Patent Description:
One form of an aerosol delivery system is a smoking-substitute system, 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 user through the mouthpiece.

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 device can be used multiple times.

An example vaping smoking substitute device is the myblu(RTM) e-cigarette. The myblu(RTM) 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 system is activated when a microprocessor on board the base unit detects a user inhaling through the mouthpiece. When the device 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/systems, it is desirable to avoid leakage of e-liquid as such leakage can result in inconvenience for the user. Leakage of e-liquid has been observed during use of the known devices and it is believed that the leakage occurs as a result of condensation of the e-liquid vapour on internal surfaces of the device. The condensed e-liquid then leaks from the device either through the mouthpiece or through air inlets provided in the device.

Document <CIT> discloses an inhaler component for producing a steam/air mixture or/and condensation aerosol in an intermittent and inhalation- or pull-synchronous manner.

Document <CIT> discloses an electronic smoking device, having an outer tube mounted around at least a portion of an inner tube.

Document <CIT> discloses a component of an electronic vapour provision device with a reservoir for storing source liquid, an atomiser for vaporising source liquid from the reservoir and delivering vapour into an air flow path through the device.

Document <CIT> proposes an electronic cigarette including a liquid tank including a bottom part, a liquid outlet, a first air inlet, a first porous liquid blocking element, and a top part.

Document <CIT> proposes an atomizer including a housing, an atomizing core arranged in the housing, and a mouthpiece at an end of the housing.

Document <CIT> proposes a personal vaporizer including a pressure-induced liquid transport device that allows a user to draw liquid from a liquid reservoir through applying a suction force on the mouthpiece.

At its most general, the present invention relates to an aerosol delivery device configured to reduce leakage by including an absorbent member to absorb condensed e-liquid vapour.

According to a first aspect, there is provided aerosol delivery device comprising:
a container defining a reservoir for storing a liquid aerosol precursor; a vaporisation chamber for vaporising the liquid aerosol precursor; a vapour outlet extending from the vaporising chamber to vapour flow passage, the vapour flow passage being in fluid communication with a mouthpiece aperture; and an absorbent member for absorbing condensed vapour within the vapour flow passage, wherein there is a deflection between the vapour outlet and the vapour flow passage and wherein the absorbent member is provided proximal the deflection.

Vapour is generated within the vaporisation chamber and is drawn through the vapour outlet into the vapour flow passage. The vapour typically slows at any deflections within the vapour flow passage and condensate will form on inner surfaces of the device in the vicinity of the deflection(s). By providing an absorbent member in the vicinity of the deflection, any condensate can be collected and retained within the absorbent member to avoid its leakage from the device.

In some embodiments, the absorbent member is a planar pad. The absorbent member (e.g. the planar pad) may extend transversely within the device i.e. may extend within the device perpendicular to the longitudinal axis of the device.

The absorbent member may extend (e.g. transversely) across the entire transverse dimension (width) of the device.

The absorbent member (e.g. pad) may be positioned within the device upstream of the deflection and/or upstream of the vapour flow passage.

The terms "upstream" and "downstream" are used 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).

In some embodiments, the vapour outlet may extend in a substantially longitudinal direction e.g. it may be aligned with the longitudinal axis of the device. In such embodiments, the absorbent member may extend within the device substantially perpendicularly to the vapour outlet. It may comprise an aperture e.g. a central/axial aperture allowing fluid communication between the vapour outlet and the vapour flow passage through the aperture.

The vapour flow passage may comprise a transverse portion proximal the vapour outlet such that the deflection is provided between the vapour outlet and the transverse portion of the vapour flow passage. The absorbent member/pad may extend in parallel alignment within the transverse portion of the vapour flow passage. In this way, condensate within the transverse vapour flow passage may be collected and retained within the absorbent member/pad.

The vaporising chamber, vaporiser outlet and container/reservoir may together form part of a cartomizer. The vaporiser outlet and vaporising chamber may fluidly connect a cartomizer inlet opening and the vapour flow passage. Thus, an airflow may be drawn into and through the cartomizer.

The aerosol delivery device/cartomizer comprises a reservoir defined by a container for containing the aerosol precursor (which may be an e-liquid). The 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 aerosol precursor in the container. The cartomizer may be referred to as a "clearomizer" if it includes a window. The vaporiser outlet may extend longitudinally through the container, wherein an outlet wall of the vaporiser outlet may define the inner wall of the container. In this respect, the container may surround the vaporiser 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 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 vaporiser outlet. This aerosol generation may be referred to as "active" aerosol generation, because it makes use of heat to generate the aerosol.

This aerosol may subsequently flow from the vaporiser outlet into the vapour flow passage.

The aerosol generated is sized for pulmonary penetration (i.e. to deliver an active ingredient such as nicotine to the user's lungs). The 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 aerosol may also be referred to as a vapour.

The aerosol delivery device may further comprise a delivery article/pod e.g. an additive delivery article/flavour pod which 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 (additive) delivery article/(flavour) pod may comprise a tank defining a storage chamber for containing a further aerosol precursor (e.g. a flavour liquid). The further 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 further 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 further aerosol precursor.

The vapour flow passage may extend through a device housing to the mouthpiece. The tank may at least partially define the vapour flow passage. For example, the vapour flow passage may be defined between an outer surface of the tank and an inner surface of the device housing. The device housing 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 (further) aerosol precursor that is removed from the storage chamber. The air bleed channel may be in fluid communication with the vapour flow passage, such that (e.g. under certain conditions) air from the vapour flow passage can enter the storage chamber through the air bleed channel.

The aerosol delivery device comprises a vapour flow passage for fluid flow therethrough. The vapour flow passage may extend generally in a longitudinal direction from an upstream end at the vapour outlet (in the cartomizer) and the mouthpiece aperture may define a downstream end of the vapour flow passage (in the (additive) delivery article/(flavour) pod ). A user may draw fluid (e.g. air) into and through the cartomizer and vapour flow passage of the aerosol delivery device by inhaling at the mouthpiece aperture.

The vapour flow passage may comprise one or more deflections. As discussed above, it may comprise a transverse portion proximal the vapour outlet such that there is a deflection between the vapour outlet and the transverse portion of the vapour flow passage. The absorbent pad may be provided proximal this deflection.

The vapour flow passage may then deflect into a generally longitudinal portion downstream of the transverse portion. The longitudinal portion may extend between the device housing and the tank. The vapour flow passage may then deflect again (e.g. radially) at an upper (downstream) surface of the tank within the mouthpiece, towards the mouthpiece aperture.

The vapour flow passage may be a single (annular) flow passage around the tank or it may comprise two braches which split around the tank and re-join within the mouthpiece.

The aerosol delivery device (i.e. the (additive) delivery article/(flavour) pod) may further comprise an aerosol generator in the form of a porous liquid transfer element (i.e. formed of a porous material). As will be described further below, the liquid transfer element may be configured to generate a further aerosol in the vapour flow passage. The liquid transfer element, however, may do this in such a way that does not use heat to form the aerosol, and therefore in some embodiments may be referred to as a "passive" aerosol generator.

The liquid transfer element may comprise a conveying portion and an aerosol generating portion. 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 of the liquid transfer element. 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 may be supported in the aerosol delivery device (i.e. in the (additive) delivery article/(flavour) pod) by the mouthpiece. That is, the mouthpiece may comprise a collar for holding (and gripping) the liquid transfer element in position within the aerosol delivery device.

The aerosol generating portion of the liquid transfer element may be disposed at a downstream end of the conveying portion and may thus define a downstream longitudinal end of the liquid transfer element. The aerosol generating portion may be at least partly located in the vapour flow passage so as to be exposed to airflow within the vapour flow passage. In particular, the aerosol generating portion of the liquid transfer element may extend into an aerosolisation chamber forming part of the vapour flow passage. The aerosolisation chamber may be located proximate to (and in fluid communication with) the mouthpiece aperture of the device and may define a portion of the vapour flow passage. Airflow through the flow passage may pass across or through the aerosol generating portion of the liquid transfer element within the aerosolisation chamber prior to being discharged through the mouthpiece aperture.

The aerosol generating portion may define an enlarged (e.g. radially enlarged) portion of the liquid transfer element. For example, the aerosol generating portion may be bulb-shaped or bullet-shaped, and may comprise a portion which is wider than the conveying portion. The aerosol generating portion may taper (inwardly) to a tip at a downstream end of the aerosol generating portion (i.e. proximate the outlet/mouthpiece aperture). The aerosol-generating portion may have a flattened downstream end surface.

The liquid transfer element may extend into the storage chamber so as to be in contact with (e.g. at least partially submerged in) the further aerosol precursor. In this way, the liquid transfer element may be configured to convey (e.g. via a wicking/capillary action) the further aerosol precursor from the storage chamber to the aerosolisation chamber. As will be described further below, this may allow the further aerosol precursor to form an aerosol and be entrained in an airflow passing through the aerosolisation chamber (i.e. for subsequent receipt in a user's mouth). Thus, the fluid received through the mouthpiece aperture of the aerosol delivery device may be a combination of the aerosol and the further aerosol.

The vapour flow passage may be constricted (i.e. narrowed) at the aerosolisation chamber. For example, the presence of the aerosol generating portion in the vapour flow passage may create a constricted or narrowed portion of the vapour flow passage (because the aerosol generating portion extends partway across the vapour flow passage). In this respect, the narrowest portion of the vapour flow passage may be at aerosolisation chamber (adjacent to the aerosol generating portion of the liquid transfer element). This constriction of the vapour flow 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 vapour flow passage 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 further aerosol precursor held in the aerosol generating portion (i.e. transferred from the storage chamber by the liquid transfer element). This aerosol, which is hereinafter referred to as the further aerosol, is entrained in the airflow passing through the constriction and is discharged from the mouthpiece aperture of the aerosol delivery device.

The further aerosol may be sized to inhibit pulmonary penetration. The further 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 further aerosol may be sized for transmission within at least one of a mammalian oral cavity and a mammalian nasal cavity. The further 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 further aerosol precursor. This isolation may, for example, be provided by a plug (e.g. formed of silicon). 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 further 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 further 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 aerosol delivery device may comprise a mouthpiece/device housing that is 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 from an internal surface of the mouthpiece. When the mouthpiece/device hosuing 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 further aerosol precursor (i.e. so as to be able to convey the further aerosol precursor to the aerosol generating portion of the liquid transfer element).

The device housing may comprise at opposing apertures for engagement with respective lugs provided on the cartomizer e.g. on the container 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 (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".

Accordingly, in a second aspect there is provided an aerosol delivery system comprising a base unit having a power source, and a device as described above with respect to the first aspect.

The device may be engageable with the base unit such that the vaporiser of the device/consumable is connected to the power source of the base unit.

For example, the cartomizer may be configured for engagement with the base unit. The cartomizer and the (additive) delivery article/(flavour) pod may be a single consumable component of the aerosol delivery system (when integrally formed) or may each define separate consumable components of the aerosol delivery system (when engageable with one another).

The aerosol precursor(s) may be replenished by replacing a used consumable with an unused consumable.

The base unit and the device/consumable (e.g. the cartomizer of the consumable) may be configured to be physically coupled together. For example, the device/consumable may be at least partially received in a recess of the base unit, such that there is snap engagement between the base unit and the consumable. Alternatively, the base unit and the device/consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

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

The base unit or the device/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 device/consumable (e.g. the cartomizer) may comprise an electrical interface for interfacing with a corresponding electrical interface of the base unit. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the base unit is engaged with the consumable/cartomizer, the electrical interface may be configured to transfer electrical power from the power source to a heater of the device/consumable/cartomizer. 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 device/consumable/cartomizer is connected to the base unit.

The base unit 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 device/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 base unit 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 base unit 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.

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 device or the base unit.

In an alternative embodiment the aerosol delivery device may be a non-consumable device in which one or both of the aerosol precursors of the device may be replenished by re-filling the reservoir or storage chamber 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 base unit. For example, the only consumable portion may be the aerosol precursor(s) contained in reservoir and storage chamber of the device. Access to the reservoir and/or storage chamber (for re-filling of the aerosol precursors) may be provided via e.g. an opening to the reservoir and/or storage chamber that is sealable with a closure (e.g. a cap).

The aerosol delivery device may be a smoking substitute device (e.g. an e-cigarette device). The consumable of the aerosol delivery device be a smoking substitute consumable (e.g. an e-cigarette consumable). The aerosol delivery system may be a smoking substitute system (e.g. an e-cigarette system).

In a third aspect there is provided a method of using a smoking substitute system as described above with respect to the second aspect, the method comprising engaging the device/consumable with the base unit so as to connect the vaporiser of the device/consumable with the power source of the base unit. The method may comprise engaging an additive delivery article/flavour pod of the device/consumable with a cartomizer of the device/consumable, such that a vapour flow passage of the additive delivery article/flavour pod is in fluid communication with the vaporiser outlet of the cartomizer.

The technology includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

So that the technology may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the technology will now be discussed in further detail with reference to the accompanying figures, in which:.

Aspects and embodiments of the present technology will now be discussed with reference to the accompanying figures. Referring to <FIG>, there is shown a schematic view of an aerosol delivery device 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 examples 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> engageable 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 <NUM>. This airflow passage <NUM> is formed (in a downstream flow direction) of a vaporising chamber <NUM> of the cartomizer, a vapour outlet <NUM> (also of the cartomizer) and a downstream vapour flow passage <NUM> of the flavour pod portion <NUM>. The mouthpiece aperture <NUM> is located at the mouthpiece <NUM> of the consumable <NUM>.

As above, the consumable <NUM> includes a flavour pod portion <NUM>. The flavour pod portion <NUM> is configured to generate a (flavour) 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 a flavoured liquid aerosol precursor 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 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 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 aerosol generating portion <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 an 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, 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 first 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 through the device, 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 vaporiser 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 <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>. 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>.

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 in the spacing between a device housing <NUM> (which is integral with the mouthpiece <NUM>) and the tank <NUM>. The vapour flow passage deflects again at the upper surface of the tank <NUM> within the mouthpiece <NUM> proximal the liquid transverse element, 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 comprise two braches which split around the tank <NUM> and re-join within the mouthpiece <NUM> (proximal the liquid transverse element).

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 <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>.

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 <NUM>. Many of the reference numerals of <FIG> are omitted from <FIG> for clarity.

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 first 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.

Although not shown in <FIG>, the device includes an absorbent pad <NUM> interposed between the cartomizer portion <NUM> and the flavour pod portion <NUM>. Such a pad is described below in more detail in relation to <FIG>, <FIG> and <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, 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 and <FIG> shows the consumable <NUM> in an activated state.

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 mouthpiece <NUM> is moved in the upstream longitudinal direction to activate the consumable <NUM>, an elongate activation member (extending inwardly from the mouthpiece <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 first 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 aerosol generating portion <NUM> of the liquid transfer element shown in the <FIG> and <FIG> has a flattened upper (downstream) surface. Such a liquid transfer element could be used in the embodiment shown in <FIG> and <FIG>.

The device comprises an absorbent pad <NUM> interposed between the cartomizer portion <NUM> and the flavour pod <NUM>. The pad <NUM> extends transversely across the width of the device perpendicular of the longitudinal axis of the device and perpendicular to the vapour outlet <NUM>. The pad <NUM> is positioned proximal (downstream) of a deflection in the airflow path between the vapour outlet <NUM> and the transverse portion of the vapour passage.

As can be seen from <FIG> (in which the flavour pod has been removed and the device housing <NUM> cut down), the pad <NUM> comprises an axial aperture <NUM> which is substantially aligned with the vapour outlet <NUM> so that vapour generated in the vaporising chamber <NUM> can pass along the vapour outlet <NUM> and to the vapour passage <NUM> through the aperture <NUM>.

It will be appreciated that the flow in the transverse portion of the vapour passage (not shown) will pass over the absorbent pad <NUM> (between the cartomizer portion <NUM> and the flavour pod <NUM>) such that any condensate forming within the transverse portion of the vapour flow passage will be collected and retained within the absorbent pad. This will prevent leakage of any condensate e.g. through the apertures <NUM> provided in the device housing <NUM> for cooperation with lugs <NUM> on the cartomizer <NUM> for retaining the device housing <NUM> in place on the cartomizer <NUM>.

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 container defining a reservoir (<NUM>) for storing a liquid aerosol precursor;
a vaporisation chamber (<NUM>) for vaporising the liquid aerosol precursor;
a vapour outlet (<NUM>) extending from the vaporising chamber to a vapour flow passage (<NUM>), the vapour flow passage being in fluid communication with a mouthpiece aperture (<NUM>); and
an absorbent member (<NUM>) for absorbing condensed vapour within the vapour flow passage,
wherein there is a deflection in a vapour airflow path between the vapour outlet and the vapour flow passage and wherein the absorbent member is provided proximal the deflection in the vapour airflow path,
characterised in that the vapour flow passage (<NUM>) comprises a transverse portion proximal the vapour outlet (<NUM>) such that the deflection is provided between the vapour outlet and the transverse portion of the vapour flow passage; and the absorbent member (<NUM>) extends in parallel alignment within the transverse portion of the vapour flow passage.