WO2025088299A1

WO2025088299A1 - Aerosol delivery systems

Info

Publication number: WO2025088299A1
Application number: PCT/GB2024/052667
Authority: WO
Inventors: Xiaofeng Xu; Hongqiang LIU; Shuai WANG
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-10-26
Filing date: 2024-10-17
Publication date: 2025-05-01
Anticipated expiration: 2026-04-26

Abstract

The present disclosure relates to a cartridge for an aerosol delivery system, the cartridge comprising a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge, and an aerosol generator for generating an aerosol for inhalation from an aerosol-generating material, wherein the aerosol generator is provided in a chamber defined at least in part by the first outer wall portion, wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface.

Description

AEROSOL DELIVERY SYSTEMS

Field

The present disclosure relates to aerosol delivery systems such as nicotine delivery systems (e.g. electronic cigarettes and the like).

Background

Electronic vapour provision systems such as electronic cigarettes (e-cigarettes) generally contain a vapour precursor material, such as a reservoir of a source liquid containing a formulation, typically including nicotine, from which a vapour is generated for inhalation by a user, for example through heat vaporisation. Thus, a vapour provision system will typically comprise a vapour generation chamber containing a vaporiser assembly arranged to vaporise a portion of precursor material to generate a vapour in the vapour generation chamber. The vaporiser assembly will often comprise a heater coil arranged around a liquid transport element (capillary wick) that is arranged to transport source liquid from a reservoir to the heater coil for vaporisation. As a user inhales on the device and electrical power is supplied to the vaporiser assembly, air is drawn into the device through an inlet hole and into the vapour generation chamber where the air mixes with vaporised precursor material to form a condensation aerosol. There is an air channel connecting the vapour generation chamber and an opening in the mouthpiece so the air drawn through the vapour generation chamber as a user inhales on the mouthpiece continues along the flow path to the mouthpiece opening, carrying the vapour with it for inhalation by the user.

The design of aspects relating to the vaporiser assembly of a vapour provision system can play an important role in the overall performance of the system, for example in terms of the reducing the overall size of such a delivery system (or components of the system) and managing the transmission of heat from an aerosol generator to an external surface of the delivery system. Various approaches are described herein which seek to help address some of these issues.

Summary

According to a first aspect of certain embodiments there is provided a cartridge for an aerosol delivery system, the cartridge comprising: a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge; and an aerosol generator for generating an aerosol for inhalation from an aerosol-generating material, wherein the aerosol generator is provided in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface. According to a second aspect of certain embodiments there is provided an aerosol delivery system for aerosolising an aerosol-generating material, the aerosol delivery system comprising a cartridge in accordance with the first aspect.

According to a third aspect of certain embodiments there is provided cartridge means for an aerosol delivery system, the cartridge means comprising: housing means comprising a first outer wall portion partially defining an exterior shape of the cartridge means; and aerosol generator means for generating an aerosol for inhalation from an aerosol-generating material means, wherein the aerosol generator means is provided in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator means is separated from the first inner surface.

According to a fourth aspect of certain embodiments there is provided a method of providing a cartridge for an aerosol delivery system, the method comprising: providing a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge and a first inner surface of a chamber; and providing an aerosol generator, for generating an aerosol for inhalation from an aerosol-generating material, in the chamber defined at least in part by the first outer wall portion, wherein the aerosol generator is separated from the first inner surface.

It will be appreciated that features and aspects of the invention described herein in relation to the various aspects of the disclosure are equally applicable to, and may be combined with, embodiments of the disclosure according to other aspects as appropriate, and not just in the specific combinations described herein.

Brief Description of the Drawings

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

Figure 1 schematically represents an aerosol delivery system comprising a cartridge and control unit in accordance with certain embodiments of the disclosure;

Figure 2 schematically represents a cross-sectional view through an example cartridge in accordance with certain embodiments of the disclosure;

Figure 3 schematically represents a further cross-sectional view through an example cartridge in accordance with certain embodiments of the disclosure; and

Figure 4 is a flow diagram schematically representing steps in a method of providing a cartridge for use in an aerosol delivery system according to an embodiment of the disclosure. Detailed Description

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

As will be explained below, the present disclosure relates to a cartridge for an aerosol delivery system, the cartridge comprising: a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge; and an aerosol generator for generating an aerosol for inhalation from an aerosol-generating material, wherein the aerosol generator is provided in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface. The above system ensures a suitable separation is maintained between the aerosol generator and the chamber surface to avoid excessive heating of the external surface of the cartridge, whilst reducing the overall size of the cartridge.

For example, the first outer wall portion defines both the external shape of the cartridge and the chamber, thereby avoiding the need for a separate chamber wall component which would contribute to the width of the cartridge. In particular, by using the outer wall to provide a surface of the chamber, the separation of the aerosol generator from the surface of the chamber can be maintained (to avoid excessive heating of the surface) whilst reducing the size of the components surrounding the chamber (by removing a chamber wall). As such, the present disclosure allows fora reduced size cartridge (e.g. reduced thickness proximal to the chamber) without substantially increasing the transmission of thermal energy to an exterior of the device. Said thermal energy may be generated by a resistive heater providing the aerosol generator, or by thermal build up in relation to the operation of a non-heater type aerosol generator (e.g. electrical power flow in components of an aerosol generator causing temperatures to rise).

The present disclosure relates to aerosol delivery systems, which may also be referred to as aerosol or vapour provision systems, such as 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, electronic aerosol delivery system I device, vapour provision system I device, and electronic vapour provision system I device. Furthermore, and as is common in the technical field, the terms "vapour" and "aerosol", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably. As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes non-combustible aerosol provision systems that

105 release compounds from an aerosol-generating material without combusting the aerosolgenerating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

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 no 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

115 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.

120 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¬

125 generating material. The solid aerosol-generating 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.

130 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.

135 The power source may, for example, be an electric 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 aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

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 one embodiment the active substance is a legally permissible recreational drug.

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. The active substance may be CBD or a derivative thereof.

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.

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 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.

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

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.

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 aerosolgenerating 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, be a material heatable by electrical conduction.

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 aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosolmodifying 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 aerosolmodifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating 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 aerosolgenerating 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. More generally, it will be appreciated certain embodiments of the disclosure are based on approaches for seeking to help optimise vaporiser assembly performance in vapour delivery systems in accordance with the principles described herein, and other constructional and functional aspects of electronic cigarettes implementing approaches in accordance with certain embodiments of the disclosure are not of primary significance and may, for example, be implemented in accordance with any established approaches.

Figure 1 is a schematic perspective view of an example aerosol delivery system I device (e- cigarette, vapour I aerosol provision system) 1 in accordance with certain embodiments of the disclosure. Positional terms concerning the relative location of various aspects of the electronic cigarette (e.g. terms such as upper, lower, above, below, top, bottom etc.) may be used herein with reference to a vertical orientation of a longitudinal axis of the e-cigarette with a mouthpiece (through which it is intended a user inhales) at an upper most end (unless the context indicates otherwise). However, it will be appreciated this is purely for ease of explanation and is not intended to indicate there is any required orientation for the electronic cigarette in use.

The e-cigarette 1 comprises two main components, namely a cartridge 4 (cartridge part) and a control unit 2 (control part). The control unit 2 and the cartridge 4 are shown coupled together.

The cartridge 4 and control unit 2 are coupled by establishing a mechanical and electrical connection between them. The specific manner in which the mechanical and electrical connection is established is not of primary significance to the principles described herein and may be established in accordance with conventional techniques, for example based around a screw thread, bayonet, latched or friction-fit mechanical fixing with appropriately arranged electrical contacts I electrodes for establishing the electrical connection between the two parts as appropriate. For the example electronic cigarette 1 represented in Figure 1 , the cartridge comprises a mouthpiece end 52 and an interface end 54 and is coupled to the control unit by inserting an interface end portion 6 at the interface end of the cartridge into a corresponding receptacle 81 receiving section of the control unit. The interface end portion 6 of the cartridge is a close fit to be receptacle 8 and may include includes protrusions (not shown) which engage with corresponding detents in the interior surface of a receptacle wall 12 defining the receptacle 8 to provide a releasable mechanical engagement between the cartridge and the control unit. An electrical connection is established between the control unit and the cartridge via a pair of electrodes providing electrical contacts on the bottom of the cartridge and corresponding sprung contact pins in the base of the receptacle 8. As noted above, the specific manner in which the electrical connection is established is not significant to the principles described herein, and indeed some implementations might not have an electrical connection between the cartridge and a control unit at all, for example because the transfer of electrical power from the reusable part to the cartridge may be wireless (e.g. based on electromagnetic induction techniques).

The electronic cigarette 1 has a generally elongate shape extending along a longitudinal axis L. When the cartridge is coupled to the control unit, the overall length of the electronic cigarette in this example (along the longitudinal axis) is around 12.5 cm. The overall length of the control unit is around 9 cm and the overall length of the cartridge is around 5 cm (i.e. there is around 3 cm of overlap between the interface end portion 6 of the cartridge and the receptacle 8 of the control unit when they are coupled together). The electronic cigarette has a cross-section which is generally oval and which is largest around the middle of the electronic cigarette and tapers in a curved manner towards the ends. The cross-section around the middle of the electronic cigarette has a width of around 2.5 cm and a thickness of around 1 .7 cm. The end of the cartridge has a width of around 2 cm and a thickness of around 0.6 mm, whereas the other end of the electronic cigarette has a width of around 2 cm and a thickness of around 1.2 cm. The outer housing of the electronic cigarette is in some examples formed from plastic. It will be appreciated the specific size and shape of the electronic cigarette and the material from which it is made is not of primary significance to the principles described herein and may be different in different implementations. That is to say, the principles described herein may equally be adopted for electronic cigarettes having different sizes, shapes and I or materials.

The control unit 2 may in accordance with certain embodiments of the disclosure be broadly conventional in terms of its functionality and general construction techniques. In the example of Figure 1 , the control unit 2 comprises outer housing 10 (formed of a plastic or metal, for example) including the receptacle wall 12 that defines the receptacle 8 for receiving the end of the cartridge as noted above.

The outer housing 10 of the control unit 2 in this example has a generally oval cross section conforming to the shape and size of the cartridge 4 at their interface to provide a smooth transition between the two parts. The receptacle wall 12 includes a control unit air inlet opening 11 (e.g. provided by one or more holes in the wall). In use, when a user inhales on the cartridge 4, air is drawn in through these holes, towards the interface end of the cartridge part 4 where the air enters the cartridge through an opening in the base end of the cartridge. It will be appreciated that the interface end portion 6 of the cartridge 4 may not form an airtight seal with the receptacle wall 12 so some air drawn may also be drawn into the cartridge through gaps between the cartridge and the control unit 2. The control unit further comprises a battery 16 for providing operating power for the electronic cigarette, control circuitry 18 for controlling and monitoring the operation of the electronic cigarette, a user input button 20, an indicator 22.

The battery 16 in this example is 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 of these examples, the battery 16 may be recharged through a charging port (not shown), which may, for example, comprise a USB connector; or the battery 16 may be recharged inductively via suitable components for inductive charging (e.g. a susceptor assembly (not shown) configured to form part of an induction circuit with an inductive charger).

The input button 20 in this example is a conventional mechanical button, for example comprising a sprung mounted component which may be pressed by a user to establish an electrical contact in underlying circuitry. In this regard, the input button may be considered an input device for detecting user input, e.g. to trigger vapour generation, and the specific manner in which the button is implemented is not significant. For example, other forms of mechanical button or touch-sensitive button (e.g. based on capacitive or optical sensing techniques) may be used in other implementations, or there may be no button and the device may rely on a puff detector for triggering vapour generation.

The indicator 22 is provided to give a user with a visual indication of various characteristics associated with the electronic cigarette, for example, an indication of an operating state (e.g. on I off / standby), and other characteristics, such as battery life or fault conditions. In some examples, the indicator 22 may be provided by one or more LEDs. Different characteristics may, for example, be indicated through different colours and I or different flash sequences in accordance with generally conventional techniques. In some other examples, the indicator 22 may be provided by a display, configured to display information to a user.

The control circuitry 18 is suitably configured I programmed to control the operation of the electronic cigarette to provide conventional operating functions in line with the established techniques for controlling electronic cigarettes. The control circuitry (processor circuitry) 18 may be considered to logically comprise various sub-units I circuitry elements associated with different aspects of the electronic cigarette's operation. For example, depending on the functionality provided in different implementations, the control circuitry 18 may comprises power supply control circuitry for controlling the supply of power from the battery to the cartridge in response to user input, user programming circuitry for establishing configuration settings (e.g. user-defined power settings) in response to user input, as well as other functional units / circuitry associated functionality in accordance with the principles described herein and conventional operating aspects of electronic cigarettes, such as indicator light display driving circuitry and user input detection circuitry. It will be appreciated the functionality of the control circuitry 18 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 applicationspecific integrated circuit(s) I circuitry I chip(s) I chipset(s) configured to provide the desired functionality.

The cartridge 4 comprises a housing 32, an end cap 34, a lower (upstream) chamber part component 36, and an upper (downstream) chamber part 38. As discussed below, the cartridge 4 is configured to contain an aerosol generating material (e.g. a liquid contained in a reservoir 44). The cartridge 4 may in some examples be termed a cartomiser in that it is configured to comprise an aerosol generator 40 and an aerosol-generating material.

The housing 32 defines the external shape (e.g. appearance) of the cartridge 4 (e.g. a portion of the aerosol delivery system 1 defined by the cartridge). In some examples, the housing 32 defines a mouthpiece configured to accommodate a user’s mouth during a puff. For example, the housing 32 may be comprise a mouthpiece opening/ vapour outlet 60 at the downstream end of the cartridge 4 (and system 1). The mouthpiece opening/ vapour outlet 60 in fluid communication with the aerosol generator 40 via an inner tube 62 connecting an aerosol generation chamber 50 to the mouthpiece opening 60. In some examples, the housing 32 defines an interface end portion 6 of the cartridge which is configured to engage with a receptacle 8 of the control unit 2, as described above.

In some examples, the housing 32 may be formed a plastic or metal material. For example, the housing 32 may be formed from a plastic material such as polypropylene or a metal material such as aluminium. In some examples, the housing 32 may be integrally formed as a single component. For example, the housing 32 may be formed from a single moulding defining the mouthpiece end including the mouthpiece opening 60, and an interface end portion 6 configured to be received by the receptacle 8. In some examples, the housing 32 may further include the inner tube 62, which may also be integrally formed with the remainder of the housing 32 as a single component. In some examples, the housing 32 the may be an assembly of multiple components which are joined together. For example, the housing 32 may be formed by joining an upper portion defining the mouthpiece end 52 to a lower portion defining the interface end 6 of the cartridge.

The cartridge 4 of figure 1 comprises an (aerosol-generating material) storage area or reservoir 44 defined between the housing 32 and the inner tube 62. The reservoir or storage area 44 is for containing aerosol generating material (e.g. liquid 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. In some examples, such as those in accordance with figure 1 , a reservoir 44 is provided which is configured to store a supply of liquid aerosol generating material. In the example of figure 1 , the liquid reservoir 44 has a substantially annular shape defined by the housing 32, defining the outer annular wall, and the inner tube 62, defining the inner annular wall. The reservoir 44 is closed at mouthpiece end 52 with an end wall to contain the aerosol generating material.

In Figure 1 , the aerosol generator 40 is located towards the interface end 54 of the cartridges 4. The aerosol generator 40 may be a heater 40 (and is referred to, interchangeably, as such below) which is configured to subject the aerosol-generating material to heat, so as to raise the temperature of the aerosol-generating material in order to release one or more volatiles from the aerosol-generating material to form an aerosol. In some other examples, 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.

In normal use, the cartridge 4 is coupled to the control unit 2, and the control unit 2 is activated to supply power to the aerosol generator 40 via an electrical connection formed at the interface between the cartridge 4 and control unit 2. Power passes through electrical leads (e.g. wires and /or conductive electrodes) from the interface end 54 to the heater 40. The heater is thus electrically heated and so vaporises or aerosolises a portion of the aerosol-generating material in the vicinity of the heater. While the heater is activated and a user inhales on the mouthpiece end 52 of the cartridge, air is drawn into the cartridge 4 through the air inlet in the interface end 54 and along an air pathway 46. The incoming air mixes with vapour generated from the heater 40 to form a condensation aerosol, which is then drawn along the inner tube 62 before exiting through the mouthpiece outlet/vapour outlet 60 for user inhalation.

In the example of Figure 1 , the cartridge 4 comprises a liquid transport element 42 for providing or conveying liquid aerosol-generating material from the reservoir 44 to the aerosol generator 40 (i.e. heater). In some examples, the liquid transport element 42 is a wick 42 (i.e. an element configured to wick the liquid aerosol-generating material) which is provided in contact with the heater 40. The wick 42 extends transversely across the primary (or first) airflow path with the ends of the wick extending into a pocket, recess or conduit 48 fluidly connected to a reservoir 44 of a liquid aerosol generating material. In some examples, the liquid transport element 42 is configured such that liquid that is vaporised or aerosolised from the liquid transport element 42 is replaced by more liquid drawn from the reservoir 44 by capillary action. The heater 40 in the example of figure 1 comprises an electrically resistive wire coiled around the wick 42. In the example of Figure 1 , the heater 40 may comprise a nickel chrome alloy (Cr20Ni80) wire and the wick 42 may comprise a glass fibre bundle. As an example, the wick 42 could instead be cotton and the heater 40 could instead be steel.

As noted above, when the cartridge 4 is assembled, a reservoir 44 for liquid is formed by the space outside the inner tube 62 and an inner surface of the housing 32. This may be filled with liquid aerosol-generating material during manufacture, for example through a filling hole which is then sealed, or by other means. The specific nature of the liquid, for example in terms of its composition, is not of primary significance to the principles described herein, and in general any conventional liquid of the type normally used in electronic cigarettes may be used. The reservoir 44 is closed at the interface end 54 of the cartridge 4 by one or more sealing elements or components.

For example, the reservoir 44 may be closed by an upper, or downstream, sealing component 38 which at least partly provides openings for receiving ends of the liquid transport element (capillary wick) 42, which extend from the air channel 46. The upper sealing component 38 additionally is configured to comprise a conduit or recess 48 fluidly connecting the reservoir 44 to the ends of the liquid transport element 42. Thus, the ends of the liquid transport element 42 are in fluid connection with the reservoir 44 from which they draw liquid through the openings in the air channel 46 to the heater 40 for subsequent vaporisation.

In the example of figure 1 , the upper, or downstream, sealing component 38 and the lower, or upstream, sealing component 36 cooperate to provide the openings for receiving the ends of the liquid transport element (capillary wick) 42. The upper sealing component 38 and the lower sealing component 36 may be considered in combination a sealing element. In some examples, the lower sealing component 36 and the upper sealing component 38 may be configured to provide apertures through which the wick 42 is extended. For example, both the lower sealing component 36 and the upper sealing component 38 may be shaped such that an inner wall of each is recessed (adjacent to the section of the airflow path 46 containing the aerosol generator 40) to define a pair of diametrically opposing slots. Each slot may provide a semi-circular surface for accommodating an end of the liquid transport element 42.

Respective slots of the upper sealing component 38 and the lower sealing component 36 are aligned so that the upper sealing component 38 and the lower sealing component 36 cooperate to define holes through which the ends of the liquid transport element 42 extend. The size of the holes through which the liquid transport element 42 passes correspond closely to the size and shape of the liquid transport element, but are slightly smaller so a degree of compression is provided by the sealing components 36,38. This allows liquid to be transported along the liquid transport element by capillary action while restricting the extent to which liquid which is not transported by capillary action can pass through the openings.

Additionally, in some examples, an outer edge of the upper sealing component 38 may be inserted into a part of the housing 32 to seal the reservoir 44. For example, the upper sealing component 38 may be shaped to be received in an aperture towards the interface end 54 of the housing part 32. The upper sealing component 38 may include one or more circumferential ridges which engage with an inner surface of the housing part 32 and ensure a tight fit, when the upper sealing component 38 is inserted into the housing part 32.

In some examples, the upper sealing component 38 comprises an additional element such as a silicone sleeve to facilitate the connection of the upper sealing component 38 to the housing 32 and the sealing of the reservoir 44. The connection may be configured such that the movement of liquid along the inner surface of the housing part 32 may be inhibited (e.g. by virtue of the tight fit). A similar, engagement mechanism could be provided between the upper sealing component 38 and the inner tube 62. The lower sealing element 36 may also be configured to be received by the housing 32, and to provide a level of sealing which inhibits or prevents the movement of liquid between the lower sealing element 36 and the housing 32.

The end cap 34 of the cartridge 4 is configured to facilitate the electronic connection of the control part 2 to the aerosol generator 40. For example, the end cap 34 may comprise electrode posts 14 on the bottom side of the end cap 34 are close to flush with the interface end 54 of the cartridge 4. These are the parts of the electrodes to which correspondingly aligned sprung contacts in the control unit connect when the cartridge is assembled and connected to the control unit. The ends of the electrode posts on the inside of the cartridge 4 extend away from the end cap 34 (e.g. towards the heater). The ends of the electrode may extend into holes in the sealing component 36. Each electrode posts 14 may be maintained in pressed contact with an electrical lead 41 connecting to the aerosol generator 40, in order to facilitate the formation of an electronic circuit between the aerosol generator 40 and the control part 2 (in particular, an electronic circuit involving the electronics of the control part 2 such as the control circuitry 18).

In the example of figure 1 , the end cap 34 also defines an air inlet through which air is drawn into the air channel 46 of the cartridge 4. In some examples, the air inlet is configured to align with an outlet of the control part 2, with the air channel 46 comprising a portion in the control part 2 (up to the control part 2 outlet) and a portion in the cartridge 4 (starting at the inlet of the cartridge 4).

The cartridge 4 further comprises an (aerosol-generation) chamber 50 which is defined by the surface of components surrounding or proximate to the aerosol generator 40. In use electrical power may be supplied to the aerosol generator 40 to vaporise or aerosolised an amount of aerosol-generating material into a region of the airflow path 46 defined by the chamber 50. The vaporised aerosol generating material may become entrained in air drawn along the airflow path 46 through the chamber 50. The region into which the aerosol is provided or released may also be called an aerosol generation region (or vaporisation region) of the airflow path 46. The chamber 50 is fluidly connected to the inlet to the cartridge 4 (e.g. by a passageway defined by the end cap 34 and the lower sealing component 36) and is fluidly connected to the mouthpiece outlet 60 (e.g. by the inner tube 62).

As will be discussed in detail below, the chamber 50 is defined by the surfaces of the components which face the aerosol generator 40 (e.g. components having surfaces with tangents directed towards and/ or no obstruction between the component and the aerosol generator 40). In some examples, the upper sealing component 38 and the lower sealing component 36 define or otherwise bound respective portions of the chamber 50. The upper sealing component 38 and the lower sealing component 36 do not fully define the boundaries of the chamber 50.

In some examples, the upper sealing component 38 and the lower sealing component 36 may only define boundaries of the chamber adjacent to where the aerosol generator 40 and or liquid transport element 42 interact with the chamber walls. In some examples, the upper sealing component 38 may also define an air outlet of the chamber 50 (e.g. the upper sealing element may be shaped to extend across the width of the chamber downstream of the aerosol generator, and the air outlet may be provided in this extension). In some examples, the lower sealing component 36 may also define an air inlet of the chamber 50 (e.g. the lower sealing element may be shaped to extend across the width of the chamber upstream of the aerosol generator, and the air inlet may be provided in this extension).

For example, the upper sealing component 38 and the lower sealing component 36 may be configured to define openings or apertures (not shown) on either side of the aerosol generator 40, exposing to airflow inner surfaces of portions of the housing 32. By define openings or apertures, it is meant that the upper sealing component 38 and the lower sealing component 36 are shaped so that they do not fully engage (e.g. contact) with each other around a perimeter or circumference of outer wall the cartridge 4. Instead, the upper sealing component 38 and the lower sealing component 36 may only be in contact towards the portions of the cartridge where they engage with the liquid transport element 42. Away from these portions the upper sealing component 38 and the lower sealing component 36 are separated such that they are not in contact, thereby exposing outer wall portions of the housing 32. In other words, one or more outer wall portions of the housing 32 (e.g. portions defining an exterior shape of the cartridge 4) comprise inner surfaces (e.g. not defining the exterior shape of the cartridge 4) which define or otherwise bound respective portions of the chamber 50 (i.e. because the upper sealing component 38 and the lower sealing component 36 are not present in these regions of the chamber). The aerosol generator 40 is provided in the chamber 50 defined at least in part by the one or more outer wall portions (e.g. defined by a first outer wall portion) with the one or more outer wall portions defining one or more, respective, inner surfaces of the chamber 50.

The aerosol generator 40 is separate from the one or more inner surfaces thereby creating a gap between the aerosol generator 40 and the inner surfaces. This provides increased space for airflow around the side(s) of the aerosol generator 40, while keeping the overall thickness of the cartridge 4 to a minimum. Furthermore, it allows overall thickness of cartridge 4 to be minimised, while still maintaining sufficient air gap between the aerosol generator 40 and outer housing 32 to avoid excessively high surface temperatures during use (which is particularly advantageous where the aerosol generator 40 is a heater).

Figure 2 is a schematic perspective view of an example cartridge 4 in accordance with certain embodiments of the disclosure. In comparison to the schematic view of figure 1 , figure 2 depicts a cross-sectional plane which is perpendicular to the extension of the aerosol generator 40 and liquid transport element 42 into the chamber 50.

In figure 2, the housing 32 comprises a first outer wall portion 81 defining a first inner surface 91 of the chamber 50 and a second outer wall portion 82 defines a second inner surface 92 of the chamber 50, the second inner surface 92 opposite to the first inner surface 82.

The cartridge 4 of figure 2 comprises an interface end portion 6 towards the interface end 54 of the cartridge 4 which is configured to be inserted into a corresponding receptacle 8 of the control unit 2. The interface end portion 6 is defined by a section of the housing 32 and the end cap 34. In some examples, such as those in accordance with figure 2, the first outer wall portion 81 and the second outer wall portion 91 are provided in the section of the housing 32 providing the interface end portion 6, and hence, are received in the receptacle 8 when the cartridge 4 is attached to the control unit 2. It will be appreciated that in other examples, not in accordance with figure 2, the first outer wall portion 81 and the second outer wall portion 91 are not in this section and hence are not received in the receptacle 8 when the cartridge 4 is attached to the control unit 2.

The chamber 50 is defined at an upstream end by the lower sealing component 36, which further comprises a passageway defining a portion of the airflow path 46 connecting to an inlet at the interface end 54. The chamber 50 is defined at a downstream end by the upper sealing component 38, which connects to the inner tube 62. While not shown the lower sealing component 36 and the upper sealing component 38 are configured to hold the liquid transport element 42 in the chamber 50. The aerosol generator 40 is attached to the liquid transport element 42 (e.g. it comprises a coil heater wrapped around a wick), and hence the lower sealing component 36 and the upper sealing component 38 further retain the aerosol generator 40 in the chamber 50.

The chamber 50 is defined on one side of the aerosol generator 40 by the first inner surface 91 and on an opposing of the aerosol generator 40 by the second inner surface 92. In some examples, the first inner surface 91 and the second inner surfaces 92 are exposed by openings provided by the engagement of the lower sealing component 36 to the upper sealing component 38. For example, the lower sealing component 36 and upper sealing component 38 may engage with each other to provide apertures for receiving the liquid transport element 42, and not engage with each other away from these apertures (e.g. regions of the chamber 50 tangential to the extension of the liquid transport element 42).

The aerosol generator 40 is separate from both of the first inner surface 91 and the second inner surface 92. The use of the first inner surface 91 and the second inner surface 92 in defining the chamber 50 provides increased space for airflow around the sides of the aerosol generator 40, while keeping the overall thickness of the cartridge 4 to a minimum. Furthermore, the use allows the overall thickness of cartridge 4 to be minimised, while still maintaining sufficient air gap between the aerosol generator 40 and outer housing 32 to avoid high external surface temperatures during use; which is particularly advantageous where the aerosol generator 40 is a heater.

In some examples, an aperture 98 may be formed between the upper and lower sealing components 36,38 (which may jointly be considered a sealing element) to expose the first inner wall surface 91 (a similar aperture may be provided to expose the second inner wall surface 92). For example, an aperture 98 may be formed by removing (or not providing) material of one or both of the upper and lower sealing components 36,38 to ensure that the upper and lower sealing components 36,38 are not in contact in the region of the first inner wall surface 91. As such, the sealing element (formed from one or both of the lower and upper sealing components 36,38) may be configured to define an aperture 98 exposing the first inner wall surface 91. In some examples, he aperture 98 may extend out of the plane shown in figure 2, towards regions of the chamber in which upper and lower sealing components 36, 38 are in contact in order to provide sealing for the liquid transport element 42.

Figure 3 is a schematic perspective view of an example cartridge 4 in accordance with certain embodiments of the disclosure. In comparison to the schematic view of figures 1 and 2, figure 3 depicts a cross-sectional plane which is perpendicular to longitudinal extension of the cartridge 4 (i.e. perpendicular to an axis extending from the interface end 54 to the mouthpiece outlet 60). The cross-sectional plane extends through the aerosol generator 40, liquid transport element 42, the (aerosol generation) chamber 50 and the components which define the limits or boundaries of the chamber 50. The components of figure 3 are substantially as described in relation to figures 1 and 2.

As depicted in figure 3, the chamber 50 is bounded in the plane by four different components. As discussed in relation to figure 2, the housing 32 comprises a first outer wall portion 81 defining a first inner surface 91 of the chamber 50 and a second outer wall portion 82 defines a second inner surface 92 of the chamber 50, with the second inner surface 92 being provided on an opposite side of the chamber 50 to the first inner surface 91 (e.g. the aerosol generator 40 is in the middle of the chamber 50 between the first inner surface 91 and the second inner surface 92).

In some examples, such as those in accordance with figure 3, the first outer wall portion 81 and the second outer wall portion 82 are formed by a single wall defining a circumference of the external shape of the cartridge 4. For example, the housing 32 may comprise a circular or elliptical wall (e.g. a tubular shaped portion) providing the first outer wall portion 81 and the second outer wall portion 82. Alternatively, a single wall providing the first outer wall portion 81 and the second outer wall portion 82 may have a polygonal outer cross-section (i.e. a straight or flat sided shape), or may be a combination of flat and curved surfaces forming an outer circumference of a cross section of the shape.

In some examples, where the first outer wall portion 81 and I or second outer wall portion 82 define parts (e.g. surfaces) of an interface end 6 of the cartridge 4, the first outer wall portion 81 and I or second outer wall portion 82 may be configured to be received within a receptacle of a control unit 2 of an aerosol delivery system 1 . For example, the first outer wall portion 81 and I or second outer wall portion 82 may be configured to have an external shape corresponding to a shape of a receptacle 8 of a control unit 2 so as to engage with the receptacle 8 when the interface end 6 is inserted into the receptacle 8 (e.g. their shape may ensure an interference fit is formed to aid retention of the interface end 6 in the receptacle 8).

In addition to the first outer wall portion 81 and I or second outer wall portion 82, figure 3 also depicts that the upper, or downstream, sealing component 38 define a third inner surface 93 and a fourth inner surface 94 of the chamber 50. The third inner surface 93 and fourth inner surface 94 bound, define or otherwise limit the extent of the chamber 50.

As described in relation to figure 1 , the upper, or downstream, sealing component 38 and the lower, or upstream, sealing component 36 cooperate to provide the openings for receiving the ends of the liquid transport element (e.g. capillary wick) 42. Ends of the liquid transport element 42 are shown to extend from the chamber 50, through the upper sealing component 38 and into respective pockets or conduits 48, which are fluidly connected to a reservoir 44 of a liquid aerosol generating material (not shown). The third and fourth inner surfaces 93,94 are adjacent to said openings, facing the chamber 50. In examples, in accordance with figure 3, the third and fourth inner surfaces 93,94 each extend from the first inner surface 91 to the second inner surface 92.

While not shown, it will be appreciated that the lower, or upstream, sealing component 36 may also provide one or more surfaces defining a boundary of the chamber 50. For example, the upper, or downstream, sealing component 38 may define, in part, the shape of the chamber 50 above (downstream of) the aerosol generator 40, while the lower, or upstream, sealing component 36 may define, in part the shape of the chamber below (upstream of) the aerosol generator 40 (not shown). The respective surfaces provided by the upper and lower sealing components 36,38 join or meet each other adjacent to the openings for receiving the liquid transport element 42.

As such, in some examples lower, or upstream, sealing component 36 and I or the upper, or downstream, sealing component 38 provide a sealing element (e.g. separately or in combination) between which the aerosol generator 40 extends within the chamber 50. In some examples, the sealing element (formed by one or both of the lower, or upstream, sealing component 36 and I or the upper, or downstream, sealing component 38) is configured to suspend the aerosol generator 40 within the chamber 50. For example, the sealing element may accommodate ends of liquid transport element 42 which forms a sub part of the aerosol generator 40, or otherwise positions the aerosol generator 40 within the chamber 50. In some examples, the sealing element comprises the lower and upper sealing components 36,38.

In some examples, the gaps shown between the third and fourth inner surfaces 93,94 in figure 3, in which the first and second inner surfaces 91 ,92 are exposed may be formed by configuring one or both of the upper and lower sealing components 36,38 to define apertures exposing the first and second inner wall surfaces 91 ,92. For example, an aperture 98 may be formed by removing (or not providing) material of one or both of the upper and lower sealing components 36,38 in the region between the third inner surface 93 and the fourth inner surface 94. As such, the sealing element (formed from one or both of the lower and upper sealing components 36,38) may be configured to define an aperture 98 exposing the first inner wall surface 91 , wherein the aperture 98 extends between the third inner surface 93 and the fourth inner surface 94. In examples, the aerosol generator 40 is separated from the first inner surface 91 by a first separation distance Di . In other words, a surface of the aerosol generator 40 is displaced from the first inner surface 91 by the first separation distance. In some examples, the first separation distance Di may be a minimum separation distance between the aerosol generator 40 and the first inner surface 91. In some examples, the first separation distance Di may be a minimum, maximum, or average separation distance between the aerosol generator 40 and the first inner surface 91. In some examples, the first separation distance Di may be measured between closest respective points of the aerosol generator 40 and the first inner surface 91 (e.g. respective points on the aerosol generator 40 and the first inner surface 91 at either end of the arrow Di in figure 3). In some examples, the first separation distance Di may be in the range of 1 to 3 mm.

In examples, the first outer wall portion 81 has a thickness T. The thickness T may be a minimum, maximum or average distance between the first inner surface 91 and the exterior shape (i.e. an outer surface of the first outer wall portion 81 defining the exterior shape). The thickness T may be measured between closest respective points on either side of the first outer wall portion 81 (e.g. respective points on either side of the first outer wall portion 81 at either end of the arrow T in figure 3). In some examples, the thickness T may be in the range of 0.5 to 2 mm.

In some examples, the ratio of the thickness T to the first separation distance Di is less than 1. In other words, the first separation distance Di is greater than the thickness T. In some particular examples, the ratio of the thickness T to the first separation distance Di is less than 0.5. In other words, the first separation distance Di is more than twice the thickness T.

As described above, the housing 32 may comprises a second outer wall portion 82 which also partially defines the exterior shape of the cartridge 4. The second outer wall portion 82 defines a second inner surface 92 of the chamber 50 which is on an opposite side of the chamber to the first inner surface 91 . The aerosol generator 40 is separated from the second inner surface 91. For example, the aerosol generator 40 may be separated from the second inner surface 91 by a second separation distance. The size of the second separation distance, the thickness of the second outer wall portion 82, and their ratio may be substantially as described above in relation to the separation of the first outer wall portion 81 and the aerosol generator 40. For example, the ratio of the thickness of the second outer wall portion 82 to the second separation distance may be less than 1 , and preferably less than 0.5. In some examples, the first separation distance and the second separation distance are equal (in other words, the aerosol generator 40 is provided equidistant between the first and second outer wall portions 81 ,82). In some examples, the chamber 50 is defined by a lateral extension X between the outer surface of the first outer wall part 81 and the outer surface of the second outer wall part 82. In other words, the lateral extension X of the chamber 50 is a dimension between the two surfaces defining the size (e.g. width) of the cartridge.

In some examples, the aerosol generator 40 comprises a width W parallel to (e.g. co-aligned with) the lateral extension X. For example, the lateral extension X may be considered to pass through the aerosol generator 40, and the width W may be equivalent to the portion of the lateral extension X passing through the aerosol generator 40. The width W is typically measured through the centre of the aerosol generator 40 (e.g. the centre of a circumferential cross section of a cylindrical liquid transport element 42 around which an resistive wire is wound to form the aerosol generator 40).

In some examples, the ratio of the width W to the lateral extension X of the cartridge is less than 0.5. In other words, the width W of the aerosol generator is less than half the lateral extension X of the cartridge. In some examples, the lateral extension of the cartridge is in a range between 5 mm and 10 mm.

Figure 4 is a flow chart of a method 400 for providing a cartridge 4 for an aerosol delivery system. The method starts at step 410 with providing a housing 32 comprising a first outer wall portion 81 partially defining an exterior shape of the cartridge 4 and a first inner surface 91 of a chamber 50.

In some examples, the housing 32 may be formed as a single component comprising the first outer wall portion 81 and other portions of the housing 32 (e.g. with the second outer wall portion 82, the mouthpiece end 52 and inner tube 62). For example the housing 32 may be manufactured as a single piece by injection moulding or additive manufacture. In other examples, the housing 32 may be constructed by combining two or more distinct components (e.g. using clips, adhesive and the like). In these examples, the first outer wall portion 81 may be integrally combined with one or more other portions of the housing 32. For example, the first outer wall portion 81 and the second outer wall portion 82 may be provided by a singular tube component (e.g. a cylindrical or elliptical tube).

The method continues at step 420 with providing an aerosol generator 40 in the chamber 50 defined at least in part by the first outer wall portion 81 , wherein the aerosol generator 40 is separated from the first inner surface 91 . The aerosol generator 40 is for generating an aerosol for inhalation from an aerosol-generating material.

In step 420, the aerosol generator 40 is provided such that it can be used to generate an aerosol within the chamber 50. For example, an aerosol-generating material may be provided in the chamber 50, such that the aerosol generator 40 is able to generate aerosol using the aerosol-generating material. In some examples the aerosol generator 40 may include, or be provided in combination with, a liquid transport element 42 configure to transfer liquid aerosolgenerating material from a reservoir 44 to the aerosol generator 40 for aerosolisation by the aerosol generator 40 (e.g. the aerosol generator 40 may be a heater configured to heat the liquid aerosol-generating material).

By providing the aerosol generator 40 separate from the first inner surface 91 , it is meant that the aerosol generator 40 does not contact the first inner surface 91 . A separation distance Di exists between the aerosol generator 40 and the first inner surface 91. The separation distance describes the size of the void or space within which air may flow (Air may also flow through other regions of the chamber 50 such as a gap between the aerosol generator 40 and the second inner surface 92).

The void provides a space in which generated aerosol (or vapour) may be released into the air pathway, and also prevents or inhibits the direct transfer of heat from the aerosol generator 40 to the first inner surface 91 via conduction. The use of the first outer wall portion 81 to also define the first inner surface 91 allows for a reduced cartridge 4 thickness while maximising the size of the void between the aerosol generator 40 and the first inner surface 91 (thereby reducing the potential transfer of heat by convection or radiation). In particular, rather than having an outer wall of a certain thickness (e.g. a structural minimum required to self-support the configuration of the wall) and an aerosol generation chamber wall of a certain thickness (e.g. a structural minimum to self-support the configuration of the wall), the functionality of a distinct aerosol generation chamber wall can additionally be provided by the outer wall (i.e. by bounding the chamber with the inner surface of the outer wall).

The method 400 then ends.

It will be appreciated that while the above description has focused on some different aspects of an aerosol generator assembly having a number of different features, it will be appreciated that arrangements in accordance with other embodiments of the disclosure may include only some of these features independently of some of the other features. For example, a chamber 50 defined by surfaces in accordance with the principles discussed herein with reference to figures 2 and 3 may be implemented with an aerosol generator other than one formed by winding a coil around a wick.

Thus, there has been described a cartridge for an aerosol delivery system, the cartridge comprising a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge, and an aerosol generator for generating an aerosol for inhalation from an aerosol-generating material, wherein the aerosol generator is provided in a chamber defined at least in part by the first outer wall portion, wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface.

There has also been described an aerosol delivery system for aerosolising an aerosolgenerating material, the aerosol delivery system comprising a cartridge as described above.

There has further been described cartridge means for an aerosol delivery system, the cartridge means comprising housing means comprising a first outer wall portion partially defining an exterior shape of the cartridge means; and aerosol generator means for generating an aerosol for inhalation from an aerosol-generating material means, wherein the aerosol generator means is provided in a chamber defined at least in part by the first outer wall portion, wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator means is separated from the first inner surface.

There has still further been described a method of providing a cartridge for an aerosol delivery system, the method comprising providing a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge and a first inner surface of a chamber, and providing an aerosol generator, for generating an aerosol for inhalation from an aerosolgenerating material, in the chamber defined at least in part by the first outer wall portion, wherein the aerosol generator is separated from the first inner surface.

While the above described embodiments have in some respects focussed on some specific example aerosol delivery systems, it will be appreciated the same principles can be applied for aerosol delivery systems using other technologies. That is to say, the specific manner in which various aspects of the aerosol delivery system function, for example in terms of how the system is activated for use and the functionality provided by the system, are not directly relevant to the principles underlying the examples described herein.

In order to address various issues and advance the art, this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and to teach the claimed invention(s). It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claims. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein, and it will thus be appreciated that features of the dependent claims may be combined with features of the independent claims in combinations other than those explicitly set out in the claims. The disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. A cartridge for an aerosol delivery system, the cartridge comprising: a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge; and an aerosol generator for generating an aerosol for inhalation from an aerosolgenerating material, wherein the aerosol generator is provided in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator is separated from the first inner surface.

2. The cartridge of claim 1 , wherein the aerosol generator is separated from the first inner surface by a first separation distance, and wherein the first outer wall portion has a thickness between the first inner surface and the exterior shape, wherein the ratio of the thickness to the first separation distance is less than 1.

3. The cartridge of claim 2, wherein the ratio of the thickness to the first separation distance is less than 0.5.

4. The cartridge of any of claims 1 to 3, wherein the housing comprises a second outer wall portion partially defining the exterior shape of the cartridge, wherein second outer wall portion defines a second inner surface of the chamber, the second inner surface on an opposite side of the chamber to the first inner surface, and wherein the aerosol generator is separated from the second inner surface.

5. The cartridge of claim 4, wherein the chamber is defined by a lateral extension between the first inner surface and the second inner surface, and wherein the aerosol generator comprises a width parallel with the lateral extension, wherein the ratio of the width to the lateral extension of the cartridge is less than 0.5.

6. The cartridge of claim 5, wherein the lateral extension of the cartridge is between 3mm and 8 mm.

7. The cartridge of any of claims 4 to 6, wherein the first outer wall portion and the second outer wall portion are formed by a single wall defining a circumference of the external shape of the cartridge.

8. The cartridge of any of claim 1 to 7, wherein the first outer wall portion partially defines an interface end of the cartridge which is configured to be received within a receptacle of a control unit of an aerosol delivery system.

9. The cartridge of any of claim 1 to 8, wherein the aerosol generator extends within the chamber between a third inner surface of the chamber and a fourth inner surface of the chamber, wherein the cartridge further comprises a sealing element defining the third inner surface and the fourth inner surface, the sealing component configured to suspend the aerosol generator within the chamber.

10. The cartridge of claim 9, wherein the sealing element is configured to define an aperture exposing the first inner wall surface, wherein the aperture extends between the third inner surface and the fourth inner surface.

11 . The cartridge of any of claim 1 to 10, wherein the aerosol generator comprises resistive heater.

12. The cartridge of claim 11 , wherein the resistive heater comprises a wick and coil heater.

13. An aerosol delivery system for aerosolising an aerosol-generating material, the aerosol delivery system comprising a cartridge in accordance with any of claims 1 to 12.

14. Cartridge means for an aerosol delivery system, the cartridge means comprising: housing means comprising a first outer wall portion partially defining an exterior shape of the cartridge means; and aerosol generator means for generating an aerosol for inhalation from an aerosolgenerating material means, wherein the aerosol generator means is provided in a chamber defined at least in part by the first outer wall portion; wherein the first outer wall portion defines a first inner surface of the chamber, and wherein the aerosol generator means is separated from the first inner surface.

15. A method of providing a cartridge for an aerosol delivery system, the method comprising: providing a housing comprising a first outer wall portion partially defining an exterior shape of the cartridge and a first inner surface of a chamber; and providing an aerosol generator, for generating an aerosol for inhalation from an aerosol-generating material, in the chamber defined at least in part by the first outer wall portion, wherein the aerosol generator is separated from the first inner surface.