Patent Description:
One form of an aerosol delivery device is a smoking-substitute system (or device), which is an electronic system that permits the user to simulate the act of smoking by producing an aerosol or vapour that is drawn into the lungs through the mouth and then exhaled. The inhaled aerosol or vapour typically bears nicotine and/or other flavourings without the odour and health risks associated with traditional smoking and tobacco products. In use, the user experiences a similar satisfaction and physical sensation to those experienced from a traditional smoking or tobacco product, and exhales an aerosol or vapour of similar appearance to the smoke exhaled when using such traditional smoking or tobacco products.

One approach for a smoking substitute system 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 heating element to produce an aerosol/vapour which is inhaled by a user. The e-liquid typically includes a base liquid as well as nicotine and/or flavourings. The resulting vapour therefore also typically contains nicotine and/or flavourings. The base liquid may include propylene glycol and/or vegetable glycerine.

A typical vaping smoking substitute system includes a mouthpiece, a power source (typically a battery), a tank for containing e-liquid, as well as a heating element. In use, electrical energy is supplied from the power source to the heating element, which heats the e-liquid to produce an aerosol (or "vapour") which is inhaled by a userthrough the mouthpiece. For example, <CIT> discloses an electronic nicotine delivery system (ENDS) comprising a mouth piece (MP), an atomizer arrangement (AA), a power supply (PS), a nicotine container (NC) and an additive container (AC). For example, <CIT> discloses a system for aerosolization of compartmentalized materials wherein the system performs operations comprising vaporizing, by a heater, at least a portion of a first material to form a first vapor. For example, <CIT> discloses an aerosol generating system, the system comprising: aerosol generating means; aerosol delivery means; and an aerosol guiding device. For example, <CIT> discloses an aerosol delivery device comprising a porous nib.

Vaping smoking substitute systems can be configured in a variety of ways. For example, there are "closed system" vaping smoking substitute systems, which typically have a sealed tank and heating element. The tank 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 systems include a base unit which includes the power source, wherein the base unit is configured to be physically and electrically coupled to a consumable including the tank and the heating element. The consumable may also be referred to as a cartomizer. In this way, when the tank of a consumable has been emptied, the consumable is disposed of. The base unit can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute systems are completely disposable, and intended for one-use only.

There are also "open system" vaping smoking substitute systems which typically have a tank that is configured to be refilled by a user. In this way the system can be used multiple times.

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

For a smoking substitute device it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. As explained above, in the vaping approach, e-liquid is heated by a heating element to produce an aerosol/vapour which is inhaled by a user. Many e-cigarettes also deliver flavour to the user, to enhance the experience. Flavour compounds are contained in the e-liquid that is heated. Heating of the flavour compounds may be undesirable as the flavour compounds are inhaled into the user's lungs. Toxicology restrictions are placed on the amount of flavour that can be contained in the e-liquid. This can result in some e-liquid flavours delivering a weak and underwhelming taste sensation to consumers in the pursuit of safety.

In aerosol delivery devices, it is desirable to be able to assembly the component parts of the device in an easy and reliable manner.

In some smoking substitute devices/systems, liquid used to form an aerosol can leak from the device and/or can collect in or on parts of the device. When such liquid collects in parts of the device that are within an airflow path of the device, such liquid can be entrained in an airflow in the airflow path. It may also be desirable to increase the degree of sanitation relating to the device.

The present disclosure has been devised in light of the above considerations.

The provision of an aerosolisation chamber having a uniform cross-sectional area, as opposed to e.g. a conical chamber, may reduce or avoid the build-up of aerosol precursor at the mouthpiece aperture. For example, a conical chamber can diverge from the aerosol generating portion of the liquid transfer element, which may result in a space between the wall(s) defining the chamber and the liquid transfer element that is larger than would otherwise be the case of a non-diverging (i.e. uniform cross-section) chamber. This larger space may allow for a greater build-up of aerosol precursory, so as to result in a larger propensity for leakage from the device and may also result in a greater propensity for large droplets of aerosol precursor to be entrained in airflow from the device. Thus, the provision of a uniform cross-section chamber may result in a more consistent droplet size in the aerosol delivered by the device.

Similarly, when the space between the chamber walls and the aerosol generating portion is minimised, the surface tension of any aerosol precursor between the chamber walls and the aerosol generating portion may be more likely to be sufficient to retain the aerosol precursor in the device.

As the aerosolisation chamber extends from the mouthpiece aperture, it may otherwise be considered an outlet (e.g. a mouthpiece outlet) of the device.

The aerosol generating portion of the liquid transfer element has a larger transverse cross-sectional area (taken at a location adjacent the conveying portion) than a transverse cross-sectional area (taken at a location adjacent the aerosol generating portion) of the conveying portion. In this respect, the aerosol generating portion may define an enlarged portion of the aerosol generator. The aerosol generating portion may have a circular transverse cross-sectional shape. The conveying portion may have a circular transverse cross-sectional shape. In this respect, the aerosol generating portion may have a larger radius than the conveying portion.

Due to the aerosol generating portion being larger than the conveying portion, a transversely (e.g. radially) extending transition surface may be defined between the conveying portion and the aerosol generating portion. The transition surface may define an outward step from the conveying portion to the aerosol generating portion. The transition surface may have a concave profile. Hence, the transition surface may form a smooth continuous transition with an outer circumferential surface of the conveying portion. On the other hand, there may be a (substantially) sharp transition between the transition surface and an outer circumferential surface of the aerosol generating portion. In this respect a leading edge of the aerosol generating portion may be defined between the transition surface and the outer circumferential surface of the aerosol generating portion.

The aerosolisation chamber may have a cylindrical shape. For example, the aerosolisation chamber may have a circular cylinder shape (i.e. having a circular transverse cross-section) or an elliptical cylinder shape (having an elliptical transverse cross-section). A transverse cross-sectional shape of the aerosol generating portion may correspond to a transverse cross-sectional shape of the aerosolisation chamber (i.e. they may both be circular or elliptical). In this way, the aerosol generating portion and a wall defining the aerosolisation chamber may be concentrically arranged.

The longitudinal length of the aerosolisation chamber may be between <NUM> and <NUM>, for example between <NUM> and <NUM>, e.g. about <NUM>.

The aerosol generating portion may be fully received in the aerosolisation chamber. A portion of the conveying portion (i.e. a portion adjacent the aerosol generating portion) may be received in the aerosolisation chamber. Alternatively, only a portion of the aerosol generating portion (or liquid transfer element) may be received in the aerosolisation chamber (i.e. at an upstream end of the aerosolisation chamber). Thus a portion of the aerosolisation chamber (e.g. at or adjacent to the mouthpiece aperture and downstream of the aerosol generating portion) may not include the aerosol generating portion.

An airflow path is defined between a wall defining the aerosolisation chamber and the liquid transfer element. Where the aerosolisation chamber is cylindrical, the airflow path may be annular. The airflow path includes a constricted region defined by the aerosol generating portion. The transverse/radial distance between the aerosol generating portion and the wall of the aerosolisation chamber at the constricted region may be less than <NUM>, for example less than <NUM>, or e.g. less than <NUM>.

The constricted region may define the narrowest part of the airflow path through the aerosolisation chamber. This constriction of the airflow passage increases the velocity of air/vapour passing through the aerosolisation chamber. In this respect, the constriction may be referred to as a Venturi aperture. The constriction may have a toroidal shape (i.e. extending about the aerosol generating portion of the liquid transfer element). The toroidal shape may, however, be interrupted by supports (e.g. projections, ribs, etc.) protruding inwardly from wall(s) of the aerosolisation chamber to support the aerosol generating portion in the aerosolisation chamber.

In addition to increasing the airflow velocity, the constriction reduces the air pressure of the airflow flowing through the constriction (i.e. in the vicinity of the aerosol generating portion). This low pressure and high velocity facilitate the generation of an aerosol from the aerosol precursor held in the aerosol generating portion (i.e. conveyed from the storage chamber by the liquid transfer element). This aerosol is entrained in the airflow passing through the constriction and is discharged from the mouthpiece aperture of the aerosol delivery device.

The airflow path may have an expansion region downstream of the constricted region, in which a cross-sectional area of the airflow path (e.g. gradually) increases in the downstream direction. The expansion region may be defined by a tapered section of the aerosol generating portion. The tapered section may taper inwardly in a direction from the constricted region to a downstream (distal) end of the aerosol generating portion. The taper may have a curved profile (i.e. in the longitudinal direction).

The terms "upstream" and "downstream" are used herein with reference to the direction of airflow through the device during normal use of the device (i.e. by way of inhalation at the mouthpiece aperture).

The transverse/radial distance between the aerosol generating portion and the wall of the aerosolisation chamber at the distal/downstream end of the aerosol generating portion may be less than <NUM>, for example less than <NUM>, or e.g. less than <NUM>. The transverse/radial distance between the aerosol generating portion and the wall of the aerosolisation chamber at the distal/downstream end of the aerosol generating portion may be less than <NUM>% of the diameter of aerosolisation chamber, for example less than <NUM>%, or e.g. less than <NUM>%.

A distal (transversely extending) end surface of the aerosol generating portion (i.e. at the extreme downstream end of the aerosol generating portion) may be being substantially planar. In other words, the aerosol generating portion (and thus the liquid transfer element) may have a flattened or truncated distal end. The combination of the planar/flattened distal end and the aerosolisation chamber of constant cross-sectional area may provide a more evenly dispersed spray from the device. For example, such an arrangement may result in a smaller gap between the aerosolisation chamber walls and the aerosol generating portion (e.g. compared with an arrangement having a conical outlet and/or a conical aerosol generating portion), which may reduce the presence of large droplets of liquid in the aerosol discharged from the device.

The distal end of the aerosol generating portion may be spaced from the mouthpiece aperture/end surface (e.g. transversely extending end surface of the mouthpiece) in an upstream longitudinal direction. That is, the distal (downstream) end of the aerosol generating portion/liquid transfer element may be recessed with respect to the end surface of the mouthpiece. For example, the distal end may be spaced (in the longitudinal direction) from the end surface of the mouthpiece or mouthpiece aperture by less than <NUM>, or less than <NUM>, or e.g. less than <NUM>.

The aerosolisation chamber may be defined by a tube extending upstream and longitudinally from the end surface of the mouthpiece. The device may comprise a retaining element for retaining the liquid transfer element in position with respect to the mouthpiece. The retaining element may comprise a mounting portion extending about the tube so as to mount the retaining element to the tube. The retaining element may comprise a collar projecting from the mounting portion and at least partly circumscribing the liquid transfer element (e.g. the conveying portion) so as to retain the liquid transfer element against movement relative to the mouthpiece. The liquid transfer element (e.g. the conveying portion) may comprise one or more recesses for receipt of a portion of the collar so as to facilitate retaining of the liquid transfer element by the collar.

The aerosol delivery device may comprise a flow passage for fluid flow therethrough. The flow passage may extend generally in the longitudinal direction between (and may fluidly connect) an inlet of the aerosol delivery device and the aerosolisation chamber. In this respect, a user may draw fluid (e.g. air) into and through the flow passage and aerosolisation chamber of the aerosol delivery device by inhaling at the mouthpiece aperture.

The flow passage may comprise one or more deflections. It may comprise a transverse portion proximal the inlet such that there is a deflection between inlet and the transverse portion of the flow passage.

The flow passage may then comprise a generally longitudinal portion downstream of the transverse portion. The longitudinal portion may extend within a spacing between a device housing (which may be integral with the mouthpiece) and a tank (discussed further below) defining the storage chamber. The flow passage may then deflect again (e.g. radially) at the upper surface of the tank within the mouthpiece, through the aerosolisation chamber, towards the mouthpiece aperture.

The flow passage may be a single (annular) flow passage around the tank or it may comprise two branches which split around the tank and re-join within the mouthpiece e.g. proximal the liquid transfer element.

As is mentioned above, the aerosol delivery device may comprise a tank defining the storage chamber for containing the aerosol precursor (which may be e.g. an e-liquid or a flavour liquid). The aerosol precursor may, for example, comprise a flavourant having a menthol, liquorice, chocolate, fruit flavour (including e.g. citrus, cherry etc.), vanilla, spice (e.g. ginger, cinnamon) and/or tobacco flavour.

The aerosol precursor may be stored in the form of a free liquid. Alternatively, a porous body may be disposed within the storage chamber, which may contain the aerosol precursor.

The tank may at least partially define the flow passage. For example, the flow passage may be defined between an outer surface of the tank and an inner surface of a device housing (which may be integral with the mouthpiece).

The aerosol delivery device may comprise an air bleed channel configured to allow the bleeding of air into the storage chamber to replace aerosol precursor that is removed from the storage chamber. The air bleed channel may be in fluid communication with the flow passage, such that (e.g. under certain conditions) air from the flow passage can enter the storage chamber through the air bleed channel.

As will be described further below, the liquid transfer element (i.e. the aerosol generating portion) is configured to generate an aerosol in the aerosolisation chamber. The liquid transfer element does this in such a way that does not use heat to form the aerosol, and therefore is referred to as a "passive" aerosol generator.

The conveying portion may be elongate and generally cylindrical, and may be at least partially enclosed within one or more internal walls of the aerosol delivery device. The one or more internal walls enclosing the conveying portion may form part of the tank defining the storage chamber. In this respect, the tank may at least partly surround (e.g. may fully surround) the conveying portion. That is, the tank may define a conduit through which the conveying portion passes. Thus, the conveying portion may extend generally longitudinally (e.g. centrally) through a portion of the tank (i.e. through the conduit defined by the tank).

The liquid transfer element (i.e. conveying portion) may extend into the storage chamber so as to be in contact with (e.g. at least partially submerged in) the aerosol precursor. Hence, the liquid transfer element may be configured to convey the aerosol precursor from the storage chamber to the aerosolisation chamber via a wicking/capillary action.

The aerosol may be sized to inhibit pulmonary penetration. The aerosol may be formed of particles with a mass median aerodynamic diameter that is greater than or equal to <NUM> microns, e.g. greater than <NUM> microns, or greater than <NUM> microns, or may be greater than <NUM> microns, or may be greater than <NUM> microns.

The aerosol may be sized for transmission within at least one of a mammalian oral cavity and a mammalian nasal cavity. The first aerosol may be formed by particles having a maximum mass median aerodynamic diameter that is less than <NUM> microns, or e.g. less than <NUM> microns, or less than <NUM> microns. Such a range of mass median aerodynamic diameter can produce aerosols which are sufficiently small to be entrained in an airflow caused by a user drawing air through the aerosol delivery device and to enter and extend through the oral and or nasal cavity to activate the taste and/or olfactory receptors.

The size of aerosol formed without heating may be typically smaller than that formed by condensation of a vapour.

It is noted that the mass median aerodynamic diameter is a statistical measurement of the size of the particles/droplets in an aerosol. That is, the mass median aerodynamic diameter quantifies the size of the droplets that together form the aerosol. The mass median aerodynamic diameter may be defined as the diameter at which <NUM>% of the particles/droplets by mass in the aerosol are larger than the mass median aerodynamic diameter and <NUM>% of the particles/droplets by mass in the aerosol are smaller than the mass median aerodynamic diameter. The "size of the aerosol", as may be used herein, refers to the size of the particles/droplets that are comprised in the particular aerosol.

The above configuration of the aerosol delivery device may be representative of an activated state of the aerosol delivery device. The aerosol delivery device may additionally be configurable in a deactivated state. In the deactivated state, the liquid transfer element may be isolated from the aerosol precursor. This isolation may, for example, be provided by a plug (e.g. formed of silicone). The plug may be located at an end (i.e. upstream end) of the conduit (defined by the tank) so as to provide a barrier between the aerosol precursor in the storage chamber and the conveying portion of the liquid transfer element. Alternatively, the aerosol delivery device may comprise a duck bill valve, a split valve or diaphragm; or a sheet of foil isolating the liquid transfer element from the first aerosol precursor.

In the deactivated state, the air bleed channel may be sealed by a sealing element. The sealing element may, for example, be in the form of a bung or plug (e.g. a silicone bung or plug). At least a portion of the bung may be received in the air bleed channel when the aerosol delivery device is in the deactivated state, so as to block the passage of airflow through the air bleed channel. The sealing element may alternatively be in the form of a pierceable membrane (e.g. formed of a metal foil) extending across the air bleed channel.

The mouthpiece/device housing of the device may be movable relative to the tank defining the storage chamber. The mouthpiece/device housing may be movable relative to the air bleed channel. In particular, movement of the mouthpiece/device housing may be in the longitudinal direction of the aerosol delivery device.

The mouthpiece may comprise an activation member, which may protrude internally (in an upstream direction) from an internal surface of the mouthpiece. When the mouthpiece/device housing is moved longitudinally in an upstream direction i.e. towards the storage tank, a distal end of the activation member may engage the sealing element so as to move the sealing element (i.e. in the upstream direction) relative to the air bleed channel. This movement of the sealing element may open the air bleed channel, so as to allow airflow therethrough and so as to move the aerosol delivery device to the activated state.

When the sealing element is a bung, the bung may comprise an enlarged end that extends fully across the air bleed channel, and a neck portion that extends only partway across the air bleed channel. Movement of the bung along the air bleed channel by the activation member may cause the enlarged end of the bung to move into the storage chamber such that only the neck portion remains in the air bleed channel. Thus, airflow may be permitted through the air bleed channel between the neck portion and the walls of the air bleed channel.

When the sealing element is a pierceable membrane, the activation member may pierce the pierceable membrane when moved in the upstream direction. To facilitate such piercing, the activation member may be in the form of a blade, or may be pointed.

The movement of the mouthpiece/device housing may also cause longitudinal upstream movement of the liquid transfer element through the conduit defined by the tank. The conveying portion of the liquid transfer element may engage the plug (or duck bill valve, split valve, etc.) so as to disengage the plug from the end of the conduit. Removal of the plug in this way means that the conveying portion comes into contact with the aerosol precursor (i.e. so as to be able to convey the aerosol precursor to the aerosol generating portion of the liquid transfer element).

The above components of the aerosol delivery device may collectively be referred to as an (additive) delivery article or (flavour) pod of the aerosol delivery device.

The aerosol delivery device may further comprise a cartomizer. The (additive) delivery article/(flavour) pod may be engageable with the cartomizer, for example, by way of an interference fit, snap-engagement, bayonet locking arrangement, etc. In other embodiments, the (additive) delivery article/(flavour) pod and cartomizer may be integrally formed.

The device housing may comprise opposing recesses or apertures for engagement with respective lugs provided on the cartomizer to secure the device housing to the cartomizer. There may be two sets of longitudinally spaced lugs and two sets of longitudinally spaced apertures with only the downstream lugs engaged within the upstream apertures when the device is in its deactivated state. Movement of the mouthpiece/device housing cases engagement of the upstream lugs in the upstream apertures and the downstream lugs in the downstream apertures.

The cartomizer may comprise a vaporising chamber and a vapour outlet for fluid flow therethrough. The vapour outlet may be fluidly connected to the flow passage of the additive delivery article/flavour pod. The vapour outlet and vaporising chamber may fluidly connect a cartomizer inlet opening and the inlet of the flow passage. Thus, an airflow may be drawn into and through the cartomizer, and subsequently through the additive delivery article/flavour pod.

The aerosol precursor stored in the storage chamber (and conveyed by the liquid transfer element) may be a first aerosol precursor, and the aerosol formed from the first aerosol precursor may be a first aerosol. The aerosol delivery device (i.e. cartomizer) may comprise a reservoir defined by a container for containing a second aerosol precursor (which may be an e-liquid). The second aerosol precursor may, for example, comprise a base liquid and a physiologically active compound e.g. nicotine. The base liquid may include an aerosol former such as propylene glycol and/or vegetable glycerine.

At least a portion of the container may be translucent. For example, the container may comprise a window to allow a user to visually assess the quantity of second aerosol precursor in the container. The cartomizer may be referred to as a "clearomizer" if it includes a window. The vapour outlet may extend longitudinally through the container, wherein an outlet wall of the vapour outlet may define the inner wall of the container. In this respect, the container may surround the vapour outlet, such that the container may be generally annular.

The aerosol delivery device (i.e. the cartomizer) may comprise a vaporiser. The vaporiser may be located in the vaporising chamber.

The vaporiser may comprise a wick. The vaporiser may further comprise a heater. The wick may comprise a porous material. A portion of the wick may be exposed to fluid flow in the vaporising chamber. The wick may also comprise one or more portions in contact with the second aerosol precursor stored in the reservoir. For example, opposing ends of the wick may protrude into the reservoir and a central portion (between the ends) may extend across the vaporising chamber so as to be exposed to air flow in the vaporising chamber. Thus, fluid may be drawn (e.g. by capillary action) along the wick, from the reservoir to the exposed portion 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 reservoir) to be heated so as to form a vapour and become entrained in fluid/air flowing through the vaporising chamber. This vapour may subsequently cool to form an aerosol in the vapour outlet. This aerosol is hereinafter referred to as the second aerosol. This aerosol generation may be referred to as "active" aerosol generation, because it makes use of heat to generate the aerosol.

This second aerosol may subsequently flow from the vapour outlet to (and through) the flow passage and aerosolisation chamber of the additive delivery article/flavour pod (e.g. when engaged with the cartomizer). Thus, the fluid received through the mouthpiece aperture of the aerosol delivery device may be a combination of the first aerosol and the second aerosol.

The second aerosol generated is sized for pulmonary penetration (i.e. to deliver an active ingredient such as nicotine to the user's lungs). The second aerosol is formed of particles having a mass median aerodynamic diameter of less than or equal to <NUM> microns, preferably less than <NUM> microns, more preferably less than <NUM> microns, yet more preferably less than <NUM> micron. Such sized aerosols tend to penetrate into a human user's pulmonary system, with smaller aerosols generally penetrating the lungs more easily. The second aerosol may also be referred to as a vapour.

The (additive) delivery article ((flavour) pod) and/or cartomizer may be a consumable part of an aerosol delivery system. In this regard, the device may be a termed "a consumable".

Referring to <FIG>, there is shown a schematic view of an aerosol delivery system in the form of a smoking substitute system <NUM>. In this example, the smoking substitute system <NUM> comprises a cartomizer <NUM> and an additive delivery article in the form of a flavour pod <NUM> connected to a base unit <NUM>. In this example, the base unit <NUM> includes elements of the smoking substitute system <NUM> such as a battery, an electronic controller, and a pressure transducer (not shown). The cartomizer <NUM> may engage with the base unit <NUM> via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. A cartomizer may also be referred to as a "pod".

The flavour pod <NUM> is configured to engage with the cartomizer <NUM> and thus with the base unit <NUM>. The flavour pod <NUM> may engage with the cartomizer <NUM> via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. <FIG> illustrates the cartomizer <NUM> engaged with the base unit <NUM>, and the flavour pod <NUM> engaged with the cartomizer <NUM>. As will be appreciated, in this example, the cartomizer <NUM> and the flavour pod <NUM> are distinct elements.

As will be appreciated from the following description, in other embodiments the cartomizer <NUM> and the flavour pod <NUM> may be combined into a single component that implements the combined functionality of the cartomizer <NUM> and flavour pod <NUM>. Such a single component may also be referred to as an aerosol delivery device. In other examples, the cartomizer may be absent, with only a flavour pod <NUM> present.

As is set forth above, reference to a "consumable" component may mean that the component is intended to be used once until exhausted, and then disposed of as waste or returned to a manufacturer for reprocessing.

Referring to <FIG>, there is shown a smoking substitute system <NUM> comprising a base unit <NUM> and a consumable <NUM>. The consumable <NUM> combines the functionality of the cartomizer <NUM> and the flavour pod <NUM>. In <FIG>, the consumable <NUM> and the base unit <NUM> are shown separated from one another. In <FIG>, the consumable <NUM> and the base unit <NUM> are engaged with each other to form the smoking substitute system <NUM>.

Referring to <FIG>, there is shown a consumable <NUM> engagable with a base unit (not shown) via a push-fit engagement. The consumable <NUM> is shown in a deactivated state. The consumable <NUM> may be considered to have two portions - a cartomizer portion <NUM> and flavour pod portion <NUM> (i.e. additive delivery article), both of which are located within a single consumable component <NUM> (as in <FIG>). It should, however, be appreciated that in a variation, the cartomizer portion <NUM> and flavour pod portion <NUM> may be separate (but engageable) components.

The consumable <NUM> includes an upstream cartomizer inlet opening <NUM> and a downstream mouthpiece aperture <NUM> (i.e. defining an outlet of the consumable <NUM>) provided in a mouthpiece portion <NUM> of a terminal element <NUM>. In other examples a plurality of inlets and/or outlets are included. Between, and fluidly connecting, the inlet opening <NUM> and the mouthpiece aperture <NUM> there is an airflow path (or passage) comprising (in a downstream flow direction) a vaporising chamber <NUM> of the cartomizer, a vapour outlet <NUM> (also of the cartomizer) and a downstream flow passage <NUM> (which will hereinafter be referred to as the vapour flow passage) of the flavour pod portion <NUM>.

As above, the consumable <NUM> includes a flavour pod portion <NUM>. The flavour pod portion <NUM> is configured to generate a first (flavoured) aerosol for output from the mouthpiece aperture <NUM>. The flavour pod portion <NUM> of the consumable <NUM> includes a liquid transfer element <NUM>. This liquid transfer element <NUM> acts as a passive aerosol generator (i.e. an aerosol generator which does not use heat to form the aerosol), and is formed of a porous material. The liquid transfer element <NUM> comprises a conveying portion <NUM> and an aerosol generating portion <NUM>, which is located in the vapour flow passage <NUM>. In this example, the aerosol generating portion <NUM> is a porous nib.

When activated, as discussed in more detail below, a storage chamber <NUM> (defined by a tank <NUM>) for storing an aerosol precursor (i.e. a liquid comprising a flavourant) is fluidly connected to the liquid transfer element <NUM>. The flavoured aerosol precursor, in this embodiment, is stored in a porous body within the storage chamber <NUM> (but may be a free-liquid). In the activated state, the liquid transfer element <NUM> is in contact with the flavoured aerosol precursor stored in the storage chamber <NUM> by way of contact with the porous body/free liquid.

The liquid transfer element <NUM> comprises an aerosol generating portion <NUM> and a conveying portion <NUM>. The aerosol generating portion <NUM> is located at a downstream end (top of <FIG>) of the liquid transfer element <NUM>, whilst the conveying portion <NUM> forms the remainder of the liquid transfer element <NUM>. The conveying portion <NUM> is elongate and substantially cylindrical. The aerosol generating portion <NUM> is bulb/bullet-shaped, and comprises a portion which is wider (has a greater radius) than the conveying portion <NUM>. The aerosol generating portion <NUM> tapers to a tip at a downstream end of the liquid transfer element <NUM>.

The liquid transfer element <NUM> extends into and through the storage chamber <NUM>, such that the conveying portion <NUM> is in contact with the contents of the storage chamber <NUM>. In particular, an inner wall of the tank <NUM> defines a conduit <NUM>, through which the liquid transfer element <NUM> extends. The liquid transfer element <NUM> and the conduit <NUM> are located in a substantially central position within the storage chamber <NUM> and are substantially parallel to a central longitudinal axis of the consumable <NUM>.

The porous nature of the liquid transfer element <NUM> means that first (flavoured) aerosol precursor in the storage chamber <NUM> is drawn into the liquid transfer element <NUM>. As the flavoured aerosol precursor in the liquid transfer element <NUM> is depleted in use, further flavoured aerosol precursor is drawn from the storage chamber <NUM> into the liquid transfer element <NUM> via a wicking action.

Before activation, the storage chamber <NUM> is fluidly isolated from the liquid transfer element <NUM>. In this example, the isolation is achieved via a plug <NUM> (preferably formed from silicone) located at one end of a conduit <NUM> surrounding the liquid transfer element <NUM>. In other examples, the plug may be replaced by any one of: a duck bill valve; a split valve or diaphragm; or a sheet of foil.

The storage chamber <NUM> further includes an air bleed channel <NUM>, which in the deactivated state is sealed by a sealing element comprising a pierceable membrane (preferably made from foil). A first activation (or piercing) member 330a, which projects inwardly from an inner surface of the mouthpiece portion <NUM>, and may take the form of a blade, pierces the pierceable membrane and opens the air bleed channel <NUM> when the consumable is moved to the activated state (as is discussed in more detail below).

The mouthpiece portion <NUM> of the terminal element <NUM> further comprises a second activation member 330b. Both activation members 330a, 330b extend symmetrically (i.e. evenly spaced) on either side of the mouthpiece aperture <NUM> and either side of the liquid transfer element <NUM>. The two activation members extend generally longitudinally parallel to the liquid transfer element and parallel to the longitudinal axis <NUM> of the device.

In the first orientation of the terminal element <NUM> shown in <FIG>, the first activation member 330a is longitudinally aligned with the sealing element. The second activation member 330b is longitudinally aligned with a filling port <NUM> which is blocked by a plug (not shown).

The device may alternatively be assembled with the terminal element <NUM> rotated through <NUM> degrees so that the second activation member 330b is longitudinally aligned with the sealing element and the first activation member 330a is longitudinally aligned with the filling port <NUM>.

The aerosol generating portion <NUM> of the liquid transfer element <NUM> is located within the vapour flow passage <NUM> that extends through the flavour pod portion <NUM>. The aerosol generating portion <NUM>, by occupying a portion of the vapour flow passage <NUM>, constricts or narrows the vapour flow passage <NUM>. This constricted or narrowed portion of the vapour flow passage <NUM> defines an aerosolisation chamber <NUM> of the consumable <NUM>. The aerosolisation chamber <NUM>, which is adjacent the aerosol generating portion <NUM>, is the narrowest portion of the vapour flow passage <NUM>. The constriction of the vapour flow passage <NUM> at the aerosolisation chamber <NUM> results in increased air velocity and a corresponding reduction in air pressure of the air flowing therethrough and thus may be referred to as a Venturi aperture. The aerosolisation chamber <NUM> is generally toroidal in shape (extending circumferentially about the aerosol generating portion <NUM>), but this toroidal shape may include one or more interruptions where supports extend inwardly to contact the aerosol generating portion <NUM> and to support the aerosol generating portion <NUM> within the aerosolisation chamber <NUM>.

The cartomizer portion <NUM> of the consumable <NUM> includes a reservoir <NUM> (defined by a container) for storing a second (e-liquid) aerosol precursor (which may contain nicotine). A wick <NUM> extends into the reservoir so as to be in contact with (i.e. partially submerged in) the e-liquid aerosol precursor. The wick <NUM> is formed from a porous wicking material (e.g. a polymer) that draws the e-liquid aerosol precursor from the reservoir <NUM> into a central region of the wick <NUM> that is located in the vaporising chamber <NUM>.

A heater <NUM> is a configured to heat the central region of the wick <NUM>. The heater <NUM> includes a resistive heating filament that is coiled around the central region of the wick <NUM>. The wick <NUM> and the heater <NUM> generally define a vaporiser, and together with the reservoir <NUM> act as an active aerosol generator. The vaporiser (i.e. wick <NUM> and heater <NUM>) and aerosol generating portion <NUM> are both at least partially located within the airflow passage, with the aerosol generating portion <NUM> being downstream of the vaporiser.

So that the consumable <NUM> may be supplied with electrical power for activation of the heater <NUM>, the consumable <NUM> includes a pair of consumable electrical contacts <NUM>. The consumable electrical contacts <NUM> are configured for electrical connection to a corresponding pair of electrical supply contacts in the base unit (not shown). The consumable electrical contacts <NUM> are electrically connected to the electrical supply contacts (not shown) when the consumable <NUM> is engaged with the base unit. The base unit includes an electrical power source, for example a battery.

<FIG> shows the consumable <NUM> of <FIG> in an activated state. To transition from the deactivated state to the activated state, terminal element <NUM> is moved along the central longitudinal axis <NUM> in an upstream direction towards cartomizer portion <NUM>. The mouthpiece portion <NUM> of the terminal element <NUM> is fixed by a collar <NUM> to the conveying portion <NUM> of the liquid transfer element <NUM> and therefore liquid transfer element <NUM> moves with the mouthpiece <NUM>. The mouthpiece <NUM> and liquid transfer element <NUM> are moved relative to the tank <NUM>.

When the mouthpiece <NUM> is moved upstream, first activation/piercing member 330a contacts and pierces the sealing element in the form of a pierceable membrane extending across the air bleed channel <NUM> thereby fluidly connecting the vapour flow passage <NUM> the storage chamber <NUM>. This allows air from the vapour flow passage <NUM> to enter the storage chamber <NUM> as aerosol precursor is removed from the storage chamber <NUM> by the liquid transfer element <NUM>.

In addition to piercing of the membrane by the first activation member <NUM>, liquid transfer element <NUM> pushes on, and moves, plug <NUM> out of the conduit <NUM> which then allows liquid transfer element <NUM> to come into contact with the flavoured aerosol precursor stored in the storage chamber <NUM>. The plug <NUM> may then be unconstrained within the storage chamber, or may be pushed by liquid transfer element <NUM> into a holding location.

As the terminal element <NUM> is moved upstream, the second activation member is received within the plug (not shown) sealing the filling port <NUM>.

Of course, when the device is assembled with the terminal element <NUM> in the second orientation, in the activated state, the second activation member 330b pierces the sealing element membrane and the first activation member 330a is received within the filling port <NUM>.

Once activated, and in use, a user draws (or "sucks", "pulls", or "puffs") on the mouthpiece portion <NUM> of the consumable <NUM>, which causes a drop in air pressure at the mouthpiece aperture <NUM>, thereby generating air flow through the inlet opening <NUM>, along the airflow path including the vapour passage, out of the mouthpiece aperture <NUM> and into the user's mouth.

When the heater <NUM> is activated by passing an electric current through the heating filament in response to the user drawing on the mouthpiece portion <NUM> (the drawing of air may be detected by a pressure transducer), the e-liquid located in the wick <NUM> adjacent to the heating filament is heated and vaporised to form a vapour in the vaporising chamber <NUM>. The vapour condenses to form the e-liquid aerosol within the vapour outlet <NUM>. The e-liquid aerosol is entrained in an airflow along the vapour flow passage <NUM> to the mouthpiece aperture <NUM> for inhalation by the user when the user draws on the mouthpiece portion <NUM>.

The base unit supplies electrical current to the consumable electrical contacts <NUM>. This causes an electric current flow through the heating filament of the heater <NUM> and the heating filament heats up. As described, the heating of the heating filament causes vaporisation of the e-liquid in the wick <NUM> to form the e-liquid aerosol.

As the air flows through the vapour flow passage <NUM>, it encounters the aerosol generating portion <NUM>. The constriction of the vapour flow passage <NUM>, at the aerosolisation chamber <NUM>, results in an increase in air velocity and corresponding decrease in air pressure in the airflow in the vicinity of the porous aerosol generating portion <NUM>. The corresponding low pressure and high air velocity region causes the generation of the flavoured aerosol from the porous surface of the aerosol generating portion <NUM> of the liquid transfer element <NUM>. The flavoured aerosol becomes entrained in the airflow and ultimately is output from the mouthpiece aperture <NUM> of the consumable <NUM> and into the user's mouth.

The flavoured aerosol is sized to inhibit pulmonary penetration. The flavoured aerosol is formed of particles with a mass median aerodynamic diameter that is greater than <NUM> microns. The flavoured aerosol is sized for transmission within at least one of a mammalian oral cavity and a mammalian nasal cavity. The flavoured aerosol is formed by particles having a maximum mass median aerodynamic diameter that is less than <NUM> microns. Such a range of mass median aerodynamic diameter will produce aerosols which are sufficiently small to be entrained in an airflow caused by a user drawing air through the device and to enter and extend through the oral and or nasal cavity to activate the taste and/or olfactory receptors.

The e-liquid aerosol generated is sized for pulmonary penetration (i.e. to deliver an active ingredient such as nicotine to the user's lungs). The e-liquid aerosol is formed of particles having a mass median aerodynamic diameter of less than <NUM> micron. Such sized aerosols tend to penetrate into a human user's pulmonary system, with smaller aerosols generally penetrating the lungs more easily. The e-liquid aerosol may also be referred to as a vapour.

The size of aerosol formed without heating is typically smaller than that formed by condensation of a vapour.

<FIG> illustrates the flow of vapour through the flavour pod portion <NUM> of <FIG> and <FIG> (although the second activation member 330b is omitted). The flavour pod portion <NUM> is shown in the activated state with the terminal housing in its first orientation. The cartomizer is not shown, but it should be appreciated that the flavour pod portions <NUM> is engaged with the cartomizer <NUM> of <FIG> and <FIG>. In other embodiments, however, the consumable <NUM> may not comprise a cartomizer portion, and may provide only flavour to the user.

As is provided above, the flavour pod portion <NUM> comprises an upstream (i.e. upstream with respect to flow of air in use) vapour passage inlet <NUM> (in fluid communication with the vapour outlet <NUM>) and a downstream (i.e. downstream with respect to flow of air in use) outlet in the form of a mouthpiece aperture <NUM>. Between, and fluidly connecting the vapour passage inlet <NUM> and the mouthpiece aperture <NUM>, is a vapour flow passage <NUM>.

The vapour flow passage <NUM> comprises a transverse portion 321a. The airflow path through the device deflects at the vapour passage inlet <NUM> i.e. there is a deflection between the vapour outlet <NUM> and the transverse portion 321a of the vapour flow passage <NUM>.

The vapour flow passage <NUM> then deflects again from the transverse portion 321a to a longitudinal portion 321b which extends generally longitudinally between a device housing <NUM> (which forms part of the terminal element <NUM> and which is integral with the mouthpiece portion <NUM>) and the tank <NUM>. The vapour flow passage deflects again at the upper surface of the tank <NUM> within the mouthpiece portion <NUM>, through the aerosolisation chamber <NUM>, towards the mouthpiece aperture <NUM>. Within the mouthpiece portion <NUM>, flow around the first and second activation members 330a, 330b is symmetrical.

The vapour flow passage <NUM> may be a single (annular) flow passage around the tank <NUM> or it may comprise two branches which split around the tank <NUM> and re-join within the mouthpiece portion <NUM> proximal the liquid transfer element <NUM>.

A transition surface <NUM>, between the aerosolisation chamber <NUM> and the mouthpiece aperture <NUM> flares outwardly in the downstream direction, such that a diameter of the mouthpiece aperture <NUM> is greater than a diameter of the aerosolisation chamber <NUM>.

In use, when a user draws on the mouthpiece portion <NUM>, air flow is generated through the air flow path through the device. Air (comprising the e-liquid aerosol from the cartomizer portion <NUM> as explained above with respect to <FIG>) flows through the vapour outlet <NUM> and into the vapour passage <NUM>. Further downstream, as air flows past the aerosol generating portion <NUM> in the aerosolisation chamber <NUM>, the velocity of the air increases, resulting in a drop in air pressure. As a result, the flavoured aerosol precursor held in the aerosol generating portion <NUM> becomes entrained in the air so as to form the flavoured aerosol. The flavoured aerosol has the particle size and other properties described above with respect to <FIG>.

As the flavoured aerosol precursor becomes entrained within the air, the liquid transfer element <NUM> transfers further flavoured aerosol precursor from the storage chamber <NUM> to the aerosol generating portion <NUM>. More specifically, the liquid transfer element wicks the flavoured aerosol precursor from the storage chamber <NUM> to the aerosol generating portion <NUM>.

<FIG> show further views of the flavour pod portion <NUM> which highlight features of the mouthpiece portion <NUM>. Many of the reference numerals of <FIG> are omitted from <FIG> for clarity. The activation members are also omitted.

An uneven inner (transition) surface <NUM> is located between the mouthpiece aperture <NUM> and the aerosolisation chamber <NUM>. In the present example, the inner surface <NUM> has the form of a substantially frustoconical surface, but includes grooves or channels <NUM> to make the inner surface <NUM> somewhat uneven. In other examples, the inner surface <NUM> may have another form (for example, the form a substantially cylindrical surface), and may include any type of protrusion or groove to make the inner surface uneven.

The inner surface <NUM> is angled with respect to an axial direction (i.e. relative to a central axis extending from a base of the consumable to the mouthpiece) such that the diameter of the passage <NUM> proximate the mouthpiece aperture <NUM> increases in the downstream direction. The inner surface <NUM> is downstream of the aerosolisation chamber <NUM> of the vapour flow passage <NUM>.

The grooves <NUM> are generally V-shaped in cross-sectional profile, and extend in the axial direction for the full length of the inner surface <NUM>. Each groove <NUM> is formed from a pair of surfaces angled at between <NUM> and <NUM> degrees (e.g. <NUM> degrees) relative to each other. The grooves <NUM> have a depth (measured normal to the inner surface <NUM>) of at least <NUM> (e.g. at least <NUM>). The grooves <NUM> have a depth of less than <NUM> (e.g. less than <NUM>). The grooves have a depth of substantially <NUM>. The inner surface <NUM> comprises <NUM> grooves <NUM>, but may comprise more or less grooves.

The grooves <NUM> are spaced apart from each other by substantially <NUM> at the downstream end of the inner surface <NUM>. In other examples, the spacing at the downstream end of grooves or protrusions may be selected such that it is equal to or less than the mass median diameter (as described above) of particles in the flavoured aerosol.

The inner surface <NUM> comprises a smooth polished surface between the grooves <NUM>. Polishing the surface in this way may provide improved aerodynamic properties. However, in other examples, the inner surface <NUM> may be textured. In such examples, the texture of the surface may provide the uneven surface, and no grooves may be required.

In use, the uneven nature of the inner surface <NUM> may make it easier for droplets to form on the inner surface <NUM>, preventing large droplets from entering the user's mouth. The grooves <NUM> may help to channel the large droplets back into the consumable.

<FIG> illustrate a variation of the embodiment shown in <FIG> and thus the same reference numerals have been used for corresponding features. Referring to <FIG>, there is shown a consumable <NUM> engagable with a base unit (not shown) via a push-fit engagement. The consumable <NUM> is shown in a deactivated state. The consumable <NUM> may be considered to have two portions - a cartomizer portion <NUM> and flavour pod portion <NUM> (i.e. additive delivery article), both of which are located within a single consumable component <NUM> (as in <FIG>). It should, however, be appreciated that in a variation, the cartomizer portion <NUM> and flavour pod portion <NUM> may be separate (but engageable) components.

The consumable <NUM> includes an upstream cartomizer inlet opening <NUM> and a downstream mouthpiece aperture <NUM> (i.e. defining an outlet of the consumable <NUM>). In other examples a plurality of inlets and/or outlets are included. Between, and fluidly connecting, the inlet opening <NUM> and the mouthpiece aperture <NUM> there is an airflow passage comprising (in a downstream flow direction) a vaporising chamber <NUM> of the cartomizer, a vapour outlet <NUM> (also of the cartomizer), a downstream flow passage <NUM> (hereinafter referred to as the vapour flow passage) of the flavour pod portion <NUM>, and an aerosolisation chamber <NUM> (also of the flavour pod portion <NUM>). The mouthpiece aperture <NUM> is located at the mouthpiece <NUM> (or mouthpiece portion) of the consumable <NUM>.

The aerosolisation chamber <NUM> extends longitudinally in an upstream direction from the mouthpiece aperture <NUM>. The aerosolisation chamber <NUM> is cylindrical (having a circular cross-sectional shape) such that a transverse cross-sectional area of the aerosolisation chamber <NUM> is uniform along a longitudinal length of the aerosolisation chamber <NUM>. The aerosolisation chamber <NUM> is defined by a tube <NUM> that extend longitudinally from a longitudinal end surface of the device.

The consumable <NUM> includes a flavour pod portion <NUM>. The flavour pod portion <NUM> is configured to generate a first (flavoured) aerosol for output from the mouthpiece aperture <NUM>. The flavour pod portion <NUM> of the consumable <NUM> includes a liquid transfer element <NUM>. This liquid transfer element <NUM> acts as a passive aerosol generator (i.e. an aerosol generator which does not use heat to form the aerosol), and is formed of a porous material. The liquid transfer element <NUM> comprises a conveying portion <NUM> and an aerosol generating portion <NUM>, which is located in aerosolisation chamber <NUM>. In this example, the aerosol generating portion <NUM> is a porous nib.

When activated, as discussed in more detail below, a storage chamber <NUM> (defined by a tank <NUM>) for storing a first aerosol precursor (i.e. a liquid comprising a flavourant) is fluidly connected to the liquid transfer element <NUM>. The flavoured aerosol precursor, in this embodiment, is stored in a porous body within the storage chamber <NUM> (but may be a free-liquid). In the activated state, the liquid transfer element <NUM> is in contact with the flavoured aerosol precursor stored in the storage chamber <NUM> by way of contact with the porous body/free liquid.

The liquid transfer element <NUM> comprises an aerosol generating portion <NUM> and a conveying portion <NUM>. The aerosol generating portion <NUM> is located at a downstream end (top of <FIG>) of the liquid transfer element <NUM>, whilst the conveying portion <NUM> forms the remainder of the liquid transfer element <NUM>. The conveying portion <NUM> is elongate and substantially cylindrical.

A distal (i.e. downstream) transversely extending end surface <NUM> of the aerosol generating portion <NUM> is planar, such that the aerosol generating portion <NUM> has a somewhat truncated bulb or bullet-shape. The aerosol generating portion <NUM> is wider (has a greater radius) than the conveying portion <NUM>. As is apparent from <FIG> (which will be discussed further below) the greater radius of the aerosol generating portion <NUM> means that a transverse transition surface <NUM>, in the form of a step, is defined between the downstream end of the conveying portion <NUM> and the upstream end of the aerosol generating portion <NUM>.

The storage chamber <NUM> further includes an air bleed channel <NUM>, which in the deactivated state is sealed by a sealing element comprising a pierceable membrane (preferably made from foil). Activation (or piercing) member <NUM>, which projects inwardly from the mouthpiece <NUM>, and may take the form of a blade, pierces the pierceable membrane and opens the air bleed channel <NUM> when the consumable is moved to the activated state (as is discussed in more detail below).

The liquid transfer element <NUM> (i.e. the aerosol generating portion <NUM>) is located within the aerosolisation chamber <NUM>, such that an airflow path is defined between the liquid transfer element <NUM> an inner surface of the tube <NUM> defining the aerosolisation chamber <NUM>. This airflow path comprises a constricted region which is defined by the aerosol generating portion <NUM>. This constriction results in increased air velocity and a corresponding reduction in air pressure of the air flowing along the airflow path and thus the constricted region may be referred to as a Venturi aperture. Although not shown, in some embodiments, one or more supports may extend inwardly from the wall defining the aerosolisation chamber <NUM> (e.g. tube <NUM>) to contact the aerosol generating portion <NUM> and to support the aerosol generating portion <NUM> within the aerosolisation chamber <NUM>.

<FIG> shows the consumable <NUM> of <FIG> in an activated state. To transition from the deactivated state to the activated state, mouthpiece <NUM> is moved along a central longitudinal axis <NUM> in an upstream direction towards cartomizer portion <NUM>. The mouthpiece <NUM> is fixed by a collar <NUM> to the conveying portion <NUM> of the liquid transfer element <NUM> and therefore liquid transfer element <NUM> moves with the mouthpiece <NUM>. The mouthpiece <NUM> and liquid transfer element <NUM> are moved relative to the tank <NUM>.

When the mouthpiece <NUM> is moved upstream, activation/piercing member <NUM> contacts and pierces a sealing element in the form of a pierceable membrane extending across the air bleed channel <NUM> thereby fluidly connecting the vapour flow passage <NUM> the storage chamber <NUM>. This allows air from the vapour flow passage <NUM> to enter the storage chamber <NUM> as aerosol precursor is removed from the storage chamber <NUM> by the liquid transfer element <NUM>.

In addition to piercing of the membrane by the piercing member <NUM>, liquid transfer element <NUM> pushes on, and moves, plug <NUM> out of the conduit <NUM> which then allows liquid transfer element <NUM> to come into contact with the flavoured aerosol precursor stored in the storage chamber <NUM>. The plug <NUM> may then be unconstrained within the storage chamber, or may be pushed by liquid transfer element <NUM> into a holding location.

Once activated, and in use, a user draws (or "sucks", "pulls", or "puffs") on the mouthpiece <NUM> of the consumable <NUM>, which causes a drop in air pressure at the mouthpiece aperture <NUM>, thereby generating air flow through the inlet opening <NUM>, along the airflow passage, out of the mouthpiece aperture <NUM> and into the user's mouth.

When the heater <NUM> is activated by passing an electric current through the heating filament in response to the user drawing on the mouthpiece <NUM> (the drawing of air may be detected by a pressure transducer), the e-liquid located in the wick <NUM> adjacent to the heating filament is heated and vaporised to form a vapour in the vaporising chamber <NUM>. The vapour condenses to form the e-liquid aerosol within the vapour outlet <NUM>. The e-liquid aerosol is entrained in an airflow along the vapour flow passage <NUM>, through the aerosolisation chamber <NUM>, to the mouthpiece aperture <NUM> for inhalation by the user when the user draws on the mouthpiece <NUM>.

As the air flows through the aerosolisation chamber <NUM>, the constricted region of the air path results in an increase in air velocity and corresponding decrease in air pressure in the airflow in the vicinity of the porous aerosol generating portion <NUM>. The corresponding low pressure and high air velocity region causes the generation of the flavoured aerosol from the porous surface of the aerosol generating portion <NUM> of the liquid transfer element <NUM>. The flavoured aerosol becomes entrained in the airflow and ultimately is output from the mouthpiece aperture <NUM> of the consumable <NUM> and into the user's mouth.

<FIG> illustrates the flow of vapour through the flavour pod portion <NUM> of <FIG> and <FIG>. The flavour pod portion <NUM> is shown in the activated state. The cartomizer is not shown, but it should be appreciated that the flavour pod portions <NUM> is engaged with the cartomizer <NUM> of <FIG> and <FIG>. In other embodiments, however, the consumable <NUM> may not comprise a cartomizer portion, and may provide only flavour to the user.

As is provided above, the flavour pod portion <NUM> comprises an upstream (i.e. upstream with respect to flow of air in use) vapour passage inlet <NUM> (in fluid communication with the vapour outlet <NUM>) and a downstream (i.e. downstream with respect to flow of air in use) outlet in the form of a mouthpiece aperture <NUM>. Between, and fluidly connecting the vapour passage inlet <NUM> and the mouthpiece aperture <NUM>, is a vapour flow passage <NUM> and aerosolisation chamber <NUM>.

The vapour flow passage <NUM> then deflects again from the transverse portion 321a to a longitudinal portion 321b which extends generally longitudinally between a device housing <NUM> (which is integral with the mouthpiece <NUM>) and the tank <NUM>. The vapour flow passage <NUM> deflects again at the upper surface of the tank <NUM> within the mouthpiece <NUM> such that airflow/vapour is directed through the aerosolisation chamber <NUM>, towards the mouthpiece aperture <NUM>.

The vapour flow passage <NUM> may be a single (annular) flow passage around the tank <NUM> or it may comprises two braches which split around the tank <NUM> and re-join within the mouthpiece <NUM> proximal the liquid transfer element <NUM>.

In use, when a user draws on the mouthpiece <NUM>, air flow is generated through the air flow passage through the device. Air (comprising the e-liquid aerosol from the cartomizer portion <NUM> as explained above with respect to <FIG>) flows through the vapour outlet <NUM> and into the vapour passage <NUM>. Further downstream, as air flows past the aerosol generating portion <NUM> in the aerosolisation chamber <NUM>, the velocity of the air increases, resulting in a drop in air pressure. As a result, the flavoured aerosol precursor held in the aerosol generating portion <NUM> becomes entrained in the air so as to form the flavoured aerosol. The flavoured aerosol has the particle size and other properties described above with respect to <FIG>.

<FIG>, <FIG> and <FIG> illustrate a further embodiment of a consumable <NUM> of an aerosol delivery device. This embodiment includes many of the same features of the embodiment described above and shown in <FIG> and <FIG> and, for that reason, corresponding reference numerals have been used (albeit with a unit increase of the first digit to represent the further embodiment). The description of those features have not been repeated here. <FIG> shows the consumable <NUM> in a deactivated state (with the terminal element <NUM> in its first orientation) and <FIG> shows the consumable <NUM> in an activated state (with the terminal element <NUM> in its first orientation). <FIG> shows an enlarged view of the mouthpiece portion <NUM> in the activated state with the terminal element in its second orientation - i.e. with the terminal housing <NUM> rotated by <NUM> degrees.

Unlike the previously described embodiment, the presently illustrated embodiment comprises a different mechanism for opening the air bleed channel <NUM> upon activation of the consumable <NUM>. In this embodiment, when in the deactivated state (<FIG>) the air bleed channel <NUM> is obstructed by a silicone bung <NUM> sealing element received in the air bleed channel <NUM>. In particular, a body <NUM> of the bung <NUM> is received in the air bleed channel <NUM>, but does not fully obstruct the air bleed channel <NUM>. That is, a portion of the air bleed channel <NUM> remains unobstructed by the body <NUM> of the bung <NUM>. However, an enlarged head <NUM> of the bung <NUM>, which is located in the storage chamber <NUM>, extends fully across the entrance to the air bleed channel <NUM> so as to obstruct the channel <NUM>.

When the terminal element <NUM>/mouthpiece portion <NUM> (alternatively referred to as the mouthpiece <NUM>) is moved in the upstream longitudinal direction to activate the consumable <NUM>, an elongate first activation member 430a (extending inwardly from an inner surface of the mouthpiece portion <NUM>) engages the body <NUM> of the bung <NUM> and pushes the bung <NUM> in the upstream direction (see <FIG>). This moves the enlarged head <NUM> of the bung <NUM> away from the entrance of the air bleed channel <NUM> such that the head <NUM> no longer obstructs the air bleed channel <NUM>. This allows air to pass from the vapour flow passage <NUM> and into the storage chamber <NUM> (which, in turn, allows for flow of the flavoured aerosol precursor from the storage chamber <NUM>).

It should be noted that the bung sealing element shown in <FIG> and <FIG> could be used in place of the pierceable membrane in <FIG> and <FIG> and vice versa.

The second activation member 430b is received within a bore provided in a bung <NUM> sealing the filling port <NUM>.

Of course, when the device is assembled with the terminal element <NUM> in its second orientation, the first activation member 430a is received within the bore provided in the bung <NUM> sealing the filling port <NUM> and the second activation member 430b moves the silicone bung <NUM> within the air bleed channel <NUM> as shown in <FIG>.

The aerosol generating portion <NUM> of the liquid transfer element shown in the <FIG> and <FIG> has a flattened (or planar) upper (downstream) surface. Such a liquid transfer element could be used in the embodiment shown in <FIG> and <FIG>.

<FIG> provides a detailed view of a mouthpiece <NUM> that is similar to that shown in <FIG>, albeit having a slightly modified shape. Given the similarity, the same references numerals have been used for corresponding features.

As is apparent from <FIG>, the conveying portion <NUM> has a smaller cross-sectional area than the aerosol generating portion <NUM> of the liquid transfer element <NUM>. As a result, a step (from the conveying portion <NUM> to the aerosol generating portion <NUM>) is defined by a radial transition surface <NUM>. The transition surface <NUM> has a concave profile such that there is a smooth transition between the conveying portion <NUM> and the transition surface <NUM> and a sharp/hard edge between the transition surface <NUM> and the aerosol generating portion <NUM>.

This edge is an upstream leading edge of the aerosol generating portion <NUM> and defines an upstream end of a constricted region <NUM> of an airflow path between the aerosol generating portion <NUM> and the tube <NUM> defining the aerosolisation chamber <NUM>. Downstream of this constricted region <NUM> is an expansion region <NUM>. In this expansion region <NUM> the airflow path gradually increases in cross-sectional area in the downstream direction. This a result of the aerosol generating portion <NUM> having a slight inward taper towards the planar distal end surface <NUM> and the cylindrical shape of the aerosolisation chamber <NUM>.

Also shown in more detail in <FIG> is the collar <NUM>, which partially circumscribes the liquid transfer element <NUM>. The collar <NUM> is connected to a mounting portion <NUM>, which surrounds the tube <NUM> so as to mount the collar <NUM> to the tube <NUM>. In this way, the liquid transfer element <NUM> is fixed with respect to the mouthpiece <NUM> (i.e. so as to move with the mouthpiece <NUM> between the activated and deactivated states discussed above).

<FIG> shows a perspective view of a consumable according to the present disclosure. The consumable includes a hinged cap <NUM> located on an exterior of the consumable. The hinged cap includes protrusions 901a and 901b, which extend from an outer housing of the consumable. Around each protrusion is an arm 902a / 902b, which is rotatable relative to the protrusion and which extends away from the protrusion towards an upper end of the consumable. Each arm widens as it projects from the protrusion, and at the end of both arms is a cap portion <NUM>. The cap portion <NUM> wider than the mouthpiece <NUM>/<NUM>, but only slightly, such that a snug interference fit is achieved between the cap portion and the mouthpiece.

The hinged cap is rotatable around axis <NUM>, which is transversal to the central longitudinal axis <NUM> discuss above. Accordingly, the cap is rotatable from the sealed configuration shown in <FIG> in which the mouthpiece <NUM>/<NUM> is sealed from the outside of the aerosol delivery device to an open configuration shown in <FIG>. In this configuration, the aerosol generating portion <NUM>/<NUM> is exposed to the outside environment, and the user can operate the aerosol delivery device. The hinged cap, and notably the arms 902a/902b and cap portion <NUM> are formed from a resiliently deformable material such as silicone. This allows the cap to fit snugly over the mouthpiece whilst also allowing it to easily be removed through deformation.

The hinged cap <NUM> of <FIG> is usable in combination with any of the consumables disclosed herein. Various changes to the described embodiments may be made without departing from the scope of the invention as defined in the claims.

Claim 1:
An aerosol delivery device comprising:
a mouthpiece (<NUM>) comprising an end surface at a longitudinal end of the mouthpiece, and a mouthpiece aperture (<NUM>) formed in the end surface;
an aerosolisation chamber (<NUM>) extending longitudinally into the device from the mouthpiece aperture (<NUM>);
a storage chamber for storing an aerosol precursor; and
a porous liquid transfer element (<NUM>) comprising an aerosol generating portion (<NUM>) at least partly received in the aerosolisation chamber (<NUM>) and a conveying portion (<NUM>) for conveying liquid from the storage chamber (<NUM>) to the aerosol generating portion (<NUM>),
wherein the aerosol generating portion of the liquid transfer element is a passive aerosol generating portion,
characterized in that
a transverse cross-sectional area of the aerosolisation chamber (<NUM>) is uniform along a longitudinal length of the aerosolisation chamber (<NUM>),
and
the aerosol generating portion (<NUM>) has a larger transverse cross-sectional area than a transverse cross-sectional area of the conveying portion (<NUM>) to define a constricted airflow passage between a wall defining the aerosolisation chamber (<NUM>) and the liquid transfer element (<NUM>).