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

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

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

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories. Some smoking substitute systems are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute systems do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form).

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

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

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

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 heater and a sealed tank which is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute systems include a device which includes the power source, wherein the device is configured to be physically and electrically coupled to a consumable component including the tank and the heater. In this way, when the tank of the consumable component has been emptied, the device can be reused by connecting it to a new consumable component. 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, so the system can be used multiple times.

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

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

As the vapour passes through the consumable (entrained in the airflow) from the location of vaporizatoion to an outlet of the consumable (e.g. a mouthpiece), the vapour cools and condenses to form an aerosol for inhalation by the user. The aerosol may contain nicotine and/or flavour compounds. As e-liquid is released from the tank and vaporised, a pressure differential is created between the inside of the tank and the rest of the system. If the pressure differential between the tank and the rest of the system is not equalised, further e-liquid cannot be drawn out by the wick from the tank. The wick therefore cannot become moistened or saturated with e-liquid and the user ends up inhaling air without the aerosol (or 'vapour') being produced. This is otherwise known as a 'dry hit'.

In order for further e-liquid to be drawn out from the tank by the wick, the volume occupied by the released e-liquid in the tank must be replaced by air. In other words, air must be able to enter the e-liquid tank and replace the volume created by the released vaporised e-liquid. By allowing air to enter the tank, the pressure differential between the tank and the rest of the system is equalised, thereby allowing the wick to draw out further e-liquid from the tank.

Further examples of vaping substitute systems are described in <CIT> and <CIT>.

Prior art vaping smoking substitute systems have attempted to equalise this pressure differential by providing an air vent in the tank to allow air to enter the tank. However, providing a vent in the tank often results in e-liquid leaking from the tank.

There is a need for an improved system which ameliorates the problem described above.

According to a first aspect there is a provided an aerosol-delivery component, comprising: a tank for containing a liquid aerosol precursor; a vaporising chamber housing a vaporiser; a wall separating the vaporising chamber from the tank; and a vent channel having a longitudinal axis, the vent channel extending through the wall from a first opening at the vaporising chamber to a second opening at the tank, wherein the longitudinal axis of the vent channel is configured to intersect the vaporiser such that leakage of aerosol precursor through the channel is discharged onto the vaporiser.

By providing a vent channel that is configured such that leakage of aerosol precursor through the channel is discharged onto the vaporiser, any aerosol precursor that leaks from the tank will be contained within the vaporiser and is less likely to leak out of the vaporising chamber.

Optional features of the first aspect will now be set out.

In some embodiments, the vent channel is configured to discharge directly onto the vaporiser. There may be no components or parts between the vent channel and the vaporiser, i.e. there is a clear, unobstructed pathway between the first opening and the vaporiser, such that any aerosol precursor that leaks from the tank will be discharged directly onto the vaporiser.

The vent channel may be an elongate channel or passage that extends through the wall.

The vent channel may be vertically above/ vertically aligned with the vaporiser.

The vaporiser may have a length and a width each substantially perpendicular to the longitudinal axis of the component such that the vaporiser extends transversely across the component. The vaporiser may have an elongate shape where the length of the vaporiser is greater than the width and depth of the vaporiser. The longitudinal axis of the elongate vent channel may intersect with the width and/or length dimension of the vaporiser.

The vaporiser may comprise a heating element for heating a wick.

The vent channel may be vertically above/ vertically aligned with the wick i.e. the elongate/longitudinal axis of the vent channel may intersect the wick.

The wick may have a length and a width each substantially perpendicular to the longitudinal axis of the component such that the wick extends transversely across the component. The wick may have an elongate shape where the length of the wick is greater than the width and depth of the wick. The longitudinal axis of the elongate vent channel may intersect with the width and/or length dimension of the wick.

The vaporiser/wick has opposing first and second longitudinal ends (spaced by the length of the vaporiser/wick). The axis of the vent channel preferably intersects the vaporiser/wick at a position that is spaced from the first longitudinal end of the vaporiser. The axis of the vent channel preferably intersects the vaporiser/wick at a position that is spaced from the second longitudinal end of the vaporiser.

The axis of the vent channel preferably intersects the vaporiser/wick at a position that is spaced from both the first and the second longitudinal ends of the vaporiser e.g. at a position equi-distant from the first and second longitudinal ends. In other words, the vent channel is transversely centred along the length of the wick.

The axis of the vent channel preferably intersects the longitudinal axis of the vaporiser/wick such that the axis of the vent channel is centred in the width dimension of the vaporiser/wick.

In especially preferred embodiments the axis of the vent channel intersects the longitudinal axis of the vaporiser/wick at a position equidistant from the longitudinal ends of the vaporiser/wick such that the axis of the vent channel is centred in both the length and width dimensions of the vaporiser/wick.

As discussed above, the vent channel is vertically above/ vertically aligned with the wick. Accordingly, at least a portion of the first opening is positioned such that it overlies the vaporiser/wick.

Preferably, the entire cross-sectional area of the first opening (in a plane extending perpendicularly to a longitudinal axis of the component) overlies the vaporiser/wick. To facilitate this, the maximum dimension of the first opening is less than or equal to the smaller of the width and length dimension of the vaporiser/wick.

In some embodiments, the first opening is circular. In these embodiments, the diameter of the first opening is equal to or smaller than the smaller of the width and length dimensions of the vaporiser/wick.

The first opening may have a greater cross-sectional area than the second opening.

In some embodiments, the vent channel comprises a channel that tapers outwardly from the second opening to the first opening i.e. the cross-sectional area of the vent channel (in a plane extending perpendicularly to a longitudinal axis of the vent channel) may increase or widen toward the first opening.

The vent channel may taper outwardly evenly/uniformly from the second opening to the first opening i.e. the cross-sectional area of the vent channel may increase gradually/constantly from the second opening to the first opening.

In some embodiments, the vent channel has a uniform cross-sectional profile i.e. the cross-sectional profile/shape may remain constant along the length of the vent channel. For example, the vent channel may have a circular cross-sectional profile. Where the vent channel has a uniform circular cross-sectional profile and the vent channel tapers uniformly, the vent channel is frustoconical. The vent channel may be in the shape of a frustum where the first and second openings are the top and bottom ends of the frustum.

Further optional features will now be set out.

The (e.g. longitudinal) axis of the elongate vent channel may be parallel to an elongate (e.g., longitudinal) axis of the component. In these embodiments, the vent channel extends through a transverse wall separating the vaporising chamber from the tank. The transverse wall has opposing first and second transverse ends. The vent channel is preferably transversely spaced from the first transverse end of the transverse wall. The vent channel is preferably transversely spaced from the second transverse end of the transverse wall.

In some embodiments, the (e.g. longitudinal) axis of the elongate vent channel is coaxial with the elongate axis of the component. In these embodiments, the vent channel may be equally transversely spaced from both the first and second transverse ends of the transverse wall.

In some embodiments, the upper surface of the transverse wall defines a lower end of the tank and a lower surface of the transverse wall defines an upper end of the vaporising chamber. In these embodiments, the first opening is formed in the lower surface of the transverse wall and the second opening is formed in the upper surface of the transverse wall.

The component comprises an airflow path that extends from an air inlet to an air outlet. The air outlet is provided in a mouthpiece portion e.g. a mouthpiece portion of a component housing.

The air outlet/mouthpiece portion may be provided at a first lateral end of the housing. The housing may comprise a base portion at the opposing lateral end.

The air flow path passes the vaporiser between the air inlet to the air outlet. The vaporiser may be housed in the vaporising chamber.

The air flow path may comprise a first portion extending from the air inlet towards the base portion of the housing (and away from the mouthpiece portion) e.g. in a substantially longitudinal direction.

The airflow path may comprise a second portion which passes the vaporiser e.g. passes through the vaporising chamber.

The airflow path may comprise a third portion extending longitudinally from the second portion to the air outlet (formed in the mouthpiece portion of the housing).

In this respect, a user may draw air into and along the airflow path by inhaling at the air outlet (i.e. using the mouthpiece portion).

The third portion of the airflow path may be substantially parallel to the first portion of the airflow path. The third portion of the airflow path may be longer (i.e. in a longitudinal direction) than the first airflow path. The second portion of the airflow path may be a transverse portion i.e. extending substantially perpendicular to the first and/or third portions of the airflow path.

The airflow path may be generally U-shaped (the first and third portions forming stems of the "U" and the second portion forming the base of the "U"). In this respect, the second portion of the airflow path may connect the first and third portions of the airflow path. The airflow path may comprise at least two turns (e.g. each of around <NUM>°) between the inlet and the vaporiser. The airflow path may comprise at least one turn between the vaporiser and the outlet.

The component comprises the tank for housing an aerosol precursor (e.g. a liquid aerosol precursor). The aerosol precursor may comprise an e-liquid, for example, comprising a base liquid and e.g. nicotine. The base liquid may include propylene glycol and/or vegetable glycerine. Hence, the component may be a vaping smoking substitute component.

The second portion of the airflow path may be disposed between (i.e. longitudinally between) the tank and the base portion of the housing. The tank may be disposed between (in a transverse direction) the first and the third portions of the airflow path.

References to "downstream" in relation to the air flow path are intended to refer to the direction towards the air outlet/mouthpiece portion. Thus the second and third portions of the air flow path are downstream of the first portion of the air flow path. Conversely, references to "upstream" are intended to refer to the direction towards the air inlet. Thus the first portion of the air flow path (and the air inlet) is upstream of the second/third portions of the air flow path (and the air outlet/mouthpiece portion).

As discussed above, the component housing may comprise a mouthpiece portion (with the air outlet) at a first lateral end and a base portion at the opposing lateral end.

The housing may further comprise one or more side walls (e.g. laterally opposed first and second side walls) extending longitudinally between the mouthpiece portion and the base portion.

The air inlet may be provided in the first side wall, longitudinally spaced (towards the mouthpiece portion) from the base portion.

The air inlet may be longitudinally spaced from the base portion/lower end of the housing by a distance that is greater than <NUM>. The distance may be greater than <NUM>, or e.g. greater than <NUM>.

The housing may further comprise opposing front and rear walls spaced by the laterally opposed first and second side walls. The distance between the first and second side walls of the housing may define a width of the housing. The distance between the front and rear walls may define a depth of the housing. The width of the housing may be greater than the depth of the housing.

The length of the housing may be greater than the width of the housing. The depth of the housing may be smaller than each of the width and the length. In this respect, the component may be an elongate component having an elongate (longitudinal) axis. As discussed above, the elongate/longitudinal axis of the vent channel may be parallel to or axially aligned with the elongate axis of the component.

The first portion of the airflow path may be defined within an inlet passage between a wall of the tank and a wall of the housing. The wall of the housing partly defining the first portion of the airflow path may be the first side wall of the housing. The wall of the tank defining the first portion of the airflow path may be a first tank wall. Thus the first portion of the airflow path/inlet passage may be defined between the first tank wall and the first side wall. The first side wall and the first tank wall may be integrally formed with one another.

The third portion of the airflow path may be defined within an outlet passage between a wall of the tank and a wall of the housing. The wall of the housing partly defining the third portion of the airflow path may be the second side wall of the housing. The wall of the tank defining the third portion of the airflow path may be a second tank wall. Thus the third portion of the airflow path/outlet passage may be defined between the second tank wall and the second side wall. The second side wall and the second tank wall may be integrally formed with one another.

All of the first side wall, second side wall, first tank wall and second tank wall may all be integrally formed and may additionally be integrally formed with the mouthpiece portion. In that way, the component may be easily manufactured using injection moulding.

References to "upper", "lower", "above" or "below" are intended to refer to the component when in an upright/vertical orientation i.e. with elongate (longitudinal/length) axis of the component vertically aligned and with the mouthpiece portion vertically uppermost and the base portion lowermost.

The tank may be disposed between (in a transverse direction) the first and the third portions of the airflow path.

The first and second tank walls may be spaced from one another so as to define the tank therebetween. The first and second tank walls may extend longitudinally from the mouthpiece portion towards the base portion of the housing. The first and second tank walls may be substantially parallel. Each of the first and second tank walls may extend between (and span) the front and rear walls of the housing.

Each of the first and second tank walls may extend from the mouthpiece portion (i.e. internally in the housing). Each of the first and second tank walls may be integrally formed with the mouthpiece portion.

The tank may be partly defined by a wall of the housing (e.g. the front or rear wall). At least a portion of one of the walls defining the tank may be translucent or transparent. That is, the tank may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a "clearomizer" if it includes a window, or a "cartomizer" if it does not.

As discussed above, the air flow path passes the vaporiser between the air inlet to the air outlet. The vaporiser/wick may be disposed between the tank and the base portion of the housing.

The vaporiser/wick may be disposed in the second portion of the air flow path.

The wick may extend across the second (transverse) portion of the air flow path. The wick may be oriented so as to extend in a direction from the front wall to the rear wall of the housing, i.e. it may be oriented in the direction of the depth dimension of the component. Thus the wick may extend in a direction perpendicular to the direction of air flow in the second portion of the air flow path.

The vaporiser may be disposed in the vaporising chamber. The vaporising chamber may form part of the airflow path (i.e. the second portion of the airflow path).

The vaporising chamber may be defined by one or more chamber walls. The wick may extend between first and second opposing chamber walls. The first and second chamber walls may separate (i.e. partially separate) the vaporising chamber from the tank. The first and second chamber walls may each comprise a respective opening through which a respective end of the wick projects such that the wick is fluid communication with aerosol precursor/e-liquid in the tank. In this way a central portion of the wick may be exposed to air in the (second portion of the) airflow path and end portions of the wick may be in contact with aerosol precursor/e-liquid stored in the tank. The wick may comprise a porous material. Thus, aerosol precursor may be drawn (e.g. by capillary action) along the wick, from the tank to the exposed portion of the wick.

As discussed above, the vent channel may be provided in a transverse wall. The transverse wall may be a transverse chamber wall separating the vaporising chamber from liquid aerosol precursor in the tank. In this respect, the transverse chamber wall may partly define the (base of the) tank.

The vent channel may be transversely spaced from the first tank wall. The vent channel may be transversely spaced from the second tank wall. The vent channel may be equally transversely spaced between the first and second tank wall (with the elongate/longitudinal axis of the vent channel axially aligned with the elongate/longitudinal axis of the component).

The vaporising chamber may be defined by an insert (e.g. an insert at least partially formed of silicone) received into an open (e.g. lower) end of the housing. The vaporising chamber walls may be walls of the insert. Thus the vent channel may be provided in a transverse wall of the insert (which is the transverse wall of the vaporising chamber). The insert may seal against the first and second tank walls so as to seal the tank.

The wick may be cylindrical. The heating element 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 (i.e. the portion of the wick extending across the airflow path). The heating element may be electrically connectable (or connected) to a power source. Thus, in operation, the power source may supply electricity to (i.e. apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e. drawn from the tank) to be heated so as to form a vapour and become entrained in fluid flowing along the airflow path. This vapour may subsequently cool to form an aerosol in the airflow path (e.g. the third portion of the airflow path).

In a third aspect there is provided an aerosol-delivery system (e.g. a smoking substitute system) comprising a component according to the first aspect and an aerosol-delivery (e.g. smoking substitute) device.

The component may be an aerosol-delivery (e.g. a smoking substitute) consumable i.e. in some embodiments the component may be a consumable component for engagement with the aerosol-delivery (e.g. a smoking substitute) device to form the aerosol-delivery (e.g. s smoking substitute) system.

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

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

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

The device may alternatively or additionally be able to detect information about the consumable component via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of the consumable. In this respect, the consumable component 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.

In other embodiments, the component may be integrally formed with the aerosol-delivery (e.g. a smoking substitute) device to form the aerosol-delivery (e.g. s smoking substitute) system.

In such embodiments, the aerosol former (e.g. e-liquid) may be replenished by re-filling a tank that is integral with the device (rather than replacing the consumable). Access to the tank (for re-filling of the e-liquid) may be provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap).

Further features of the device are described below. These are applicable to both the device for receiving a consumable component and to the device integral with the component.

The device may comprise a power source. The device may comprise a controller.

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 device 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 a heating element in response to airflow detection by the sensor. The control may be in the form of activation of the heating element in response to a detected airflow. The airflow sensor may form part of the device.

In a fourth aspect there is provided a method of using the aerosol-delivery (e.g. smoking substitute) consumable component according to the first aspect, the method comprising engaging the consumable component with an aerosol-delivery (e.g. smoking substitute) device (as described above) having a power source so as to electrically connect the power source to the consumable component (i.e. to the vaporiser of the consumable component).

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

Aspects and embodiments will now be discussed with reference to the accompanying figures.

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

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

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

The consumable component <NUM> comprises a housing <NUM> having a base portion <NUM> (at a lower end), a mouthpiece <NUM> (at an upper end), and walls extending longitudinally from the base portion <NUM> to the mouthpiece <NUM>. In particular, the consumable component <NUM> comprises front 108a and rear walls spaced by opposing first 108c and second 108d side walls. The distance between the front 108a and rear 108b walls defines a depth of the housing <NUM> and the distance between the side walls 108c, 108d defines a width of the housing <NUM>. The width of the housing <NUM> is greater than the depth of the housing <NUM>.

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

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

<FIG> are schematic drawings of the device <NUM> and consumable component <NUM>. These figures provide an overview of the components that form part of the consumable component <NUM> and device <NUM>. As is apparent from <FIG>, the device <NUM> includes a power source <NUM>, a controller <NUM>, a memory <NUM>, a wireless interface <NUM>, an electrical interface <NUM>, and, optionally, one or more additional components <NUM>.

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

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

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

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

The additional components <NUM> of the device <NUM> may comprise an indicator (e.g. the light <NUM> discussed above), a charging portion, a battery charging control circuit, a sensor or e.g. user input.

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

The battery charging control circuit may be configured for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

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

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

The consumable component <NUM>, which is shown in <FIG>, includes the tank <NUM>, an electrical interface <NUM>, a vaporiser <NUM>, an air inlet <NUM>, an air outlet <NUM> (e.g. formed in the mouthpiece <NUM>), and one or more additional components <NUM>.

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

The vaporiser <NUM> is configured to heat and vaporise e-liquid contained in the tank <NUM> using electrical energy supplied from the power source <NUM>. As will be described further below, the vaporiser <NUM> heats the e-liquid received from the tank <NUM> to vaporise the e-liquid. The air inlet <NUM> is configured to allow air to be drawn into the smoking substitute system <NUM> when a user inhales using the air outlet <NUM> formed in the mouthpiece <NUM>, such that the vaporised e-liquid is drawn through the consumable component <NUM> for inhalation by the user.

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

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

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

<FIG>, <FIG> are section views of the consumable component <NUM> described above. The air inlet <NUM> of the consumable component <NUM> is in the form of an aperture formed in the first side wall 108c of the housing <NUM>. In particular, the air inlet <NUM> is spaced along the first side wall 108c (in a longitudinal direction) from the base portion <NUM> of the housing <NUM> so as to be partway along the first side wall 108c from the base portion <NUM>. The air outlet <NUM> is formed in the mouthpiece <NUM> and an airflow path <NUM> extends from the air inlet <NUM> to the air outlet <NUM>, such that a user can draw air through the airflow path <NUM> by inhaling at the air outlet <NUM>. As will be described in more detail below, the airflow path <NUM> follows a generally U-shaped path through the consumable component <NUM>.

The airflow path <NUM> comprises first 138a, second and third 138c airflow path portions. The first airflow path portion is defined by an inlet passage 125a extending longitudinally from the air inlet <NUM> towards the base portion <NUM> of the consumable component <NUM>. This inlet passage 125a is defined between a first tank wall 126a that is laterally (i.e. transversely) spaced from the first side wall 108c (in which the air inlet <NUM> is formed) and that extends longitudinally from an internal surface of the mouthpiece <NUM>.

The third airflow path is similarly defined by an outlet passage 125b that is formed between a second tank wall 126b and the second side wall 108d. The second tank wall 126b extends longitudinally from an internal surface of the mouthpiece <NUM> and is laterally spaced from the second side wall 108d. Both the first 126a and second 126b tank walls span the front 108a and rear 108b (see <FIG>) walls of the housing <NUM>. In this way, the tank <NUM> is partly defined between the first and second tank walls 126a, 126b, the front 108a and rear 108b walls, and an internal surface of the mouthpiece <NUM>.

The tank walls 126a, 126b and the mouthpiece <NUM> are integrally formed with each other so as to form a single unitary component that may e.g. be formed by way of an injection moulding process. Such a component may be formed of a thermoplastic material such as polypropylene. To facilitate this (e.g. to allow removal from a mould), each of the tank walls 126a, 126b is tapered from a proximal end at which it is connected to the mouthpiece <NUM> to an opposing distal end.

The second airflow path portion is in the form of a vaporising chamber <NUM> that extends transversely across the housing <NUM> so as to connect lower ends of the first 125a and second 125b passages. Thus, upon inhalation by a user, air may flow into the inlet <NUM>, through the inlet passage 125a, through the vaporising chamber <NUM> (where vapour may be entrained in the air) and subsequently through the outlet passage 125b where it is discharged (into a user's mouth) from the outlet <NUM> at an upper end of the outlet passage 125b. Thus, the airflow path <NUM> comprises at least two turns (at the inlet <NUM> and the connection between the vaporising chamber <NUM> and the inlet passage 125a) between the vaporiser chamber <NUM> and the inlet <NUM>. This may reduce the propensity for leakage of e-liquid out of the inlet <NUM> (i.e. from the vaporising chamber <NUM>).

The vaporiser <NUM> is located in the vaporising chamber <NUM> and comprises a porous wick <NUM> and a heater filament <NUM> coiled around the porous wick <NUM>. The wick <NUM> extends across the vaporising chamber <NUM> (perpendicular to the direction of airflow through the chamber <NUM>). That is, the wick <NUM> extends in the depth direction of the housing <NUM>.

The vaporising chamber <NUM> is formed within an insert <NUM> that is received in an open lower end of the housing <NUM> so as to define the base portion <NUM> of the consumable component <NUM>. The insert <NUM> seals against the walls of the housing <NUM> so as to define a lower end of the tank <NUM>. Thus, the walls of the insert <NUM> (defining the vaporising chamber <NUM>) separate the vaporising chamber <NUM> from the tank <NUM>. In particular, an upper transverse wall <NUM> of the insert <NUM> extends from the first tank wall 126a to the second tank wall 126b so as to separate the vaporising chamber <NUM> from the tank <NUM> (and so as to define a lower surface of the tank <NUM>).

To form a seal with the tank walls 126a, 126b, the upper wall comprises grooves 134a, 134b that extend in a direction of the depth of the housing <NUM> and receive distal ends of the tank walls 126a, 126b. This arrangement also seals the tank <NUM> from the air passages 125a, 125b, which connect to the vaporising chamber <NUM> via respective channels 135a, 135b formed in the insert <NUM>.

As shown in <FIG>, the insert <NUM> comprises two apertures 131a, 131b formed in opposing walls of the insert <NUM> for receipt of respective ends of the wick <NUM> therethrough. The insert <NUM> is spaced from each of the front 108a and rear 108b walls, such that gaps 132a, 132b are formed between the insert <NUM> and each of the front 108a and rear 108b walls. These gaps 132a, 132b are arranged such that the ends of the wick <NUM> projecting through the apertures 131a, 131b in the insert <NUM> are received in the gaps 132a, 132b. In this way, the ends of the wick <NUM> are in contact with aerosol precursor (e-liquid) stored in the tank <NUM>. This e-liquid is transported along the wick <NUM> (e.g. by capillary action) to a central portion of the wick <NUM> that is exposed to airflow flowing through the vaporising chamber <NUM>. The transported e-liquid is heated by the heater filament <NUM> (when activated e.g. by detection of inhalation), which causes the e-liquid to be vaporised and to be entrained in air flowing across the wick <NUM>. This vaporised liquid may cool to form an aerosol in the passage <NUM>, which may then be inhaled by a user.

The insert also <NUM> accommodates the electrical interface <NUM> of the consumable component <NUM>. The electrical interface <NUM> comprises two electrical contacts 136a, 136b that are electrically connected to the heating filament <NUM>. In this way, when the consumable component <NUM> is engaged with the device <NUM>, power can be supplied from the power source <NUM> of the device to the heating filament <NUM>.

As shown in <FIG>, <FIG>, the upper transverse wall <NUM> of the insert <NUM> separates the vaporising chamber <NUM> from the tank <NUM> and includes a vent channel <NUM>. The vent channel <NUM> extends through the transverse wall <NUM> from a first opening <NUM> at the vaporising chamber <NUM> to a second opening <NUM> at the tank <NUM>. The vent channel <NUM> is generally formed as an elongate tubular passage.

The longitudinal axis <NUM> of the elongate vent channel <NUM> intersects the vaporiser, which in this embodiment, includes an elongate cylindrical wick <NUM> with a length <NUM> that is greater than its width 128W and its depth 128D. The length <NUM> and width 128W are both perpendicular to the length <NUM> of the wick. The wick <NUM> extends transversely across the component and includes opposing first 153a and second longitudinal ends.

Accordingly, the vent channel <NUM> is vertically above/ vertically aligned with the wick <NUM>.

The axis <NUM> of the vent channel <NUM> intersects the wick <NUM> at a position that is equally spaced from the first longitudinal end 153a and the second longitudinal end 153b of the wick <NUM>. Thus the vent channel <NUM> is transversely centred along the length <NUM> of the wick <NUM>.

The axis <NUM> of the vent channel <NUM> intersects the longitudinal axis of the wick <NUM> such that the axis <NUM> of the vent channel <NUM> is centred in the width dimension 128W of the wick <NUM>.

Accordingly, the axis <NUM> of the vent channel <NUM> is centred in both the length <NUM> and width 128W dimensions of the wick <NUM>.

The first opening <NUM> is positioned such that it overlies the wick <NUM>. The entire cross-sectional area of the first opening <NUM> overlies the wick <NUM>. The maximum dimension of the first opening <NUM> is less than the smaller of the width 128W and length <NUM> dimension of the wick <NUM>.

The first opening <NUM> is circular and the diameter of the first opening <NUM> is equal to or smaller than the smaller of the width 128W and length <NUM> dimensions of the wick <NUM>. The second opening <NUM> is circular.

The first opening <NUM> has a greater cross-sectional area/diameter than the second opening <NUM>. In this embodiment, the first opening <NUM> has a greater diameter than the second opening <NUM>.

The vent channel <NUM> tapers evenly/uniformly and constantly outwardly from the second opening <NUM> to the first opening <NUM> i.e. the cross-sectional area of the vent channel <NUM> (in a plane extending perpendicularly to the longitudinal axis <NUM> of the vent channel <NUM>) increases toward the first opening <NUM>.

The vent channel <NUM> has a uniform circular cross-sectional profile i.e. the cross-sectional profile/shape remains constant along the length of the vent channel <NUM>. Accordingly, the vent channel <NUM> is frustoconical. The vent channel <NUM> is shaped as a hollow conical frustum.

The longitudinal axis <NUM> of the elongate vent channel <NUM> is coaxial with the elongate axis of the component.

The silicone insert <NUM> forms the walls of the vaporising chamber <NUM> and separates the vaporising chamber <NUM> from the tank <NUM>. The insert <NUM> seals the vaporising chamber <NUM> from the tank <NUM> other than at the vent channel <NUM> and the openings 131a, 131b through which the ends of the wick <NUM> project for contact with the aerosol precursor. The upper transverse wall <NUM> of the insert <NUM> includes an upper surface <NUM> which defines the lower end of the tank <NUM> and a lower surface <NUM> of the wall <NUM> which defines the upper end of the vaporising chamber <NUM>. The first opening <NUM> is formed in the lower surface <NUM> of the wall and the second opening <NUM> is formed in the upper surface <NUM> of the wall.

As described above, in use aerosol precursor is drawn from the tank <NUM> and into the wick <NUM>. As the aerosol precursor is drawn out from the tank <NUM>, a pressure differential is created between the inside of the tank <NUM> and the vaporising chamber <NUM>. This pressure difference causes air to be drawn into the tank <NUM> via the vent channel <NUM>.

Air is thus able to enter the tank <NUM> and replace the volume created by the vaporised aerosol precursor. By allowing air to enter the tank <NUM>, the pressure differential between the tank <NUM> and the vaporising chamber <NUM> is equalised. Further aerosol precursor can therefore be released or drawn out from the tank <NUM> by the wick <NUM> as needed.

As described above, air passes through the vent channel <NUM> and into the tank <NUM>. Liquid aerosol precursor in the tank <NUM> may leak from the tank <NUM> through the vent channel <NUM>. Any liquid aerosol precursor that leaks from the tank <NUM> through the vent channel <NUM> is discharged onto the wick <NUM>. The aerosol precursor that leaks onto the wick <NUM> can be heated and vaporised as described above. In a further embodiment, in which the component is the same as that shown in <FIG>, <FIG>, the second opening <NUM> is sized to prevent flow of liquid aerosol precursor therethrough. The second opening <NUM>, or specifically the cross-sectional area of the second opening <NUM>, may thus be sufficiently small to prevent flow of liquid aerosol precursor through the vent channel <NUM>. In practice, the second opening <NUM> is sufficiently small such that the surface tension of the liquid aerosol precursor prevents the liquid aerosol precursor from passing through the second opening <NUM>. In such an embodiment, the second opening <NUM> prevents liquid aerosol precursor from leaking from the tank <NUM> and into the vaporising chamber <NUM>. The vent channel <NUM> is sized to allow air to pass therethrough. In particular, the first <NUM> and second <NUM> openings are sized to allow air to pass therethrough. Specifically, the cross-sectional areas of the first <NUM> and second <NUM> openings are sufficiently large to allow air to pass through them. Air is therefore able to pass freely through the first and second openings <NUM>, <NUM> of the vent channel <NUM>. In other words, air is flowable from the vaporising chamber <NUM> through the first opening <NUM> and into the tank through the second opening <NUM>.

While exemplary embodiments have been described above, many modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments set forth above are considered to be illustrative and not limiting.

Claim 1:
An aerosol-delivery component (<NUM>) comprising:
a tank (<NUM>) for containing a liquid aerosol precursor;
a vaporising chamber (<NUM>) housing a vaporiser (<NUM>);
a wall (<NUM>) separating the vaporising chamber (<NUM>) from the tank (<NUM>); and
a vent channel (<NUM>) having a longitudinal axis (<NUM>), the vent channel (<NUM>) extending through the wall (<NUM>) from a first opening (<NUM>) at the vaporising chamber (<NUM>) to a second opening (<NUM>) at the tank (<NUM>);
characterised in that the longitudinal axis (<NUM>) of the vent channel (<NUM>) is configured to intersect the vaporiser (<NUM>) such that leakage of aerosol precursor through the channel (<NUM>) is discharged onto the vaporiser (<NUM>).