Patent ID: 12213537

DETAILED DESCRIPTION

Referring toFIG.1, a schematic of an aerosol provision device100is illustrated. The aerosol provision device100is an inhalation device (i.e. a user uses it to inhale an aerosol provided by the system100) and the device100is a hand-held device. In this example, the device100is an electronic device.

In broad outline, the device100volatilizes an aerosol provision material20provided in a cartridge200. In this example the aerosol provision material20is a liquid, for example, an e-cigarette liquid, however in other examples the aerosol provision material may any other type of aerosolizable material, such as a gel. The device100in the example is a so-called hybrid device since any aerosol and/or vapor produced from the cartridge200passes through a material chamber430for containing a material30before being inhaled by a user.

The material30may impart to or modify a property, for example the flavor, of the vapor and/or aerosol before the vapor and/or aerosol passes out of the device100for inhalation by a user. The material30may, for example, consist of or comprise tobacco. As the aerosol passes through and over the material30, for example tobacco, the aerosol entrains organic and other compounds or constituents from the material30that lend the material30, for example tobacco, its organoleptic properties, thus imparting the flavor of the material30to the aerosol as it passes through the material chamber430.

Suitable examples of the material30may comprise tobacco per se, different varieties of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, ground tobacco, tobacco extract, homogenized tobacco or tobacco substitutes. In the case of tobacco, the material30, etc. may be in the form of a rod of tobacco, a pod or plug of tobacco, loose tobacco, agglomerates, etc., and may be in relatively dry form or in relatively moist form for example. The material30may be in the form of a plug of tobacco rod which is cut to length and placed into the material chamber430. The material30may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine.

The material30may be for modifying a property of the aerosol other than (or in addition) to flavor.

In some examples, the material30may be or include a substance that modifies one or more other organoleptic properties of the aerosol (e.g. modifying the feel or smell or look of the aerosol to the user).

In some examples, the material30may be or include a substance that modifies the PH of the aerosol by either lowering or raising the PH (e.g. modifying the acidity or the basicity of the aerosol).

In some examples, the material30may be or include a substance that modifies (e.g. reduces) the amount of aldehydes in the aerosol.

In some examples, the material30may be or include a substance that modifies different combinations of two or more of these or indeed other properties of the aerosol flow.

It will be understood however that materials other than tobacco may be used to impart different flavors to the aerosol.

If the material30is or includes tobacco, it may be that the aerosol flow draws sufficient nicotine from the material30. Alternatively or additionally, if the material30does not contain any tobacco, the material30may be enhanced with nicotine, for example by coating the material with nicotine. Indeed, even in the case that the material30is or includes tobacco, the material30may be coated or otherwise enhanced with nicotine. As another example, whether or not the material30is or includes tobacco and/or includes nicotine, nicotine may be provided in the aerosol provision material, in this example liquid20. Accordingly, where it is intended that the system100provides nicotine for the user, the nicotine may be provided in the aerosol provision material20, may be obtained from the material30in the case that the material is or includes tobacco, may be provided as a coating or the like on the material30if it is non-tobacco material, may be provided as a coating or the like on the material30if it is tobacco material, or any combination of these. Likewise, flavorings may be added to the material30(whether or not the substance is or includes tobacco) and/or to the aerosol provision material.

In at least some examples a vapor is produced that then at least partly condenses to form an aerosol before exiting the aerosol provision device100through the material chamber430for inhalation by a user (not shown).

In this respect, first it may be noted that, in general, a vapor is a substance in the gas phase at a temperature lower than its critical temperature, which means that for example the vapor can be condensed to a liquid by increasing its pressure without reducing the temperature. On the other hand, in general, an aerosol is a colloid of fine solid particles or liquid droplets, in air or another gas. A “colloid” is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance.

For reasons of convenience, as used herein the term aerosol should be taken as meaning an aerosol, a vapor or a combination of an aerosol and vapor.

Returning toFIG.1, the device100of this example comprises a cartridge200, a body portion300, and a mouthpiece assembly600. The mouthpiece assembly600comprises a first housing500, which is a mouthpiece for being received in the mouth of a user, and a second housing400which is for containing a material30. The first housing500will be referred to herein as a mouthpiece, while the second housing400will be referred to as a container.

The cartridge200is for containing aerosol provision material20, which in this case, as mentioned above, is e-liquid, while the body portion300is for powering and controlling the device100.

The cartridge200comprises a third “upper” housing210and the body portion300comprises a fourth “lower” housing310. The upper housing210is releasably attached to the lower housing310through a first connector arrangement270. The first connector arrangement270is discussed in more detail below.

The cartridge200comprises a liquid reservoir220for containing the e-liquid. The material container400comprises a chamber430for receiving a material30. The material may comprise tobacco, or may not comprise tobacco.

In the example ofFIG.1, the cartridge200also contains a heating arrangement240. The heating arrangement is for heating e-cigarette liquid20from the liquid reservoir220to generate a flow of aerosol (not shown).

The heating arrangement240may comprise at least one heating element (not shown). While the liquid reservoir220is shown above the heating arrangement240inFIG.1, the liquid reservoir220may comprise an annular chamber (not shown) surrounding a central aperture (not shown) through which generated aerosol flows. The heating arrangement240may then comprise at least one wick (not shown) for supplying liquid20from the liquid reservoir220to the at least one heating element.

The heating arrangement240may be referred to as an “atomizer”, and where the liquid cartridge200comprises an atomizer, the cartridge may be referred to as a “cartomizer.” Alternatively to comprising a heating arrangement240, the device may aerosolize liquid via non-heating means, such as via an ultrasonic atomizer.

The material30, such as tobacco, can be heated by heat transfer from the aerosol flow to the material. In use, and particularly in the case that the material is tobacco, the tobacco, or at least the surface of the tobacco, can be heated to a temperature of between around 120° C. to 170° C., for example around 150° C., so as to ensure that an adequate or appropriate amount of the compounds are released from the tobacco. The amount of tobacco present may be for example in the range 100 to 400 mg or so. A most suitable value for the amount of tobacco may be for example in the range 150 to 380 mg which may found to be particularly suitable in some applications such as when the tobacco used in pH treated tobacco. In another example, a most suitable value for the amount of tobacco may be for example in the range 120 to 190 mg which may be found to be particularly suitable when ground tobacco is used. In a typical example, the amount of tobacco that is heated per operation of the system (i.e. per puff) may be in the corresponding range of around 8 to 50 mg.

The liquid20can be a liquid that is volatilizable at reasonable temperatures, such as in the range of 100−300° C. or more particularly around 150-250° C., as that helps to keep down the power consumption of the system100. Suitable materials include those conventionally used in e-cigarette devices, including for example propylene glycol and glycerol (also known as glycerine).

The lower housing310contains a power source320, typically a battery, which is electrically connected to various components of the device100, including the heating arrangement240.

The battery320may be a rechargeable battery or a disposable battery. A controller330, which may comprise a micro-chip and associated circuitry is also provided in the second housing310for controlling the operation of various components of the device100. A user input means340, for example one or more control buttons, may be provided on the exterior of the second housing310for a user to operate the controller330.

Accordingly, in use, a user draws on the mouthpiece500, and air is drawn through one or more air inlets111. The heater arrangement240is powered by the user operating the control button340(or alternatively by a puff detector (not shown), as is known per se) and liquid20drawn from the liquid reservoir220is heated by the heater arrangement240to volatilize the liquid20to generate aerosol which mixes with air flowing from the air inlet111to produce a flow of aerosol. The flow of aerosol is drawn through the material30in the chamber430and then out of the device100through an aperture590in the mouthpiece500for inhalation by the user. As the aerosol flow passes through the material30, one or more components of the material30become entrained in the aerosol flow which may alter, or add to, a property of the aerosol, such as its taste.

The upper housing210has a distal end, or base end,260and a proximal end, or mouth end,250. As mentioned above, the cartridge200comprises the liquid reservoir220which may take various different forms. In one example, the liquid reservoir220is in the form of an annular chamber which extends axially in the first housing210between the proximal end250and the base end260. The distal end260of the cartridge200comprises a first connector arrangement270for releasably attaching the cartridge housing210to the body portion housing310. At a proximal end, or mouth end,250of the cartridge200, the cartridge comprises a second connector arrangement280which releasably connects the cartridge200to the material container400by releasably connecting the cartridge housing210to a material container housing410. The first connector arrangement270and second connector arrangement280will be discussed in more detail below.

In some examples, it may be that the user only needs to top up or replace the material30from time to time, with sufficient liquid20being provided for several uses. In the example ofFIG.1, the cartridge200is releasably attached to the body portion300, and once the liquid20has been consumed, the user disposes of the cartridge200and provides a new cartridge. In other examples, the cartridge200is not designed to be disposable and instead the user only needs to top up or replace the liquid20from time to time. In other examples, the cartridge200and the device body portion300are integrated in a single device and are not arranged to be detachable from each other. In such examples, the device may comprise a replaceable atomizer or replaceable heating means for producing aerosol from the aerosolizable substance.

The mouthpiece500in the example ofFIG.1is shown connected to the material container400by a first attachment580to form a mouthpiece assembly600. The first attachment580may be a releasable attachment, or alternatively, the mouthpiece500and the container400may be attached non-releasably, for example by ultrasonic welding or by an adhesive. Examples of the mouthpiece assembly will be discussed below with reference toFIGS.4aand4b,FIGS.6aand6bandFIG.7.

Referring now toFIG.2, a perspective view of the example aerosol provision device100ofFIG.1is shown. The aerosol provision device comprises the body portion300, the e-liquid cartridge200, and the mouthpiece assembly600comprising a material container400. In this example, the material container400is contains tobacco, but a non-tobacco material, such as any of the materials listed above, may additionally or alternatively be contained within the chamber430of the container400.

First Connector Arrangement

The cartridge200in this example comprises a first connector arrangement270for releasably attaching the cartridge200to the body portion300. The first connector arrangement270may be configured in a locked state, wherein it is not possible for a user to detach the cartridge200from the device body100, or the first connector arrangement may be configured in an unlocked state, wherein a user can detach the cartridge200from the device body by pulling the cartridge200and body portion300apart. When the first connector arrangement270is configured in the locked state the cartridge and body portion may not be separated by pulling. The first connector arrangement270can be configured in the unlocked configuration while the cartridge remains stationary with respect to the body portion. That is, the cartridge does not have to be rotated or otherwise moved to unlock the first connector arrangement270.

For example, the first connector arrangement270may comprise a first element207on the cartridge200which interacts with a corresponding second element (not shown) on the body portion300when the first connector arrangement is in the locked configuration. The first connector arrangement270can be released by moving the first element207with respect to the second element while the cartridge200remains stationary with respect to the body portion300. Here, it may be the first element207which is moved while the second element (not shown) remains stationary with respect to the body portion300, it may be the second element which is moved while the first element remains stationary, or both the first and second elements may be moved with respect to the body portion.

In the example ofFIG.2,FIG.3andFIG.5, the first connector arrangement270is a clip. To remove the cartridge200from the body portion300the clip270is configured in the unlocked configuration by moving the first element, a tab207, with respect to a second element, a detent (not shown) on the body portion while the cartridge200remains stationary with respect to the body portion300. The cartridge200can then be pulled free of the body portion300.

The first connector arrangement270can thus be rapidly configured from being in the locked configuration to being in the unlocked configuration without having to rotate or otherwise move the cartridge with respect to the device body, such as would be the case where a cartridge is screw-fit to a device body. Additionally, in the examples ofFIGS.2and3, the first connector arrangement270automatically enters the locked configuration when the cartridge200is pushed together with the device body300with their longitudinal axes suitably aligned. That is, the clip207automatically snaps into the locked configuration, providing for the cartridge and device body to be rapidly attached, again not requiring screwing together of any components.

The example first connector arrangement270ofFIG.2,FIG.3andFIG.5has one tab, a first tab207, which interfaces with a respective detent (not shown) in the body portion300. In other examples, the first connector arrangement270may comprise a plurality of tabs and may comprise two, three, four, five or more tabs situated at any point around the circumference of the distal end260of the cartridge. In another advantageous example, the clip270has two tabs which are advantageously situated on opposite sides of the distal end260of the cartridge200. Each tab207may be flexible and may be formed of a flexible plastics material.

The cartridge200in the example ofFIG.2is shaped with a proximal end250having a smaller cross-sectional area than a distal end260.

When the cartridge200and body portion300are attached with the clip270in the locked configuration, the cartridge200makes the necessary electrical connections with the body portion such that power is supplied to the cartridge200. The device100is shown inFIG.2with the clip270in this locked configuration.

In order to release the cartridge200from the body portion300the first connector arrangement270must be configured in an unlocked state. In the example ofFIG.2andFIG.3, to configure the first connector arrangement in an unlocked state the user presses the first tab207radially inwards, towards the longitudinal axis of the device100.

Now with reference toFIG.3(the first connector arrangement ofFIG.5also comprises the same features now to be described), an example first tab207is shown comprising a hooked portion208at the distal end of the first tab207. The first tab207is flexible and is biased to the position in which it is shown. The hooked portion208becomes hooked in a detent (not shown) in the body portion300when in the locked configuration, preventing the cartridge200being pulled free of the body portion300. When a user presses radially inwards on the first tab207the tab flexes radially inwards and frees the hooked portion208from the detent in the body portion300. The clip270thereby enters an unlocked configuration. The user may then detach the cartridge200from the body portion300by pulling the cartridge and the body portion apart while keeping tab207depressed (and thus keeping the first connector arrangement270in the unlocked configuration).

In other examples comprising more than one tab207, each tab may interacts with a respective detent and may be released in the same way as described for the first tab207such that a user must keep all tabs depressed to configure the first connector arrangement270in the unlocked state.

In other examples not shown, the first connector arrangement may comprise a release button which a user presses to configure the first connector arrangement in the unlocked configuration.

Providing a first connector arrangement which is in a locked state by default but which may be unlocked by pressing and detached by pulling, such as in the example ofFIG.2, provides a secure attachment while allowing for a user to quickly and easily detach a cartridge200from the device body300.

Second Connector Arrangement

The cartridge200also comprises a second connector arrangement280, through which the mouthpiece assembly600, comprising material container400, may be attached to the cartridge200. The second connector arrangement280is advantageously an arrangement that allows the mouthpiece assembly600to be push-fit to the cartridge200.

That is, advantageously, as in the examples shown inFIGS.2to7, the second connector arrangement280is a push-fit attachment which allows the user to separate the mouthpiece assembly600from the cartridge200by pulling the two apart. This provides for quick and easy detachment of the mouthpiece assembly600from the device100, for example when the user wishes to replace the material container.

InFIG.2,FIG.3, andFIG.5, examples of the second connector arrangement280are shown, comprising a recess290at the proximal end250of the cartridge200for accommodating a portion of the mouthpiece assembly600. To attach to a mouthpiece assembly600, the container400is inserted into the recess290and a portion of the container400is held in the recess290by friction or snap-fitting.

In advantageous examples the material container400comprises at least one first surface formation208b,208c, on its outer surface which interacts via friction with a corresponding at least one second surface formation208a,208don an inner surface of the recess290.

The at least one first surface formation208b,208con the surface of the container400interacts with the at least one second surface formation208a,208don the inner surface of the recess290to form a substantially airtight seal around the container400when the container400is connected to the cartridge200via the second connector arrangement280. In this way, the second connector arrangement280substantially prevents leakage of aerosol or loss of pressure from the device.

Each of the at least one first surface formation208b,208cmay comprise at least one formation, such as a rib, protruding radially outwards from the surface of the container400, and/or may comprise at least one depression, such as a groove, in the surface of the container400. Similarly, the at least one second formation208a,208don the inner surface of the recess290may comprise at least one formation protruding radially from the inner surface of the recess290and/or at least one depression in the inner surface of the recess290.

In advantageous examples, interaction between the at least one first surface formation208b,208cand the at least one second surface formation208a,208dprovides for the second releasable attachment280to provide for snap-fitting of the container400to the cartridge200. In some examples (not shown), one of the at least one first surface formations may be a surface formation which is biased and which at least partially retracts when the container400is in the process of being connected to the cartridge200and snaps into interaction with a corresponding second surface formation, providing a substantially airtight seal, when the container400is inserted into the recess290.

In other examples, such as the examples shown inFIG.3andFIG.5, the tolerances of the dimensions of the container400; the recess290; and their respective surface formations; may be such that the surface formations need not be biased and the container400is held in place, and a substantially airtight seal made, by interactions between fixed surface formations (first surface formations208b,208cand second surface formations208).

In the example ofFIG.3andFIGS.4aand4b, the first surface formations on the surface of the container400comprise at least one groove208bwhile the at least one second surface formation208aof the recess290comprises at least one circumferential ridge208afor interacting with the at least one groove208bon the surface of the container400. In this example, the groove208bcan have a width of between about 0.15 mm and about 0.17 mm. In the example ofFIG.4aandFIG.4b, the surface of the container400comprises a longitudinal formation208c, which may be a ridge or a groove, for interacting with a corresponding longitudinal formation (208d,FIG.2) on the inner surface of the recess290.

In contrast, in the example ofFIG.5,FIG.6aandFIG.6b, andFIG.7, the first surface formations on the surface of the container400comprise at least one ridge208b,208c, for interacting with at least one groove208a,208din the inner surface of the recess290. The surface formations208a,208b,208cin the example ofFIGS.5to7will be discussed below in more detail.

As best seen inFIG.2, when the first connector arrangement270of the cartridge200is configured in a locked state, wherein the cartridge cannot be separated from the body portion300by pulling unless a user presses the tab207, inadvertent detaching of the cartridge from the device body can be avoided. That is, a user can easily separate the mouthpiece assembly600from the cartridge200by pulling, without separating the cartridge from the device body300. With a device100such as in this example, the material30is often changed more frequently that the liquid20; this arrangement makes replacement of the material30easier and more efficient.

Mouthpiece Assembly

An example of the mouthpiece assembly600will now be described in more detail with reference toFIG.6a,FIG.500detached from the second, material container, housing400to provide a view of the proximal end407of the container400.

The mouthpiece assembly600comprises a material container400and mouthpiece500. As mentioned above, the container400comprises at least one first surface formation208b,208c, in this case a set of first ridges or ribs208b,208con its outer surface for interacting via friction with the cartridge200into which the container400is fit in use.

In the example ofFIG.6a,FIG.6bandFIG.7, first ridges208bextend circumferentially around an outer surface of the container400. The first ridges208b,208c, in this example also comprise one or more circumferential ridges208b. Advantageously the container comprises two or more circumferential ridges208bor three or more circumferential ridges208b. In this example, as seen best inFIG.6b, there are three circumferential ridges208b, with one central circumferential ridge and two peripheral circumferential ridges. In this example, the central circumferential ridge extends further radially from the surface of the container400than the peripheral circumferential ridges extend radially from the surface of the container and the width of the central circumferential ridge can be between about 0.15 mm and about 0.17 mm.

In this example, the second surface formation208a,208don the inner surface of recess290of the cartridge200may comprise at least one circumferential groove (208aFIG.5) with which the first ridges208b,208cinteract. Continuing with the example ofFIG.6a,FIG.6bandFIG.7, at least one of the first surface formations may be a rib208bof flexible and/or compressible material, such as a rubber or a plastics material, for example silicone, which may compress to allow the material container400to be fitted into the recess290and expand to interact with a corresponding groove208ain the surface of recess290, thus holding the container400in place and contributing to forming a substantially airtight seal.

The set of first ridges of the example container400shown inFIG.6a,FIG.6bandFIG.7also comprises at least one longitudinal ridge208cwhich extends along the surface of the container400. InFIGS.4a,4b, it can be seen that the container400in this example comprises a plurality of longitudinal ridges208c. The longitudinal ridges208cmay interact with the inner surface of the recess290and may interact with at least one corresponding longitudinal groove (208d,FIG.2) on the inner surface of the recess290. The longitudinal ridges208con the container400may assist with providing a substantially airtight seal and may additionally assist with achieving correct alignment between the container400and the cartridge200when the container400is being inserted into the recess290. In other examples (not shown), the recess290may comprise a longitudinal ridge while the container400comprises a longitudinal groove.

The container400may comprise any number of ridges or grooves extending in any direction along its surface. In other examples, the container400may not comprise any surface formations and may be push-fit to the cartridge200purely by friction between the surfaces of the container and the recess290in the cartridge200. The surface of the container400may comprise a material with a high coefficient of friction, such as a plastics or rubber material, to assist with friction-fitting. The container400may comprise a plastics material, such as polypropylene.

With reference toFIG.7, the container400is shown to comprise a chamber430containing material30. During manufacture, the container400is formed comprising a chamber430and a material30is then provided in the chamber. The material30is enclosed in the chamber by a first barrier404enclosing the chamber430near the proximal end450and a second barrier405enclosing the chamber430near the distal end460.

The first barrier404and second barrier405comprise a mesh which is porous to the flow of aerosol and which prevents material30, such as tobacco material, from exiting the chamber430. The mesh is formed of a heat-resistant material, and is advantageously a heat-conductive material, such as a metal, since this aids in transferring heat to the material30in order to release more desired compounds from the material. The mesh being porous, allows aerosol to pass into the chamber430from the cartridge200at a distal end460and allows aerosol to pass out at a proximal end450into the inhalation aperture590for inhalation by a user. At the proximal end250, the mesh prevents the material30from passing into the mouthpiece500and being inadvertently inhaled by a user.

In the case that the first barrier404and the second barrier405are both a mesh, the mesh may comprise a plastics material, such as polypropylene, or a metal, such as stainless steel or aluminum, and may comprise, for example, an aluminum foil. In some embodiments, the mesh is a stainless steel mesh. The mesh may have a thickness of between about 0.1 mm and about 1.2 mm and, for example, may have a thickness of around 1.2 mm when mesh comprises a plastics material; or a thickness of about 0.1 mm to about 0.3 mm when the mesh comprises a metal such as stainless steel; or a thickness of about 0.3 mm when the mesh comprises aluminum foil. The mesh is advantageously a mesh with a maximum aperture size which is advantageously smaller than the diameter of the material30to be contained. For example, where the material30is tobacco, the maximum mesh aperture size may be between about 0.2 mm and about 0.7 mm, and the maximum mesh aperture size may be chosen dependent on the type of tobacco used.

During construction, the first, mouthpiece housing500and the second, container, housing400are formed separately. The container400and the mouthpiece500are then attached to form the mouthpiece assembly600.

The mouthpiece500may be formed, for example, from a plastics material, such as polypropylene, by injection molding. The shape of the mouthpiece500in the example ofFIG.7is such that it is flared towards its distal end508. This provides an ergonomic shape for a user's mouth to contact. In this example, at its distal end508the mouthpiece500has a diameter larger than the diameter of the proximal end of the cartridge200. The mouthpiece500is formed such that it is configured to accommodate the material pod housing409. The mouthpiece has an aperture590at its proximal end which may in some examples, such as that ofFIG.4b, comprise longitudinal fins591for channeling the flow of aerosol along the aperture590.

The container400may also be formed from a plastics material by injection molding. The container400may for example be formed of polypropylene or of polyethylene terephthalate (PET). In this example, the proximal end407of the container comprises a step formation corresponding to a complementary shape of the interior surface507of the mouthpiece housing500.

The container400further comprises a protrusion406which extends circumferentially around the surface of the container. This protrusion406is configured to abut with a distal end508of the mouthpiece housing500and further to provide a substantially airtight seal between the mouthpiece assembly600and the cartridge200when the two are fitted together via the second connector arrangement280. The protrusion406may, in some examples such as the example ofFIGS.6aand6b, comprise a plurality of substantially triangular prism portions406aand a plurality of substantially flat portions406bwherein a substantially flat portion406bis located between each triangular prism portion406aand the triangular prism portions406aprotrude a greater distance radially outwards than the flat portions406bprotrude radially outwards. The protrusion406in the example ofFIGS.6aand6balso comprises at least one trapezoidal prism portion406c, which is located adjacent a triangular prism portion406aand is located further towards a proximal end450of the container400. The planes of the non-parallel faces of the trapezoidal prism portion406care aligned along the longitudinal axis of the container400. In attaching the mouthpiece500to the material pod400, a portion of the container housing400is inserted into a recess at the distal end of the mouthpiece housing500. When the container is inserted in this recess, the step formation at the proximal end407of the container400abuts against the interior surface507of the mouthpiece, and the distal end508of the mouthpiece500abuts against the protrusion406.

Advantageously, the container housing400and mouthpiece housing500are attached via ultrasonic welding. The protrusion406then may provide the point of contact for an ultrasonic welding apparatus to attach the container400to the mouthpiece500.

Alternatively, an adhesive at the points of contact (for example 407 and 507, and 406 and 508) may be used to attach the mouthpiece500to the material pod400. In yet other alternatives, the mouthpiece500and container400may be releasably attached, for example via friction-fit or a snap-fit, in which case no adhesive is used.

In some examples the first mesh404, and second mesh405is fitted to both the proximal end450and distal end460of the container400after the container400is formed and after the material30is provided in the chamber430. In other examples, the first mesh404at either the proximal end450or the second mesh405at the distal end460of the container400, advantageously the first mesh404at the proximal end450, is formed integrally with the container400. For example the first mesh404at the proximal end450may be formed during a process of molding the container400and material30may then be provided in the container before being enclosed by a second mesh405at the distal end460. In advantageous examples where the mouthpiece500and container400are joined by ultrasonic welding, the first mesh404is advantageously fitted to the proximal end250of the container400during the ultrasonic welding process.

Providing the container400and the mouthpiece500as a single mouthpiece assembly600provides ergonomic benefits to a user. For example, the user may grip and pull the mouthpiece500in order to remove the assembly600when the material30needs replacing. The user can then replace the assembly600as a whole, avoiding the time-consuming task of removing and replacing a material container which is separate from a mouthpiece. The assembly also ensures that a new mouthpiece is fitted with the same frequency that the material30needs replacing. This provides a hygiene benefit over mouthpieces in other devices which are used for more prolonged periods of time.

The mouthpiece assembly600also has benefits over hybrid devices which have a container which acts as a mouthpiece but which have no separate mouthpiece. Among other advantages, the mouthpiece assembly600provides an ergonomically shaped mouthpiece500and the flared shape reduces contact of the user's mouth with other parts of the device, thereby improving hygiene. Further, the inclusion of the mouthpiece500in addition to a material container400(as opposed to the container400acting as a contact point for a user's mouth) provides a spatial separation of the material pod from the user's mouth, preventing contact of the user with potentially hot material and reducing the likelihood that any of said material is inadvertently inhaled. The mouthpiece aperture590provides a space between the proximal end450of the container400and the proximal end of the mouthpiece aperture590—this space may provide an improvement to the quality of aerosol flow delivered to a user. For example, the provision of this space may provide an improvement in any one of or any combination of the following properties of the aerosol flow delivered to a user: particle size in the aerosol; the degree of condensation of the aerosol from the aerosol flow; and the temperature of the aerosol flow.

As discussed above, the method of manufacturing the mouthpiece assembly600comprises: providing the container400; providing a material30in the container; enclosing the material in the container with a first barrier; providing the mouthpiece500; and attaching the container400to the mouthpiece500. This is a cost-effective process resulting in an ergonomic and convenient product.

It should be noted that a number of other variations and alternatives to the examples described above are possible.

As an example, the material may be omitted from the material chamber, for example at the option of the user. This provides the user with more flexibility over the use of the cartridge as the user can use the cartridge as a classic “e-cigarette” device, only aerosolizing liquid and not having the aerosol pass over or through material, from time to time if they choose.

As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers. They may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie™, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, or powder.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration and example various embodiments in which the claimed invention may be practiced and which provide for a superior system arranged to generate an inhalable medium. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed and otherwise disclosed features. It is to be understood that advantages, embodiments, examples, functions, features, structures and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist in essence of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. The disclosure may include other inventions not presently claimed, but which may be claimed in future.