Field

The present disclosure relates to aerosol delivery systems such as, but not exclusively, nicotine delivery systems including e-cigarettes. More particularly, the present disclosure relates to method of assembling an aerosol delivery system.

Background

Aerosol delivery systems such as electronic cigarettes (e-cigarettes) generally contain an aerosol generating material, such as a chamber of a source solid or liquid, which may contain an active substance and / or a flavour, from which an aerosol or vapour is generated for inhalation by a user, for example through heat vaporisation. Thus, an aerosol delivery system will typically comprise an aerosol generation area containing an aerosol generator, e.g. a heating element, arranged to vaporise or aerosolise a portion of precursor material to generate a vapour or aerosol in the aerosol generation area. As a user inhales on the device and electrical power is supplied to the vaporiser, air is drawn into the device through an inlet hole and along an inlet air channel connecting to the aerosol generation area, where the air mixes with vaporised precursor material to form a condensation aerosol. There is an outlet channel connecting the aerosol generation area to an outlet in the mouthpiece and the air drawn into the aerosol generation area as a user inhales on the mouthpiece continues along the outlet flow path to the mouthpiece outlet, carrying the aerosol with it, for inhalation by the user. Some electronic cigarettes may also include a flavour element in the air flow path through the device to impart additional flavours. Such devices may sometimes be referred to as hybrid devices, and the flavour element may, for example, include a portion of tobacco arranged in the air flow path between the aerosol generation area and the mouthpiece such that aerosol I condensation aerosol drawn through the device passes through the portion of tobacco before exiting the mouthpiece for user inhalation.

It is of interest to develop approaches enabling an aerosol delivery system to be assembled, repaired and/or recycled more readily, to increase production efficiency, improve sustainability and reduce wastage. Various approaches are described herein which seek to help address or mitigate at least some of these issues.

Terminology

Delivery System

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user in use, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosolgenerating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolgenerating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

Combustible Aerosol Provision System

According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosolmodifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

Non-Combustible Aerosol Provision System

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosolgenerating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

Aerosol-Free Delivery System

In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

Active Substance

In some embodiments, the substance to be delivered comprises an active substance. The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.

Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

Flavours

In some embodiments, the substance to be delivered comprises a flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour 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, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

Aerosol-generating material

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

Aerosol-former material

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

Functional material The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

Substrate

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

Consumable

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

Susceptor

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

Aerosol-modifying agent

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosolmodifying agent. The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

Aerosol generator

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosolgenerating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The present disclosure relates to aerosol delivery systems (which may also be referred to as vapour delivery systems) such as nebulisers or e-cigarettes. Throughout the following description the term “e- cigarette” or “electronic cigarette” may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol delivery system I device and electronic aerosol delivery system I device. Furthermore, and as is common in the technical field, the terms "aerosol" and "vapour", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably.

Aerosol delivery systems (e-cigarettes) often, though not always, comprise a modular assembly comprising a reusable device part and a replaceable (disposable/consumable) cartridge part. Often, the replaceable cartridge part will comprise the aerosol generating material and the vaporiser (which may collectively be called a ‘cartomizer’) and the reusable device part will comprise the power supply (e.g. rechargeable power source) and control circuitry. It will be appreciated these different parts may comprise further elements depending on functionality. For example, the reusable device part will often comprise a user interface for receiving user input and displaying operating status characteristics, and the replaceable cartridge device part in some cases comprises a temperature sensor for helping to control temperature. Cartridges are electrically and mechanically coupled to the control unit for use, for example using a screw thread, bayonet, or magnetic coupling with appropriately arranged electrical contacts. When the aerosol generating material in a cartridge is exhausted, or the user wishes to switch to a different cartridge having a different aerosol generating material, the cartridge may be removed from the reusable part and a replacement cartridge attached in its place. Systems and devices conforming to this type of two-part modular configuration may generally be referred to as two-part systems/devices. It is common for electronic cigarettes to have a generally elongate shape. For the sake of providing a concrete example, certain embodiments of the disclosure will be taken to comprise this kind of generally elongate single use disposable system. However, it will be appreciated that the underlying principles described herein may equally be adopted for different configurations, for example two-part systems having a disposable cartridge or modular systems comprising more than two parts, refillable devices, as well as other overall shapes, for example based on so-called box-mod high performance devices that typically have a boxier shape. More generally, it will be appreciated certain embodiments of the disclosure are based on aerosol delivery systems which are operationally configured to provide functionality in accordance with the principles described herein and the constructional aspects of systems configured to provide the functionality in accordance with certain embodiments of the disclosure is not of primary significance.

Brief summary of the invention

The present invention also provides a method of assembling an aerosol delivery system comprising a reservoir housing defining a reservoir having an open end and a sealing component, the method comprising: orientating the reservoir housing to provide the open end as an uppermost side of the reservoir; filling the reservoir housing with a liquid aerosol-generating material via the open end; and inserting the sealing component into the open end, the sealing component forming a seal with a surface of the reservoir housing defining a periphery of the open end, wherein the sealing component is retained in the reservoir housing by an interference fit.

The present invention provides an aerosol delivery system for generating an aerosol from a liquid aerosol generating material, the aerosol delivery system comprising: a reservoir housing defining a reservoir having an open end configured to receive the liquid aerosol-generating material when the reservoir housing is orientated with the open end as an uppermost side of the reservoir; and a sealing component, wherein the sealing component is inserted into the open end, the sealing component forming a seal with a surface of the reservoir housing defining a periphery of the open end, wherein the sealing component is retained in the reservoir housing by an interference fit.

The present invention also provides an aerosol delivery means for generating an aerosol from liquid aerosol generating means, the aerosol delivery means comprising: a reservoir housing means defining a reservoir having an open end configured to receive the liquid aerosol-generating means when the reservoir housing means is orientated with the open end as an uppermost side of the reservoir; and a sealing means, wherein the sealing means is inserted into the open end, the sealing means forming a seal with a surface of the reservoir housing means defining a periphery of the open end, wherein the sealing means is retained in the reservoir housing means by an interference fit.

The present invention further provides additional embodiments as claimed in the dependent claims. Brief description of the figures

Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic cross-section view of an aerosol delivery system in accordance with some embodiments of the disclosure.

Figure 2 , 3 and 4 are schematic cross-sectional views depicting the assembly of sections of an aerosol delivery system 1 in accordance with some embodiments of the disclosure.

Figure 5 is a flow chart of a method for assembling an aerosol delivery system 1 in accordance with some embodiments of the disclosure.

Figure 6 is a further flow chart of a method for assembling an aerosol delivery system 1 in accordance with some embodiments of the disclosure.

Figure 7 is a schematic illustration of the assembly process for an aerosol delivery system 1 in accordance with some embodiments of the disclosure.

Detailed description of the disclosure

Aspects and features of certain examples and embodiments are described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not described in detail in the interest of brevity. It will thus be appreciated that aspects and features of apparatuses and methods discussed herein which are not described in detail may be implemented in accordance with any suitable conventional techniques.

Figure 1 is a cross-sectional view through an example aerosol delivery system 1 in accordance with certain embodiments of the disclosure, providing an introduction to a single-part aerosol delivery systems, the components therein and their functionality.

The aerosol delivery system 1 comprises a reservoir housing 42. Within the reservoir housing 42 is a chamber or reservoir 44 that contains a liquid aerosol-generating material. In the example shown schematically in figure 1 , the reservoir 44 stores the supply of liquid aerosol generating material. In this example, the liquid reservoir 44 has an annular shape with an outer wall and an inner wall that defines part of an airflow path 52 through the aerosol delivery system 1 . Both the inner wall and the outer wall can be defined by the reservoir housing 42 (e.g. they can be formed as a single integrally moulded piece). The reservoir 44 is closed at one end (by an end wall 43) to contain the aerosol generating material, and open at the other end (i.e. the open end 45) to allow filling of the reservoir with the aerosol generating material during assembly, and to allow the liquid aerosol generating material to exit the reservoir. The reservoir 44 defines a cavity or void which is empty prior to filling with liquid aerosol generating material. In particular, the reservoir 44 is not filled with an absorbent material (such as cotton) which is configured to absorb liquid aerosol generating material, and instead (prior to sealing of the open end 45) the liquid aerosol generating material is retained solely by gravity retaining the liquid aerosol generating material reservoir within the end wall 43 and side walls (or equivalent wall arrangement in other examples).

In examples where the reservoir housing 42 defines an annular reservoir 44, then the open end 45 may have a corresponding ring shape (e.g. an circular or elliptical ring shape) defining a annular plane at the end of the annular reservoir 44 (i.e. between an inner all and an outer wall of the reservoir).

The assembly and configuration of an aerosol delivery system 1 in accordance with the principles set out below allows for a faster, more convenient and less damaging assembly process, in particular in relation to the filling of the system with liquid aerosol generating material. Moreover, the process is reversible and thus increases recyclability, which is particularly important for disposable devices which are normally single-use and discarded as complete units (and so not recycled).

In the example of figure 1 , the reservoir housing 42 comprises an engagement portion 60. The engagement portion 60 extends from, or as part of, the outer wall of the reservoir 44 beyond the open end 45 of the reservoir housing in 42. The engagement portion 60 may be integrally moulded as a single piece with the remainder of the reservoir housing 42.

In the example of figure 1 , the reservoir housing 44 further defines the mouthpiece of the aerosol delivery system 1 . The reservoir housing 44 comprises a mouthpiece outlet 50 in fluid connection with the airflow path 52 (e.g. at the end of the airflow path 52, at an end of the aerosol delivery system 1 , as shown). The reservoir housing 44 may also be shaped to facilitate a user’s mouth. For example, by contouring or tapering an outer surface to accommodate a user making a seal around the mouthpiece outlet 50 with their lips.

The reservoir housing 42 may be formed in accordance with conventional techniques, for example it may comprise a plastics material and be integrally moulded as a single piece so as to form the reservoir 44, the portion of the airflow path 52, the mouthpiece outlet 50, the engagement portion 60 and the external shape defining the mouthpiece. In this example, the reservoir housing 42 has a length of around 4 cm and a diameter of around 1 .5 cm, and is generally circular or elliptical about a longitudinal axis. However, it will be appreciated the specific geometry, and more generally the overall shapes and materials used, may be different in different implementations. The aerosol delivery system 1 further comprises an aerosol generator 48 located towards an end of the reservoir 44 opposite to the mouthpiece outlet 50. The aerosol generator 48 may be provided in an aerosol generator housing 40 which retains the aerosol generator 48 within the aerosol delivery system 1 .

For example, in some examples, the aerosol generator 48 (e.g. a heater, which may be in the form of a wick and coil arrangement as shown, or which may be formed from a sintered metal fibre material or other porous conducting material, or any suitable alternative aerosol generator) is brought into proximity with the liquid aerosol generating material in reservoir 44 when the aerosol generator housing 40 is engaged with the reservoir housing 42.

In some example, the sealing component (or seal component) is the aerosol generator housing 40 which is configured to seal the open end 45 of the reservoir housing 42 by interacting with or otherwise closing off the open end 45. For example, at least a portion of the aerosol generator housing 40 may be inserted into the open end 45, such that the inserted portion of the aerosol generator housing 40 forms a seal with a periphery of the open end 45 of the reservoir housing 42. By periphery, it is meant the inner edge or surface, or boundary defining the extent or plane of the open end.

In some examples such as those in accordance with figure 1 , the reservoir 44 is an annular space. In these examples, the open end comprises an annular plane between an inner surface defining an inner periphery of the open end and an outer surface defining an outer periphery of the open end. In these examples the sealing component forms a seal with both the inner surface (defining the inner periphery) and the outer surface (defining the outer periphery).

By engaged it is meant that the aerosol generator housing 40 is connected, attached or otherwise held in a position relative to the reservoir housing 42. In some examples, the aerosol generator housing 40 may be inserted into the engagement portion 60 of the reservoir housing 42, such that the engagement portion 60 surrounds the aerosol generator housing 40, as shown in figure 1 . The aerosol generator housing 40 is retained in the reservoir housing by an interference fit. As will be discussed in more detail below, the aerosol generator housing 40 may have outer dimensions selected relative to the inner dimensions of the engagement portion 60 that ensure an interference fit between the aerosol generator housing 40 and the reservoir housing 42. Advantageously, this prevents the need for fasteners (e.g. screws) or adhesive, which may make separating different components upon disposal easier, which may consequently aid recycling.

In some examples, the interference fit between the aerosol generator housing 40 and the reservoir housing 42 is a tight fit in that it requires a substantial force in order to separate the aerosol generator housing 40 from the reservoir housing 42. In particular, the dimensions of the aerosol generator housing 40 and the reservoir housing 42, and also the materials of the aerosol generator housing 40 and the reservoir housing 42, may be selected so that a force of between 10-35 kgf is required in order to separate the aerosol generator housing 40 from the reservoir housing 42. By a force of between 10 - 35 kgf, it is meant a force equivalent to a force applied by gravity to a mass of 10 - 35 kg. In some examples a force of between 20 to 30 kgf is required in order to separate the aerosol generator housing 40 from the reservoir housing 42. As such the reservoir housing and the aerosol generator housing 40 (which provides a sealing component in accordance with some embodiments) are joined by an interference fit requiring a force of around 20-30 kg to overcome. This may ensure that a user does not inadvertently detach the aerosol generator housing 40 from the reservoir housing 42 in use, thereby potentially exposing the user to the liquid aerosol generating material, whilst still allowing separation of the aerosol generator housing 40 from the reservoir housing 42 upon disposal.

A suitable interference fit can be provided by configuring the components involved in the connection to control characteristics generating the interference force such as the size and length of the region in which the force is generated (i.e. the interference region). In some examples, the interference region may be only a portion of the overlapping region (i.e. where the walls of each are adjacent to each other)between the connected components. For example, when the aerosol generator housing 40 and the reservoir housing 42 are joined the interference fit may be generated by only a portion of overlapping region between the aerosol generator housing 40 and the engagement portion 60. For example the interference region may be formed by a band or distinct regions comprising a portion of the overlapping region in which the separation of the aerosol generator housing 40 and the engagement portion 60 is reduced.

For example, the overlapping region may have a length of around 10 to 20mm, whereas the interference region may have a length of between 3 and 8 mm, and preferably around 5 mm. In the interference region the separation of the aerosol generator housing 40 and the engagement portion 60 may be between 0.03 and 0.1 mm, and preferably around 0.05 mm. The separation of the aerosol generator housing 40 and the engagement portion 60 outside of the interference region is larger than inside the interference region. In some examples, the overlapping region that does not form part of the interference region may act to guide the connection of the two components. For example the surfaces may be chamfered outside of the interference region in orderto direct the connection towards the narrowest separation, or guiding structures may be provided in the surfaces of one or both of the aerosol generator housing 40 and the engagement portion 60.

Furthermore, the aerosol generator housing 40 and the engagement portion 60 may be configured to balance the interference fit between different sides of the connection. In some examples the interference fit may be arranged by symmetrically arranged lines or regions of interference. For example, the lines or regions may be symmetric about a longitudinal axis of the aerosol delivery system 1 or the connection. It will be appreciated that in other examples, not shown, different means of attachment may be used to engage the aerosol generator housing 40 and the reservoir housing 42. For example, adhesive, fasteners, screw threads, and clips.

In example of figure 1 , a wick 46 in contact with the aerosol generator 48 extends transversely across the airflow path 52 with its ends extending into liquid conduits 47 which are in fluid connection with the reservoir 44. In particular, the liquid conduits 47 define a fluid pathway in the aerosol generator housing 40 having first openings which aligns with the open end 45 of the reservoir housing 42 when the aerosol generator housing 40 is engaged with the reservoir housing 42, and second openings through which the ends of the wick 46 extend. The second openings of the liquid conduits 47 are sized to broadly match the dimensions of the wick 46 to provide a reasonable seal against leakage from the liquid reservoir 44 into the airflow path 52 without unduly compressing the wick 46, which may be detrimental to its fluid transfer performance. In these examples the first opening of the liquid conduit 47 is an opening configured to allow liquid aerosol-generating material to flow from the reservoir 44 to the aerosol generator 48.

The wick 46 and aerosol generator 48 are arranged in the airflow path 52 such that a region of the airflow path 52 around the wick 46 and heater 48 in effect defines a vaporisation region for the aerosol delivery system 1 . Aerosol generating material in the reservoir 44 infiltrates the wick 46 through the ends of the wick extending into the reservoir 44 and is drawn along the wick by surface tension I capillary action (i.e. wicking). The aerosol generator 48 in this example comprises an electrically resistive wire coiled around the wick 46. In the example of figure 1 , the heater 48 comprises a nickel chrome alloy (Cr20Ni80) wire and the wick 46 comprises a glass fibre bundle, but it will be appreciated the specific aerosol generator configuration is not significant to the principles described herein. In use, electrical power may be supplied to the aerosol generator 48 to vaporise an amount of aerosol generating material (aerosol generating material) drawn to the vicinity of the aerosol generator 48 by the wick 46. Vaporised aerosol generating material may then become entrained in air drawn along the airflow path 52 from the vaporisation region towards the mouthpiece outlet 50 for user inhalation.

As noted above, the rate at which aerosol generating material is vaporised by the aerosol generator 48 will depend on the amount (level) of power supplied to the aerosol generator 48. Thus electrical power can be applied to the aerosol generator 48 to selectively generate aerosol from the aerosol generating material in the reservoir 44, and furthermore, the rate of aerosol generation can be changed by changing the amount of power supplied to the aerosol generator 48, for example through pulse width and/or frequency modulation techniques.

The aerosol delivery system 1 further comprises an housing part 12, a power source 26 (for example a battery) for providing operating power for the electronic cigarette, control circuitry I controller 22 for controlling and monitoring the operation of the electronic cigarette, a first user input button 14, a second user input button 16, a visual display 24, and an airflow sensor 30. The housing part 12 is configured to contain (e.g. protect or house) the power source 26 and the control circuitry I controller 22 within the aerosol delivery system 1 , as well as other components such as the airflow sensor 30. The housing part 12 may also be configured to position the first user input button 14, the second user input button 16, and visual display 24, if present. The housing part 12 comprises an opening that defines an air inlet 28 for the aerosol delivery system 1 . The housing part 12 also defines a portion of the airflow path 52 in connection with the air inlet 28.

While not shown a bracket may also be provided in the housing part (i.e. contained within) which is configured to retain the power source and control circuitry within the aerosol delivery system (i.e. the power source and control circuitry may attach to the bracket). Such a bracket may be a substantially tubular or cylindrical mounting bracket which is configured to receive a power supply 26. For example the power supply 26 may have a body with a pair of electrodes extending therefrom. The bracket may comprise a first (upper) portion having a pair of apertures configured to receive the pair of electrodes and present them for connection at an end of the bracket 72, and a second portion having a cavity configured to receive the power supply body. The bracket may therefore facilitate the retention of the power supply and connection of the power supply with components such as the control circuitry 22 and aerosol generator 48.

The housing part 12 is configured to engage with the reservoir housing 42 and I or the aerosol generator housing 40 or an intermediate component between the housing part 12 and the reservoir housing 42. The housing part 12 may be formed, for example, from a plastics or metallic material and in this example has a circular or elliptical cross section generally conforming to the shape and size of the reservoir housing 42 so as to provide a smooth transition. In this example, the housing part 12 has a length of around 8 cm so the overall length of the aerosol delivery system 1 when the housing part 12 and the reservoir housing 42 are engaged is around 12 cm. However, and as already noted, it will be appreciated that the overall shape and scale of the aerosol delivery system 1 implementing an embodiment of the disclosure is not significant to the principles described herein.

The air flow path 52 of the aerosol delivery device 1 extends from the air inlet 28 to the mouthpiece outlet 50. Thus, when a user inhales on the mouthpiece outlet 50, air is drawn into the airflow path 52 through the air inlet 28, is drawn along a first part of the airflow path 52 to the aerosol generation area in the vicinity of the aerosol generator 48 (where vaporised aerosol generating material becomes entrained in the air flow), and is finally drawn along a second part of the airflow path 52 towards and out through the mouthpiece outlet 50 for user inhalation. As noted previously, the aerosol delivery device 1 may have a generally elongated shape. In the example of figure 1 , the mouthpiece outlet 50 is provided at one end, whilst the air inlet 28 is provided at the opposing end (i.e. the base of the device). In view of the airflow direction in use, the end of the elongate aerosol delivery device 1 having the mouthpiece outlet 50 can be consider the downstream end, and the opposing end can be considered the upstream end. Even in other examples where the air inlet 28 is not provided at an opposite end to the mouthpiece end 50, but is instead provided on a side of the aerosol delivery device 1 , the end opposing the mouthpiece outlet 50 can be considered the upstream end due to the general direction of airflow towards the mouthpiece outlet 50.

The power source or supply 26 in this example is non-rechargeable and may be of a conventional type, for example of the kind normally used in electronic cigarettes and other applications requiring provision of relatively high currents over relatively short periods.

In some examples, first and/or second user input buttons 14, 16 may be provided. First and/or second user input buttons 14, 16 may be conventional mechanical buttons, for example comprising a spring mounted component which may be pressed by a user to establish an electrical contact. In this regard, the input buttons may be considered input devices for detecting user input and the specific manner in which the buttons are implemented is not significant. The buttons may be assigned to functions such as switching the aerosol delivery system 1 on and off, and adjusting user settings such as a power to be supplied from the power source 26 to the aerosol generator 48. However, the inclusion of user input buttons is optional, and in some embodiments buttons may not be included.

In some examples, a display 24 may be provided to give a user with a visual indication of various characteristics associated with the aerosol delivery system, for example current power setting information, remaining power source power, and so forth. The display may be implemented in various ways. In this example the display 24 comprises a conventional pixilated LCD screen that may be driven to display the desired information in accordance with conventional techniques. In other implementations, the display may comprise one or more discrete indicators, for example LEDs, that are arranged to display the desired information, for example through particular colours and I or flash sequences. More generally, the manner in which the display 24 is provided and information is displayed to a user using the display is not significant to the principles described herein. For example, some embodiments may not include a visual display and/or may include other means for providing a user with information relating to operating characteristics of the aerosol delivery system, for example using audio signalling, or may not include any means for providing a user with information relating to operating characteristics of the aerosol delivery system.

A controller 22 is suitably configured I programmed to control the operation of the aerosol delivery system 1 to provide functionality in accordance with embodiments of the disclosure as described further herein, as well as for providing conventional operating functions of the aerosol delivery system 1 in line with the established techniques for controlling such devices. The controller (processor circuitry) 22 may be considered to logically comprise various sub-units I circuitry elements associated with different aspects of the operation of the aerosol delivery system 1 . In this example the controller 22 comprises power supply control circuitry for controlling the supply of power from the power source 26 to the aerosol generator 48 in response to user input, as well as other functional units I circuitry associated functionality in accordance with the principles described herein and conventional operating aspects of electronic cigarettes, such as display driving circuitry and user input detection circuitry. It will be appreciated that the functionality of the controller 22 can be provided in various different ways, for example using one or more suitably programmed programmable computer(s) and I or one or more suitably configured application-specific integrated circuit(s) I circuitry I chip(s) I chipset(s) configured to provide the desired functionality.

The functionality of the controller 22 is described further herein. For example, the controller 22 may comprise an application specific integrated circuit (ASIC) or microcontroller, for controlling the aerosol delivery device. The microcontroller or ASIC may include a CPU or micro-processor. The operations of a CPU and other electronic components are generally controlled at least in part by software programs running on the CPU (or other component). Such software programs may be stored in nonvolatile memory, such as ROM, which can be integrated into the microcontroller itself, or provided as a separate component. The CPU may access the ROM to load and execute individual software programs as and when required.

An airflow sensor 30 may be provided which is electrically connected to the controller 22. In most embodiments, the airflow sensor 30 comprises a so-called “puff sensor”, in that the airflow sensor 30 is used to detect when a user is puffing on the device. In some embodiments, the airflow sensor 30 comprises a switch in an electrical path providing electrical power from the power source 26 to the aerosol generator 48. In such embodiments, the airflow sensor 30 generally comprises a pressure sensor configured to close the switch when subjected to a particular range of pressures, enabling current to flow from the power source 26 to the aerosol generator 48 once the pressure in the vicinity of the airflow sensor 30 drops below a threshold value. The threshold value can be set to a value determined by experimentation to correspond to a characteristic value associated with the initiation of a user puff. In a buttonless aerosol delivery system, the airflow sensor 30 may provide the sole user input mechanism for the user to provide input to the aerosol delivery system 1 to enable current to flow from the power source 26 to the aerosol generator 48.

In other embodiments, the airflow sensor 30 is connected to the controller 22, and the controller distributes electrical power from the power source 26 to the aerosol generator 48 in dependence of a signal received from the airflow sensor 30 by the controller 22. The specific manner in which the signal output from the airflow sensor 30 (which may comprise a measure of capacitance, resistance or other characteristic of the airflow sensor, made by the controller 22) is used by the controller 22 to control the supply of power from the power source 26 to the aerosol generator 48 can be carried out in accordance with any approach known to the skilled person.

The airflow sensor 30 may comprise any sensor which is configured to determine a characteristic of airflow in an airflow path 52 disposed between air inlet 28 and mouthpiece opening 50, for example a pressure sensor or transducer (for example a membrane or solid-state pressure sensor), a combined temperature and pressure sensor, or a microphone (for example an electret-type microphone), which is sensitive to changes in air pressure, including acoustical signals. The airflow sensor 30 may be situated within a sensor cavity or chamber, which comprises an interior space defined by one or more chamber walls. Such a sensor cavity comprises a region internal to one or more chamber walls in which an airflow sensor 30 can be fully or partially situated. A deformable membrane may be disposed across an opening communicating between the sensor cavity containing the sensor 30, and a portion of the airflow path 52 disposed between air inlet 28 and mouthpiece opening 50. The deformable membrane covers the opening, and is attached to one or more of the chamber walls according to approaches described further herein.

The aerosol delivery system 1 may further comprise communication circuitry configured to enable a connection to be established with one or more further electronic devices (for example, a storage I charging case, and / or a refill I charging dock) to enable data transfer between the aerosol delivery system 1 and further electronic device(s). In some embodiments, the communication circuitry is integrated into controller 22, and in other embodiments it is implemented separately (comprising, for example, separate application-specific integrated circuit(s) I circuitry I chip(s) I chipset(s)). For example, the communication circuitry may comprise a separate module to the controller 22 which, while connected to controller 22, provides dedicated data transfer functionality for the aerosol delivery device. In some embodiments, the communication circuitry is configured to support communication between the aerosol delivery system 1 and one or more further electronic devices over a wireless interface.

The communication circuitry may be configured to support wireless communications between the aerosol delivery system 1 and other electronic devices such as a case, a dock, a computing device such as a smartphone or PC, a base station supporting cellular communications, a relay node providing an onward connection to a base station, a wearable device, or any other portable or fixed device which supports wireless communications. Wireless communications between the aerosol delivery system 1 and a further electronic device may be configured according to data transfer protocols such as Bluetooth®, ZigBee, WiFi®, Wifi Direct, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or generally any other wireless, and/or wired, network protocol or interface.

The communication circuitry may comprise any suitable interface for wired data connection, such as USB-C, micro-USB or Thunderbolt interfaces, and may comprise pin or contact pad arrangements configured to engage cooperating pins or contact pads on a dock, case, cable, or other external device which can be connected to the aerosol delivery system 1 . More generally, the presence of communication circuitry, or the manner in which the communication circuitry is provided, is not significant to the principles described herein.

As such, the example aerosol delivery system 1 depicted in figure 1 can provides an introduction to a single-part aerosol delivery systems, the components therein and their functionality. The aerosol delivery system 1 comprises a reservoir housing 42 defining a reservoir 44 containing liquid aerosol- generating material, an aerosol generator 48, a power source 26, control circuitry 22 and an air pathway 52 extending between an air inlet 28 and a mouthpiece outlet 52 via a vaporisation region associated with the aerosol generator 48. Such an aerosol delivery system 1 may be considered disposable such that when the aerosol delivery system 1 is exhausted, the user disposes of the aerosol delivery system 1 (e.g. by deconstructing the aerosol delivery system 1 into component parts for recycling), rather than attempting to refill or reuse the aerosol delivery system 1 .

It will be appreciated that aspects of the present invention may be applicable to aerosol delivery systems having two main parts, namely a reusable part and a replaceable / disposable consumable cartridge part, with some of the components above being provided in the reusable part (e.g. power source 26 and circuitry 22) and some of the components above being provided in the cartridge part (e.g. the reservoir 44). In normal use, the reusable part and the cartridge part are releasably coupled together at an interface. The interface provides a structural, electrical and airflow path connection between the two parts and may be established in accordance with conventional techniques, for example based around a screw thread, magnetic or bayonet fixing with appropriately arranged electrical contacts and openings for establishing the electrical connection and airflow path between the two parts as appropriate. The specific manner by which the cartridge part mechanically mounts to the reusable part is not significant to the principles described herein, but for the sake of a concrete example is assumed here to comprise a magnetic coupling. It will also be appreciated the interface in some implementations may not support an electrical and I or airflow path connection between the respective parts. For example, in some implementations an aerosol generator may be provided in the reusable part rather than in the cartridge part, or the transfer of electrical power from the reusable part to the cartridge part may be wireless (e.g. based on electromagnetic induction), so that an electrical connection between the reusable part and the cartridge part is not needed. Furthermore, in some implementations the airflow through the electronic cigarette might not go through the reusable part, so that an airflow path connection between the reusable part and the cartridge part is not needed. In some instances, a portion of the airflow path may be defined at the interface between portions of the reusable part and cartridge part when these are coupled together for use.

Figure 2 is a cross-sectional view through a section of an aerosol delivery system 1 in accordance with some embodiments of the disclosure. In comparison to the aerosol delivery system 1 of figure 1 , the aerosol delivery system 1 of figure 2 depicts an example of components involved in the engagement between the reservoir housing 42 and the aerosol generator housing 40, and the resultant sealing of the open end 45 of the reservoir housing 42. All other components are substantially as described in relation to figure 1 .

In line with figure 1 , the reservoir housing 42 of figure 2 comprises an engagement portion 60. The engagement portion 60 extends from, or as part of, the outer wall of the reservoir 44 beyond the open end 45 of the reservoir housing in 42. Liquid aerosol-generating material 70 may be provided in the reservoir housing 42. In examples, the reservoir housing is orientated during filling to provide the open end 45 as an uppermost side of the reservoir 44. When the reservoir housing 42 is orientated so that the open end 45 is (substantially) at or towards an upper side (i.e. positioned as the uppermost side), then the liquid aerosol-generating material 70 is retained in the reservoir housing 42 by gravity. By an upper side it is meant that the reservoir housing 42 is arranged so that the open end is vertically higher (with respect to gravity) than the side walls of the reservoir housing 42 and the base 43 which contain the liquid in use. It will be appreciated that the engagement portion 60 extends above the open end 45, with respect to gravity, and is therefore higher than the open end 45. Furthermore, in some examples, the reservoir 44 is provided by a void or cavity which is empty of any absorbent material (e.g. cotton), which would act to absorb the liquid aerosol-generating material 70. Hence, in these examples, while the reservoir housing 42 is maintained in this orientation with the open face as the uppermost side, the liquid will be unable to spill from the reservoir housing 42.

In examples in accordance with figure 2, the aerosol generator housing 40 is a sealing component comprising a first seal portion 62. The first seal part 62 is inserted into the open end 45 of the reservoir housing 42 as shown by arrow A of figure 2. In the example, the aerosol generator housing 40 is engaged with the engagement portion 60 of the reservoir housing 42 with the first seal part 62 at a lower side, so that the first seal part 62 is inserted into the engagement portion 60 first. In the example, the aerosol generator housing 40 is configured to be received entirely within the engagement portion 60 (i.e. the length of the aerosol generator housing 40 in the direction aligning with arrow A, is less than the length of the engagement portion 60 in this direction).

The first seal part 62 is further inserted into the open end 45 and contacts (e.g. engages) a periphery of the open end 45 (e.g. the ring shaped inner and outer walls of the open end 45 of the annular reservoir 44 of figure 2). The contact or engagement of the first seal part 62 with the open end 45 acts to seal the open end 45 to prevent the liquid aerosol generating material 70 from leaving the reservoir housing by the periphery of the open end 45 (e.g. the flow of liquid along the walls of the reservoir housing is prevented). This form of engagement may be termed an interference fit because the force resulting from the interaction or engagement of the reservoir housing 42 and the first seal part 62 retains the two components together (i.e. their interference with each other produces a retaining force).

The first seal part 62 may also engage with part of the engagement portion 60 of the reservoir housing 42 (i.e. above the open end 45). This may aid with the retention of the aerosol generator housing 40 within the engagement portion 60, and also aid the prevention of the leakage of liquid via the outer wall of the reservoir housing 42.

In some examples, the first seal part 62 may be formed from a silicone material or similar elastically deformable material (e.g. a rubber material). The first seal part 62 is compressed at least partly upon insertion into the reservoir housing 42 such that the first seal part 62 exerts a force retaining the first seal part 62 against the reservoir housing 42, the force being generated by the elastic nature of the first seal part 62 (i.e. upon compression the first seal part 62 produces a force biasing the first seal part 62 towards its initial non-compressed configuration). In some examples, the engagement of the reservoir housing and the aerosol generator housing 40 via the first seal part 62 (i.e. the interference fit) requires a force of between 10-35 kgf to overcome, and preferably a force in the range of between 20 and 30 kgf to overcome. By a force of a force of between 10-35 kgf, it is meant a force equivalent to the force applied by gravity to a mass of 10 - 35 kg.

The first seal part 62 may comprise one or more protrusions 64 which act to enhance the engagement of the first seal part 62 with the reservoir housing 42. For example, the protrusions 64 are able to deform more readily upon insertion into the reservoir housing 42, whilst still providing a suitable retaining force after insertion. In some examples, the protrusions 64 may comprise a ring or ridge which extends around a circumference of the first seal part 62. In some examples, the protrusions 64 may comprise (or consist of) one or more O-rings which are provided around the circumference of the aerosol generator housing 40 before the aerosol generator housing 40 is inserted into the reservoir housing 42. Alternatively, the protrusion 64 may be features such as ridges that are integrally formed in a surface of the first seal part 62.

In some examples the engagement of the reservoir housing 42 with the aerosol generator housing 40 may also act to retain the first seal part 62 in position relative to the aerosol generator housing 40. In some examples, the first seal part 62 may be stretched over a part of aerosol generator housing 40, thereby producing a retention force which acts to restore the first seal part 62 to its original configuration (e.g. the first seal part may be stretched such that a first part is on one side of the walls providing a liquid conduit 47, and a second part is on a different side of the walls providing a liquid conduit 47). In other examples, different means of attachment may be used such as adhesive and /or the interaction with the reservoir housing 42 may be sufficient to retain the first seal part 62 in position relative to the aerosol generator housing 40.

Where the first seal part 62 overlaps the liquid conduits 47 of the aerosol generator housing 40, the first seal part 62 comprises corresponding openings 66, each of which is aligned with a corresponding liquid conduits 47 (it will be appreciated that in systems where there is a single liquid conduit 47, then there will also be a single corresponding opening 66). Each opening 66 enable liquid aerosol generating material 70 to enter the liquid conduit 47. In other words, an opening 66 is configured to allow liquid aerosol-generating material 70 to flow from the reservoir 44 to an aerosol generator 48.

The aerosol generator housing 40 may further comprise a second seal part 68. The second seal part 68 may be formed from a similar material, such as silicone, to the first seal part 62. The second seal part 68 acts to engage the aerosol generator housing 40 with the engagement portion 60, and also provides a barrier inhibiting the movement of liquid along the engagement portion 60, thereby reducing the potential for leakage. The second seal part 68 may comprise one or more protrusions 69. The protrusions 69 are able to deform more readily upon insertion into the reservoir housing 42, whilst still providing a suitable retaining force after insertion. In line with the protrusions 64 of the first seal part 62, the protrusions 69 may, for example, be provided by an integrally formed ridge, or by a separate feature such as an O-ring.

The second seal part 68 may also act to provide suitable clamping of the wick 56 in position against the remainder of the aerosol generator housing 40. For example, as stated above the aerosol generator housing 40 comprises liquid conduits 47 having second openings through which the ends of the wick 46 extend. The second openings of the liquid conduits 47 are sized to broadly match the dimensions of the wick 46 to provide a reasonable seal against leakage from the liquid reservoir 44 into the airflow path 52 without unduly compressing the wick 46, which may be detrimental to its fluid transfer performance. The second seal part 68 may form a part of the second opening in which the wick is retained. For example, the second seal part 68 may comprise a semi-circular cut-out which aligns with an opposing semi-circular cut out in the remainder of the aerosol generator housing 40, the two cut outs forming the second opening of a liquid conduit 47. The use of the second seal part 68 in this example, aids the sealing of the wick whilst avoiding undue compression of the wick 46. For example, because the wick and the second seal part may both be formed from elastic materials, an equilibrium is established wherein both components are compressed to some extent such that the forces balance (the materials can then be selected to ensure that the wick is not overly compressed).

While not shown, a portion of the housing part 12 may subsequently be inserted and I or connected to the engagement portion 60. For example, the housing part 12 and the engagement feature 60 may include corresponding attachment features such as clips or latches and corresponding recesses. The attachment features retain the housing part 12 and engagement feature 60 in position relative to each other. The attachment of the housing part 12 to the engagement feature 60 may also fully contain the aerosol generator housing 40 within the combined housing of the housing part 12 and the engagement feature 60, thereby holding the aerosol generator housing 40 within the aerosol delivery system 1 . As such the system 1 can thus readily be disassembled, without tools, by disengaging the housing part 12 from the engagement feature 60, which removes all of the components contained within the housing part 12, and extracting the aerosol generator housing 40 from within the reservoir housing 42.

Figure 3 is a cross-sectional view through a section of an aerosol delivery system 1 in accordance with some embodiments of the disclosure. Figure 3 depicts a further example of components involved in the engagement between the reservoir housing 42 and the aerosol generator housing 40. The aerosol delivery system 1 of figure 3 differs from that described in relation to figure 2, in that sealing component is a first seal part 62 which is separate from the aerosol generator housing 40, at least prior to insertion of the sealing component into the reservoir housing 42. All other components are substantially as described in relation to figure 1 and figure 2. In examples in accordance with figure 3, at least the first seal part 62 is configured to be inserted into the reservoir housing 42 independently of the aerosol generator housing 40. As such, the first seal part 62 may be considered a separate component to the aerosol generator housing 40. In these examples, the first seal part is inserted into the reservoir housing 42 so as to seal the open end 45 of the reservoir housing 42. For example, substantially as described in relation to figure 2, the first seal part 62 is inserted into the open end 45 (as shown by arrow A) and forms an interference fit with the walls defining the open end 45. The resultant force arising due to the interference fit acts to retain the first seal part 62 in place with respect to the reservoir housing 42. In some examples the reservoir housing 42 and the first seal part 62 are joined by an interference fit requiring a force of between 10- 35 kgf to overcome, and preferably between 20 and 30 kgf to overcome. The engagement of the first seal part 62 with the periphery of the open end 45 effectively seals the open end by preventing liquid from moving between the first seal part 62 and the reservoir housing 42. In some of these examples, the sealing component is a seal part 62 formed from silicone, or a rubber material.

In examples in accordance with figure 3, the aerosol generator housing 40 can subsequently be inserted into the reservoir housing 42 and engaged with the first seal part 62 (as shown by arrow B). For example, the aerosol generator housing 40 may be inserted into a space or void formed by the first seal part 62. In these examples, the aerosol generator housing 40 and the first seal part may have complimentary shapes to facilitate the engagement of the aerosol generator housing 40 with the first seal part 62. The aerosol generator housing 40 and the first seal part 62 may be configured to engage so as to align any liquid conduits 47 with corresponding openings 64. It will be appreciated that the above mechanism similarly aids assembly and disassembly of the components of the system 1 without tools because the retention is of various components is ensure by interference fits rather than other attachment means (e.g. adhesive or fixing means such as screws).

It will be appreciated that the reservoir housing 42 is generally maintained in a vertical orientation with the open end 45 as the uppermost side of the reservoir (e.g. on an upper side) until the first seal part 62 and the aerosol generator housing 40 have both been inserted correctly into the reservoir housing 42. Furthermore, while not shown, in some examples, the wick 46 and aerosol generator 48 may be inserted (or connected) in a separate step after the insertion of the aerosol generator housing 40 into the first seal part 62. In these examples, the second seal part 68 is subsequently inserted (or connected) after the wick 46 and aerosol generator 48 to retain the wick 46 and aerosol generator 48 in position. Only when the wick 46 has been correctly sealed, should the orientation of the reservoir housing 42 be altered so that the open end 45 is no longer provided as the uppermost side of the reservoir.

Figure 4 is a cross-sectional view through a section of an aerosol delivery system 1 in accordance with some embodiments of the disclosure. Figure 4 depicts a further example of components involved in the engagement between the reservoir housing 42 and the aerosol generator housing 40. The aerosol delivery system 1 of figure 4 differs from that described in relation to figures 2 and 3, in that the aerosol generator 40 (comprising the first seal part 62) combined with the housing part 12 prior to insertion with the reservoir housing 42. All other components are substantially as described in relation to figure 1 and figure 2.

In examples in accordance with figure 4, the aerosol generator 40 and the housing part 12 are assembled prior to connection with the reservoir housing 42 (as shown by arrow A). Additionally, as shown, components contained within the housing part 12 may also be provided prior to connection of the aerosol generator 40 and housing part 12 with the reservoir housing 42. For example, the power source 26, control circuitry 22 and airflow sensor 30 may be included in the housing part 12. Alternatively, in some other examples, not shown, the housing part 12 and the aerosol generator 40 may be combined and subsequently connected with the reservoir housing 42, and then subsequently at least one of the power source 26, control circuitry 22 and airflow sensor 30 (or other components) may be included in the housing part 12.

The housing part 12 may also include a groove or recess feature 80 for engagement with the engagement feature 60. For example the groove or recess feature 80 may have a shape that is an inversion of a part of the engagement feature 60, such that the groove or recess feature 80 and the engagement feature 60 overlap and provide a smooth transition between the reservoir housing 42 and housing part 12 after connection. While not shown, in some examples, the housing part 12 and the engagement feature 60 may include corresponding attachment features such as clips or latches and corresponding recesses The attachment features retain the housing part 12 and engagement feature 60 in position relative to each other. The attachment of the housing part 12 to the engagement feature 60 also fully contains the aerosol generator housing 40 within the combined housing of the housing part 12 and the engagement feature 60.

Figure 5 is a flow chart of a method for assembling an aerosol delivery system 1 comprising a reservoir housing 42 having an open end 45, and a sealing component, in accordance with some embodiments of the disclosure. The method begins at step 510 in which the reservoir housing is orientated so that the open end is the uppermost side of the reservoir. In other words, so that the open end 45 of the reservoir housing 42 is at, or towards, an upper side. For example, the reservoir housing 42 may have an elongated shape corresponding to the elongated shape of the aerosol delivery system 1 , the elongated shape having a longitudinal axis. The longitudinal axis may be aligned vertically with the open end 45 towards a top end of the elongated shape (and for example a base 43 of the reservoir housing towards a bottom end of the elongated shape).

The method proceeds to step 520 in which the reservoir housing 42 is filled with liquid aerosol generating material 70 via the open end 45. For example, as shown in figures 2, 3 and 4, the reservoir housing 42 is filled with liquid aerosol generating material 70 to a level that is below the position or periphery of the open end 45 when the reservoir is orientated vertically with the open end 45 towards a top side. The reservoir housing 42 is (substantially) maintained in the orientation selected in earlier step 510 for the duration of the filling. Liquid aerosol generating material 70 is retained in the reservoir housing 42 during filling by gravity.

The method continues with step 530 in which a sealing component is inserted into the open end. The sealing component forms a seal with a periphery of the open end 45. The periphery defining the extent or boundary of the open end 45. For example, in accordance with figures 1 to 4 the periphery may be formed by inner and outer walls of the reservoir housing 42 which define the chamber or reservoir 44 that contains a liquid aerosol-generating material in use. In particular, in these figures the periphery is defined by both the uppermost extension of the inner wall (which defines the airflow path 52 on an inner side) and a corresponding height of the outer wall (which is extended above the open end 45 by the extension portion 60); the open end 45 extending in a substantially ring shaped or annular plane between the above locations on each wall.

In some examples, such as those in accordance with figure 2 and figure 4, the sealing component comprises the aerosol generator housing 40. In these examples, the aerosol generator housing 40 is inserted into the reservoir housing 42 such that a portion of the aerosol generator housing engages with and forms a seal with the periphery of the open end. For example, the aerosol generator housing 40 may comprise a first seal part 62 which compresses upon insertion into the open end 45; the compressed surfaces of the first seal part 62 forming a barrier inhibiting the movement of liquid aerosol generating material along the walls of the reservoir housing 42. In some other examples, such as those in accordance with figure 3, the sealing component may be independent of the aerosol generator housing 40. For example, the sealing component may be an independent first seal part 62 which is inserted into the open end before the aerosol generator housing 40 is engaged with the reservoir housing 42 (e.g. in different steps).

The method then ends. Where the method of assembly is implemented via a computer (e.g. a computer system controlling an assembly line), software may be provided to the computer which, when executed by the computer, implements the method.

While not shown, in some other examples, there may be further steps occurring after step 530, such as a first step of connecting an aerosol generator housing to the sealing component subsequent to inserting the sealing component into the open end (e.g. in line with figure 3), a second step of connecting the sealing component and I or the reservoir housing to a housing part configured to contain a power source and control circuitry within the aerosol delivery system, and / or a third step of inserting the power source and control circuitry into the housing part.

Figure 6 is a flow chart of a further method for assembling an aerosol delivery system 1 comprising a reservoir housing 42 having an open end 45, and a sealing component. The method begins at step 600 with the sealing component being combined with a housing part 12 which is configured to hold (e.g. house, contain or protect) a power source 26, control circuitry / controller 22, and, for example, an air flow sensor. In line with step 600 the method connecting the sealing component to the housing part prior to inserting the sealing component into the open end.

The method continues with step 610, in which the reservoir housing is orientated so that the open end 45 of the reservoir housing 42 is the uppermost side of the reservoir. In other words, so that the open end 45 is at, or towards, an upper side (similarly to step 510 of figure 5). For example, the reservoir housing 42 may have an elongated shape corresponding to the elongated shape of the aerosol delivery system 1 , the elongated shape having a longitudinal axis. The longitudinal axis may be aligned vertically with the open end 45 towards a top end of the elongated shape (and for example a base 43 of the reservoir housing towards a bottom end of the elongated shape).

The method continues with step 620, in which in which the reservoir housing 42 is filled with liquid aerosol generating material 70 via the open end 45 (similarly to step 520 of figure 5). For example, as shown in figure 4, the reservoir housing 42 is filled with liquid aerosol generating material 70 to a level that is below the position or periphery of the open end 45 when the reservoir is orientated vertically with the open end 45 towards a top side. The reservoir housing 42 is (substantially) maintained in the orientation selected in earlier step 510 for the duration of the filling. Liquid aerosol generating material 70 is retained in the reservoir housing 42 during filling by gravity.

The method continues with step 630 in which the combined housing part 12 and sealing component is inserted into the open end. The combined housing part 12 and sealing component forms a seal with a periphery of the open end 45. The periphery defining the extent or boundary of the open end 45. For example, in accordance with figures 4 the periphery may be formed by inner and outer walls of the reservoir housing 42 which define the chamber or reservoir 44 that contains a liquid aerosolgenerating material in use. In particular, in figure 4 the periphery is defined by both the uppermost extension of the inner wall (which defines the airflow path 52 on an inner side) and a corresponding height of the outer wall (which is extended above the open end 45 by the extension portion 60); the open end 45 extending in a substantially ring shaped plane between the above locations on each wall.

In examples such as those in accordance with figure 4, the power source 26, control circuitry I controller 22, and the air flow sensor 30 are provided within the housing part 12 prior to engaging the combined housing part 12 and sealing component with the periphery of the open end 45.

The method then ends. Where the method of assembly is implemented via a computer (e.g. a computer system controlling an assembly line), software may be provided to the computer which, when executed by the computer, implements the method. It will be appreciated that step 600 is substantially independent of steps 610 and 620 because the sealing component does not interact with the reservoir housing 40 until step 630. Therefore, in some examples, step 600 may occur after steps 610 and 620, or in parallel to one or both of steps 610 and 620. While not shown, in some other examples, there may be a further step occurring after step 630, in which the power source 26, control circuitry I controller 22, and the air flow sensor 30, as well as any other desired electronics or components, may be inserted into the housing part 12.

Figure 7 is a schematic illustration of the assembly process for an aerosol delivery system 1 in accordance with some embodiments of the disclosure. The overall system 1 can readily be assembled and disassembled because the subsystem 100 comprises a bracket 110 which houses components of the aerosol delivery system 1 , enabling these to be installed/removed in/from the system 1 collectively. In some embodiments, the various components and/or parts are retained with an interference fit to provide a tool-less assembly.

The process starts with step 700 in which the reservoir housing is orientated so that the open end 45 of the reservoir housing 42 is the uppermost side of the reservoir. In other words, so that the open end 45 is at, or towards, an upper side. Step 700 is substantially as described in relation to step 510 of figure 5. The process continues with step 710 in which the reservoir housing 42 is filled with liquid aerosol generating material 70. Step 710 is substantially as described in relation to step 520 of figure 5.

The process continues with step 720 in which the aerosol generator housing 40 is inserted into the reservoir housing 42; a first seal part 62 of, or connected to, the aerosol generator housing 40 providing a sealing component which is configure to be inserted into the open end 45 (not shown) of the reservoir housing 42 to form a seal with a periphery of the open end 45. In some other examples, the aerosol generator housing 40 may be the sealing component. For example, it may be formed at least in part from materials configured to form a seal with at the periphery of the open end 45 (for example the first seal part 62 may be integrally formed with a further part of the aerosol generator housing 40).

As shown in figure 7, the aerosol generator housing 40 is attached to a bracket 72 prior to insertion of the aerosol generator housing 40 into the reservoir housing 42. The bracket 72 is configured to support various components of the aerosol delivery system 1 including the control circuitry 22 (not shown) and the power source 26. The bracket 72 may further be configured to support the position of electrodes and I or electrical contacts for connecting at least the aerosol generator 48 (not shown) to the control circuitry 22 and I or power source 26. A second seal part 68 is positioned between the bracket 72 and the aerosol generator housing 40. In some examples, the second seal part 68 may be configured to attach to the bracket 72, while in some other examples the second seal part 68 may be retained between the bracket 72 and the aerosol generator housing 40, by the connection of the bracket 72 and the aerosol generator housing 40. The connection of either of the aerosol generator housing 40 and I or the second seal part 68 to the bracket 72 can be facilitated by an interference fit, or a conventional mechanism such as clips or latching mechanisms. In examples in accordance with figure 7, the process or method of assembly comprises connecting the sealing component (e.g. the aerosol generator housing 40 or first seal part 62) to a bracket 72 configured to retain a power source 26 and control circuitry 22 within the aerosol delivery system 1 . Furthermore, in examples in accordance with figure 7, the process or method of assembly comprises connecting the sealing component (e.g. the aerosol generator housing 40 or first seal part 62) to the bracket 72 prior to inserting the sealing component into the open end 45. In other examples, the bracket 72 could be attached to the sealing component after the sealing component has been inserted into the open end 45.

The process continues with step 730 in which an airflow sensor 30 is attached to the control circuitry 22 via wiring 31 (or a similar electrical connection) which extends through the bracket 72 or connects with electrical connectors (or electrodes) provided by the bracket 72. The wiring 31 may be of a sufficient length to enable the airflow sensor 30 to be positioned at an upstream end of the device (i.e. away from the aerosol generator 48 and the reservoir housing 42. For example, the wiring may have a length equal to or longer than the length of the aerosol delivery system 1 between the control circuitry 22 and the upstream end of the housing part 12 (for example, the wiring 31 may be between 7 and 10 cm where the aerosol delivery system is around 12 cm).

The process continues with step 740 in which a power source 26 (such as a battery) is attached to the bracket 72. The power source 26 may also be connected to the control circuitry 22 and /or the aerosol generator 40 via electrical connections which extend through the bracket 72 or are provided by the bracket 72 (e.g. built into the bracket 72). In some examples, the attachment of the power source 26 to the bracket 72 may involve the insertion of electrodes provided by the bracket 72 into the power source 26, or vice versa (e.g. power source 26 provides insertable electrodes).

In examples in accordance with figure 7, the process or method of assembly comprises connecting one or more of the power source 26 and control circuitry 22 to the bracket 72 subsequent to (e.g. after) inserting the sealing component into the open end 45. In particular, in examples in accordance with figure 7, the process or method of assembly comprises connecting the control circuitry 22 to the bracket 72 prior to inserting the sealing component (e.g. aerosol generator housing 40 or first seal part 62) into the open end 45, and comprises connecting the power source 26 to the bracket 72 subsequent to (e.g. after) inserting the sealing component into the open end 45.

The process continues with step 750 in which one or more portions of a barrier material 74 may be attached to the power source 26. The barrier material 74 may provide both physical protection to the power source 26 and also electrical insulation. In some examples, the barrier material 74 may be a polyethylene terephthalate material such as Mylar. The process continues with step 760 in which at least the power source 26 is surrounded by a thermal barrier 76 (e.g. a material having a resistance to high temperatures and / or a low thermal conductivity). The thermal barrier 76 may in some examples be a high-temperature tape which is a thermal insulator. In these examples, the high-temperature tape may be wrapped around the power source 76.

The process continues with step 770 in which a housing part 12 is attached to the reservoir housing 42. In examples in accordance with figure 7, the housing part 12 overlaps the reservoir housing 42 for at least a portion of the reservoir housing 42. As such, in these examples the reservoir housing 42 is inserted into the housing part 12. The outer surface of the reservoir housing 42 and/ or the inner surface of the housing part 12 in the overlapping region may be provided with features that facilitate the engagement of the reservoir housing 42 and the housing part 12. Said features which may include for example ridges, protrusions, and corresponding recesses may guide or enhance an interference fit between the components, thereby securing the housing part 12 to the reservoir housing 42. For example, the interference fit may be formed as discussed in relation to the aerosol generator and reservoir housing of figure 1. In some examples, clip or latch mechanisms could be utilised in order to connect the housing part 12 to the reservoir housing 42. Additionally or alternatively, the bracket 72 may also include features that are configured to engage with the housing part 12 (or vice versa). For example the housing part 21 may be secured with an interference fit to the bracket.

Therefore in examples in accordance with figure 7, the process or method of assembly comprises connecting the housing part 12 to one or more of the bracket 72, the reservoir housing 42 or the sealing component (e.g. aerosol generator housing 40) subsequent to connecting one or more of the power source 26 and control circuitry 22 to the bracket 72.

The process continues with step 780 in which a sensor mount 78 is inserted into the housing part 12 at the upstream end (the downstream end being inaccessible due to the connection with the reservoir housing 42). The sensor mount 78 is configured to position and hold the air flow sensor 30 in the housing part 12. For example, the sensor mount 78 may define at least a portion of the air pathway 52 towards the upstream end of the aerosol delivery system 1 , and may further retain the airflow sensor 30 in a position associated with the air pathway 52 which enables the airflow sensor 30 to measure an air pressure or flow rate within the air pathway 52. In some examples, the sensor mount 78 may be formed of a silicone material.

The process continues with step 790 in which an end cap 80 is attached to the housing part 12 to close of the upstream end of the housing part 12. The end cap 80 may include one or more air inlets 28 configured to allow air to enter the housing part 12. Said one or more air inlets 28 may be positioned or otherwise configured to direct air flow towards the sensor mount 78 and airflow sensor 30. The end cap 80 may comprise an airflow adjuster 82 configured to alter an airflow rate or resistance to draw through the end cap 80. For example, the airflow adjuster 82 may be a slider which is manually operated by the user to cover or uncover one or more inlets of a plurality of inlets 28. In other words, a user may manually adjust the slider 82 to cover or uncover a desired number of air inlets 28 to change the flow rate or resistance to draw through the end cap 80 (and the aerosol delivery system 1 as a whole). Additionally as part of, or after, this step, the entire aerosol delivery system 1 may be pressed (e.g. by squeezing the system 1 between the upstream and downstream ends) with a sufficient force to ensure all components have been correctly inserted.

The process as described by figure 7 then ends. It will be appreciated that there may be further steps which are not shown in figure 7, such as steps related to weighting the liquid aerosol generating material 70, performing a vaping check (to determine that the device works as expected), a final inspection step, and I or the insertion of silicone plug into the mouthpiece to prevent leakage from the device during transport.

By providing a method of assembly which avoids the need for complex filling processes and relies on interference fits to hold each component in place, the present method provides a faster, more convenient and less damaging assembly process (in other words the method does not require the use of glue or fasteners such as screws). Moreover, the process is reversible and thus increases recyclability, which is particularly important for disposable devices which are normally single-use and discarded as complete units (and so not recycled). In prior arrangements, these connections would typically be soldered and fixed in place within the system directly, one-by-one, and thus be more timeconsuming and fiddly to assemble and disassemble, increasing the likelihood of damage when assembling/disassembling. Accordingly, the present invention not only provides a simplified filling method but also greatly increases recyclability since the various components can readily be removed and sent to appropriate recycling centres.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention.

Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. Protection may be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.