Patent Description:
A smoking-substitute device is an electronic device that permits the user to simulate the act of smoking by producing an aerosol mist or vapour that is drawn into the lungs through the mouth and then exhaled. The inhaled aerosol mist 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 mist or vapour of similar appearance to the smoke exhaled when using such traditional smoking or tobacco products.

One approach for a smoking substitute device is the so-called "vaping" approach, in which a vaporisable liquid, typically referred to (and referred to herein) as "e-liquid", is heated by a heater to produce an aerosol vapour which is inhaled by a user. 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 device includes a mouthpiece, a power source (typically a battery), a tank for containing e-liquid, as well as a heater. In use, electrical energy is supplied from the power source to the heater, which heats the e-liquid to produce an aerosol (or "vapour") which is inhaled by a user through the mouthpiece.

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

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

An example vaping smoking substitute device is the myblu™ e-cigarette. The myblu™ e cigarette is a closed system device which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid (also referred to as an aerosol precursor), as well as a heater, which for this device 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 main body detects a user inhaling through the mouthpiece. When the device is activated, electrical energy is supplied from the power source to the heater, 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 so-called "vaping" approach, "e-liquid" is heated by a heating device 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 avoid large liquid droplets reaching a user's mouth.

<CIT> describes an atomizer and electronic cigarette.

The present disclosure provides a heater of an aerosol delivery device that is supported by a resilient sealing body. The resilient sealing body seals to both a first casing containing a reservoir for holding aerosol precursor and a second casing which supports the heater. The first and second casings are separable and the sealing of the resilient sealing body to the first casing containing the reservoir is also releasable when the first casing is separated from the second casing.

The first casing supports a wick arranged to receive aerosol precursor from the reservoir, with an activation surface of that wick making abutting unbonded contact with the heater so it would interact thermally therewith when the first and second casings are connected.

In this way, the resilient sealing body performs three functions, supporting the heater, and sealing each of the first and second casings. The sealing allows the first casing to be separated from the second casing, for example when the aerosol precursor in the reservoir with the first casing has been consumed. The heater remains with the second casing, held thereto by the resilient sealing body, so the heater does not need to be replaced when the first casing is removed. Thus, the second casing may form the casing of the main body, including the power source, in the second casing its contents may form a consumable.

Thus, the present invention may provide an aerosol delivery device comprising a first casing and a second casing separably connected to said first casing, said first casing containing a reservoir for holding an aerosol precursor, said first casing also supporting a wick arranged to receive aerosol precursor from said reservoir, said second casing supporting a heater, said heater making abutting unbonded contact with an activation surface of said wick so as to interact thermally with said activation surface; wherein said heater is supported by said second casing via a resilient sealing body, said resilient sealing body sealing to said second casing to be held thereby, and releasably sealing to said first casing such that the seal of said resilient sealing body is releasable when said first casing is separated from said second casing.

Preferably, the resilient sealing body has at least one bore (also referred to hereinafter as a passage) therethrough for passage of air from the interior of the second casing to the activation surface of the wick. That bore may have a mouth adjacent the heater and the activation surface, which mouth widens towards the activation surface. This contributes to a good distribution of air over the activation surface, to allow the air to mix with vapourised aerosol precursor, released from the wick due to the heating effect of the heater. Preferably, the resilient sealing body has a planar heater support surface, with the heater mounted thereon. That heater support service may have a slot therein, which may communicate with the bore referred to previously which allows for a passage of air through the resilient sealing body.

In addition to the bore described above, the resilient sealing body may have at least one further bore therethrough, being for the passage of one or more electrical leads from the heater to the interior of the second casing, for connection to an electrical power source. The electrical power source maybe, for example, a battery.

It is desirable that the resilient sealing body is heat resistant, since it must withstand the heat generated by the heater. It may be, for example, of silicone material. The first casing preferably has an outlet, which may form a mouthpiece for the user, with there being a first air-flow pathway from the activation surface to the outlet. In a similar way, the second casing may have an inlet, with a second air-flow pathway from the inlet to the activation surface. The second air-flow pathway may pass through the bore (or some or all of the bores) in the resilient sealing body. In this way, when the user draws on the mouthpiece, air is drawn into the inlet and through the second air-flow pathway to the activation surface, where it mixes with the vaporised aerosol precursor, and the resulting mixture can then pass along the first air-flow pathway to the user.

Referring to <FIG>, there is shown a smoking substitute system comprising a smoking substitute device <NUM>. In this example, the substitute smoking system comprises a cartomiser <NUM> and a flavour pod <NUM>. The cartomiser <NUM> may engage with the smoking substitute device <NUM> via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. A cartomiser may also be referred to as a "pod". The smoking substitute system may be an aerosol delivery device according to the present invention.

The flavour pod <NUM> is configured to engage with the cartomiser <NUM> and thus with the substitute smoking device <NUM>. The flavour pod <NUM> may engage with the cartomiser <NUM> via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. <FIG> illustrates the cartomiser <NUM> engaged with the substitute smoking device <NUM>, and the flavour pod <NUM> engaged with the cartomiser <NUM>. As will be appreciated, in this example, the cartomiser <NUM> and the flavour pod <NUM> are distinct elements. Each of the cartomiser <NUM> and the flavour pod may be an aerosol delivery device.

As will be appreciated from the following description, the cartomiser <NUM> and the flavour pod <NUM> may alternatively be combined into a single component that implements the functionality of the cartomiser <NUM> and flavour pod <NUM>. Such a single component may also be an aerosol delivery device according to the present invention. In other examples, the cartomiser may be absent, with only a flavour pod <NUM> present or vice versa.

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 comprising a smoking substitute device <NUM> and a consumable <NUM>. The consumable <NUM> combines the functionality of the cartomiser <NUM> and the flavour pod <NUM>. In <FIG>, the consumable <NUM> and the smoking substitute device <NUM> are shown separated from one another. In <FIG>, the consumable <NUM> and the smoking substitute device <NUM> are engaged with each other.

Referring to <FIG>, there is shown a consumable <NUM> engaged with a smoking substitute device <NUM> via a push-fit engagement. The consumable <NUM> may be considered to have two portions - a cartomiser portion <NUM> and a flavour pod portion <NUM>, both of which are located within a single component (as in <FIG>).

The consumable <NUM> includes an upstream airflow inlet <NUM> and a downstream airflow outlet <NUM>. In other examples a plurality of inlets and/or outlets are included. Between and fluidly connecting the inlet <NUM> and the outlet <NUM> there is an airflow passage <NUM>. The outlet <NUM> is located at the mouthpiece <NUM> of the consumable <NUM>, and is formed by a mouthpiece aperture.

As above, the consumable <NUM> includes a flavour pod portion <NUM>. The flavour pod portion <NUM> is configured to generate a first (flavour) aerosol for output from the outlet <NUM> of the mouthpiece <NUM> of the consumable <NUM>. The flavour pod portion <NUM> of the consumable <NUM> includes a member <NUM>. The member <NUM> acts as a passive aerosol generator (i.e. an aerosol generator which does not use heat to form the aerosol, also referred to as a "first aerosol generator" in this example), and is formed of a porous material. The member <NUM> comprises a supporting portion <NUM>, which is located inside a housing, and an aerosol generator portion <NUM>, which is located in the airflow passage <NUM>. In this example, the aerosol generator portion <NUM> is a porous nib.

A first storage reservoir <NUM> (in this example a tank) for storing a first aerosol precursor (i.e. a flavour liquid) is fluidly connected to the member <NUM>. The porous nature of the member <NUM> means that flavour liquid from the first storage <NUM> is drawn into the member <NUM>. As the first aerosol precursor in the member <NUM> is depleted in use, further flavour liquid is drawn from the first storage reservoir <NUM> into the member <NUM> via a wicking action.

As described above, the aerosol generator portion <NUM> is located within the airflow passage <NUM> through the consumable <NUM>. The aerosol generator portion <NUM> therefore constricts or narrows the airflow passage <NUM>. The aerosol generator portion <NUM> occupies some of the area of the airflow passage, resulting in constriction of the airflow passage <NUM>. The airflow passage <NUM> is narrowest adjacent to the aerosol generator portion <NUM>. Since the constriction results in increased air velocity and corresponding reduction in air pressure at the aerosol generator portion <NUM>, the constriction is a Venturi aperture <NUM>.

The cartomiser portion <NUM> of the consumable <NUM> includes a second storage reservoir <NUM> (in this example a tank) for storing a second aerosol precursor (i.e. e-liquid, which may contain nicotine). At one end of the second storage reservoir <NUM> is a wick support element <NUM>, which supports a wick <NUM>. As will be described in more detail later, aerosol precursor passes through one or more bores (not shown in <FIG>) in the wick support element <NUM> to reach the wick <NUM>. The surface of the wick furthest from the reservoir then acts as an activation surface from which aerosol precursor will be released in the form of a vapour, or a mixture of vapour and aerosol.

A heater <NUM> is a configured to heat the wick <NUM>. The heater <NUM> may be in the form of one or more resistive heating filaments that abut the wick <NUM>. The wick <NUM>, the heater <NUM> and the e-liquid storage reservoir <NUM> together act as an active aerosol generator (i.e. an aerosol generator which uses heat to form the aerosol, referred to as a "second aerosol generator" in this example). The second storage reservoir <NUM>, the wick support element, and the wick <NUM> form a fluid-transfer article, as they transfer aerosol precursor to the activation surface to be heated by the heater <NUM>.

The heater <NUM> is supported in the smoking substitute device <NUM> by a heater support element <NUM>. There may be one or more passages (not shown in <FIG>) through the heater support element <NUM> to allow air to reach the activation surface of the wick <NUM> from an inlet (again not shown in <FIG>) of the smoking substitute device.

The smoking substitute device <NUM> includes an electrical power source (not shown), for example a battery. That battery is then connected via suitable electrical connections to the heater <NUM>. The heater <NUM>, the battery, and other components of the smoking substitute system device <NUM> form a non-consumable part of the device from which the consumable <NUM> may be connected and disconnected.

In the arrangement of the smoking substitute device <NUM> of <FIG>, and in the arrangement to be described later, the consumable <NUM> is separable from the rest of the smoking substitute device <NUM>. This allows the consumable <NUM> to be replaced, or possibly refilled, when the first and/or second aerosol precursor have been consumed by the user. Since the consumable <NUM> includes the wick <NUM> and the wick support element <NUM>, these components will be removed when the consumable <NUM> is separated from the rest of the smoking substitute device <NUM>. The heater <NUM>, on the other hand, will remain when the consumable <NUM> is removed, so that it is non-consumable.

In use, a user draws (or "sucks", or "pulls") on the mouthpiece <NUM> of the consumable <NUM>, which causes a drop in air pressure at the outlet <NUM>, thereby generating air flow through the inlet, through the passages in the heater support element <NUM>, past the activation surface of the wick <NUM>, along the airflow passage <NUM>, out of the outlet <NUM> and into the user's mouth.

When the heater <NUM> is activated (by passing an electric current through one or more heating filaments in response to the user drawing on the mouthpiece <NUM>) the e-liquid (aerosol precursor) located in the wick <NUM> at the activation surface adjacent to the or each heating filament is heated and vaporised to form a vapour. The vapour condenses to form the second aerosol within the airflow passage <NUM>. Accordingly, the second aerosol is entrained in an airflow along the airflow flow passage <NUM> to the outlet <NUM> and ultimately out from the mouthpiece <NUM> for inhalation by the user when the user <NUM> draws on the mouthpiece <NUM>.

The substitute smoking device <NUM> supplies electrical current to the heating filament or filaments of the heater <NUM> and the heating filament or filaments heat up. As described, the heating of the heating filament or filaments causes vaporisation of the e-liquid in the wick <NUM> to form the second aerosol.

As the air flows up through the airflow passage <NUM>, it encounters the aerosol generator portion <NUM>. The constriction of the airflow passage <NUM> caused by the aerosol generator portion <NUM> results in an increase in air velocity and corresponding decrease in air pressure in the airflow in the vicinity of the porous surface <NUM> of the aerosol generator portion <NUM>. The corresponding low pressure region causes the generation of the first (flavour) aerosol from the porous surface <NUM> of the aerosol generator portion <NUM>. The first (flavour) aerosol is entrained into the airflow and ultimately is output from the outlet <NUM> of the consumable <NUM> and thus from the mouthpiece <NUM> into the user's mouth.

The first aerosol may be sized to inhibit pulmonary penetration. The first aerosol may be formed of particles with a mass median aerodynamic diameter that is greater than or equal to <NUM> microns, in particular, greater than <NUM> microns, more particularly greater than <NUM> microns, yet more particularly greater than <NUM> microns, and even more particularly greater than <NUM> microns.

The first 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, in particular less than <NUM> microns, yet more particularly 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 flavour element and to enter and extend through the oral and or nasal cavity to activate the taste and/or olfactory receptors.

The second aerosol generated may be sized for pulmonary penetration (i.e. to deliver an active ingredient such as nicotine to the user's lungs). The second aerosol may be 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 size of aerosol formed without heating is typically smaller than that formed by condensation of a vapour.

As a brief aside, it will be appreciated 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.

Referring to <FIG>, there is shown a flavour pod portion <NUM> of a consumable, the consumable providing an aerosol delivery device in accordance with the invention. The consumable further comprises a cartomiser portion (not shown in <FIG>) having all of the features of the cartomiser portion <NUM> described above with respect to <FIG>.

The flavour pod portion <NUM> comprises an upstream (i.e. upstream with respect to flow of air in use) inlet <NUM> and a downstream (i.e. downstream with respect to flow of air in use) outlet <NUM>. Between and fluidly connecting the inlet <NUM> and the outlet <NUM> the flavour pod portion <NUM> comprises an airflow passage <NUM>. The airflow passage <NUM> comprises a first airflow branch <NUM> and a second airflow branch <NUM>, each of the first airflow branch <NUM> and the second airflow branch <NUM> fluidly connecting the inlet <NUM> and the outlet <NUM>. In other examples the airflow passage <NUM> may have an annular shape. The outlet <NUM> is located at the mouthpiece <NUM> of the consumable <NUM>, and is also referred to as a mouthpiece aperture <NUM>.

The flavour pod portion <NUM> comprises a storage <NUM>, which stores a first aerosol precursor. The storage <NUM> comprises a reservoir <NUM> located within a chamber <NUM>. The reservoir <NUM> is formed of a first porous material.

The flavour pod portion <NUM> comprises a member <NUM>, which comprises an aerosol generator portion <NUM> and a supporting portion <NUM>. The aerosol generator portion <NUM> is located at a downstream end (an upper end in <FIG>) of the member <NUM>, while the supporting portion <NUM> makes up the rest of the member <NUM>. The supporting portion <NUM> is elongate and substantially cylindrical. The aerosol generator portion <NUM> is bulb-shaped, and comprises a portion which is wider than the supporting portion <NUM>. The aerosol generator portion <NUM> tapers to a tip at a downstream end of the aerosol generator portion <NUM>.

The member <NUM> extends into and through the storage <NUM>. The member <NUM> is in contact with the reservoir <NUM>. More specifically, the supporting portion <NUM> extends into and through the storage <NUM> and is in contact with the reservoir <NUM>. The member <NUM> is located in a substantially central position within the reservoir <NUM> and is substantially parallel to a central axis of the consumable. The member <NUM> is formed of a second porous material.

The first and second airflow branches <NUM>, <NUM> are located on opposite sides of the member <NUM>. Additionally, the first and second airflow branches <NUM>, <NUM> are located on opposite sides of the reservoir <NUM>. The first and second airflow branches <NUM>, <NUM> branch in a radial outward direction (with respect to the central axis of the consumable <NUM>) downstream of the inlet <NUM> to reach the opposite sides of the reservoir <NUM>.

The aerosol generator portion <NUM> is located in the airflow passage <NUM> downstream of the first and second airflow branches <NUM>, <NUM>. The first and second airflow branches <NUM>, <NUM> turn in a radially inward direction to merge at the member <NUM>, at a point upstream of the aerosol generator portion <NUM>.

The aerosol generator portion <NUM> is located in a narrowing section <NUM> of the airflow passage <NUM>. The narrowing section <NUM> is downstream of the point at which the first and second airflow branches <NUM><NUM> merge, but upstream of the mouthpiece aperture <NUM>. The mouthpiece aperture <NUM> flares outwardly in the downstream direction, such that a width of the mouthpiece aperture <NUM> increases in the downstream direction.

In use, when a user draws on the mouthpiece <NUM>, air flow is generated through the air flow passage <NUM>. Air (comprising the second aerosol from the cartomiser portion as explained above with respect to <FIG>) flows through the inlet <NUM> before the air flow splits to flow through the first and second airflow branches <NUM>, <NUM>. Further downstream, the first and second airflow branches <NUM>, <NUM> provide inward airflow towards the member <NUM> and the aerosol generator portion <NUM>.

As air flows past the aerosol generator portion in the narrowing section <NUM>, the velocity of the air increases, resulting in a drop in air pressure. This means that the air picks up the first aerosol precursor from the aerosol generator portion <NUM> to form the first aerosol. The first aerosol has the particle size and other properties described above with respect to <FIG>.

As the first aerosol precursor is picked up by the air, the member <NUM> transfers further first aerosol precursor from the storage <NUM> to the aerosol generator portion <NUM>. More specifically, the member <NUM> wicks the first aerosol precursor from the storage <NUM> to the aerosol generator portion <NUM>.

In other examples, the storage <NUM> comprises a tank containing the first aerosol precursor as free liquid, rather than the reservoir <NUM> and the chamber <NUM>. In such examples, the member <NUM> still extends into the tank to transfer first aerosol precursor from the tank to the aerosol generator portion <NUM>.

Further arrangements of the present invention will now be described, which arrangements incorporate one or more features of the aspects of the present invention. In the subsequent arrangements, the smoking substitute device <NUM> includes a consumable <NUM> in the form of a cartomiser, but does not include a flavour pod. However the smoking substitute device <NUM> of the subsequent arrangements may be modified to incorporate a flavour pod in a way similar to the arrangement of <FIG> and <FIG>.

As mentioned above, the wick <NUM> is supported by a wick support element <NUM>. <FIG> illustrates an arrangement of a smoking substitute system in which these components are illustrated in more detail, and in an exploded view. The wick support element <NUM> is mounted at an end of the second storage reservoir <NUM> and has bores <NUM> therethrough to allow aerosol precursor in the second storage reservoir <NUM> to pass to the wick <NUM>. These bores may be sized so that aerosol precursor may flow therethrough in a non-capillary manner. Although, two bores <NUM> are visible in <FIG>, there may be more arranged around the wick support element <NUM>.

In the arrangement of <FIG>, the wick support element <NUM> is made of a resilient material, such as rubber, and thus may deform when force is applied thereto. In particular, when the consumable <NUM> is mounted on the main body <NUM>, the wick <NUM> is brought into contact with the heater <NUM>, and is held thereto by the resilience of the wick support element <NUM>. The wick support element <NUM> may be sized so that it deforms slightly when the wick <NUM> is in contact with the heater <NUM>, so as to provide a biasing force to urge the wick <NUM> into firm contact with the heater <NUM>.

The wick <NUM> has an opening <NUM> at its centre, which is aligned with a passageway <NUM> through the wick support element <NUM>. The passageway <NUM> communicates with the air-flow passage <NUM> shown in <FIG> so that air, together with vapour or a mixture of vapour and aerosol, will pass to the user. The surface of the wick <NUM> closest to the heater <NUM> acts as an activation surface for the aerosol precursor and, as the wick <NUM> is heated by the heater <NUM>, aerosol precursor is released from the activation surface in the form of vapour or a mixture of vapour and aerosol, it can then pass through the opening <NUM> and the passageway <NUM> into the air-flow passage <NUM>.

As illustrated in <FIG>, the heater <NUM> is mounted on a heater support element <NUM>, which may act as an end wall of a battery housing and which may itself be supported by a support wall <NUM>. The casing of the main body <NUM> (not shown in <FIG>) will enclose the support wall <NUM> and parts of the heater support element <NUM>. In order for air to flow from the activation surface of the wick <NUM> through the opening <NUM> and into the passage <NUM>, air must first reach the activation surface of the wick <NUM>. The support wall <NUM> may thus have a bore <NUM> therethrough, which communicates with passages <NUM> (not shown in <FIG>) through the heater support element <NUM>. <FIG> illustrates these passages <NUM> and shows that they open immediately adjacent the heater <NUM> and hence adjacent the activation surface of the wick <NUM>. The casing of the main body <NUM> may be provided with an inlet at a suitable location, to allow air to reach the bore <NUM>, and hence to flow to the passages <NUM> in the heater support element <NUM>. Hence, when the user draws on the mouthpiece <NUM> of the consumable <NUM>, air is drawn into the casing of the main body <NUM> through the bore <NUM> and the passages <NUM> to reach the activation surface of the wick <NUM> adjacent the heater <NUM>. That air then passes, together with vapour or mixture of aerosol and vapour generated by heating of the aerosol precursor by the heater <NUM>, through the opening <NUM> in the wick <NUM> to the passage <NUM>, and hence to the air-flow passage <NUM>, and then to user, as has previously been described.

Note that in the arrangement of <FIG> and <FIG>, the heater <NUM> will need to be connected to a power source, such as a battery, and there may then need to be additional bores (not shown in <FIG> and <FIG>) through the heater support element <NUM> and the support wall <NUM> to allow electrical leads to pass therethrough.

<FIG> illustrates another arrangement of a smoking substitute system, in which the consumable has a single reservoir for aerosol precursor which corresponds to the second storage reservoir <NUM> in the embodiment of <FIG>. In this arrangement, the consumable does not have a flavour pod portion. For simplicity, parts corresponding to those of <FIG> are indicated by the same reference numerals. Note that in <FIG>, the support wall <NUM> has multiple bores <NUM> therethrough, aligned with the passages <NUM> in the heater support element <NUM>.

<FIG> also shows the casings of the device. In particular, there is a casing <NUM> (the "first" casing), being a casing of the consumable <NUM>. That casing contains the reservoir <NUM> for aerosol precursor, and also supports the wick support element <NUM> and the wick <NUM>. A tube <NUM> within that first casing <NUM> forms a bounding wall of the air-flow passage <NUM>, and the mouthpiece <NUM> is formed at an end of the first casing <NUM>. The main device <NUM> also has a casing <NUM> (the "second" casing) on which are mounted the support wall <NUM> and the heater support element <NUM>. There is a space <NUM> within the second casing <NUM> for a battery and other electronic components used to power the heater <NUM>, and the second casing <NUM> may also have an inlet <NUM> to allow air to enter the space <NUM> and hence pass to the bores <NUM> and the passages <NUM> to enable it to reach the activation surface of the wick <NUM>.

<FIG> also shows electrical leads <NUM> which extend through the support wall <NUM> and the heater support element <NUM> to enable the heater <NUM> to be connected to a battery in space <NUM>. Small bores may be formed in the heater support element <NUM> and the support wall <NUM> through which the leads <NUM> may pass. The first and second casings <NUM>, <NUM> are separable and held together by a "click" engagement <NUM>. When the two casings <NUM>,<NUM> are interconnected, as shown in <FIG>, the wick <NUM> is forced into contact with the heater <NUM> by the resilience of the wick support element <NUM>, so that good heating of the activation surface of the wick <NUM> will occur when the heater <NUM> is active. The separability of the two casing <NUM>, <NUM> allows the consumable <NUM> to be removed from the main body <NUM>, and replaced, e.g. when the aerosol precursor in the reservoir <NUM> is exhausted.

<FIG> shows a perspective view of the consumable <NUM> in <FIG>, with the part of the first casing <NUM> removed so that the wick <NUM> and the wick support element <NUM> are clearly visible. It can be seen from <FIG> that the wick <NUM> is flat and so has a planar activation surface (the exposed surface of the wick <NUM> in <FIG> also shows clearly the opening <NUM> in the wick <NUM>, which allows communication with the passageway <NUM> through the wick support element <NUM>. The wick support element <NUM> in this embodiment, and in some other embodiments, is preferably made of rubber material. In a similar way, the wick <NUM> is preferably made of silica material, which material is suitably porous to allow the aerosol precursor to pass therethrough. Alternatively, the wick may be of fibrous material, woven material or porous ceramic material.

<FIG> and <FIG> illustrate two alternative configurations of a heater support element <NUM> which may be used in the present invention. They differ in the shape of the mouth of the passage <NUM> through the heater support element <NUM> which allows air to pass through the heater support element from e.g. the interior of the casing of the main body <NUM> to the vicinity of the heater <NUM> and the activation surface of the wick <NUM>. Note that, in <FIG> and <FIG>, the heater itself is not shown and there is a single passage <NUM> through the heater support element <NUM>. In each of the alternative configurations, the heater support element <NUM> is preferably made of resilient material, which must also be suitable to resist the heat generated by the heater <NUM>.

In <FIG>, the heater support element <NUM> comprises a body part <NUM> which has a peripheral seal surface <NUM> which seals to the casing <NUM> (not shown in <FIG>). The seal between the seal surface <NUM> and the casing <NUM> needs to be sufficiently strong to prevent, or at least significantly resist, movement of the heater support element <NUM> in the casing <NUM>, particularly when the consumable <NUM> is removed from the main body <NUM>.

A projecting part <NUM> projects from the body part <NUM>, terminating in a flat heater support face <NUM>. The periphery of the projecting part <NUM> seals to the casing <NUM> of the consumable <NUM>, and for this purpose may have ribs <NUM> on its side surface. However, unlike the sealing of the seal surface <NUM> to the casing <NUM> of the main body <NUM>, the sealing of the projecting part <NUM> to the casing <NUM> of the consumable <NUM> needs to allow the consumable <NUM> to be removed to allow another consumable <NUM> to be mounted thereon without too much resistance. Nevertheless, the sealing must be sufficiently good to limit leakage of any aerosol precursor which has passed through the wick <NUM> but has not been vaporised by the heater <NUM>. As in the arrangement of <FIG>, the passage <NUM> passes through the heater support element <NUM> to enable air to pass towards the heater <NUM> and the wick <NUM>. In the heater support element <NUM> shown in <FIG>, the passage <NUM> terminates in a splayed or funnelled mouth <NUM>, which opens into a slot <NUM> in the heater support surface <NUM>, so that air which has passed through the bore <NUM> can expand in the funnelled mouth <NUM> before reaching the heater <NUM>.

<FIG> also shows bores <NUM> through which pass leads from the heater <NUM>, which leads will provide electrical connection to the battery.

The heater support element <NUM> shown in <FIG> is resilient and is preferably made of silicone material, with provision to resist high temperatures which may be generated by the heater <NUM>. For example, the material known as Polygraft HT-<NUM> silicone, which is a two-part mix, may be a suitable material from which the heater support element <NUM> may be made. The configuration shown in <FIG> will normally be made by moulding the silicone material in a suitable mould.

<FIG> illustrates an alternative heater support element <NUM>. It is generally similar to the heater support element <NUM> shown in <FIG> and the same reference numerals indicate corresponding parts. It may be made of the same materials as the heater support element <NUM> of <FIG>. The heater support element <NUM> of <FIG> differs from that of <FIG> in that the passage <NUM> opens directly into the channel <NUM> in the heater support surface <NUM>. There is thus a flat face <NUM> at the bottom of the channel <NUM>, rather than the funnel mouth <NUM> shown in <FIG>.

<FIG> shows a heater that may be used with the heater support element <NUM> shown in <FIG> or <FIG>. The heater comprises a heater filament <NUM> which is generally flat and rests on the heater support face <NUM> of the heater support element <NUM>. For this reason, the filament <NUM> is not straight but meanders in its plane. <FIG> also shows the leads <NUM> which extend through the bores <NUM> of the heater support <NUM> shown in <FIG> or <FIG>, to enable the heater <NUM> to be connected to a battery.

<FIG> illustrates an arrangement of a smoking substitute system which incorporates the heater support element <NUM> of <FIG>, and also the heater <NUM> of <FIG>. The arrangement of <FIG> is generally similar to that of <FIG>, and corresponding parts are indicated by the same reference numerals. As mentioned previously, when the heater support element <NUM> of <FIG> is used, there is only a single bore <NUM> therein for air, hence there is only a single bore <NUM> in the support <NUM> in the main body <NUM>. The bore <NUM> extends to the funnelled mouth <NUM> which opens into the slot <NUM> directly below the heater <NUM>. Note that the leads <NUM> of the heater <NUM> are not visible in <FIG>.

<FIG> illustrates how the seal surface <NUM> of the main body <NUM> seals to the second casing <NUM>, and the projecting part <NUM> seals to the first casing <NUM>. This sealing is illustrated in more detail in the enlarged view of <FIG>. In particular, the first casing <NUM> of the consumable <NUM> extends sufficiently far within the second casing <NUM> of the main body <NUM> so as to contact the projecting part <NUM> of the heater support element <NUM> at a sealing interface <NUM>. Similarly, the main body <NUM> of the heater support element <NUM> seals at a sealing interface <NUM> with the casing <NUM> of the main body <NUM>. As mentioned previously, the degrees of sealing at these two sealing interfaces <NUM> and <NUM> are preferably different, since the heater support element <NUM> does not normally release from the second casing <NUM>, but must release from the first casing <NUM> when the consumable <NUM> is removed.

<FIG> also shows how the funnelled mouth <NUM> of the passage <NUM> opens within the heater support element <NUM> towards the heater <NUM> and the wick <NUM>. This causes the air flow from the passage <NUM> to expand, as illustrated by the arrows <NUM>, so that there is a good air flow where the heater <NUM> meets the wick <NUM>, to entrain vapour therein prior to flow to the passage <NUM> in the wick support element <NUM>.

With the arrangement shown in <FIG>, as in the other arrangements, the sealing between the first casing <NUM> and the heater support element <NUM> at the sealing interface <NUM> prevents any leakage of aerosol precursor which has come from the wick <NUM> and has not been vaporised by the heater <NUM>. Hence, when the consumable <NUM> is fitted in place on the main body <NUM>, the only escape route for the aerosol precursor is via the air flow passage <NUM> and the mouthpiece <NUM>. This helps to ensure efficient consumption of the aerosol precursor.

The arrangement of <FIG> also differs from the arrangement of <FIG> (and also that of <FIG>), in that the wick <NUM> extends across the whole of the end face of the wick support element <NUM>, as in the arrangement of <FIG>. As before, the wick <NUM> has an opening <NUM> therein to allow air to pass through the wick <NUM> and into the passage <NUM>, and hence through the air-flow passage <NUM> so that it can reach the outlet <NUM> and thus pass to the user.

<FIG> shows another arrangement of a smoking substitute system, which is generally similar to that of the embodiment of <FIG> and <FIG> and corresponding parts are indicated by the same reference numerals. In the embodiment of <FIG>, however, there is no heater support element <NUM>, and instead the heater <NUM> is a coil or other filament held within the second casing <NUM>, which has a space <NUM> adjacent thereto. The space <NUM> communicates with inlets (not shown in <FIG>) which allow air to enter the casing <NUM> and pass to the activation surface of the wick <NUM>. Again, the wick <NUM> is forced into contact with the heater <NUM> by the resilience of the wick support element <NUM>. In this arrangement, the flow of air to the activation surface is not restricted by the size of the passage or passages through the heater support element <NUM>. In this arrangement the heater <NUM> needs to be sufficiently stiff that it is not deformed when the wick <NUM> is urged into contact therewith by the resilient wick support element <NUM>.

In the arrangements of the smoking substitute system described above, the wick support element <NUM> is a separate element from the first casing <NUM> of the consumable <NUM>. <FIG> illustrates an alternative arrangement, in which the wick support element is integral with part of the first casing <NUM>.

In the arrangement of <FIG>, parts which correspond to arrangements described previously are indicated by the same reference numerals. Note that, in <FIG>, the main body <NUM> is not shown. It may be the same as in the other arrangements of a smoking substitute system described previously.

In the arrangement of <FIG>, the first casing <NUM> has a lower part 300a and an upper part 300b. The mouthpiece <NUM> is in the upper part 300b, and the tube <NUM> is also integral with that upper part 300b. The lower part 300a has an upper rim which meets a lower rim of the upper part 300b at a sealing surface <NUM>, and has an internal flange <NUM> adjacent its lower end. The internal flange <NUM> corresponds to the wick support element <NUM> of the arrangements previously described. The internal flange <NUM> has a central bore forming passage <NUM>, which passage is aligned with the passage <NUM> within the tube <NUM>. The end of the tube <NUM> furthest from the mouth piece <NUM> engages the flange <NUM> and is sealed thereto.

The interiors of the upper and lower parts 300b and 300a of the casing <NUM> are hollow, and form the reservoir <NUM>. There are bores <NUM> in the flange <NUM> to allow the reservoir <NUM> to communicate with the wick <NUM>, in the same way as the bores <NUM> in the earlier arrangements described previously. Thus, aerosol precursor in the reservoir <NUM> may pass through the bores <NUM> to saturate the wick <NUM>, and then be heated by the heater <NUM> (not visible in <FIG>). The arrangement of <FIG> prevents any leakage of aerosol precursor between the wick support element <NUM> and the casing <NUM>. Whilst there could be leakage between the upper and lower parts 300b, 300a of the casing <NUM>, this can be prevented by suitable configuration of the sealing interface <NUM>. However, if the sealing of the reservoir <NUM> is too good, air may not be able to enter it to replace aerosol precursor which has been consumed.

Therefore, <FIG> shows that there may be at least one additional bore <NUM> in the flange <NUM>, to allow passage of air to the reservoir <NUM> from outside the first casing. The or each additional bore <NUM> needs to be sufficiently small that it will not allow a significant amount of aerosol precursor to pass therethrough. For example, the or each additional bore <NUM> may be e.g. <NUM> to <NUM> in diameter, more preferably <NUM> to <NUM>, even more preferably <NUM> to <NUM>. If the flange has a thickness of e.g. <NUM> to <NUM>, preferably <NUM> to <NUM>, aerosol precursor should not be able to escape reservoir <NUM> through the or each additional bore <NUM>. In general, the thicker the flange <NUM>, the greater the possible diameter of the or each additional bore <NUM> may be, without it allowing aerosol precursor to flow therethrough. A thin flange <NUM> (which thinness may be desirable for manufacture) will thus need the diameter of the or each additional bore to be small.

The upper and lower parts 300a, 300b of the casing <NUM> may be separable to allow for refiling of the reservoir <NUM> once the aerosol precursor wherein has been consumed. In such an arrangement, the sealing at the sealing surface <NUM> needs to be sufficiently good to prevent leakage of aerosol precursor therethrough when the smoking substitute system is in use. Alternatively, the seal at the sealing surface <NUM> may be a permanent one, with the upper and lower parts 300a and 300b if the casing bonded together. In such an arrangement, the reservoir <NUM> may not be refillable, and the consumable <NUM> would need to be replaced once the aerosol precursor in the reservoir <NUM> had been consumed.

In the arrangements described previously, the bores <NUM> in the wick support element <NUM> (or in the flange <NUM> in the case of <FIG>) were described as being sized so that aerosol precursor may flow therethrough in a non-capillary manner. In an alternative, applicable to all the arrangements described previously, the bores <NUM> may be capillary ducts (hereinafter referred to as capillary bores) which allow aerosol precursor to flow therethrough in a capillary manner. The capillary bores allow the flow of aerosol precursor to the wick <NUM>, in a controlled manner, so that there is less chance of there being excess aerosol precursor at the wick <NUM>. In general, the capillary bores may have a diameter range of <NUM> to <NUM>, as a diameter of less than <NUM> will generally not allow sufficient aerosol precursor to pass to the wick <NUM>. Preferably, the diameter is at least <NUM>, preferably <NUM> to <NUM>, and more preferably <NUM> or <NUM>. In practice, the diameter of the capillary bores may be affected by the thickness of the wick support element <NUM>, which can have a thickness of e.g. <NUM> to <NUM>, more preferably <NUM> to <NUM>, such as <NUM>, <NUM>, <NUM> and <NUM>. In general, the width of the capillary bores will need to be greater with greater thickness of the wick support element <NUM>.

In the arrangements of <FIG>, the wick support element <NUM> is made of resilient material such as rubber. In the arrangement of <FIG> on the other hand, the support for the wick <NUM> is rigid, because it was formed by the internal flange <NUM> which was integral with, and therefore made of the same material as, the casing <NUM>. <FIG> and <FIG> then illustrate another arrangement in which the wick is supported by a rigid element. Unlike the arrangement of <FIG>, however, in the arrangement of <FIG> and <FIG>, that rigid element is a separate wick support element <NUM>. In <FIG> and <FIG>, parts which correspond to parts of earlier arrangements are indicated by the same reference numerals. Moreover, as in <FIG>, only the consumable <NUM> is illustrated. The main part <NUM> may be the same as in earlier arrangements.

In particular, in the arrangements of <FIG> and <FIG>, the rigid wick support element <NUM> is formed at an end of the reservoir <NUM>, within the first casing <NUM>. Bores <NUM> through the wick support element <NUM> allow aerosol precursor from the reservoir <NUM> to pass to wick <NUM>. Whilst the bores <NUM> may be non-capillary bores, they are preferably capillary bores. The diameter of the capillary bores may be as previously described, as may the thickness of the wick support element <NUM>. Although not illustrated in <FIG> and <FIG>, there may need to be an additional bore or bores in the wick support element <NUM> to allow passage of air to the reservoir <NUM>, corresponding to the at least one additional bore <NUM> in <FIG>.

In order to prevent escape of liquid from the reservoir, the wick support element <NUM> is preferably sealed to the first casing <NUM> by seals <NUM>. For example, the seals <NUM> may be O-ring seals extending around the wick support element <NUM>. The seals can be seen clearly in <FIG>, as can the opening <NUM> in the wick <NUM>, which leads to the passage <NUM> through the wick support element <NUM> to the air-flow passage <NUM>. The wick support element <NUM> also needs to be sealed to the tube <NUM>, to prevent escape of aerosol precursor from the reservoir <NUM>. To achieve this, the wick support element <NUM> may have an upstanding ring <NUM>, which then seals (e.g. by O-rings and/or an interference fit) to the tube <NUM>. Grooves for those O-rings are illustrated in <FIG>. Another possibility is for the tube <NUM> to be integral with the wick support element <NUM>, with the end of the tube <NUM> being sealed to the casing <NUM> adjacent the mouthpiece <NUM>.

The rigidity of the wick support element <NUM> and the tube <NUM> means that the positioning of the wick support element <NUM> on the tube <NUM> and the positioning of the tube <NUM> relative to the casing <NUM> may be determined to good precision. This ensures that the wick <NUM> is accurately positioned relative to the casing <NUM>, and hence accurately positioned relative to the casing <NUM> and the heater <NUM>.

In the arrangement of <FIG> and <FIG>, the wick support element <NUM> may be made of the same material as the casing <NUM> (and the casing <NUM>) such as being made from moulded polypropylene plastics material. Other suitable materials to form the wick support element <NUM> include ABS and PEAK materials. The seals <NUM> may be O-rings of e.g. rubber material or silicone seals co-moulded with the wick support element <NUM>, but preferably are nitrile or thermoplastic polymer O-ring seals. The moulding of the wick support element <NUM> and the first and second casings <NUM>, <NUM> simplifies manufacture.

Because the wick support element <NUM> is rigid in the arrangement of <FIG> and <FIG>, it may be thinner than the resilient wick support elements <NUM> described with reference to e.g. <FIG>. Thus, it may then be possible to have a wick support element <NUM> with a thickness of e.g. <NUM> to <NUM>, preferably <NUM>, allowing the bores <NUM> to have a small diameter, and still provide a capillary effect. The same is true in the arrangement of <FIG>. Thus, at least in the arrangements of <FIG>, the bores <NUM> may have a diameter of <NUM> to <NUM>, most preferably <NUM>. If one or more additional bores are provided, corresponding to the additional bores <NUM> in the arrangement of <FIG>, to allow air to enter the reservoir volume to replace aerosol precursor which has passed to the wick <NUM>, those additional bores will have small diameters, due to the reduced thickness of the wick support element <NUM>, so e.g. less than <NUM>. The diameter of the additional bores will always be less than the diameter of the capillary bores. It should be noted that, even in the arrangements of <FIG>, it may be possible to have small diameter capillary bores, if the wick support element <NUM> thin enough.

In the arrangements of <FIG>, the position of the wick <NUM> is precisely determined, relative to the casing <NUM>, either because the wick support element is part of the casing itself, as in the arrangement of <FIG>, or because the position of the wick support element <NUM> is determined by a component of the casing such as the tube <NUM>, as in the arrangement of <FIG> and <FIG>. This precise positioning of the wick <NUM> in the casing <NUM> means that manufacture will be consistent and hence replacement of one consumable with another will not alter the relationship between the wick <NUM> and the heater <NUM>, and so will not affect the efficiency of the smoking substitute device.

The use of capillary bores <NUM> in the wick support element <NUM> in the arrangements of <FIG> mean that it is possible to optimise the flow of aerosol precursor to the wick <NUM> to minimise leakage. The length and diameter of the capillary bores <NUM> may be chosen to control the flow of a specific aerosol precursor formulation to the wick <NUM>, based on the viscosity and liquid characteristics of that aerosol precursor. When aerosol precursor is vaporised from the wick <NUM> by the heater <NUM>, there will be an available volume of air in the wick <NUM> allowing additional aerosol precursor to flow into the wick <NUM>, so that the wick <NUM> is maintained in a saturated state when the device is in use. The rigid nature of the wick support element <NUM> improves the consistency of liquid flow to the wick <NUM>, compared to a wick support element <NUM> of resilient material, so that efficient operation may be achieved.

The sealing configuration in the arrangement of <FIG> and <FIG> makes use of O-rings, with the effect of minimising leakage in use and in transit, as a robust seal is created between the wick support element <NUM> and the casing <NUM>, so that there is no leakage path therebetween. O-ring technology is well established, so it is straight forward to put in to practice in the smoking substitute device to reduce or eliminate variation between parts, improving repeatability of manufacture.

The use of a rigid wick support element <NUM> in the arrangements of <FIG> means that the wick support element <NUM> is easy to manufacture with high precision, and the assembly of the consumable may easily be automated. This ensures efficient manufacture, thereby reducing costs.

While the invention has been described in conjunction with the exemplary embodiments described above, many modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made.

Claim 1:
An aerosol delivery device (<NUM>) comprising a second casing separably connectable to a first casing that contains a reservoir for holding an aerosol precursor and supports a wick (<NUM>) arranged to receive aerosol precursor from the reservoir;
characterised in that
the second casing supports a heater (<NUM>) that is configured to make abutting unbonded contact with an activation surface of the wick so as to interact thermally with the activation surface; and
said heater (<NUM>) is supported by said second casing (<NUM>) via a resilient sealing body (<NUM>), said resilient sealing body (<NUM>) sealing to said second casing (<NUM>) to be held thereby, and said resilient sealing body (<NUM>) being releasably sealable to said first casing (<NUM>) such that the seal of said resilient sealing body (<NUM>) is releasable when said first casing (<NUM>) is separated from said second casing (<NUM>).