46.

[0134] The method proceeds to step S2, with the step of providing an aerosol-generating material storage portion (reservoir 44) for storing an aerosol-generating material (such as a liquid). The aerosolgenerating material storage portion 44 is provided in fluid communication with at least the rear surface of the aerosol generator such that aerosol-generating material is able to be provided to the rear surface of the aerosol generator. It should be appreciated that step S1 may be performed after step S2 - that is, the aerosol-generating material storage portion 44 may be manufactured first, and then the aerosol generator may be provided (and installed into the cartridge 4). DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0135] Finally, the method proceeds to step S3, with the step of providing a flow path 52 extending from the aerosol generator to an air outlet of the article. The aerosol generator is arranged, in use, to provide vaporised aerosol-generating material to the flow path 52. It should also be appreciated that step S3 may be performed at the same time or prior to step S1 . For example, both the reservoir 44 and the air path 52 may be formed at the same time (e.g., via injection moulding the cartridge housing 42).

[0136] It should be understood that, in accordance with the principles of the present disclosure, the method comprises arranging the aerosol generator such that the at least one side surface comprises an exposed region 46a that is exposed to the flow path, and arranging the exposed region 46a such that condensed liquid present in the flow path 52 is capable of flowing to, and being absorbed by, the exposed region 46a of the at least one side surface of the porous substrate 46, as described above.

[0137] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. Any functions of a processor (e.g. controller) may be shared between processors on the various devices / systems in the wider system and / or a remote server. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention.

[0138] Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. Protection may also be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.

[0139] The present disclosure relates to aerosol delivery systems (which may also be referred to as vapour delivery systems) such as nebulisers or e-cigarettes. Throughout the following description the term “e- cigarette” or “electronic cigarette” may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol delivery system I device and electronic aerosol delivery system I device. Furthermore, and as is common in the technical field, the terms "aerosol" and "vapour", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably. DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526

[0140] Aerosol delivery systems (e-cigarettes) often, though not always, comprise a modular assembly comprising a reusable device part and a replaceable (disposable / consumable) cartridge part. Often, the replaceable cartridge part will comprise the aerosol generating material and the vaporiser (which may collectively be called a ‘cartomizer’) and the reusable device part will comprise the power supply (e.g. rechargeable power source) and control circuitry. It will be appreciated these different parts may comprise further elements depending on functionality. For example, the reusable device part will often comprise a user interface for receiving user input and displaying operating status characteristics, and the replaceable cartridge device part in some cases comprises a temperature sensor for helping to control temperature. Cartridges are electrically and mechanically coupled to the control unit for use, for example using a screw thread, bayonet, or magnetic coupling with appropriately arranged electrical contacts. When the aerosol generating material in a cartridge is exhausted, or the user wishes to switch to a different cartridge having a different aerosol generating material, the cartridge may be removed from the reusable part and a replacement cartridge attached in its place. Systems and devices conforming to this type of two-part modular configuration may generally be referred to as two-part systems / devices.

[0141] It is common for electronic cigarettes to have a generally elongate shape. For the sake of providing a concrete example, certain embodiments of the disclosure will be taken to comprise this kind of generally elongate two-part system employing disposable cartridges. However, it will be appreciated that the underlying principles described herein may equally be adopted for different configurations, for example single-part systems or modular systems comprising more than two parts, refillable devices and single-use disposables, as well as other overall shapes, for example based on so-called box-mod high performance devices that typically have a boxier shape. More generally, it will be appreciated certain embodiments of the disclosure are based on aerosol delivery systems which are operationally configured to provide functionality in accordance with the principles described herein and the constructional aspects of systems configured to provide the functionality in accordance with certain embodiments of the disclosure is not of primary significance.

[0142] Throughout the disclosure, the terms ‘substantially’, ‘approximately’ and ‘about’ should be considered to mean within + / - 10% unless indicated otherwise.

Claims

DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526Claims1 . An article for use with an aerosol provision system for generating an aerosol from an aerosolgenerating material, the article comprising: an aerosol generator comprising a porous substrate and a heating element, wherein the porous substrate comprises a front surface on which the heating element is disposed, a rear surface opposite the front surface, and at least one side surface connecting the front surface and the rear surface; an aerosol-generating material storage portion for storing an aerosol-generating material, wherein the aerosol-generating material storage portion is provided in fluid communication with at least the rear surface of the aerosol generator such that aerosol-generating material is able to be provided to the rear surface of the aerosol generator; and an airflow path extending from the aerosol generator to an air outlet of the article, wherein the aerosol generator is arranged, in use, to provide vaporised aerosol-generating material to the airflow path, wherein the aerosol generator is arranged such that the at least one side surface comprises an exposed region that is exposed to the airflow path, and wherein the exposed region is arranged such that condensed liquid present in the airflow path is capable of flowing to, and being absorbed by, the exposed region of the at least one side surface of the porous substrate.

2. The article of claim 1 , wherein the aerosol generator protrudes into the airflow path, wherein the exposed region of the at least one side surface is arranged to be perpendicular, or substantially perpendicular, to the direction of extent of the airflow path at the location of the aerosol generator.

3. The article of claim 2, wherein the airflow path extends along a straight line from the aerosol generator to the air outlet, and wherein the front surface of the aerosol generator is parallel to the straight line.

4. The article of any of the preceding claims, wherein the airflow path comprises a wall defining at least a part of the airflow path, and wherein condensed liquid that collects on the wall is capable of flowing along the wall in the direction towards the aerosol generator.

5. The article of any of the preceding claims, wherein the porous substrate of the aerosol generator comprises six surfaces, wherein the front surface and rear surface form two larger surfaces of the porous substrate with the porous substrate comprising four side surfaces, wherein at least a part of one of the side surfaces forms the exposed region.

6. The article of any of the preceding claims, wherein the airflow path comprises a first side and a second side, and wherein the aerosol generator is provided on a first side of the airflow path.

7. The article of any one of the preceding claims, wherein the article comprises an aerosol generator support comprising a recessed portion sized to receive the aerosol generator.DYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 830555268. The article of claim 7, wherein the recessed portion comprises a length, width and depth dimension, and wherein the length and width of the recessed portion are sized to receive at least the rear surface of the aerosol generator.

9. The article of claim 8, wherein the depth dimension is less than the distance between the front surface and the rear surface of the aerosol generator such that, when the aerosol generator is received in the aerosol generator support, at least a part of the at least one side surface protrudes from the recessed portion to form the exposed region, or wherein the article further comprises a seal element positioned between the aerosol generator and the recessed portion and wherein the depth dimension of the recessed portion minus the thickness of the seal element is less than the distance between the front surface and the rear surface of the aerosol generator such that, when the aerosol generator is received in the aerosol generator support, at least a part of the at least one side surface protrudes from the recessed portion to form the exposed region.

10. The article of any one of claims 7 to 9, wherein the recessed portion comprises an opening in fluid communication with the aerosol-generating material storage portion and configured to allow aerosol-generating material from the aerosol-generating material storage portion to be provided to the aerosol generator when the aerosol generator is located in the recessed portion.11 . The article of any of the preceding claims, wherein the article further comprises a condensation trap arranged to receive and collect at least some of the excess condensed liquid present in the airflow path that is not absorbed by the exposed region.

12. The article of claim 11 , wherein the condensation trap comprises a protrusion that protrudes into the airflow path and a storage reservoir coupled to the protrusion, wherein the protrusion is configured to guide condensed liquid from the airflow path to the storage reservoir.

13. The article of claim 11 or 12, when dependent on claim 6, wherein the condensation trap is provided on a second side of the airflow path, opposite the aerosol generator.

14. An aerosol provision system for generating an aerosol from an aerosol-generating material, the aerosol provision system comprising: the article of any of the preceding claims; and an aerosol provision device comprising a power source capable of selectively providing power to the aerosol generator of the article.

15. A method for manufacturing an article for use with an aerosol provision system for generating an aerosol from an aerosol-generating material, the method comprising: providing an aerosol generator comprising a porous substrate and a heating element, wherein the porous substrate comprises a front surface on which the heating element is disposed, a rear surface opposite the front surface, and at least one side surface connecting the front surface and the rear surface; providing an aerosol-generating material storage portion for storing an aerosol-generating material, wherein the aerosol-generating material storage portion is provided in fluid communicationDYC ref: P129962PCT; BAT ref: P20025594W001 ; AID: 83055526 with at least the rear surface of the aerosol generator such that aerosol-generating material is able to be provided to the rear surface of the aerosol generator; and providing an airflow path extending from the aerosol generator to an air outlet of the article, wherein the aerosol generator is arranged, in use, to provide vaporised aerosol-generating material to the airflow path, wherein the method comprises arranging the aerosol generator such that the at least one side surface comprises an exposed region that is exposed to the airflow path, and arranging the exposed region such that condensed liquid present in the airflow path is capable of flowing to, and being absorbed by, the exposed region of the at least one side surface of the porous substrate.

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