Patent Description:
Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute devices in order to avoid the smoking of tobacco.

Such smoking substitute devices can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute devices, which may also be known as electronic nicotine delivery systems, may comprise electronic systems that permit a user to simulate the act of smoking by producing an aerosol, also referred to as a "vapour", which is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour and health risks associated with traditional smoking.

In general, smoking substitute devices are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and tobacco products.

The popularity and use of smoking substitute devices has grown rapidly in the past few years. Some smoking substitute devices are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute devices do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form).

There are a number of different categories of smoking substitute devices, each utilising a different smoking substitute approach. A smoking substitute approach corresponds to the manner in which the substitute system operates for a user.

One approach for a smoking substitute device is the so-called "vaping" approach, in which a vaporisable liquid, typically referred to (and referred to herein) as "e-liquid", is heated by a heater to produce an aerosol vapour which is inhaled by a user. An e-liquid typically includes a base liquid as well as nicotine and/or flavourings. The resulting vapour therefore typically contains nicotine and/or flavourings. The base liquid may include propylene glycol and/or vegetable glycerine.

A typical vaping smoking substitute device includes a mouthpiece, a power source (typically a battery), a tank or liquid reservoir for containing e-liquid, as well as a heater. In use, electrical energy is supplied from the power source to the heater, which heats the e-liquid to produce an aerosol (or "vapour") which is inhaled by a user through the mouthpiece. The document <CIT> discloses a vaping smoking substitute device.

Vaping smoking substitute devices can be configured in a variety of ways. For example, there are "closed system" vaping smoking substitute devices which typically have a heater and a sealed tank which is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute devices include a main body which includes the power source, wherein the main body is configured to be physically and electrically coupled to a consumable including the tank and the heater. In this way, when the tank of a consumable has been emptied, the main body can be reused by connecting it to a new consumable. Another subset of closed system vaping smoking substitute devices are completely disposable, and intended for one-use only.

There are also "open system" vaping smoking substitute devices which typically have a tank that is configured to be refilled by a user, so the device can be used multiple times.

An example vaping smoking substitute device is the myblu™ e-cigarette. The myblu™ e cigarette is a closed system device which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid, as well as a vaporiser, which for this device is a heating filament coiled around a portion of a wick which is partially immersed in the e-liquid. The device is activated when a microprocessor on board the main body detects a user inhaling through the mouthpiece. When the device is activated, electrical energy is supplied from the power source to the vaporiser, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.

Another example vaping smoking substitute device is the blu PRO™ e-cigarette. The blu PRO™ e cigarette is an open system device which includes a main body, a (refillable) tank, and a mouthpiece. The main body and tank are physically and electrically coupled together by screwing one to the other. The mouthpiece and refillable tank are physically coupled together by screwing one into the other, and detaching the mouthpiece from the refillable tank allows the tank to be refilled with e-liquid. The device is activated by a button on the main body. When the device is activated, electrical energy is supplied from the power source to a vaporiser, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.

In prior art smoking substitute devices, some of the unvaporised e-liquid passes through the wick and to the mouthpiece. This may result in unvaporised e-liquid passing into the user's mouth, which may be unpleasant for the user. Further leakage occurs due to leakage paths present between the components of the consumable.

Additionally, it is desirable to provide consumables which are easier and cheaper to manufacture.

At its most general, the present disclosure relates to an aerosol delivery device in which an airflow path through a vaporising chamber is a single, deflected path through a lateral aperture on a transverse baffle.

In a first aspect, there is provided an aerosol delivery device according to claim <NUM>.

The inclusion of a baffle downstream of the vaporiser may help to reduce (or prevent) unvaporised liquid from the vaporiser passing to the user during smoking of the device. The unvaporised liquid may collect on an upstream surface of the baffle facing the vaporiser, whilst vapour is able to through the aperture in the baffle towards the user.

Known devices have two laterally opposed apertures on the baffle so that vapour can flow in a bifurcated path through the vaporising chamber. It has been found that the provision of two lateral apertures can result in collection of liquid within one of the apertures during storage on the device on its side (whilst not being vaped). With two holes, liquid can flow into one (under gravity) whilst air within the device is equalised through the other hole. The collected liquid is then inhaled by the user during commencement of vaping. By providing a baffle having only a single lateral aperture, liquid flow into the aperture during storage (and therefore subsequent liquid inhalation) is reduced as air equalisation is only possible through the same, single aperture.

The terms "transversely" and "transverse" are used herein in relation to the cross-sectional area of the airflow path to describe a direction that is substantially perpendicular to the airflow path. The terms "transversely" and "transverse" are used herein in relation to components of the device to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The device has a device airflow path extending from at least one inlet of the device to an outlet of the device with the vaporising chamber interposed between the inlet(s) and the outlet. The term "upstream" is used to define a direction towards the inlet(s) of the device. The term "downstream" is used to define a direction towards the outlet of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the present disclosure.

In some embodiments, the aperture is defined by a transverse edge of the baffle. For example, the aperture may be defined by an upstream edge of a transverse baffle mounted downstream from the vaporiser.

The chamber airflow path is partly defined by one or more walls of the vaporising chamber. For example, the aperture may be defined by the upstream edge of the baffle and a sidewall of the vaporising chamber facing the upstream edge of the baffle.

The baffle may depend laterally from a sidewall of the vaporising chamber i.e. the baffle may extend laterally from the sidewall of the vaporising chamber that does not define the aperture. Thus the vaporising chamber may comprise a first sidewall which (along with the baffle) defines the aperture (and chamber airflow path) and a laterally opposing second sidewall from which the baffle depends.

In some embodiments, the chamber airflow path has a portion extending from the aperture to a downstream edge of the transverse baffle. In some embodiments, the portion of the chamber airflow path extending from the aperture to the downstream edge of the transverse baffle has a constant transverse cross-sectional area. Where there is a constant transverse cross-sectional area between the aperture and the downstream edge of the baffle, the transverse width of the aperture (i.e. the transverse spacing between the upstream edge of the baffle and the first sidewall of the vaporising chamber) equals the transverse spacing between the downstream edge of the baffle and the first sidewall of the vaporising chamber.

In some embodiments, the device comprises a passage extending longitudinally from the vaporising chamber to the outlet of the device. In these embodiments, the chamber airflow path extends to a passage opening which may be provided in a downstream end wall of the vaporising chamber.

The aperture (and the upstream/downstream edges of the baffle) is/are offset transversely (i.e. laterally) from the longitudinal axis of the passage (e.g. may be radially outwards of the passage opening).

In some embodiments, the chamber airflow path may comprise at least one deflection. The chamber airflow path may comprise a single, undivided chamber airflow path having at least one lateral deflection (e.g. two lateral deflections) between a generally longitudinal portion and a generally radial portion. The chamber airflow path may further comprise at least one axial deflection (e.g. two axial deflections) between a generally radial portion and generally longitudinal portion.

For example, a first portion of the chamber airflow path may extend in a generally longitudinal direction to the vaporiser (e.g. from the inlet(s)) and may be aligned with the axial centre of the device. A second portion of the chamber airflow path may then extend generally radially from the vaporiser to the aperture. Thus there is a first lateral deflection in the chamber airflow path as it passes from the vaporiser to the aperture.

A third portion of the chamber airflow path from the aperture (i.e. the upstream edge of the baffle) to the downstream edge of the baffle may be generally longitudinal and is laterally offset from the axial centre of the device. Thus there is a first axial deflection between the second and third portions of the chamber air flow path.

A fourth portion of the chamber airflow path between the third portion and the passage, may extend generally radially (laterally) e.g. generally parallel to a planar upper surface of the baffle, such that there is a second lateral deflection between the third and fourth portions of the chamber airflow path.

The chamber airflow path may then comprise a second axial deflection from the lateral direction (of the fourth portion) to a longitudinal direction as it leaves the vaporising chamber at the passage opening.

The baffle may be configured (i.e. shaped and positioned) such that there is no direct longitudinal line of sight between the vaporiser and the passage. A transverse width of the baffle may be substantially the same or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially the same or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than <NUM>% of a corresponding transverse width of the vaporising chamber, or may e.g. be greater than <NUM>%, or <NUM>%.

The passage opening (i.e. the opening from the vaporising chamber into the passage) may have a transverse cross-sectional area of more than <NUM><NUM>. The passage opening may have a transverse cross-sectional area of no more than <NUM><NUM>. The passage opening may have an internal diameter of more than <NUM>. The passage opening may have an internal diameter of no more than <NUM>. The transverse cross-sectional area of the aperture may be less than the cross-sectional area of the passage opening.

There may be an inlet substantially transversely aligned with the baffle (i.e. both may be aligned along a shared longitudinal axis). The inlet may be substantially transversely aligned with the passage opening (e.g. the inlet may be aligned on the longitudinal axis). The inlet, baffle and passage opening may be aligned along the longitudinal axis.

The vaporising chamber may comprise opposing first and second parallel sidewalls that are substantially parallel to the longitudinal axis, and a downstream (e.g. end) wall extending transversely between the sidewalls. The passage opening may be formed in the downstream end wall of the vaporising chamber.

The device comprises a tank (reservoir) for containing the vaporisable liquid (e.g. an e-liquid) with the vaporiser being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and e.g. nicotine. The base liquid may include propylene glycol and/or vegetable glycerine.

The tank is defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a "clearomizer" if it includes a window, or a "cartomizer" if it does not.

The passage may extend longitudinally within the tank and a passage wall may define the inner wall of the tank. In this respect, the tank may surround the passage e.g. the tank may be annular. The passage wall may comprise longitudinal ribs extending therealong. These ribs may provide support to the passage wall. The ribs may extend for the full length of the passage wall. The ribs may project (e.g. radially outwardly) into the tank.

The device comprises an insert defining the device inlet(s). The insert is inserted into an open end of the tank so as to seal against an inside surface of the tank housing. The insert comprises an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporising chamber and seals against the passage (e.g. seals against outer surfaces of the passage wall). The insert may be configured to support the vaporiser within the vaporising chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle are integrally formed.

The vaporiser may comprise a heater and a wick (e.g. comprising a porous material). The wick may be elongate and extend transversely across the vaporising chamber between wall(s) (e.g. between the first and second sidewalls) of the vaporising chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g. one or both of its opposing transverse ends may extend into the tank, e.g. through the sidewalls of the vaporising chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g. by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the aperture at least partly defined by the baffle (e.g. defined between the upstream edge and first sidewall of the vaporising chamber). In this respect, the chamber airflow path may pass around, through or proximal the wick and through the aperture. The upstream edge (and downstream edge of the baffle) may extend across the vaporising chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g. the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e. apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e. drawn from the tank) to be heated so as to form a vapour and become entrained in the chamber airflow path. This vapour may subsequently cool to form an aerosol in the vaporising chamber.

The device may be in the form of a consumable. The consumable may be configured for engagement with a main body (i.e. so as to form a smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g. power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g. e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is snap engagement between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with a main body. In this way, one end of the device (i.e. the inlet end) may be coupled with the main body, whilst an opposing end (i.e. the outlet end) of the consumable may define a mouthpiece.

The main body or the consumable may comprise a power source or be connectable to a power source. The power source may be electrically connected (or connectable) to the heater. The power source may be a battery (e.g. a rechargeable battery). An external electrical connector in the form of e.g. a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to a heater of the consumable. The electrical interface may also be used to identify the consumable from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable is connected to the main body.

The main body may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The consumable or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g. via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The consumable or main body may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e. puff) sensor may be provided that is configured to detect a puff (i.e. inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e. puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the main body.

In an alternative embodiment the device may be a non-consumable device in which an aerosol former (e.g. e-liquid) of the system may be replenished by re-filling the tank of the device (rather than replacing the consumable). In this embodiment, the consumable described above may instead be a non-consumable component that is integral with the main body. Thus the device may comprise the features of the main body described above. In this embodiment, the only consumable portion may be e-liquid contained in the tank of the device. Access to the tank (for re-filling of the e-liquid) may be provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap).

The device may be a smoking substitute device (e.g. an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g. an e-cigarette consumable).

In a second aspect there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect, the consumable being engageable with the main body such that vaporiser of the consumable is connected to the power source of the main body.

The consumable may be an e-cigarette consumable. The main body may be as described above with respect to the first aspect. The main body may, for example, be an e-cigarette device for supplying power to the consumable.

<FIG> shows a first embodiment of a smoking substitute system <NUM>. In this example, the smoking substitute system <NUM> includes a main body <NUM> and an aerosol delivery device in the form of a consumable <NUM>. The consumable <NUM> may alternatively be referred to as a "pod", "cartridge" or "cartomizer". It should be appreciated that in other examples (i.e. open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system <NUM> is a closed system vaping system, wherein the consumable <NUM> includes a sealed tank <NUM> and is intended for single-use only. The consumable <NUM> is removably engageable with the main body <NUM> (i.e. for removal and replacement). <FIG> shows the smoking substitute device <NUM> with the main body <NUM> physically coupled to the consumable <NUM>, <FIG> shows the main body <NUM> of the smoking substitute system <NUM> without the consumable <NUM>, and <FIG> shows the consumable <NUM> of the smoking substitute system <NUM> without the main body <NUM>.

The main body <NUM> and the consumable <NUM> are configured to be physically coupled together by pushing the consumable <NUM> into a cavity at an upper end <NUM> of the main body <NUM>, such that there is an interference fit between the main body <NUM> and the consumable <NUM>. In other examples, the main body <NUM> and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable <NUM> includes a mouthpiece (not shown in <FIG>) at an upper end <NUM> of the consumable <NUM>, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable <NUM> when a user inhales through the mouthpiece. The tank <NUM> containing e-liquid is located at the lower end <NUM> of the consumable <NUM>.

The tank <NUM> includes a window <NUM>, which allows the amount of e-liquid in the tank <NUM> to be visually assessed. The main body <NUM> includes a slot <NUM> so that the window <NUM> of the consumable <NUM> can be seen whilst the rest of the tank <NUM> is obscured from view when the consumable <NUM> is inserted into the cavity at the upper end <NUM> of the main body <NUM>.

The lower end <NUM> of the main body also includes a light <NUM> (e.g. an LED) located behind a small translucent cover. The light <NUM> may be configured to illuminate when the smoking substitute system <NUM> is activated. Whilst not shown, the consumable <NUM> may identify itself to the main body <NUM>, via an electrical interface, RFID chip, or barcode.

<FIG> are schematic drawings of the main body <NUM> and consumable <NUM>. As is apparent from <FIG>, the main body <NUM> includes a power source <NUM>, a controller <NUM>, a memory <NUM>, a wireless interface <NUM>, an electrical interface <NUM>, and, optionally, one or more additional components <NUM>.

The power source <NUM> is preferably a battery, more preferably a rechargeable battery. The controller <NUM> may include a microprocessor, for example. The memory <NUM> preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller <NUM> to perform certain tasks or steps of a method.

The wireless interface <NUM> is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface <NUM> could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface <NUM> may also be configured to communicate wirelessly with a remote server.

The electrical interface <NUM> of the main body <NUM> may include one or more electrical contacts. The electrical interface <NUM> may be located in a base of the aperture in the upper end <NUM> of the main body <NUM>. When the main body <NUM> is physically coupled to the consumable <NUM>, the electrical interface <NUM> is configured to transfer electrical power from the power source <NUM> to the consumable <NUM> (i.e. upon activation of the smoking substitute system <NUM>).

The electrical interface <NUM> may be configured to receive power from a charging station when the main body <NUM> is not physically coupled to the consumable <NUM> and is instead coupled to the charging station. The electrical interface <NUM> may also be used to identify the consumable <NUM> from a list of known consumables. For example, the consumable <NUM> may be a particular flavour and/or have a certain concentration of nicotine (which may be identified by the electrical interface <NUM>). This can be indicated to the controller <NUM> of the main body <NUM> when the consumable 10nected to the main body <NUM>. Additionally, or alternatively, there may be a separate communication interface provided in the main body <NUM> and a corresponding communication interface in the consumable <NUM> such that, when connected, the consumable <NUM> can identify itself to the main body <NUM>.

The additional components <NUM> of the main body <NUM> may comprise the light <NUM> discussed above.

The additional components <NUM> of the main body <NUM> may also comprise a charging port (e.g. USB or micro-USB port) configured to receive power from the charging station (i.e. when the power source <NUM> is a rechargeable battery). This may be located at the lower end <NUM> of the main body <NUM>. Alternatively, the electrical interface <NUM> discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components <NUM> of the main body <NUM> may, if the power source <NUM> is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components <NUM> of the main body <NUM> may include a sensor, such as an airflow (i.e. puff) sensor for detecting airflow in the smoking substitute system <NUM>, e.g. caused by a user inhaling through a mouthpiece <NUM> of the consumable <NUM>. The smoking substitute system <NUM> may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable <NUM>. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components <NUM> of the main body <NUM> may include a user input, e.g. a button. The smoking substitute system <NUM> may be configured to be activated when a user interacts with the user input (e.g. presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system <NUM>.

As shown in <FIG>, the consumable <NUM> includes the tank <NUM>, an electrical interface <NUM>, a vaporiser <NUM>, one or more air inlets <NUM>, a mouthpiece <NUM>, and one or more additional components <NUM>.

The electrical interface <NUM> of the consumable <NUM> may include one or more electrical contacts. The electrical interface <NUM> of the main body <NUM> and an electrical interface <NUM> of the consumable <NUM> are configured to contact each other and thereby electrically couple the main body <NUM> to the consumable <NUM> when the lower end <NUM> of the consumable <NUM> is inserted into the upper end <NUM> of the main body <NUM> (as shown in <FIG>). In this way, electrical energy (e.g. in the form of an electrical current) is able to be supplied from the power source <NUM> in the main body <NUM> to the vaporiser <NUM> in the consumable <NUM>.

The vaporiser <NUM> is configured to heat and vaporise e-liquid contained in the tank <NUM> using electrical energy supplied from the power source <NUM>. As will be described further below, the vaporiser <NUM> includes a heating filament and a wick. The wick draws e-liquid from the tank <NUM> and the heating filament heats the e-liquid to vaporise the e-liquid.

The one or more air inlets <NUM> are preferably configured to allow air to be drawn into the smoking substitute system <NUM>, when a user inhales through the mouthpiece <NUM>. When the consumable <NUM> is physically coupled to the main body <NUM>, the air inlets <NUM> receive air, which flows to the air inlets <NUM> along a gap between the main body <NUM> and the lower end <NUM> of the consumable <NUM>.

In operation, a user activates the smoking substitute system <NUM>, e.g. through interaction with a user input forming part of the main body <NUM> or by inhaling through the mouthpiece <NUM> as described above. Upon activation, the controller <NUM> may supply electrical energy from the power source <NUM> to the vaporiser <NUM> (via electrical interfaces <NUM>, <NUM>), which may cause the vaporiser <NUM> to heat e-liquid drawn from the tank <NUM> to produce a vapour which is inhaled by a user through the mouthpiece <NUM>.

An example of one of the one or more additional components <NUM> of the consumable <NUM> is an interface for obtaining an identifier of the consumable <NUM>. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable <NUM> may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body <NUM>.

It should be appreciated that the smoking substitute system <NUM> shown in <FIG> is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

<FIG> is a section view of the consumable <NUM> described above. The consumable <NUM> comprises a tank <NUM> for storing e-liquid, a mouthpiece <NUM> and a passage <NUM> extending along a longitudinal axis of the consumable <NUM>. In the illustrated embodiment the passage <NUM> is in the form of a tube having a substantially circular transverse cross-section (i.e. transverse to the longitudinal axis). The tank <NUM> surrounds the passage <NUM>, such that the passage <NUM> extends centrally through the tank <NUM>.

A tank housing <NUM> of the tank <NUM> defines an outer casing of the consumable <NUM>, whilst a passage wall <NUM> defines the passage <NUM>. The tank housing <NUM> extends from the lower end <NUM> of the consumable <NUM> to the mouthpiece <NUM> at the upper end <NUM> of the consumable <NUM>. At the junction between the mouthpiece <NUM> and the tank housing <NUM>, the mouthpiece <NUM> is wider than the tank housing <NUM>, so as to define a lip <NUM> that overhangs the tank housing <NUM>. This lip <NUM> acts as a stop feature when the consumable <NUM> is inserted into the main body <NUM> (i.e. by contact with an upper edge of the main body <NUM>).

The tank <NUM>, the passage <NUM> and the mouthpiece <NUM> are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to <FIG>, this component may be formed by way of an injection moulding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing <NUM> tapers, such that the thickness of the tank housing <NUM> decreases in a first demoulding direction (as will be discussed further with respect to <FIG>). In <FIG> the first demoulding direction is in a downward direction away from the mouthpiece <NUM>. This means that, aside from a small number of indents (which provide physical connection between the consumable <NUM> and the main body <NUM>), the thickness of the tank housing <NUM> decreases with increasing distance away from the mouthpiece <NUM>. In particular, the tank housing <NUM> tapers in this way, because internal and external surfaces of the tank housing <NUM> are angled with respect to the first demoulding direction. This tapering assists in forming the tank housing <NUM> and passage wall <NUM> as a single (i.e. unitary) component.

Like the tank housing <NUM>, the passage wall <NUM> is also tapered such that the thickness of the passage wall <NUM> decreases along the first demoulding direction. Again, the thickness of the passage wall <NUM> decreases due to internal and external surfaces of the passage wall <NUM> being angled with respect to the first demoulding direction. As a result of the tapering of the passage wall <NUM>, the passage <NUM> has an internal diameter that decreases in a downstream direction (i.e. an upward direction in <FIG>). For example, the passage <NUM> has an internal width less than <NUM> and greater than <NUM> at an upstream end of the passage <NUM> (e.g. approximately <NUM>). On the other hand, the passage <NUM> has an internal width of less than <NUM> and greater than <NUM> at the downstream end of the passage <NUM> (e.g. approximately <NUM>).

The mouthpiece <NUM> comprises a mouthpiece aperture <NUM> defining an outlet of the passage <NUM>. The mouthpiece aperture <NUM> has a radially inwardly directed inner surface <NUM>, which joins an outer surface <NUM> of the mouthpiece <NUM> (i.e. a surface which contacts a user's lips in use) at an outer edge <NUM> of the mouthpiece aperture <NUM>. At this outer edge <NUM>, the included angle between the inner surface <NUM> of the mouthpiece aperture <NUM> and the outer surface <NUM> of the mouthpiece <NUM> (i.e. the "mouthpiece angle") is greater than <NUM> degrees. In the illustrated embodiment, this is due to the outer edge <NUM> being rounded. This edge <NUM> may otherwise be chamfered or bevelled.

The vaporiser <NUM> is located in a vaporising chamber <NUM> of the consumable <NUM>. This is best shown in <FIG>, which provides a detailed view of the vaporising chamber <NUM>. The vaporising chamber <NUM> is downstream of the inlet <NUM> of the consumable <NUM> and is fluidly connected to the mouthpiece aperture <NUM> (i.e. outlet) by the passage <NUM>. In particular, the passage <NUM> extends between the mouthpiece aperture <NUM> and an opening <NUM> from the vaporising chamber <NUM>. This opening <NUM> is formed in a downstream (i.e. upper) wall <NUM> of the vaporising chamber <NUM>.

The vaporiser <NUM> comprises a porous wick <NUM> and a heater filament <NUM> coiled around the porous wick <NUM>. As is apparent from <FIG> and <FIG>, the wick <NUM> extends transversely across the vaporising chamber <NUM> between sidewalls 166a, 166b of the vaporising chamber <NUM> which form part of an inner sleeve <NUM> of a silicone insert <NUM> that defines the lower end <NUM> of the consumable <NUM> that connects with the main body <NUM>. The insert <NUM> is inserted into an open lower end of the tank <NUM> so as to seal against the internal surface of the tank housing <NUM>.

In this way, the inner sleeve <NUM> projects into the tank <NUM> and seals with the passage <NUM> (around the passage wall <NUM>) so as to separate the vaporising chamber <NUM> from the e-liquid in the tank <NUM>. Ends of the wick <NUM> project through apertures in the inner sleeve <NUM> and into the tank <NUM> so as to be in contact with the e-liquid in the tank <NUM>. In this way, e-liquid is transported along the wick <NUM> (e.g. by capillary action) to a central portion of the wick <NUM>. The transported e-liquid is heated by the heater filament <NUM> (when activated e.g. by detection of inhalation), which causes the e-liquid to be vaporised and to be entrained in air flowing in the vaporising chamber <NUM>. This vaporised liquid may cool to form an aerosol in the passage <NUM>, which may then be inhaled by a user.

In some cases, unvaporised liquid can be carried by air flowing through the vaporising chamber <NUM>. This may be undesirable for a user. To reduce or avoid this, the consumable <NUM> comprises a baffle <NUM>, which is shown in more detail in <FIG>. The baffle <NUM> extends across the vaporising chamber <NUM> so as to be interposed between the vaporiser <NUM> and the passage opening <NUM>. In this way, unvaporised liquid from the wick <NUM> may collect on an upstream (i.e. lower) planar surface <NUM> of the baffle <NUM> rather than entering the passage opening <NUM>. The baffle <NUM> also causes the chamber airflow path from the vaporiser <NUM> to the passage opening <NUM> to be redirected around the baffle <NUM>.

The baffle <NUM> depends from and is integral with a (second) side wall 166b of the vaporising chamber <NUM> i.e. the baffle <NUM> is integral with the silicone insert <NUM>. The baffle <NUM> comprises an upstream edge <NUM> around which the airflow is redirected. This upstream edge <NUM> and the (first) sidewall 166a of the vaporising chamber <NUM> define a single aperture <NUM> at a lateral edge of the baffle <NUM>. The aperture <NUM> is laterally offset from the longitudinal axis of the passage opening <NUM>. The baffle <NUM> further comprises a downstream edge <NUM>.

As shown in <FIG>, first portion <NUM> of the chamber airflow path extends in a generally longitudinal direction to the vaporiser <NUM> from the inlet <NUM> and is aligned with the axial centre of the device (i.e. aligned with the longitudinal axis of the passage <NUM>). A second portion <NUM> of the chamber airflow path then extends generally radially from the vaporiser <NUM> to the aperture <NUM>. Thus there is a first lateral deflection in the chamber airflow path as it passes from the vaporiser <NUM> to the aperture <NUM>.

A third portion <NUM> of the chamber airflow path from the aperture <NUM> (i.e. the upstream edge <NUM> of the baffle <NUM>) to the downstream edge <NUM> of the baffle <NUM> is generally longitudinal and is laterally offset from the axial centre of the device. Thus there is a first axial deflection between the second and third portions <NUM>, <NUM> of the chamber air flow path. The transverse cross-sectional area of the third portion <NUM> of the chamber air flow path as it passes between the upstream and downstream edges <NUM>, <NUM> is substantially constant.

A fourth portion <NUM> of the chamber airflow path between the third portion <NUM> and the passage <NUM> extends generally radially (laterally) parallel to a planar upper surface of the baffle <NUM>, such that there is a second lateral deflection between the third and fourth portions <NUM>, <NUM> of the chamber airflow path.

The chamber airflow path may then comprise a second axial deflection from the lateral direction (of the fourth portion) to a longitudinal direction as it leaves the vaporising chamber <NUM> at the passage opening <NUM>.

Upon inhalation by a user at the mouthpiece aperture <NUM>, air flows along the single, unified chamber airflow path around the wick <NUM>, through the aperture <NUM> and into the passage <NUM> via the passage opening <NUM>.

<FIG> shows a drawing of a manufacturing assembly <NUM> which is used to manufacture the consumable <NUM>. The manufacturing assembly <NUM> comprises a first mould <NUM> and a second mould <NUM>.

The first mould <NUM> has a shape which complements that of a first end of the integrally formed tank housing <NUM> and mouthpiece <NUM>. The first mould <NUM> therefore has a shape which matches the inner surfaces defining the tank <NUM>.

The second mould <NUM> has a shape which complements that of a second end of the integrally formed tank housing <NUM> and mouthpiece <NUM>. The second mould <NUM> has a shape which matches the outer surface of the mouthpiece <NUM> and the inner surface of the mouthpiece aperture <NUM>.

When the first mould <NUM> and the second mould <NUM> are brought together, they define a closed cavity which has the shape of the tank housing <NUM>, the mouthpiece <NUM> and the passage walls <NUM>.

To manufacture these components, heated material is injected into the cavity between the first mould <NUM> and the second mould <NUM>. At this point, the first mould <NUM> and the second mould <NUM> meet at a boundary between external surfaces of the mouthpiece <NUM> and the tank housing <NUM>.

The material is subsequently cooled, and the first mould <NUM> and the second mould <NUM> are separated, with the first mould <NUM> travelling in the first demoulding direction <NUM> (i.e. away from the second mould <NUM>) and the second mould <NUM> travelling in a second demoulding direction <NUM> (i.e. away from the first mould <NUM> and opposite to the first demoulding direction <NUM>). For a particular component, a demoulding direction is a direction along which a mould which contacts that component is removed during an injection moulding process.

The insert <NUM> and any additional components are subsequently inserted into the tank <NUM>.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention defined by the claims.

Claim 1:
An aerosol delivery device comprising:
a vaporising chamber (<NUM>) housing a vaporiser (<NUM>);
a chamber airflow path through the vaporising chamber (<NUM>), the chamber airflow path being a unitary, deflected path extending through a single lateral aperture (<NUM>) on a transverse baffle (<NUM>) mounted within the vaporising chamber downstream of the vaporiser;
a tank housing (<NUM>) defining a tank (<NUM>) for containing vaporisable liquid; and
an insert (<NUM>) integral with the transverse baffle and having an inner longitudinally-extending sleeve that defines the vaporising chamber, characterised in that:
the insert (<NUM>) is inserted into an open end of the tank (<NUM>) so as to seal against an inside surface of the tank housing (<NUM>).