CN118436134A

CN118436134A - Aerosol delivery subsystem and method of making same

Info

Publication number: CN118436134A
Application number: CN202310094047.8A
Authority: CN
Inventors: 李瑞凡
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-02-03
Filing date: 2023-02-03
Publication date: 2024-08-06
Also published as: GB202307358D0

Abstract

An aerosol delivery subsystem and method of manufacturing the same are disclosed. An aerosol delivery subsystem (100) for adjusting a fluid flow in an aerosol delivery system (1), comprising: a primary air inlet (28) into the subsystem (100); a secondary air inlet (128) into the subsystem (100); a fluid flow sensor (30); and a baffle assembly (150), wherein: the primary air inlet (28) provides an air flow path into the subsystem (100) via the fluid flow sensor (30); the secondary air inlet (128) provides an air flow path into the subsystem (100) bypassing the fluid flow sensor (30); and the baffle assembly (150) is movable to a plurality of positions relative to the subsystem (100) to selectively vary the air flow through one or more of the primary air inlet (28) and the secondary air inlet (128).

Description

Aerosol delivery subsystem and method of making same

Technical Field

The present disclosure relates to aerosol delivery systems, such as, but not exclusively, nicotine delivery systems (e.g., e-cigarettes).

Background

Aerosol delivery systems, such as electronic cigarettes (e-cigarettes), typically contain an aerosol-generating material, such as a chamber of a source solid or liquid, which may contain an active substance and/or a flavoring agent, from which an aerosol or vapor is generated for inhalation by a user, for example by thermal evaporation. Accordingly, aerosol delivery systems generally comprise an aerosol-generating region comprising an aerosol generator (e.g. a heating element) arranged to evaporate or atomize a portion of the precursor material to generate a vapour or aerosol in the aerosol-generating region. When a user inhales on the device and powers the vaporiser, air is drawn into the device through the inlet aperture and along the inlet channel connected to the aerosol-generating region, where it mixes with the vaporised precursor material to form a condensed aerosol. There is an outlet channel connecting the aerosol-generating region to an outlet in a mouthpiece (mouthpiece) and air inhaled into the aerosol-generating region continues along an outlet flow path to the mouthpiece outlet as it is inhaled on the mouthpiece, carrying aerosol therewith for inhalation by the user. Some electronic cigarettes may also include a flavoring element in the airflow path through the device to impart additional flavor. Such devices may sometimes be referred to as mixing devices, and the flavouring element may for example comprise a portion of tobacco arranged in the airflow path between the aerosol-generating region and the mouthpiece such that aerosol/condensed aerosol inhaled by the device passes through the portion of tobacco before exiting the mouthpiece for inhalation by a user.

WO 2016/012774, incorporated herein by reference, discloses an electronic vapor supply system that includes a collar surrounding a housing for a user to adjust the alignment between one or more air inlet holes of the housing and the collar to provide different levels of ventilation to the system.

WO 2017/046566, incorporated herein by reference, discloses an aerosol supply system having an airflow regulator downstream of an air inlet in an airflow path.

The user experience of electronic aerosol delivery systems is continually improving as such systems become finer in the nature of the vapors they provide to the user for inhalation, for example in terms of deep lung delivery, mouthfeel and performance consistency. Nevertheless, methods for further improving these aspects of electronic vapor supply systems remain of interest. In particular, it is of interest to develop such methods wherein the aerosol delivery system includes functionality that enables the operational characteristics of the system to be adjusted to address certain operational characteristics that may be desired by a user.

Various approaches are described herein that seek to help solve or mitigate at least some of the problems discussed above.

Terminology

Conveying system

As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user in use, and includes:

Combustible sol supply systems such as cigarettes, cigarillos, cigars, and tobacco (based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials) that is used or self-rolled or self-made into cigarettes;

a non-combustible aerosol supply system that releases a compound from an aerosol-generating material without burning the aerosol-generating material, such as an electronic cigarette, a tobacco heating product, and a combined aerosol-generating hybrid system that uses an aerosol-generating material; and

An aerosol-free delivery system for orally, nasally, transdermally or otherwise delivering at least one substance to a user without forming an aerosol, including but not limited to a lozenge, chewing gum, patch, article comprising an inhalable powder, and oral product such as oral tobacco comprising snuff or snuff, wherein the at least one substance may or may not comprise nicotine.

Combustible sol supply system

In accordance with the present disclosure, a "combustible" aerosol supply system is a system in which the constituent aerosol-generating materials (or components thereof) of the aerosol supply system burn or burn away during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible sol supply system, such as a system selected from cigarettes, cigarillos, and cigars. In some embodiments, the present disclosure relates to components for a combustible sol supply system, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components such as capsules, filaments or beads, or papers such as filter plug wrap, tipping paper or cigarette paper.

Non-combustible sol supply system

According to the present disclosure, a "non-combustible" aerosol-supply system is a system in which the constituent aerosol-generating materials (or components thereof) of the aerosol-supply system do not burn or combust in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible sol supply system, such as a powered non-combustible sol supply system. In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also referred to as a vaporisation 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 sol supply system is an aerosol-generating material heating system, also referred to as a non-combustion thermal system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials, one or more of which may be heated, to generate an aerosol. Each aerosol-generating material may be in the form of a solid, liquid or gel, for example, and may or may not comprise nicotine. In some embodiments, the mixing system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

In general, a non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply device. In some embodiments, the present disclosure relates to a consumable comprising an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These consumables are sometimes referred to throughout this disclosure as articles of manufacture.

In some embodiments, the non-combustible sol supply system (such as its non-combustible sol supply device) may include a power source and a controller. The power source may be, for example, a power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate that can be energized to distribute power in the form of heat to the aerosol-generating material or to a heat transfer material in the vicinity of the exothermic power source.

In some embodiments, the non-combustible aerosol supply system may include a region for receiving a consumable, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and/or an aerosol modifier. In some embodiments, a consumable for use with a non-combustible aerosol provision device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

No aerosol delivery system

In some embodiments, the delivery system is an aerosol-free delivery system that orally, nasally, transdermally, or otherwise delivers at least one substance to a user without aerosol formation, including but not limited to lozenges, chewing gums, patches, products comprising inhalable powders, and oral products such as oral tobacco comprising snuff or wet 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 aerosolized. Any of the materials may include one or more active ingredients, one or more flavoring agents, one or more aerosol former materials, and/or one or more other functional materials, as appropriate.

Active substances

In some embodiments, the substance to be delivered comprises an active substance. An 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 health foods, nootropic agents and psychotropic agents. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise, for example, nicotine, caffeine, taurine, theophylline, vitamins such as B6 or B12 or C, melatonin, cannabinoids or components, derivatives or combinations thereof. The active substance may comprise one or more ingredients, derivatives or extracts of tobacco or other plant preparations.

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

As described herein, the active may include one or more cannabinoids or terpenes. As described herein, the active substance may comprise or be derived from one or more botanical preparations or components, derivatives or extracts thereof. As used herein, the term "plant preparation" includes any material derived from a plant preparation including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, husks, and the like. Alternatively, the material may comprise a synthetically derived active compound naturally occurring in a plant preparation. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, flakes, or the like.

Examples of botanical agents are tobacco, eucalyptus, star anise, cocoa, fennel, citronella, spearmint, loyo Bai Si tea tree, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice, green tea, mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, star anise, basil, bay leaf, cardamon, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, sambucus chinensis, vanilla, wintergreen, perilla, turmeric, sandalwood, coriander, bergamot, orange flower, myrtle, blackcurrant, valerian, peppermint, nutmeg, damiana (damien), marjoram, olive, melissa leaf, lemon basil, vanilla, caraway, verbena, long Songshe, pelargil, mulberry, korean ginseng, tea, matrine, tea, macadamia, chlorophyll, macadamia, or any combination thereof. The mint may be selected from the following mint varieties: peppermint, spearmint, peppermint, pineapple, spearmint, and apple mint.

In some embodiments, the active substance comprises or is derived from one or more botanical agents or ingredients, derivatives or extracts thereof, and the botanical agent is tobacco. In some embodiments, the active substance comprises or is derived from one or more botanical agents or ingredients, derivatives or extracts thereof, and the botanical agents are selected from eucalyptus, star anise, cocoa. In some embodiments, the active substance comprises or is derived from one or more botanical preparations or ingredients, derivatives or extracts thereof, and the botanical preparations are selected from the group consisting of loyi Bai Si tea tree and fennel.

Flavoring agent

In some embodiments, the substance to be delivered includes a flavoring agent. As used herein, the terms "flavor" and "flavoring" refer to substances that can be used to produce a desired taste, aroma, or other somatosensory sensation in an adult consumer product, as permitted by local regulations. They may include naturally occurring flavoring materials, botanical preparations, synthetically obtained materials or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, japanese white magnolia leaf, chamomile, fenugreek, clove, maple, green tea, menthol, japanese mint, anise, cinnamon, turmeric, indian flavoring, asian flavoring, herb, wintergreen, cherry, berry, raspberry, cranberry, peach, apple, orange, mango, radix Clematidis, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, red plum, bouillon, su Lan, gold, black nightshade, spearmint, peppermint, lavender, aloe, cardamom, celery, west indian bitter tree, nutmeg, sandalwood, bergamot, geranium, arabian tea, sorghum, betel leaf, coriander, pine, honey, vanilla, lemon oil, orange, cinnamon oil, lemon oil, orange, willow leaf, peppermint, camphor tree, chamomile, jasmine, tree, jasmine, leaf, black nightshade, herba Solani Nigri, herba Salvia officinalis, herba Sali, herba Salvia officinalis, tea such as green or black tea, thyme, juniper, elderberry, basil, laurel leaf, cumin, oregano, chilli powder, rosemary, saffron, lemon peel, peppermint, perilla, turmeric, coriander, myrtle, blackcurrant, valerian, sweet pepper, nutmeg, damiana, marjoram, olive, chive leaf, lemon basil, chive, caraway, verbena, long Songshe, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, dextrose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic or natural ingredients or mixtures thereof. They may be in any suitable form, for example, a liquid such as oil, a solid such as powder, or a gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes a flavoring component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring component extracted from tobacco.

In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory sensation generally induced and perceived by the stimulation chemistry of the fifth cranial nerve (trigeminal nerve), in addition to or in lieu of the flavor or gustatory nerve, and these may include agents that provide heating, cooling, tingling, numbing effects. Suitable thermal effectors may be, but are not limited to, vanillyl diethyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

Aerosol generating material

An aerosol-generating material is a material capable of aerosol generation, for example when heated, irradiated or energized in any other way. The 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 a flavour. In some embodiments, the aerosol-generating material comprises an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments of the present invention, in some embodiments,

The amorphous solid may be a xerogel. Amorphous solids are solid materials in which some fluid, such as a liquid, may be retained. In some embodiments, the aerosol-generating material may comprise, for example, from about 50 wt%, 60 wt% or 70 wt% amorphous solids to about 90 wt%, 95 wt% or 100 wt% amorphous solids.

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 materials.

Aerosol former material

The aerosol former material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, glycerol tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

Functional material

The one or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

Substrate material

The material may be present on or in a carrier to form a substrate. The carrier may be or comprise, for example, paper, card, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the carrier comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is located on one or both sides of the material.

Consumable product

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

Susceptor

Susceptors are materials that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that penetration of it with a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that penetration of the heating material with a varying magnetic field causes hysteresis heating of the heating material. The susceptor may be either electrically conductive or magnetic such that the susceptor may be heated by two heating mechanisms. The device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

Aerosol modifier

An aerosol-modifying agent is a substance typically located downstream of the aerosol-generating region that is configured to alter the aerosol generated, for example by altering the taste, flavor, acidity or other characteristics of the aerosol. The aerosol modifier may be provided in an aerosol modifier release component operable to selectively release the aerosol modifier. The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifiers may, for example, include one or more of flavours, colourants, water and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid or a gel. The aerosol modifier may be in the form of a powder, wire or particle. The aerosol modifier may be free of filter material.

Aerosol generator

An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy in order 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 generation of an aerosol 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 vapor delivery systems), such as nebulizers or e-cigarettes. Throughout the following description, the term "e-cigarette" or "e-cigarette" may be used at times, but it will be appreciated that this term may be used interchangeably with aerosol delivery system/device and electronic aerosol delivery system/device. Furthermore, as is common in the art, the terms "aerosol" and "vapor" and related terms such as "vaporization," "volatilization," and "aerosolization" are often used interchangeably.

Aerosol delivery systems (e-cigarettes) typically (but not always) include a modular assembly comprising a reusable device portion and a replaceable (disposable/consumable) cartridge portion. The replaceable cartridge device portion will typically include an aerosol-generating material and a vaporizer (which may be collectively referred to as a "aerosol cartridge"), and the reusable device portion will include a power source (e.g., a rechargeable-element, for example, the reusable device portion typically includes a user interface for receiving user input and displaying operating status characteristics, and the replaceable cartridge device portion in some cases includes a temperature sensor for helping control of temperature.

Electronic cigarettes typically have a generally elongated shape. To provide a specific example, certain embodiments of the present disclosure will be considered to include such generally elongate two-part systems employing disposable cartridges. However, it should be understood that the basic principles described herein may be equally applicable to different configurations, such as single-part systems or modular systems comprising more than two parts, refillable devices and disposable disposables, as well as other monolithic shapes, e.g. based on so-called box-mode high performance devices that typically have a box shape. More generally, it will be understood that certain embodiments of the present disclosure are based on aerosol delivery systems that are operatively configured to provide functionality according to the principles described herein, and that the configuration aspects of the system configured to provide functionality according to certain embodiments of the present disclosure are not of major significance.

Disclosure of Invention

The present invention provides an aerosol delivery subsystem 100 for regulating fluid flow in an aerosol delivery system 1, the aerosol delivery subsystem comprising: an air inlet 28; a baffle assembly 150 having an aperture 154 therethrough; and an engagement mechanism for positively engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, wherein different ones of the plurality of predetermined positions result in different degrees of alignment between the baffle assembly aperture 154 and the air inlet 28 to vary the air flow through the air inlet 28.

The present invention also provides a method of manufacturing an aerosol delivery subsystem for an aerosol delivery system, the method comprising providing: an air inlet 28; a baffle assembly 150 having an aperture 154 therethrough; a coupling mechanism; the method includes configuring the engagement mechanism for securely engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, wherein different ones of the plurality of predetermined positions result in different degrees of alignment between the baffle assembly aperture 154 and the air inlet 28 to vary the air flow through the air inlet 28.

The present invention also provides an aerosol delivery subsystem 100 for regulating fluid flow in an aerosol delivery system 1, the aerosol delivery subsystem comprising: a primary air inlet 28 into subsystem 100; a secondary air inlet 128 into subsystem 100; a fluid flow sensor 30; and a baffle assembly 150, wherein: the primary air inlet 28 provides an air flow path into the subsystem 100 via the fluid flow sensor 30; secondary air inlet 128 provides an air flow path that bypasses fluid flow sensor 30 into subsystem 100; and the baffle assembly 150 may be moved to a plurality of positions relative to the subsystem 100 to selectively vary the flow of air through one or more of the primary air inlet 28 and the secondary air inlet 128.

The present invention also provides a method of manufacturing an aerosol delivery subsystem for an aerosol delivery system, the method comprising providing: a main air inlet 28; a secondary air inlet 128; a fluid flow sensor 30; and a baffle assembly 150, the method comprising configuring the subsystem, wherein: the primary air inlet 28 provides an air flow path into the subsystem 100 via the fluid flow sensor 30; secondary air inlet 128 provides an air flow path that bypasses fluid flow sensor 30 into subsystem 100; and the baffle assembly 150 may be moved to a plurality of positions relative to the subsystem 100 to selectively vary the flow of air through one or more of the primary air inlet 28 and the secondary air inlet 128.

The invention also provides additional embodiments as described in the dependent claims.

The claimed invention generally provides a sub-assembly or subsystem that is suitable for use in, or is configured for use in, an aerosol delivery system. The subsystem may form part of an aerosol delivery system in general and may form part of a reusable device and/or a consumable cartridge in particular.

The claimed invention may advantageously provide adjustable operating characteristics to address certain characteristics that may be desired by a user.

Drawings

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

fig. 1 is a schematic cross-sectional view of an aerosol delivery system according to some embodiments of the present disclosure.

Fig. 2 is a schematic perspective view of an aerosol delivery system including a baffle assembly for adjusting air flow through the system according to some embodiments of the present disclosure.

Fig. 3 is a schematic perspective end view of an aerosol delivery subsystem including a baffle assembly for adjusting air flow according to some embodiments of the present disclosure.

Fig. 4 a-4 c are schematic perspective views of an aerosol delivery subsystem according to a first specific embodiment of the present disclosure.

Fig. 5 a-5 e are schematic perspective views of an aerosol delivery subsystem according to a second specific embodiment of the present disclosure.

Fig. 6 a-6 c are schematic perspective views of an aerosol delivery subsystem according to a third particular embodiment of the present disclosure.

Fig. 7 a-7 c are schematic perspective views of an aerosol delivery subsystem according to a fourth particular embodiment of the present disclosure.

Fig. 8 a-8 c are schematic illustrations of how the baffle assembly of the first embodiment of fig. 4 a-4 c moves to adjust the air flow through the subsystem.

Fig. 9 a-9 c are schematic illustrations of how the baffle assembly of the second embodiment of fig. 5 a-5 d moves to adjust the air flow through the subsystem.

Fig. 10 a-10 c are schematic illustrations of how the baffle assembly of the third embodiment of fig. 6 a-6 c moves to adjust the air flow through the subsystem.

Fig. 11 a-11 c are schematic illustrations of how the baffle assembly of the fourth embodiment of fig. 7 a-7 c moves to adjust the air flow through the subsystem.

Fig. 12 a-12 c are schematic diagrams of an aerosol delivery subsystem according to a fifth particular embodiment of the present disclosure.

Detailed Description

Aspects and features of certain examples and embodiments are described herein. Certain aspects and features of certain examples and embodiments may be routinely implemented and for brevity these will not be described in detail. Accordingly, it should be understood that aspects and features of the apparatus and methods discussed herein, which are not described in detail, may be implemented in accordance with any suitable conventional technology.

Fig. 1 is a cross-sectional view of an aerosol delivery system 1 according to certain embodiments of the present disclosure, providing an introduction to the components and their functionality of a two-part aerosol delivery system. The system 1 includes a baffle assembly 150 that will be described in more detail later with reference to the drawings.

In this first embodiment, the aerosol delivery system 1 comprises two main parts, namely a reusable part 2 and a replaceable/disposable cartridge part 4. In normal use, the reusable part 2 and the cartridge part 4 are releasably coupled together at the junction 6. When the cartridge portion 4 runs out or the user simply wishes to switch to a different cartridge portion 4, the cartridge portion 4 may be removed from the reusable portion 2 and a replacement cartridge portion 4 attached to the reusable portion 2 at its location. The joint 6 provides structural, electrical and gas flow path connection between the two parts 2, 4 and may be established according to conventional techniques, for example based on screw threads, magnetic or bayonet fastening, with suitably arranged electrical contacts and openings for suitably establishing electrical connection and gas flow path between the two parts 2, 4. The particular manner in which the cartridge portion 4 is mechanically mounted to the reusable portion 2 is not critical to the principles described herein, but is assumed herein to include magnetic couplings (not shown in fig. 1) for purposes of specific examples. It should also be appreciated that in some implementations, the junction 6 may not support electrical and/or airflow path connections between the respective portions 2, 4. For example, in some implementations, the aerosol generator may be provided in the reusable portion 2 rather than in the cartridge portion 4, or the power transfer from the reusable portion 2 to the cartridge portion 4 may be wireless (e.g., based on electromagnetic induction) such that an electrical connection between the reusable portion 2 and the cartridge portion 4 is not required. Furthermore, in some implementations, the airflow through the e-cigarette may not pass through the reusable portion 2, thereby eliminating the need for an airflow path connection between the reusable portion 2 and the cartridge portion 4. In some cases, when these reusable portion 2 and cartridge portion 4 are coupled together for use, a portion of the airflow path may be defined at the junction between a portion of reusable portion 2 and a portion of cartridge portion 4.

According to certain embodiments of the present disclosure, the cartridge/consumable portion 4 may be substantially conventional. In fig. 1, the cartridge portion 4 includes a cartridge housing 42 formed of a plastic material. The cartridge housing 42 supports the other components of the cartridge portion 4 and provides a mechanical interface 6 with the reusable portion 2. The cartridge housing 42 is generally circularly symmetric about a longitudinal axis along which the cartridge portion 4 is coupled to the reusable portion 2. In this example, the barrel portion 4 has a length of about 4cm and a diameter of about 1.5 cm. However, it should be understood that in different implementations, the specific geometry, and more generally, the overall shape and materials used may be different.

Within the cartridge housing 42 is a chamber or reservoir 44 containing an aerosol-generating material. In the example schematically illustrated in fig. 1, the reservoir 44 stores a supply of liquid aerosol-generating material. In this example, the reservoir 44 has an annular shape with an outer wall defined by the cartridge housing 42 and an inner wall defining an airflow path 52 through the cartridge portion 4. The reservoir 44 is closed at each end with an end wall to contain aerosol-generating material. The reservoir 44 may be formed in accordance with conventional techniques, for example, it may comprise a plastic material and be integrally molded with the cartridge housing 42.

The cartridge/consumable portion 4 further comprises an aerosol generator 48 positioned towards the end of the reservoir 44 opposite the mouthpiece outlet 50. It should be appreciated that in a two-part system such as that shown in fig. 1, the aerosol generator 48 may be in either the reusable part 2 or the cartridge part 4. For example, in some embodiments, an aerosol generator 48 (e.g., a heater, which may be in the form of a wick and coil arrangement as shown, a ceramic heater, a distiller, which may be formed of sintered metal fiber material or other porous conductive material, or any suitable alternative aerosol generator) may be included in the reusable portion 2 and brought into proximity with a portion of the aerosol generator material in the cartridge portion 4 when the cartridge portion 4 is engaged with the reusable portion 2. In such embodiments, the cartridge portion 4 may comprise a portion of the aerosol-generating material and the aerosol generator 48 comprising a heater is at least partially inserted into or at least partially surrounds the portion of the aerosol-generating material when the cartridge portion 4 is engaged with the reusable portion 2.

In the example of fig. 1, a wick 46 in contact with the aerosol generator 48 extends transversely through the cartridge air flow channel 52, the ends of which extend into the reservoir 44 of liquid aerosol-generating material through openings in the inner wall of the reservoir 44. The opening in the interior wall of reservoir 44 is sized to substantially match the size of wick 46 to provide a reasonable seal against leakage from reservoir 44 into the cartridge airflow path without unduly compressing wick 46, which may be detrimental to its fluid transfer performance.

The wick 46 and aerosol generator 48 are arranged in the cartridge airflow path 52 such that the area of the cartridge airflow path 52 surrounding the wick 46 and heater 48 effectively defines the vaporisation area of the cartridge portion 4. The aerosol-generating material in the reservoir 44 permeates the wick 46 through the end of the wick that extends into the reservoir 44 and is drawn along the wick by surface tension/capillary action (i.e., wicking). Aerosol generator 48 in the example includes a resistive wire wrapped around wick 46. In the example of fig. 1, heater 48 comprises a nichrome (Cr 20Ni 80) wire and wick 46 comprises a glass fiber bundle, but it should be understood that the particular aerosol generator configuration is not critical to the principles described herein. In use, power may be supplied to the aerosol generator 48 to evaporate an amount of aerosol-generating material (aerosol-generating material) that is drawn by the wick 46 into the vicinity of the aerosol generator 48. The vaporized aerosol-generating material may then be entrained in air drawn along the cartridge airflow path from the vaporization region toward the mouthpiece outlet 50 for inhalation by a user.

As described above, the rate at which the aerosol-generating material is vaporized by the aerosol generator 48 will depend on the amount (level) of power supplied to the aerosol generator 48. Accordingly, electrical power may be applied to the aerosol generator 48 to selectively generate aerosol from the aerosol-generating material in the cartridge portion 4, and furthermore, the rate of aerosol generation may be varied by varying the amount of power supplied to the aerosol generator 48, for example by pulse width and/or frequency modulation techniques.

The reusable portion 2 comprises a housing 12 having an opening defining an air inlet 28 for the electronic cigarette, a power source 26 (e.g., a battery) for providing operating power to the electronic cigarette, a control circuit/controller 22 for controlling and monitoring operation of the electronic cigarette, a first user input button 14, a second user input button 16, and a visual display 24. The reusable portion 2 further includes a baffle assembly 150 across the inlet 28. The baffle assembly 150 is adjustable to vary the flow of air through the downstream air inlet 28 and will be described in more detail later with reference to subsequent figures.

The housing 12 may be formed of, for example, a plastic or metal material and in this example has a circular cross-section that generally conforms to the shape and size of the barrel portion 4 so as to provide a smooth transition between the two portions 2, 4 at the junction 6. In this example, the reusable portion 2 has a length of about 8cm, so that when the cartridge portion 4 and the reusable portion 2 are coupled together, the overall length of the e-cigarette is about 12cm. However, as already noted, it should be understood that the overall shape and proportions of an electronic cigarette implementing embodiments of the present disclosure are not critical to the principles described herein.

The air inlet 28 is connected to the air flow path 51 through the reusable part 2. When the reusable part 2 and the cartridge part 4 are connected together, the airflow path 51 is in turn connected to the cartridge airflow path 52 through the junction 6. Thus, when a user inhales on the mouthpiece opening 50, air is drawn through the air inlet 28, along the reusable portion of the airflow path 51, through the junction 6, through the aerosol-generating region (vaporized aerosol-generating material is entrained in the airflow) adjacent the aerosol generator 48, along the cartridge airflow path 52, and out through the mouthpiece opening 50 for inhalation by the user.

The power supply 26 in this example is rechargeable and may be of a conventional type, such as is commonly used in electronic cigarettes and other applications where a relatively high current is required to be provided in a relatively short period of time. The power supply 26 may be recharged through a charging connector (e.g., a USB connector) in the reusable part housing 12.

A first user input button 14 and/or a second user input button 16 may be provided, which in this example is a conventional mechanical button, for example comprising a spring-mounted part that can be pressed by a user to establish electrical contact. In this regard, an input button may be considered an input device for detecting user input, and the particular manner in which the button is implemented is not important. These buttons may be assigned for a variety of functions, such as turning the aerosol delivery system 1 on and off, and adjusting user settings such as the power to be supplied from the power supply 26 to the aerosol generator 48. However, including user input buttons is optional, and in some embodiments buttons may not be included.

A display 24 may be provided to provide a visual indication to the user of various characteristics associated with the aerosol delivery system, such as current power setting information, remaining power supply power, etc. The display may be implemented in various ways. In this example, display 24 comprises a conventional pixelated LCD screen that may be driven to display desired information according to conventional techniques. In other implementations, the display may include one or more discrete indicators, such as LEDs, arranged to display desired information, such as by a particular color and/or sequence of flashes. More generally, the manner in which the display 24 is provided and the information is displayed to the user using the display is not critical to the principles described herein. For example, some embodiments may not include a visual display and/or may include other means for providing information to a user related to the operating characteristics of the aerosol delivery system, such as using an audio signal, or may not include any means for providing information to a user related to the operating characteristics of the aerosol delivery system.

The controller 22 is suitably configured/programmed to control the operation of the aerosol delivery system 1 to provide functionality in accordance with embodiments of the present disclosure as further described herein, as well as to provide conventional operational functionality of the aerosol delivery system 1 consistent with established techniques for controlling such devices. The controller (processor circuit) 22 may be considered to logically comprise various sub-units/circuit elements associated with different aspects of the operation of the aerosol delivery system 1. In this example, the controller 22 includes: a power supply control circuit for controlling the supply of power from the power supply 26 to the aerosol generator 48 in response to user input; user programming circuitry 20 for establishing configuration settings (e.g., user-defined power settings) in response to user input; and other functional units/circuits associated with the conventional operational aspects of the e-cigarette, such as display driver circuitry and user input detection circuitry, in accordance with the principles described herein. It should be appreciated that the functionality of the controller 22 may be provided in a variety of different ways, for example using one or more suitably programmed programmable computers and/or one or more suitably configured application specific integrated circuits/chips/chipsets to provide the desired functionality.

The function of the controller 22 is further described herein. For example, the controller 22 may include an Application Specific Integrated Circuit (ASIC) or microcontroller for controlling the aerosol delivery device. The microcontroller or ASIC may include a CPU or microprocessor. The operation of the CPU and other electronic components is typically controlled, at least in part, by software programs running on the CPU (or other components). Such software programs may be stored in a non-volatile memory such as ROM, which may be integrated into the microcontroller itself, or provided as a separate component. The CPU can access the ROM to load and execute the respective software programs when necessary.

The reusable portion 2 includes an airflow sensor 30 electrically connected to the controller 22. In most embodiments, the airflow sensor 30 comprises a so-called "puff sensor", wherein the airflow sensor 30 is used to detect when a user is inhaling on the device. In some embodiments, the airflow sensor 30 includes a switch in the electrical path that provides 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 a switch when subjected to a particular range of pressures such that once the pressure in the vicinity of the airflow sensor 30 drops below a threshold, current can flow from the power source 26 to the aerosol generator 48. The threshold value may be set to an experimentally determined value to correspond to a characteristic value associated with the start of user suction. In other embodiments, the airflow sensor 30 is connected to the controller 22, and the controller distributes power from the power source 26 to the aerosol generator 48 according to signals received by the controller 22 from the airflow sensor 30. The particular manner in which the signal output from the airflow sensor 30 (which may include a measurement of the 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 may be performed according to any method known to those skilled in the art.

In the example shown in fig. 1, the airflow sensor 30 is mounted on a Printed Circuit Board (PCB) 31, but this is not required. The airflow sensor 30 may include any sensor configured to determine an airflow characteristic in an airflow path 51 disposed between the air inlet 28 and the nozzle opening 50, such as a pressure sensor or transducer (e.g., a membrane or solid state pressure sensor), a combined temperature and pressure sensor, or a microphone (e.g., an electret-type microphone) that is sensitive to changes in air pressure including acoustic signals. The airflow sensor 30 is located within a sensor cavity or chamber 32 that includes an interior space defined by one or more chamber walls 34. The sensor cavity 32 includes one or more areas inside the chamber wall 34 in which the airflow sensor 30 may be located, either entirely or partially. In some embodiments, PCB 31 comprises one of the chamber walls of a sensor housing that includes sensor chamber/cavity 32.

The deformable membrane is disposed across an opening that communicates between the sensor cavity 32 containing the sensor 30 and a portion of the airflow path disposed between the air inlet 28 and the suction nozzle opening 50. The deformable membrane covers the opening and is attached to one or more chamber walls according to the methods described further herein.

As further described herein, the aerosol delivery system 1 comprises a communication circuit configured to enable a connection to be established with one or more further electronic devices (e.g., a storage/charging tank, and/or a refill/charging base) to enable data transfer between the aerosol delivery system 1 and the further electronic devices. In some embodiments, the communication circuitry is integrated into the controller 22, while in other embodiments it is implemented separately (e.g., including separate application specific integrated circuits/chips/chipsets). For example, the communication circuit may comprise a separate module to the controller 22 that provides dedicated data transfer functions for the aerosol delivery device when connected to the controller 22. In some embodiments, the communication circuit is configured to support communication between the aerosol delivery system 1 and one or more further electronic devices via a wireless interface. The communication circuit may be configured to support wireless communication between the aerosol delivery system 1 and other electronic devices, such as a housing, a docking station, a computing device (such as a smart phone or PC), a base station supporting cellular communication, a relay node providing a forward connection to a base station, a wearable device, or any other portable or stationary device supporting wireless communication.

The wireless communication between the aerosol delivery system 1 and the further electronic device may be configured according to a data transmission protocol, such asZigBee、WIFI DIRECT, GSM, 2G, 3G, 4G, 5G, LTE, NFC, RFID, or generally any other wireless and/or wired network protocol or interface. The communication circuit may comprise any suitable interface for wired data connection, such as a USB-C, micro-USB or Thunderbolt interface, and may comprise pin or contact pad devices configured to engage a mating pin or contact pad on a dock, housing, cable, or other external device that may be connected to the aerosol delivery system 1.

Fig. 2 is a schematic perspective view of an aerosol delivery system 1 including a baffle assembly 150 for a user to adjust the flow of air through the system 1, according to some embodiments of the present disclosure. Unlike fig. 1, the baffle assembly 150 is located at the proximal end of the system 1, rather than at the junction 6 between the device and barrel portions 2, 4. The system 1 of fig. 2 and any other embodiments may comprise a two-part reusable system as in fig. 1, or a single-use, disposable, integral or two-part system. The system 1 further comprises a nozzle housing 60 leading at its distal end to the nozzle outlet 50.

Fig. 3 is a schematic perspective end view of the aerosol delivery subsystem 100 including a baffle assembly 150 for adjusting the airflow. The subsystem 100 may form part of the aerosol delivery system 1 in general and the reusable device 2 and/or the consumable cartridge 4 in particular. The baffle assembly 150 advantageously enables a user to vary the air flow into the system 1 and thereby vary the pressure drop they experience as they inhale on the nozzle. This provides adjustable operating characteristics to address certain characteristics that may be desired by a user.

The variable air flow may be used to adjust the resistance to draw of the aerosol delivery system. When the user inhales, the lungs actually work against the resistance to aspiration, i.e., the work required to draw air into and then through the system into the lungs. For most users, there is a range of resistance to suction that helps them to inhale steadily. However, if the suction resistance is too low, the inhalation may become too fast and unstable, whereas if the suction resistance is too high, the inhalation may become too heavy. The most suitable level of resistance to aspiration varies from one user to another depending on, for example, physiological factors. Thus, providing variable ventilation and fluid (air) flow as described herein may help a user configure the resistance to draw to appropriate values for their own personal preferences and characteristics.

In the example of fig. 3, the subsystem 100 includes a housing 12 having an opening defining an air inlet 28, 128, and a baffle assembly cavity 135 for receiving a baffle assembly 150. The baffle assembly 150 includes a baffle slider 152 and has an aperture 154 therethrough. In fig. 3, the baffle aperture 154 is aligned with a first opening in the center of the housing 12 defining the first air inlet 28, thereby providing an airflow path through both the baffle assembly 150 and the housing 12 when the first air inlet 28 and the baffle aperture 154 are aligned, as shown. The housing 12 also has an off-center second opening that is not obscured by the baffle assembly 150, forming a second (bypass) air inlet 128.

The baffle assembly 150 is movable relative to the first air inlet 28 in the housing 12, and the subsystem 100 further includes an engagement mechanism for positively engaging the baffle assembly 150 relative to the subsystem 100 in at least one of a plurality of predetermined positions (e.g., a fully open position, a fully closed position, and at least one discrete intermediate position) as the baffle assembly 150 moves relative to the air inlet 28 (or equivalently, relative to the subsystem 100 or any static portion thereof, such as the housing 12), wherein the different positions of the plurality of predetermined positions allow different amounts of air flow into the system, e.g., the different positions result in different degrees of alignment between the baffle assembly aperture 154 and the air inlet 28, to vary the air flow through the air inlet 28.

In some embodiments, the engagement mechanism includes one or more pairs of cooperating, contacting, engaging or interlocking protrusions and recesses. Any suitable shape, configuration, and combination of protrusions and recesses may be used, such as spherical caps, hemispherical or interlocking shapes, or other detent mechanisms. In particular, in some embodiments, the engagement mechanism includes a baffle assembly 150 having a baffle assembly protrusion 157 or recess 158 and a subsystem 100 (i.e., any other sub-component thereof) having a complementary protrusion 257 or recess 258 for engaging with the protrusion 157 or recess 158 on the baffle assembly 150. Further, in some embodiments, the engagement mechanism includes a baffle assembly ramp 159 and/or a complementary ramp 259 for guiding and/or biasing the baffle assembly 150 into one or more of a plurality of predetermined positions.

In some embodiments, the baffle assembly 150 includes one or more snap-fit protrusions 155 for securing the baffle assembly 150 within the subsystem 100. Such snap-fit protrusions 155 are beneficial because they provide a reliable tool-less structure. In some embodiments, the baffle snap-fit protrusion 155 includes one or more cantilevered, twisted, and/or annular snap-fit protrusions 155; baffle assembly protrusions 157 or recesses 158; and/or baffle assembly ramps 159.

In some embodiments, the baffle assembly 150 includes a baffle assembly seal 156 for sealing around the baffle assembly 150 or a portion thereof (such as the slider 152) to minimize leakage of fluid in use (particularly liquid from a cartridge having liquid in the reservoir) and/or leakage of air into or out of the baffle assembly 150 or the wider system 1. In some embodiments, the seal 156 includes a baffle assembly protrusion 157 or recess 158. The seal 156 is compressible and may include silicone.

Fig. 4 a-11 c illustrate certain exemplary embodiments of the present disclosure. All embodiments are provided as representative examples only, and are not intended to be exhaustive and/or exclusive. The features of the embodiments are considered in isolation and any feature may be selectively combined in any combination. Essentially, these embodiments detail a mechanical engagement or interlock arrangement to provide a high friction path between low friction endpoints corresponding to each engagement position (airflow configuration) to give feedback to the user so that they can understand where they are. The plurality of predetermined positions generally includes a fully open, fully closed, and one or more different partially open (intermediate) configurations, which will be discussed in more detail below with reference to fig. 8 a-11 c. Preferably, the subsystem includes an engagement mechanism for providing positive engagement in at least one partially open configuration (i.e., at least one intermediate position between the fully open and fully closed positions) to confirm to a user that they are in a predetermined intermediate position (e.g., 25%, 50%, 75% of the inlets are open). In some embodiments, the fully open and fully closed configurations may correspond to the endpoints of the shutter assembly 150, and thus these configurations do not necessarily require an active engagement mechanism to inform the user that they are in this configuration, although this may still be beneficial, such as providing a child resistant lock feature in the closed configuration.

Fig. 4 a-4 c are schematic diagrams of an aerosol delivery subsystem 100 according to a first specific embodiment of the present disclosure. Fig. 4a illustrates a slider 152 of the baffle assembly 150. Here, the slider 152 is sized and shaped to be operable by a user's finger or thumb from the base of the system (see fig. 4 c), the slider 152 being disk-shaped (stadium) in shape and having a length of about 10mm and a width of about 5 mm. More generally, the slider may be about 5-50mm long and 2-25mm wide.

The slider 152 includes an aperture 154 therethrough and two snap-fit protrusions 155 in the form of cantilevered protrusions on opposite long sides of the slider 152 for securing the baffle assembly 150 to the housing 12. In fig. 4a, each snap-fit protrusion 155 includes a baffle assembly recess 158 in the form of a hemispherical groove or spherical cap recess 158, providing secure engagement and user feedback confirming the engagement. The snap-fit protrusions 155 also include tapered walls forming baffle assembly ramps 159, as shown in fig. 4b, for guiding and/or biasing the baffle assembly 150 between and into predetermined positions, enhancing tactile feedback to a user as they engage the mechanism to alter the airflow through the system 1. Figures 8 a-8 c, discussed later, illustrate how the shutter assembly 150 moves between the predetermined positions of this first particular embodiment.

Fig. 4b also shows that the housing 12 includes complementary projections 257 in the form of spherical caps 257 for positive engagement with the baffle assembly recesses 158. For clarity, only the cap 257 is shown in fig. 4b, but in embodiments any number and/or arrangement of protrusions 157, 257 and recesses 158, 258 may be used, in particular, it is contemplated that a second opposing complementary protrusion 257 is used to engage an opposing baffle assembly recess 158. Fig. 4b also shows four baffle assembly ramps 159 on the snap-fit protrusions 155, one on each side of the recess 158. Further, the housing 12 has 3 openings: an elongated oval opening defining the central air inlet 28 and two side bypass inlets 128. In this arrangement, the baffle assembly 150 may be moved to cover the aperture 154 or align the aperture 154 with the air inlet 28.

The subsystem may include a fluid flow sensor 30 for detecting air flow through the air inlet 28, which in some embodiments has a sensor seal 130 with a cavity for receiving/positioning the sensor 30 in the subsystem and providing an air flow path thereto. Preferably, the fluid flow sensor 30 is located near or proximal to at least one of the air inlets 28, and/or the sensing portion of the fluid flow sensor 30 is exposed directly to the fluid flow path from the air inlet 28 toward the aerosol generator 48 or within the fluid flow path from the air inlet 28 toward the aerosol generator 48. The seal 130 is compressible and may include silicone.

Bypass inlet 128 provides a secondary inlet for the system to bypass some components of the subsystem, such as, for example, bypass baffle assembly 150, orifice 154 therethrough, and/or fluid flow sensor 30. The bypass inlet 128 may still be covered by the baffle assembly 150 at one or more predetermined locations to prevent air flow therethrough. The main air inlet 28 and the bypass air inlet 128 may all be the same size, e.g., about 0.5-5.0mm, 0.5-3.0mm, 0.5-2.5mm, or about 1.0-2.0mm in diameter, respectively, or they may be different sizes or shapes. In some embodiments, the diameter of the outermost bypass air inlet 128 is greater than the diameter of the innermost bypass air inlet 128. Changing the number and/or size of air inlets 28, 128 allows for fine tuning of the pressure drop performance of the device.

In some embodiments, the subsystem includes a fluid flow sensor 30 and a plurality of air inlets 28, 128, wherein the plurality of air inlets 28, 128 includes one or more primary air inlets 28 leading to the fluid flow sensor 30 and one or more secondary bypass air inlets 128 bypassing the fluid flow sensor 30, optionally wherein:

a. The primary air inlet 28 of the fluid flow sensor 30 is configured to deliver air to the aerosol generator 48 in use; and/or

B. the secondary bypass air inlet 128 is configured to deliver air to the aerosol generator 48 in use; and/or

C. The secondary bypass air inlet 128 is configured to provide an air flow through the system that bypasses the aerosol generator 48 in use.

In some embodiments, the subsystem is configured to:

When one or more primary air inlets 28 are open and provide an air flow path therethrough, power can be supplied to the aerosol generator 48; and/or

When one or more of the primary air inlets 28 or the secondary air inlets 128 are open and provide an airflow path therethrough, power can be supplied to the aerosol generator 48; and/or

Adjusting the power to the aerosol generator 48 when moving between the predetermined positions, thereby providing a non-zero degree alignment between the baffle assembly aperture 154 and the primary air inlet 28; and/or

When all of the primary air inlets 28 are closed, power to the aerosol generator 48 is inhibited; and/or

When all of the air inlets 28, 128 are closed, such as to provide a child resistant lock, power to the aerosol generator 48 is inhibited.

The subsystem 100 may be configured to activate the aerosol generator 48 in response to the fluid (air) flow sensor 30 sensing fluid (air) flow and/or deactivate the aerosol generator 48 when no fluid (air) flow is sensed. The fluid flow sensor 30 or sensor seal 130 may include a complementary protrusion 257 or recess 258 for engagement with the baffle assembly protrusion 157 or recess 258.

Fig. 4c shows an axial vertical cross-section through the subsystem 100 and illustrates that the baffle assembly 150 includes a baffle assembly seal 156 for sealing around the baffle assembly aperture 154. Fig. 4c also shows that the shutter assembly slider 152 has surface features in the form of a plurality of alternating ridges and recesses extending along its length that extend perpendicular to the axis of movement of the shutter between predetermined positions to provide a tactile sensation to the slider 152. In further embodiments, the baffle assembly slider 152 includes one or more curved recesses, such as rounded corners, for receiving a portion of a user's finger or thumb to engage the slider 152 in use. In one embodiment, the slider 152 includes curved recesses and/or a central curved recess at each end of its length. In other embodiments, other surface features such as knurling may be provided. Such surface features may provide a more comfortable grip and make the slider 152 easier to handle.

Fig. 5 a-5 d are schematic diagrams of aerosol delivery subsystems according to a second specific embodiment of the present disclosure. Key differences from the first specific embodiment of fig. 4 a-4 c are described herein. In particular, in this embodiment, although the slider 152 includes a baffle assembly aperture 154 therethrough and a snap-fit protrusion 155 in the form of a cantilevered protrusion on the opposite long side of the slider 152, the slider 152 does not include a baffle assembly protrusion 157 or recess 158 nor any ramp 159. Instead, the baffle assembly seal 156 (see fig. 5 c-5 d) between the slider 152 and the housing 12 includes a hole therethrough (continuing the baffle assembly aperture 154 in one or more open positions), and the baffle assembly seal 156 includes two recesses 158 in the form of hemispherical grooves 158 on either side of the aperture 154.

As shown in fig. 5 b-5 c, the housing 12 includes complementary projections 257 in the form of spherical caps 257 between the elongated primary air inlet 28 and the two secondary bypass inlets 128 for engagement with the one or more baffle assembly recesses 158.

Fig. 5c is a vertical cross-section showing the subsystem 100 in a partially open configuration (see fig. 9b, discussed later) with the projection 257 engaged with a right-hand side recess in the baffle assembly recess 158. As described above, when the slider is moved to the partially open configuration of fig. 5c (also shown in fig. 9a, discussed later), the complementary projection 257 engages with the right-hand flapper assembly recess 158, providing a predetermined partially open configuration, and when the slider 152 is moved to the right, the complementary projection 257 engages with the flapper assembly aperture 154, into a closed configuration (see fig. 9c, discussed later).

Fig. 5d shows an isolated baffle seal 156 illustrating the central aperture 154 between the left and right baffle assembly recesses 158. Although fig. 5d depicts the recesses 158 on either side of the aperture 154, the left hand side recesses 158 may not be necessary for engagement with the protrusions 257, but may simply be provided to aid assembly such that the seal 156 is symmetrical and thus may be installed in any manner.

Fig. 5e shows a variant of the baffle seal 156 of fig. 5d with two recesses 158 on the right hand side of the central aperture 154. The configuration of fig. 5e does not have the symmetrical nature of the variation of fig. 5d, but in contrast to the flapper seal 156 of fig. 5d, the two (right) recesses 158 provide reliable engagement feedback when the flapper assembly 150 is moved into each of the predetermined open, partially open and closed configurations, i.e., feedback is additionally provided when moved into the fully open position. Fig. 9 a-9 c illustrate the movement of the flapper seal 156 of fig. 5d into each position/configuration.

Fig. 6 a-6 c are schematic diagrams of aerosol delivery subsystems according to a third specific embodiment of the present disclosure. Key differences from the first specific embodiment of fig. 4 a-4 c are described herein. Fig. 6a illustrates a slider 152 of the baffle assembly 150. Here, instead of two elongated protrusions 155 having recesses 158 and ramps 159 as shown in fig. 4a, the slider 152 includes an aperture 154 therethrough, and in fig. 6a, each side of the slider 152 includes a pair of snap-fit cantilever protrusions 155, each pair forming a baffle assembly recess 158 therebetween.

Fig. 6 b-6 c illustrate that subsystem 100 includes a sensor seal 130 for receiving an airflow sensor 30 proximate or adjacent inlet 28 to detect an airflow therethrough. Fig. 6c is a cross-sectional view through the slider 152 showing the baffle assembly recess 158 on the slider 152, wherein the seal 130 includes complementary protrusions 257 (not shown) on opposite sides thereof for positively engaging the baffle assembly recess 158 on the baffle slider 152. (the protrusions 257 on the seal 130 are not shown in fig. 6c, because the cross-section passes through the middle of the seal 130 and not through the engagement/sealing surface-see fig. 10 a-10 c, which show the protrusions 257 on the seal 130).

In this embodiment, as shown in fig. 6c, the secondary bypass inlet 128 bypasses the air flow sensor 30, while the central primary air inlet 28 provides air flow to the sensor 30 (not shown, but housed within the seal 130), which may be used to trigger activation/deactivation of the device, such as providing/preventing power to the aerosol generator 48.

Fig. 7 a-7 c are schematic diagrams of aerosol delivery subsystems according to a fourth specific embodiment of the present disclosure. Key differences from the first specific embodiment of fig. 4 a-4 c are described herein. In particular, in this embodiment, while the slider 152 includes a baffle assembly aperture 154 therethrough and snap-fit protrusions 155 in the form of cantilevered protrusions on opposite long sides of the slider 152, the slider 152 includes cantilevered baffle assembly protrusions 157 instead of the recesses 158 and ramps 159 of fig. 4 a. The housing 12 includes a set of 6 complementary recesses 258 for engaging the protrusions 157, as shown in fig. 7 b-7 c, where fig. 7c is an axial cross-section through the subsystem 100.

Fig. 8 a-11 c illustrate how each of the subsystems 100 of fig. 4 a-7 c may be moved between a plurality of configurations, i.e., how the baffle assembly 150 engages in at least one of a plurality of predetermined positions relative to the subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, including fully open, fully closed, and at least one intermediate open position, altering the airflow through the device, e.g., resulting in varying degrees of alignment between the baffle assembly aperture 154 and the air inlet 28.

In all of the exemplary embodiments of fig. 4 a-11 c, the subsystem 100 includes one (central) primary air inlet 28 and two secondary bypass inlets 128, and the engagement mechanism provides 3 reliable engagement positions for the baffle assembly 150 relative to the air inlet 28. In these figures, the opening in the housing 12 defining the air inlet 28 is larger than the baffle assembly aperture 154. This enables the baffle assembly aperture 154 to be aligned with the opening in the housing 12 in more than one position, as particularly highlighted in fig. 8 a-8 b and 10 a-10 b, such that the multiple positions of the baffle assembly 150 are "open" and allow airflow therethrough. Alternatively or additionally, there may be a plurality of openings defining a plurality of primary air inlets 28 and/or a plurality of baffle assembly apertures 154 configured to align with one or more of the openings.

Specifically, referring to fig. 8a, the width y ₁ of the opening in the housing 28 defining the air inlet 28 may be at least 10%, 25%, 50%, 75%, or 100% wider than the diameter y ₂ of the opening for the bypass air inlet 128 and/or the baffle assembly aperture 154. The length x ₁ of the opening in the housing 28 defining the air inlet 28 may be configured to enable the baffle assembly 150 to move between at least two engaged positions (e.g., corresponding to the fully open and partially open positions shown in fig. 8a and 8 b), maintain an airflow path through the air inlet 28 and selectively provide an airflow path through one or both of the bypass inlets 128. As shown in fig. 8a, the length x ₁ of the opening in the housing 12 defining the air inlet 28 may be equal to or greater than the distance x ₂ between the outermost edges of the bypass inlet 128 to provide such functionality.

Fig. 8 a-8 c illustrate how the subsystem 100 of fig. 4 a-4 c moves between a plurality of predetermined positions. In fig. 8 a-8 c, the snap-fit protrusion 155 provides 3 positions for engagement with the spherical cap 257 on the housing 12, these positions being the lowest (terminal) points of the ramp 159 and the recess 158 therebetween.

In fig. 8a, the subsystem is fully open, i.e. all air inlets 28, 128 are open; is not covered or blocked, thereby providing minimal resistance to air drawn into the system when a user inhales on the mouthpiece. Here, the housing protrusion 257 engages with the lowest extremity of the right baffle assembly ramp 159.

In fig. 8b, the subsystem is partially open, the central air inlet 28 and the outermost bypass inlet 128 are open, but the innermost bypass inlet 128 is covered by a baffle assembly 150. Here, the projection 257 engages with a hemispherical recess 158 in the snap-fit projection 155 of the slider 152.

In fig. 8c, the subsystem is closed and all air inlets 28, 128 are covered by a baffle assembly 150. The closed configuration may effectively disable operation of the device (e.g., prevent power to the aerosol generator) and thus provide a child resistant locking function. Here, the projection 257 engages with the lowest extremity of the left baffle assembly ramp 159.

Fig. 9 a-9 c show how the subsystem 100 of fig. 5 a-5 d moves between predetermined positions, similar to the first embodiment of fig. 8 a-8 c. In fig. 9a, the subsystem is fully open, corresponding to fig. 8a of the first specific embodiment. Here, the housing protrusion 257 is pressed into the baffle assembly seal 156, as shown, but there is no recess 158 in the seal 156 of fig. 5d to provide a positive engagement feedback mechanism in this position. However, because the user cannot move the shutter assembly 150 any further, they are confident that the device is in the fully open position. In contrast, the alternative baffle assembly seal 156 of fig. 5e provides a second, rightmost recess 158 in which the projection 257 will be received in this fully open position, thus giving a positive engagement feedback mechanism when the user moves the baffle assembly 150 into this position.

In fig. 9b, the subsystem is partially open, the central air inlet 28 and the outermost bypass inlet 128 are open, but the innermost bypass inlet 128 is covered by a baffle assembly 150. Here, the complementary protrusion 257 in the housing 12 engages with the right-hand hemispherical recess 158 of the baffle assembly seal 156 of fig. 5d, thus providing a positive engagement feedback mechanism when the user moves the component 150 to this position. Similarly, for the alternative baffle assembly seal 156 of fig. 5e, the complementary projection 257 will engage the interior right-hand side recess 158.

In fig. 9c, the subsystem is closed and all air inlets 28, 128 are covered by a baffle assembly 150. Here, the projection 257 engages the flapper orifice 154, thereby again giving a positive engagement feedback mechanism when the user moves the member 150 to this position (and in the same manner as the flapper assembly seal 156 of fig. 5d and 5 e). As described above with respect to fig. 5d, the left hand recess 158 of fig. 5d does not engage any protrusions 257 and is only to aid assembly.

Fig. 10 a-10 c show how the subsystem 100 of fig. 6 a-6 c moves between predetermined positions, similar to the first embodiment of fig. 8 a-8 c. In fig. 10a, the subsystem is fully open. Here, the sensor seal complementary protrusion 257 abuts and engages the outer edge of the rightmost one of the protrusions 155.

In fig. 10b, the subsystem is partially open, the central air inlet 28 and the outermost bypass inlet 128 are open, but the innermost bypass inlet 128 is covered by a baffle assembly 150. Here, complementary projections 257 in the seal 130 engage in recesses 158 between the projections 155.

In fig. 10c, the subsystem is closed and all air inlets 28, 128 are covered by a baffle assembly 150. Here, the complementary protrusion 257 in the seal 130 engages the outer edge of the leftmost protrusion 155.

Fig. 11 a-11 c show how the subsystem 100 of fig. 7 a-7 c moves between predetermined positions, similar to the first embodiment of fig. 8 a-8 c. In fig. 11a, the subsystem is fully open. Here, the pair of baffle assembly projections 158 engage a first pair of complementary recesses 257 (not shown in fig. 11 a) in the housing 12 furthest from the bypass inlet 128.

In fig. 11b, the subsystem is partially open, the central air inlet 28 and the outermost bypass inlet 128 (not shown) are open, but the innermost bypass inlet 128 (not shown) is covered by the baffle assembly 150. Here, the pair of baffle assembly projections 158 engage with an intermediate pair of complementary recesses 257.

In fig. 11c, the subsystem is closed and all air inlets 28, 128 are covered by a baffle assembly 150. Here, a pair of baffle projections 158 engage a pair of complementary recesses 257 closest to the bypass inlet 128 (not shown).

Generally, in some embodiments, the air inlets 28, 128 include one or more primary air inlets 28 and one or more secondary bypass air inlets 128, and the plurality of predetermined locations include:

a. A first position wherein the baffle assembly aperture 154 is not aligned with any of the primary air inlets 28, optionally wherein the first position comprises a closed position wherein none of the air inlets 28, 128 provides an air flow path therethrough;

b. a second intermediate position in which the baffle assembly aperture 154 is aligned with at least one of the primary air inlets 28, and optionally one or more of the bypass air inlets 128 provides an air flow path therethrough; and

C. A third fully open position in which the baffle assembly aperture 154 is aligned with at least one of the primary air inlets and all of the bypass air inlets provide an air flow path therethrough.

In some embodiments, one or more protrusions 157, 257, recesses 158, 258, and/or ramps 159, 259 are described or depicted. In embodiments, any number of protrusions and/or recesses may be provided, particularly arranged in pairs on opposite sides of the relevant component, e.g. to provide a multi-dimensional constraint.

In some embodiments, the subsystem includes a housing 12 having an opening defining an air inlet; and/or a housing having a baffle assembly cavity 135, the baffle assembly cavity 135 configured to receive a baffle assembly 150; and/or a housing having a power cavity 126 configured to receive the power source 26. In some such embodiments, the baffle assembly cavity 135 or the power supply cavity 126 may include a complementary protrusion 257 or recess 258 for engagement with the baffle assembly protrusion 157 or recess 258.

In some embodiments, the subsystem 100 includes a plurality of air inlets 28, 128 and/or a plurality of apertures 154 in the baffle assembly 150. In some embodiments, different ones of the plurality of predetermined positions of the baffle assembly 150 result in different degrees of alignment between the single or multiple baffle apertures 154 and the single or multiple air inlets 28, 128 to vary the air flow through the air inlets 28, 128. In some embodiments, there are a plurality of air inlets 28, 128, wherein movement of the baffle assembly 150 alters the flow of air through one or more of the plurality of air inlets 28, 128.

In some embodiments, the axis of extension of the baffle assembly aperture 154 is substantially parallel to the straight flow path between the air inlet 28 and the outlet 50, thereby minimizing disruption of the air flow through the system by the baffle assembly 150.

In some embodiments, for the baffle assembly aperture 154, the plurality of predetermined positions includes or consists of three or more positions, the aperture positions forming a substantially straight line. In some embodiments, as shown in fig. 8 a-11 c, for example, the plurality of predetermined positions provide, in sequence, a minimum or zero alignment, a partial alignment, and a maximum or full alignment between the baffle assembly aperture 154 and the air inlet 28.

In some embodiments, the plurality of predetermined positions define a range of movement of the baffle assembly 150 relative to the subsystem 100, and the subsystem 100 is configured to prevent the baffle assembly 150 from moving beyond the range, for example, by the subsystem 100 or the baffle assembly 150 including a shoulder for abutting the other of the subsystem 100 or the baffle assembly 150 at each end of the range. In some embodiments, the baffle assembly 150 is moved by translation (e.g., sliding). In a further embodiment, the baffle assembly 150 is rotatable.

In some embodiments, different ones of the plurality of predetermined locations provide a flow path through a different number of the plurality of air inlets 28, 128. In some embodiments, different ones of the plurality of predetermined positions provide for a different number of alignments between the plurality of primary air inlets 28 and the baffle assembly aperture 154.

In some embodiments, the extreme positions of the plurality of predetermined positions are spaced apart in the range of 1-50mm, 2-40mm, 3-30mm, 4-20mm, or approximately 5-10 mm. In some embodiments, adjacent ones of the plurality of predetermined locations are spaced apart in the range of 0.5-5mm, 1-3mm, or approximately 2 mm.

Orifice-free baffle assembly

In further embodiments (not specifically shown), the baffle assembly 150 does not include the aperture 154. However, the baffle assembly 150 remains movable to allow different amounts of air flow into the system-the baffle assembly 150 is movable to cover or expose the air inlets 28, 128, without simply aligning the baffle apertures 154 with one or more of the inlets 28, 128.

For example, the shutter assembly 150 may slide between the closed, partially open, and fully open positions shown in fig. 8 a-11 c, except without the shutter aperture 154. For example, referring to the end view closed position in fig. 11c, the baffle assembly 150 without the aperture 154 covers/blocks all of the inlets 28, 128. In the partially open position, the baffle assembly 150 may partially or fully expose the main inlet 28 (e.g., the rightmost exposed inlet in the end view of fig. 11 b), and may optionally partially or fully expose one or more additional inlets 28, 128, such as when the baffle assembly 150 slides from the closed position toward the open position. In the fully open position, the baffle assembly 150 exposes all of the inlets 28, 128 (e.g., the inlets otherwise exposed in the end view of fig. 11 a). Such a baffle assembly 150 without apertures 154 may thus provide the same function as in fig. 8 a-11 c, wherein the baffle assembly 150 has different positions providing different degrees of opening of the air inlets 28 to vary the air flow therethrough, but will generally provide a less compact arrangement (as the baffle assembly 150 must be moved, e.g., translated completely away from all of the inlets 28, 128 to fully expose them).

Accordingly, the present invention may provide an aerosol delivery subsystem 100 for adjusting fluid flow in an aerosol delivery system 1, the aerosol delivery subsystem comprising:

An air inlet 28;

A baffle assembly 150; and

An engagement mechanism for positively engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, wherein different ones of the plurality of predetermined positions result in different degrees of opening of the air inlet 28 to vary the air flow through the air inlet 28.

The arrangement described above may be combined with any of the other features disclosed herein, such combinations being particularly contemplated.

Baffle assembly without joint mechanism

Fig. 12 a-12 c are schematic perspective and end views of an aerosol delivery subsystem according to a fifth particular embodiment of the present disclosure, highlighting different aspects of further embodiments. In contrast to the embodiment of fig. 4 a-11 c, the embodiment of fig. 12 a-12 c does not include an engagement mechanism for reliably engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the subsystem 100. Here, the flapper assembly 150 is free to move between the fully open position and the fully closed position without a discontinuous intermediate open position in which the flapper assembly 150 may be consistently engaged via an engagement mechanism.

Fig. 12a illustrates a slider 152 of a baffle assembly 150 that includes the slider 152 and a baffle assembly seal 156, and is similar to the previous embodiment, but without an engagement mechanism. The slider 152 includes an aperture 154 therethrough and two snap-fit protrusions 155 in the form of cantilevered protrusions on opposite long sides of the slider 152 for securing the baffle assembly 150 within the subsystem 100, e.g., to the housing 12. The slider 152 is sized and shaped to be manipulated by a user's finger or thumb from the base of the system, is disk-shaped (stadium) in shape, and includes a curved recess at its center and at each axial end (see fig. 12 b). These features are designed to be operated by the user's finger, thereby increasing the usability of the baffle assembly 150, making the slider 152 easier to move.

Fig. 12b shows a perspective end view of the subsystem 100 without the baffle assembly 150. As shown, the housing 12 has 3 aligned openings: the elongated oval opening defines a primary air inlet 28 and two side secondary air inlets 128. As shown, the first outside primary air inlet 128a has a larger opening diameter than the innermost secondary air inlet 128 b. The air inlet openings 28, 128 may generally be of different sizes and/or may be substantially in the range of 0.5-5.0mm, 0.5-3.0mm, 0.5-2.5mm, or 1.0-2.0mm diameter. In the arrangement shown in fig. 12 a-12 c, the innermost secondary inlet 128 is eventually exposed when the slider 152 is moved from a closed position (to the left) covering all inlets 28, 128 to a fully open position to the right as shown in fig. 12c, and such a tapered secondary inlet 128 allows the user to fine tune the resistance to suction. Additional secondary air inlets 128 may be provided, preferably with a diameter that decreases in the direction of the slide 152 as the slide 152 moves toward the fully open position.

The subsystem 100 includes a fluid flow sensor 30 (not shown), and the primary air inlet 28 (shown as elongated, but alternatively including a plurality of inlets 28) provides an air flow path into the subsystem 100 via the fluid flow sensor 30, while the secondary air inlet 128 provides an air flow path into the subsystem 100 bypassing the fluid flow sensor 30. Such an arrangement is beneficial in that the primary air inlet 28 can be used to provide air flow to the sensor 30 and thus can be used to reliably trigger operation of the device (e.g. enable an aerosol generator) in use, and likewise disable the device when the primary air inlet 28 is closed, acting as a safety feature, while the secondary air inlet 128 allows for adjustment of the resistance to draw, i.e. provide variable ventilation, without complicating the airflow path through the system or requiring multiple flow sensors 30. Conversely, if all of the inlets 28, 128 provide an air flow path into the subsystem 100 via the fluid flow sensor 30, this may result in a less compact design and/or unreliable triggering of the flow sensor 30.

Fig. 12c shows the assembled subsystem 100 with the baffle assembly 150 installed therein. The baffle assembly 150 may be moved to a plurality of positions relative to the subsystem 100 to selectively vary the flow of air through one or more of the primary air inlet 28 and the secondary air inlet 128. In particular, the baffle assembly 150 is movable to selectively cover the primary air inlet 28 and the secondary air inlet 128.

In fig. 12c, the baffle assembly 150 is in a fully open position with the baffle assembly aperture 154 aligned with the rightmost end of the elongated primary air inlet 28 and the baffle assembly 150 does not cover any of the secondary air inlets 128, which are exposed/unobstructed, thus allowing maximum air flow into the system, minimizing pressure drop in use. By sliding the baffle assembly 150 to the left, the baffle assembly 150 can be moved from the fully open position of fig. 12c to a partially open position to partially or fully cover the smaller interior secondary air inlet 128b, reducing the air flow into the system. The primary air inlet 28 remains uncovered/open because the baffle assembly aperture 154 remains aligned with the elongated inlet 28 (e.g., aligned with a middle portion of the elongated inlet 28). When moved further to the left, the baffle assembly 150 may completely cover the innermost secondary air inlet 128b and partially or completely cover the outermost secondary air inlet 128a, thereby further reducing air flow into the system. Preferably, there is a minimum open position in which the primary air inlet 28 is at least partially, but preferably fully, open/open, while all of the secondary air inlets 128 are covered.

The user may thus move the baffle assembly 150 to progressively expose more air inlet openings to allow more air to flow into the subsystem 100 during use. Thus, the plurality of positions may include a first (closed) position in which the baffle assembly 150 covers at least the primary air inlet 28, optionally all of the inlets 28, 128; a second (intermediate open) position in which the baffle assembly 150 exposes the primary air inlet 28; a third (intermediate open) position in which the baffle assembly 150 exposes the primary air inlet 28 and the secondary air inlet 128; and a fourth (fully open) position in which the baffle assembly 150 exposes the primary air inlet 28 and all of the plurality of secondary air inlets 128.

The subsystem may include a sensor seal 130 having a cavity for receiving/positioning the sensor 30 in the subsystem and providing an airflow path thereto. Preferably, the fluid flow sensor 30 is located near or proximal to at least one of the air inlets 28, and/or the sensing portion of the fluid flow sensor 30 is exposed directly to the fluid flow path from the air inlet 28 toward the aerosol generator 48 or within the fluid flow path from the air inlet 28 toward the aerosol generator 48.

In the embodiment of fig. 12 a-12 c, a single (elongated) primary air inlet 28 is provided that provides an air flow path into the subsystem 100 via a single fluid flow sensor 30. In further embodiments, additional primary air inlets 28 may be provided that provide an air flow path into the subsystem 100 via a single fluid flow sensor 30, or additional fluid flow sensors may be provided. For example, instead of a single elongated inlet 28, a plurality of discrete primary air inlets 28 may be provided. Similarly, a single baffle assembly aperture 154 is illustrated, and in further embodiments, the baffle assembly 150 does not include a hole or includes a plurality of apertures 154.

Although the secondary air inlet openings 128 are illustrated as circular, these and all other openings may be any shape. In particular, the secondary air inlet opening 128 may be elongated in the direction of axial movement of the baffle assembly 150, similar to the primary inlet 28, which would effectively provide a continuously variable adjustment within a predetermined range.

The arrangements of fig. 12 a-12 c may be combined with any other feature disclosed herein-such combinations are specifically contemplated. In particular, although the embodiment of fig. 12 a-12 c is not shown as including an engagement mechanism, in a further embodiment, the subsystem includes an engagement mechanism, for example, for positively engaging the flapper assembly 150 in at least one position, preferably in a closed position (providing a safety lock feature) and/or one or more partially open configurations, relative to the subsystem 100, thereby defining a predetermined, consistently engageable partially open position.

The various embodiments described herein are only used to aid in understanding and teaching the claimed features. These embodiments are provided as representative examples of embodiments only, and are not intended to be exhaustive and/or exclusive. It is to be understood that the 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 utilized and modifications may be made without departing from the scope of the invention as claimed.

The various embodiments of the disclosure may suitably comprise, consist of, or consist essentially of the appropriate combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. Furthermore, the present disclosure may include other inventions not presently claimed but which may be claimed in the future. Protection may also be sought for any feature disclosed in any one or more of the publications cited herein in connection with the present disclosure.

Index of reference numerals

1. Aerosol delivery system

2. Reusable part

4. Barrel portion

6 Junction between reusable part and cartridge part

12 Reusable part of the housing

14. 16 User input buttons

20. User programming circuit

22. Controller for controlling a power supply

24. Display device

26. Power supply

28. Air inlet

30. Fluid flow sensor

31 Printed Circuit Board (PCB)

32. Sensor cavity or chamber

34. Chamber wall

42. Barrel casing

44. Chamber or reservoir

46. Liquid absorbing core

48. Aerosol generator

50. Nozzle outlet

51 Airflow path through reusable part

52 Reusable part of the airflow path

60. Suction nozzle shell

100. Aerosol delivery subsystem

126. Power cavity

128. Bypass air inlet

130. Sensor seal

135. Baffle assembly cavity

150. Baffle plate assembly

152. Baffle assembly slider

154. Baffle assembly orifice

155. Baffle assembly snap fit protrusion

156. Baffle assembly seal

157. Baffle assembly protrusions

158. Baffle assembly recess

159. Baffle assembly ramp

257. Complementary protrusions

258. Complementary recess

259 Complementary ramp

Any reference signs in the claims are purely for the sake of clarity and do not in any way affect the scope of protection.

Representative features

1. An aerosol delivery subsystem 100 for regulating fluid flow in an aerosol delivery system 1, comprising:

a. An air inlet 28;

b. A baffle assembly 150 having an aperture 154 therethrough; and

C. an engagement mechanism for positively engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the aerosol delivery subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, wherein different ones of the plurality of predetermined positions result in different degrees of alignment between the baffle assembly aperture 154 and the air inlet 28 to vary the air flow through the air inlet 28.

2. The subsystem of clause 1, wherein the engagement mechanism comprises one or more pairs of engaged or interlocked protrusions and recesses.

3. The subsystem according to any preceding clause, wherein:

a. The engagement mechanism includes the baffle assembly 150 having a projection 157 or recess 158 and the subsystem 100 having a complementary projection 257 or recess 258 for engagement with the baffle assembly projection 157 or recess 158; and/or

B. The engagement mechanism is used to positively engage the baffle assembly 150 relative to the subsystem 100 in at least one intermediate open position of the baffle assembly 150 relative to the air inlet 28.

4. The subsystem of clause 2 or 3, wherein one or more of the protrusions 157, 257 and/or the recesses 158, 258 comprise spherical caps or hemispheres.

5. The subsystem according to any preceding clause, wherein the engagement mechanism comprises ramps 159, 259 for guiding and/or biasing the shutter assembly 150 into one or more of the plurality of predetermined positions.

6. The subsystem according to any preceding clause, wherein the baffle assembly 150 comprises one or more snap-fit protrusions 155 for securing the baffle assembly 150 within the subsystem 100.

7. The subsystem of clause 6, wherein the baffle snap-fit protrusion 155 comprises:

a. one or more cantilevered, twisted and/or annular snap-fit protrusions 155; and/or

B. the baffle assembly protrusions 157 or recesses 158; and/or

C. The ramp 159.

8. The subsystem of any preceding clause, wherein the baffle assembly 150 comprises a baffle assembly seal 156, optionally wherein the baffle assembly seal 156 comprises the baffle assembly protrusion 157 or recess 158.

9. The subsystem of any preceding clause, configured to:

a. The aerosol generator 48 can be powered when one or more of the air inlets 28, 128 are open and provide an airflow path therethrough; and/or

B. Adjusting the power to the aerosol generator 48 when moving between predetermined positions, thereby providing a non-zero degree alignment between the baffle assembly aperture 154 and the air inlet 28; and/or

C. When all air inlets 28, 128 are closed, power to the aerosol generator 48 is disabled.

10. The subsystem according to any preceding clause, further comprising:

a. a housing 12 having an opening defining the air inlet 28; and/or

B. a housing 12 having a baffle assembly cavity 135 configured to receive the baffle assembly 150; and/or

C. The housing 12 having a power cavity 126 configured to receive the power source 26;

And/or

D. A sensor seal 130 for receiving the sensor 30.

11. The subsystem of clause 10, wherein the baffle assembly cavity 135, the power supply cavity 126, or the sensor seal 130 comprises the complementary protrusion 257 or recess 258 for engaging with the baffle assembly protrusion 157 or recess 158.

12. The subsystem according to any preceding clause, comprising:

a. a plurality of air inlets 28, 128 and/or a plurality of apertures 154 in the baffle assembly 150; or (b)

B. A plurality of air inlets 28, 128, wherein movement of the baffle assembly 150 alters the flow of air through one or more of the plurality of air inlets 28, 128; or (b)

C. A plurality of air inlets 28, 128 and a plurality of apertures 154 in the baffle assembly 150, wherein different ones of the plurality of predetermined positions of the baffle assembly 150 result in different degrees of alignment between the plurality of baffle apertures 154 and the plurality of air inlets 28, 128 to vary the air flow through the air inlets 28, 128.

13. The subsystem according to any preceding clause, comprising:

a. A sensor seal 130 having a cavity for receiving a fluid flow sensor 30 adjacent or near the air inlet 28; and/or

B. A fluid flow sensor 30 adjacent to or near the air inlet 28; and/or

C. a fluid flow sensor 30, wherein the subsystem 100 is configured to activate the aerosol generator 48 in response to sensing a fluid flow; and/or

D. A fluid flow sensor 30, wherein a sensing portion of the fluid flow sensor 30 is directly exposed to fluid flow from the air inlet 28 toward an aerosol generator 48

The path or exposure is within a fluid flow path from the air inlet towards the aerosol generator. 14. The subsystem of clause 13, comprising the fluid flow sensor 30 and a plurality of voids

A gas inlet 28, 128, wherein the plurality of air inlets 28, 128 includes one or more primary air inlets 28 leading to the fluid flow sensor 30 and one or more secondary bypass air inlets 128 bypassing the fluid flow sensor 30, optionally wherein:

a. The primary air inlet 28 of the fluid flow sensor 30 is configured to deliver air to an aerosol generator 48 in use; and/or

15. The subsystem according to any preceding clause, wherein the axis of extension of the baffle assembly aperture 154 is substantially parallel to a straight flow path between the air inlet 28 and outlet 50.

16. The subsystem according to any preceding clause, wherein the baffle assembly 150 has:

a. one or more surface features; and/or

B. a plurality of alternating ridges and valleys extending perpendicular to an axis of movement of the baffle assembly between the predetermined positions; and/or

C. A length of about 5-50 mm; and/or

D. a width of about 2-25 mm; and/or

E. Rounded rectangle discorectangular shape.

17. The subsystem according to any preceding clause, wherein:

a. The plurality of predetermined positions includes three or more positions for the baffle assembly aperture 154, the aperture positions forming a substantially straight line; and/or

B. The plurality of predetermined positions includes a plurality of positions for the baffle assembly aperture 154, the aperture positions forming a substantially straight line; and/or

C. the plurality of predetermined positions in turn provide minimum or zero alignment, partial alignment, and maximum or full alignment between the baffle assembly aperture 154 and the air inlet 28; and/or

D. the plurality of predetermined positions define a range of movement of the baffle assembly 150 relative to the subsystem 100, and the subsystem 100 is configured to prevent movement of the baffle assembly 150 beyond the range, preferably by the subsystem 100 or the baffle assembly 150 including shoulders for abutting the other of the subsystem 100 or the baffle assembly 150 at each end of the range; and/or

E. Different ones of the plurality of predetermined locations provide flow paths through different numbers of the plurality of air inlets 28, 128; and/or

F. Different ones of the plurality of predetermined positions provide alignment between different numbers of the plurality of air inlets 28 and the baffle assembly aperture 154; and/or

G. The limit positions of the preset positions are 1-50mm, 2-40mm and 3-30 mm

Spaced apart in the range of mm, 4-20mm or substantially 5-10 mm; and/or

H. Adjacent ones of the plurality of predetermined locations are spaced apart in the range of 0.5-5mm, 1-3mm, or substantially 2 mm.

18. The subsystem according to any preceding clause, wherein the air inlets 28, 128 comprise one or more primary air inlets 28 and one or more secondary bypass air inlets 128, and the plurality of predetermined locations comprise:

a. A first position wherein the baffle assembly aperture 154 is not aligned with any of the primary air inlets 28, optionally wherein the first position comprises a closed position wherein none of the air inlets 28, 128 provides air therethrough

A flow path;

b. a second intermediate position wherein the baffle assembly aperture 154 is aligned with at least one of the primary air inlets 28 and optionally one or more of the bypass air inlets 128 provide an air flow path therethrough;

And

C. a third fully open position wherein the baffle assembly aperture 154 is aligned with at least one of the primary air inlets and all bypass air inlets provide an air flow path therethrough.

19. A subsystem according to any preceding clause, or including a subsystem according to any preceding clause

The aerosol delivery system of the subsystem further comprises:

a. An aerosol generator; and/or

B. a cartridge or cartomizer containing aerosol-generating material for generating an aerosol for inhalation by a user; and/or

C. A suction nozzle; and/or

D. A controller; and/or

E. And a power supply.

20. The aerosol delivery subsystem of clause 3, further comprising a housing configured to receive the baffle assembly, wherein:

a. The baffle assembly includes a baffle slider having a snap-fit protrusion with a hemispherical baffle assembly recess therein and a ramp for guiding the baffle assembly into at least one of the plurality of predetermined positions; and

B. The housing includes a spherical cap complementary protrusion for positive engagement with the recess on the baffle assembly.

21. The aerosol delivery subsystem of clause 3, further comprising a housing configured to receive the baffle assembly, wherein:

a. the baffle assembly includes a seal including a hemispherical baffle assembly recess; and

B. The housing includes a spherical cap complementary protrusion for positive engagement with the baffle assembly recess on the seal.

22. The aerosol delivery subsystem of clause 3, further comprising a sensor for detecting fluid flow and a sensor seal for sealing around the sensor, wherein:

a. The baffle assembly includes a baffle slider having a snap-fit protrusion with the baffle assembly recess therein; and

B. the sensor seal includes the complementary protrusion.

23. The aerosol delivery subsystem of clause 3, further comprising a housing configured to receive the baffle assembly, wherein:

a. The baffle assembly includes a baffle slider having the baffle assembly protrusion; and

B. The housing includes the complementary recess.

24. A method of manufacturing an aerosol delivery subsystem for an aerosol delivery system, comprising providing:

a. An air inlet 28;

b. A baffle assembly 150 having an aperture 154 therethrough; and

C. An engagement mechanism;

The method includes configuring the engagement mechanism for securely engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, wherein

Different ones of the plurality of predetermined positions result in different degrees of alignment between the baffle assembly aperture 154 and the air inlet 28 to vary the air flow through the air inlet 28.

25. An aerosol delivery subsystem 100 for regulating fluid flow in an aerosol delivery system 1, comprising:

a. An air inlet device 28;

b. A baffle assembly device 150 having an aperture 154 therethrough; and

Engagement means for positively engaging the baffle assembly 150 in at least one of a plurality of predetermined positions relative to the subsystem 100 as the baffle assembly 150 moves relative to the air inlet 28, wherein different ones of the plurality of predetermined positions result in different degrees of alignment between the baffle assembly aperture 154 and the air inlet 28 to vary the air flow through the air inlet 28.

Claims

1. An aerosol delivery subsystem (100) for adjusting a fluid flow in an aerosol delivery system (1), comprising:

a. a primary air inlet (28) into the subsystem (100);

b. a secondary air inlet (128) into the subsystem (100);

c. A fluid flow sensor (30); and

D. a baffle assembly (150), wherein:

i. The primary air inlet (28) provides an air flow path into the subsystem (100) via the fluid flow sensor (30);

The secondary air inlet (128) provides an air flow path into the subsystem (100) bypassing the fluid flow sensor (30); and

The baffle assembly (150) is movable to a plurality of positions relative to the subsystem (100) to selectively vary air flow through one or more of the primary and secondary air inlets (28, 128).

2. The subsystem of claim 1, wherein the baffle assembly (150) is movable relative to the subsystem (100) to selectively cover the primary air inlet (28) and the secondary air inlet (128).

3. The subsystem of any preceding claim, wherein the plurality of locations comprises:

a. a first position wherein the baffle assembly (150) covers at least the primary air inlet (28);

b. A second position wherein the baffle assembly (150) exposes the primary air inlet (28); and

C. a third position in which the baffle assembly (150) exposes both the primary air inlet (28) and the secondary air inlet (128).

4. The subsystem of any preceding claim, wherein the plurality of locations comprises:

a. A baffle assembly (150) exposes the locations of the primary air inlet (28) and the plurality of secondary air inlets (128).

5. The subsystem according to any preceding claim, wherein the primary and/or secondary air inlet openings (28, 128) are substantially in the range of 0.5-5.0mm, 0.5-3.0mm, 0.5-2.5mm or 1.0-2.0mm diameter.

6. The subsystem according to any preceding claim, wherein the primary and secondary air inlet openings (28, 128) have different sizes.

7. The subsystem according to any preceding claim, wherein at least two of the secondary air inlets (128) have openings of different sizes.

8. The subsystem of claim 7, wherein the external secondary air inlet (128) is larger in diameter than the internal secondary air inlet (128).

9. The subsystem according to any preceding claim, wherein the subsystem comprises only a single fluid flow sensor (30).

10. The subsystem according to any preceding claim, comprising an engagement mechanism for securely engaging the baffle assembly (150) in at least one of the plurality of positions relative to the subsystem (100).

11. The subsystem of claim 10, wherein the engagement mechanism comprises one or more pairs of engaged or interlocked protrusions and recesses.

12. The subsystem of claim 10 or 11, wherein:

a. The engagement mechanism includes a baffle assembly (150) having a protrusion (157) or recess (158) and the subsystem (100) having a complementary protrusion (257) or recess (258) for engaging the baffle assembly protrusion (157) or recess (158); and/or

B. The engagement mechanism is for securely engaging the baffle assembly (150) in at least one intermediate open position of the baffle assembly (150) relative to the air inlet (28, 128) relative to the subsystem (100).

13. The subsystem of claim 10, 11 or 12, wherein:

one or more of the protrusions (157, 257) and/or the recesses (158, 258) comprise spherical caps or hemispheres; and/or

The engagement mechanism includes a ramp (159, 259) for guiding and/or biasing the flapper assembly (150) into one or more of the plurality of positions.

14. The subsystem according to any preceding claim, wherein the baffle assembly (150) comprises one or more snap-fit protrusions (155) for securing the baffle assembly (150) within the subsystem (100).

15. The subsystem of claim 14, wherein the baffle snap-fit protrusion (155) comprises:

a. One or more cantilevered, twisted and/or annular snap-fit protrusions (155); and/or

B. -said baffle assembly protrusions (157) or recesses (158); and/or

C. the ramp (159).

16. The subsystem according to any preceding claim, wherein the baffle assembly (150) comprises a baffle assembly seal (156), optionally wherein the baffle assembly seal (156) comprises the baffle assembly protrusion (157) or recess (158).

17. The subsystem of any preceding claim, configured to:

a. Is capable of powering an aerosol generator (48) when one or more of the primary air inlets (28) are open and provide an airflow path therethrough; and/or

B. Adjusting the power to the aerosol generator (48) when moving between the plurality of positions; and/or

C. When at least the primary air inlet (28) is closed, power to the aerosol generator (48) is inhibited.

18. The subsystem of any preceding claim, further comprising:

a. -a housing (12) having an opening defining the primary air inlet and/or the secondary air inlet (28, 128); and/or

B. A housing (12) having a baffle assembly cavity (135) configured to receive the baffle assembly (150); and/or

C. A housing (12) having a power cavity (126) configured to receive a power source (26); and/or

D. a sensor seal (130) for receiving the sensor (30).

19. The subsystem of claim 18, wherein the baffle assembly cavity (135), the power supply cavity (126), or the sensor seal (130) comprises the complementary protrusion (257) or recess (258) for engagement with the baffle assembly protrusion (157) or recess (158).

20. A subsystem according to any preceding claim, comprising:

a. A sensor seal (130) having a cavity for receiving a fluid flow sensor (30) adjacent or proximate to the primary air inlet (28); and/or

B. -a fluid flow sensor (30) near or adjacent to the primary air inlet (28); and/or

C. The subsystem (100) is configured to activate an aerosol generator (48) in response to the fluid flow sensor (30) sensing fluid flow; and/or

D. A sensing portion of the fluid flow sensor (30) is exposed directly to or within a fluid flow path from the primary air inlet (28) toward an aerosol generator (48).

21. The subsystem of any preceding claim, wherein:

a. -the main air inlet (28) of the fluid flow sensor (30) is configured to deliver air to an aerosol generator (48) in use; and/or

B. The secondary air inlet (128) is configured to deliver air to the aerosol generator (48) in use; and/or

C. the secondary air inlet (128) is configured to provide an air flow through the system that bypasses the aerosol generator (48) in use.

22. The subsystem according to any preceding claim, wherein the baffle assembly (150) has:

a. one or more surface features; and/or

B. One or more curved recesses; and/or

C. A plurality of alternating ridges and valleys extending perpendicular to the axis of movement of the baffle between the predetermined positions; and/or

D. A length of about 5-50 mm; and/or

E. A width of about 2-25 mm; and/or

F. Rounded rectangular shape.

23. The subsystem according to any preceding claim, wherein the baffle assembly (150) has an aperture (154) therethrough and:

a. The plurality of positions includes three or more positions for the baffle assembly aperture (154), the aperture positions forming a substantially straight line; and/or

B. The plurality of positions includes a plurality of positions for the baffle assembly aperture (154), the aperture positions forming a substantially straight line; and/or

C. The plurality of positions in turn provide a minimum or zero alignment, partial alignment, and maximum or full alignment between the baffle assembly aperture (154) and the primary air inlet (28); and/or

D. The plurality of positions define a range of movement of the baffle assembly (150) relative to the subsystem (100), and the subsystem (100) is configured to prevent movement of the baffle assembly (150) beyond the range, preferably by the subsystem (100) or the baffle assembly (150) including a shoulder for abutting the other of the subsystem (100) or the baffle assembly (150) at each end of the range; and/or

E. different ones of the plurality of locations provide flow paths through different numbers of air inlets (28, 128); and/or

F. Different ones of the plurality of positions provide alignment between different numbers of the plurality of primary air inlets (28) and the baffle assembly aperture (154); and/or

G. the extreme positions of the plurality of positions are spaced apart in the range of 1-50mm, 2-40mm, 3-30mm, 4-20mm, or substantially 5-10 mm; and/or

H. adjacent ones of the plurality of locations are spaced apart in the range of 0.5-5mm, 1-3mm, or substantially 2 mm.

24. The subsystem of any preceding claim, wherein the plurality of locations comprises:

a. A first position wherein the baffle assembly aperture (154) is not aligned with the primary air inlet (28) or any of these primary air inlets, wherein the first position comprises a closed position wherein none of the primary air inlets and optionally none of the secondary air inlets (28, 128) provide an air flow path therethrough;

b. A second intermediate position wherein the baffle assembly aperture (154) is aligned with at least one of the primary air inlets (28); and optionally one or more of the secondary air inlets (128) provide an air flow path therethrough; and

C. A third fully open position wherein the baffle assembly aperture (154) is aligned with the at least one primary air inlet (28) and all secondary air inlets (128) provide an air flow path therethrough.

25. A subsystem according to any preceding claim, or an aerosol delivery system comprising a subsystem according to any preceding claim, further comprising:

a. An aerosol generator; and/or

C. A suction nozzle; and/or

D. A controller; and/or

E. And a power supply.

26. A method of manufacturing an aerosol delivery subsystem for an aerosol delivery system, the method comprising providing:

a. a primary air inlet (28);

b. a secondary air inlet (128);

c. A fluid flow sensor (30); and

D. a baffle assembly (150), the method comprising configuring the subsystem wherein:

27. An aerosol delivery subsystem (100) for adjusting a fluid flow in an aerosol delivery system (1), comprising:

a. A primary air inlet means (28);

b. secondary air inlet means (128);

c. A fluid flow sensing device (30); and

D. a baffle assembly arrangement (150), wherein:

i. -said primary air inlet means (28) providing an air flow path into said subsystem (100) via said fluid flow sensor (30);

the secondary air inlet means (128) provides an air flow path into the subsystem (100) bypassing the fluid flow sensor (30); and

The baffle assembly (150) device is movable to a plurality of positions relative to the subsystem (100) to selectively vary the flow of air through one or more of the primary air inlet device (28) and the secondary air inlet device (128).