EP4401590A1

EP4401590A1 - Aerosol delivery device/system

Info

Publication number: EP4401590A1
Application number: EP22782481.0A
Authority: EP
Inventors: Peter Lomas; Molly MCGUINNESS; Carlos FABRELLAS-GARCIA
Original assignee: Imperial Tobacco Ltd
Current assignee: Imperial Tobacco Ltd
Priority date: 2021-09-15
Filing date: 2022-09-09
Publication date: 2024-07-24
Also published as: WO2023041442A1

Abstract

Disclosed is an aerosol delivery device (102), engageable with a component (104) for containing an aerosol precursor. The device (102) comprising a controller (120) for controlling an operation of the device (102), an airflow sensor (213) and a user input device (227, 226) concealed within a chamber (211) of the aerosol delivery device (102). The user input device (227, 226) is configured to provide, when actuated, a control signal to the controller (120). The device (102) also comprises an opening (212) to the chamber (211) providing fluid communication between the chamber (211) and an airflow passage (236). The opening (212) arranged such that the user input device (227, 226) is actuatable by insertion of a pin through the opening (212).

Description

AEROSOL DELIVERY DEVICE/SYSTEM

TECHNICAL FIELD

The present disclosure relates to an aerosol delivery device and an aerosol delivery system such as a smoking substitute device/system.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

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

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

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

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

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

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

One approach for a smoking substitute system is the so-called “vaping” approach, in which a vaporisable liquid, typically referred to (and referred to herein) as “e-liquid”, is heated by a heater to produce an aerosol vapour which is inhaled by a user. An e-liquid typically includes a base liquid as well as nicotine and/or flavourings. The resulting vapour therefore typically contains nicotine and/or flavourings. The base liquid may include propylene glycol and/or vegetable glycerine.

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

Vaping smoking substitute systems can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute systems which typically have a heater and a sealed tank which is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute systems include a device which includes the power source, wherein the device is configured to be physically and electrically coupled to a component including the tank and the heater. In this way, when the tank of a component has been emptied, the device can be reused by connecting it to a new component. Another subset of closed system vaping smoking substitute systems are completely disposable, and intended for one-use only.

There are also “open system” vaping smoking substitute systems which typically have a tank that is configured to be refilled by a user, so the system can be used multiple times.

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

Another example vaping smoking substitute system is the blu PRO™ e-cigarette. The blu PRO™ e cigarette is an open system which includes a device, a (refillable) tank, and a mouthpiece. The device and tank are physically and electrically coupled together by screwing one to the other. The mouthpiece and refillable tank are physically coupled together by screwing one into the other, and detaching the mouthpiece from the refillable tank allows the tank to be refilled with e-liquid. The system is activated by a button on the device. When the system is activated, electrical energy is supplied from the power source to a vaporiser, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece. As the vapour passes through the consumable component (entrained in the airflow) from the location of vaporization to an outlet of the component (e.g. a mouthpiece), the vapour cools and condenses to form an aerosol for inhalation by the user. The aerosol may contain nicotine and/or flavour compounds.

Some devices include a user interface (e.g. touchscreen, buttons, etc.) that allows a user to interact with the device. In some cases, the interaction may involve altering the device in an irreversible manner (e.g. a factory reset). One issue, however, with providing such function is that it is possible for a user to inadvertently cause changes to the device that cannot be subsequently be undone by the user.

Further, as mentioned above, some smoking substitute systems include an airflow sensor for detecting airflow in the consumable and/or device. It is desirable for such sensors to provide an accurate indication of one or more characteristics of airflow in the system (e.g. the presence of an airflow). One issue in providing such sensors, especially when positioned in, or close to, a tank and/or vaporiser of a system, is a risk of fouling of the sensor by way of contact with e-liquid.

Accordingly, there is a need for an improved aerosol delivery device/system which addresses at least some of the problems of the known devices and systems.

SUMMARY

According to a first aspect, there is provided an aerosol delivery device (e.g. a smoking substitute device) comprising: a controller for controlling an operation of the device; an airflow sensor and a user input device concealed within a chamber of the device, the user input device configured to provide, when actuated, a control signal to the controller, and an opening to the chamber providing fluid communication between the chamber and an airflow passage, the opening arranged such that the user input device is actuatable by insertion of a pin through the opening.

The present arrangement may allow the airflow sensor to detect an airflow passing into the component, from pressure changes in the chamber. Such pressure changes may result from a drop in air pressure externally of the opening. The drop in pressure may be a result of an airflow passing across (or near to) the opening, which subsequently enters the component (i.e. caused by inhalation by a user).

The provision of a user input device concealed within the chamber provides a means of interaction with the device that is not susceptible to accidental actuation. A user input device arranged in this manner may be particularly useful for controlling operations of the device that are irreversible (such as e.g. a factory reset of the device).

By providing an opening that facilitates both of these functions, design and manufacture of the device is simplified. Optional features of the first aspect will now be set out. These are applicable singly or in any combination with any aspect.

The device of the first aspect may comprise a transversely extending interface wall at least partly defining the chamber. The interface wall may have a first side at least partly defining the airflow passage, and a second side at least partly defining the chamber. The opening to the chamber may be formed in the interface wall. The device of the first aspect may be engageable with a component for containing an aerosol precursor.

The airflow sensor may be spaced in a transverse direction from the opening. The transverse spacing of the airflow sensor from the opening in the interface wall may help to isolate the airflow sensor from foreign matter that may enter the chamber through the opening. For example, the airflow sensor may be isolated from aerosol precursor that enters the chamber due to leakage from the component (when engaged).

According to a second aspect, there is provided an aerosol delivery device (e.g. a smoking substitute device) engageable with a component for containing an aerosol precursor, the device comprising: a transversely extending interface wall having a first side at least partly defining an airflow passage when the device is engaged with the component, and a second side at least partly defining an internal chamber of the device; an opening formed in the interface wall for airflow into and/or out of the chamber; and an airflow sensor concealed in the chamber and spaced in a transverse direction from the opening.

The present arrangement may allow the airflow sensor to detect, from pressure changes in the chamber, an airflow passing into the component (e.g. along the airflow passage). Such pressure changes may result from a drop in air pressure externally of the opening. The drop in pressure may be a result of an airflow passing across (or near to) the opening, which subsequently enters the component (i.e. caused by inhalation by a user). The provision of the airflow sensor proximate to the component facilitates accurate detection (by simplification of the air pathway between the sensor and the airflow to the component).

Further, the transverse spacing of the airflow sensor from the opening in the interface wall helps to isolate the airflow sensor from foreign matter that may enter the chamber through the opening. For example, the airflow sensor may be isolated from aerosol precursor that enters the chamber due to leakage from the component.

Optional features of the second aspect will now be set out. These are applicable singly or in any combination with any aspect. The device of the second aspect may further comprise a user input device. The opening may be arranged such that the user input device is actuatable by insertion of a pin through the opening. In this way, the opening may provide two functions: a Venturi aperture for airflow measurement and access for actuating the user input device.

The device of the second aspect may comprise a controller. The controller may control an operation of the device in response to a control signal received from the user input device upon actuation.

Optional features of the first and second aspects will now be set out. These are applicable singly or in any combination with any aspect.

The opening may be configured (e.g. sized and/or shaped) to prevent access to the user input device through the opening by a user’s finger. The opening may have a width (e.g. diameter) that is less than 7 mm or e.g. less than 5 mm, or less than 3 mm, or less than 2 mm, or less than 1 mm. The opening may otherwise be referred to as a pinhole.

The opening may be configured (e.g. sized and/or shaped) so as to provide a Venturi effect (i.e. a drop in pressure as air passes therethrough). In this respect, the opening may be referred to as a Venturi aperture or orifice.

The user input device may be aligned with the opening. The user input device may be aligned on a line of sight extending through the opening. The user input device may be arranged such that an axis extending through the opening, and that is normal to the opening, extends through the user input device. The axis may extend centrally through the opening. The user input device may be directly below the opening.

The controller may be configured, upon receipt of the control signal from the user input device, to control an operation of the device. The operation of the device may be an irreversible operation. Controlling the operation of the device may comprise, altering a state of the device. Altering a state of the device may comprise reverting the state of the device to a factory state. For example, altering the state may comprise adjusting one or more device settings, and adjusting the device settings may comprise reverting the one or more device settings to a previous state. The previous state may, for example be the state of the settings at manufacture (i.e. factory settings).

The user input device may comprise a switch. The switch may be e.g. a press button. The user input device may comprise an actuator. The actuator may comprise an actuating arm for actuating the switch. The actuating arm may extend transversely within the chamber. The actuating arm may have a proximal end mounted in the chamber and an opposing distal end extending over the switch. The distal end may overlie the switch (e.g. an underside of the distal end may contact/abut the switch). Thus, the distal end may be arranged so as to be moveable (towards the switch) by insertion of a pin through the opening. That is, a pin may be used to move the distal end toward the switch, thereby actuating the switch. The actuating arm may therefore be moveable between an activated position (in which it actuates the switch) and a deactivated position. The distal end of the actuating arm may be disposed between the opening and the switch.

The actuating arm may be flexible. The actuating arm may be resilient (i.e. formed of a resilient material). The deactivated position of the actuating arm may be the natural position of the actuating arm. In this way, the actuating arm may be configured to return to the deactivated position after release (e.g. after removal of a pin from engagement with the actuating arm).

The actuating arm may comprise a weakened region. The weakened region may be disposed at or near to the proximal end of the actuating arm. The weakened region may be in the form of a narrowed portion of the actuating arm. The narrowed portion may be defined by a notch or recess formed in an upper side and/or an underside of the actuating arm.

The distal end of the actuating arm may be a free end. That is, the distal end may be cantilevered from the proximal end.

The distal end may comprise an end-stop. The end-stop may comprise a protrusion formed on an underside of the actuating arm (i.e. a side of the actuating arm facing the switch) at the distal end. The end-stop may abut a surface defining the chamber upon movement of the distal end by e.g. a pin towards the switch. The end-stop may, in this way, restrict further movement of the actuating arm (i.e. beyond the point at which the arm actuates the switch).

The proximal end of the actuating arm may comprise a mounting portion, mounting the actuating arm within the chamber. The mounting portion may be an enlarged portion of actuating arm. The mounting portion may comprise a projection, which may project from an upper side or an underside of the actuating arm. The mounting portion may comprise two projections, each projecting from a respective one of the upper side and underside of the actuating arm. At least a portion of the or each projection may be tapered (e.g. in a direction from the base/proximal end of the projection to the distal end). For example, a portion at the distal end of at least one of the projections may be tapered.

The first side of the interface wall may interface with the component for containing an aerosol precursor. The interface wall may define an end wall of the device. An end of the device may comprise a component receiving cavity for receipt of the component. The interface wall (e.g. the first side of the interface wall) may define a base of the cavity.

The interface wall may comprise a retaining portion for retaining the mounting portion of the actuating arm. The retaining portion may comprise a retaining recess for receipt of (at least part of) the mounting portion. The retaining portion may comprise one or more retaining protrusions that protrude from the second side of the interface wall and define the retaining recess. For example, the retaining portion may comprise first and second retaining protrusions that protrude from the second side of the interface wall and define the retaining recess therebetween.

The interface wall may form part of a socket member of the device. The socket member may further comprise a skirt depending (e.g. extending downwardly) from a periphery of the interface wall. In this way an inner surface of the skirt and the second side of the interface wall may at least partly define the chamber. In other words, the interface wall may define a top of the chamber and the skirt may define one or more side walls of the chamber.

The interface wall may be integrally formed with the skirt. The socket member may be unitary (i.e. a single piece). The socket member may be configured so as to be formable by injection moulding (e.g. by way of a straight-pull moulding process).

The chamber may be sealed, other than for the opening formed in the interface wall. That is, the opening may be the only opening to the chamber.

The device may comprise a separator element (that may define a base of the chamber). The separator element may separate the chamber from an internal cavity of the device. The separator element may extend transversely across the internal cavity. The separator element may be spaced from the interface wall, with the chamber defined therebetween. The separator element may be substantially parallel to the interface wall. The separator element may be in the form of a printed circuit board (PCB). The airflow sensor may be supported on the separator element (e.g. PCB). The airflow sensor may be electronically connected to the PCB. The switch may be supported on the separator element (e.g. PCB). The switch may be electronically connected to the PCB.

The separator element (e.g. PCB) may be sealed against one or more side walls defining the chamber. Thus, for example, the separator element (e.g. PCB) may be sealed to the skirt of the socket member. A periphery (e.g. the entire periphery) of the separator element (e.g. PCB) may be sealed to the one or more side walls (e.g. skirt). The separator element may be sealed within the skirt (e.g. the skirt may extend about the periphery of the separator). The separator element may be sealed to the skirt or side wall by way of an adhesive. The adhesive may be applied to a periphery of the separator element.

The airflow sensor may be a pressure sensor (e.g. air pressure sensor). The airflow sensor may be a differential air pressure sensor. The airflow sensor may extend through the separator element so as to be configured to detect an air pressure outside of the chamber. Thus, the airflow sensor may be configured to detect a pressure difference between air external to the chamber and air inside the chamber. The airflow sensor may otherwise be an acoustic sensor.

The first side of the interface wall may comprise a spacer for spacing the component (e.g. an underside of the component) from the first side of the interface wall (i.e. when the component is engaged with the device). The spacer may be in the form of a protrusion. An underside of the component may abut the distal end of the protrusion when engaged with the device. In this way, the protrusion may space the component from the first side of the interface wall. The airflow passage may be defined in the space between the component and the interface wall. The interface wall may comprise a plurality of spacers (e.g. protrusions).

The opening may be disposed at a first transverse end of the chamber and the airflow sensor may be disposed at a second transverse end of the chamber that is opposite to the first transverse end. The opening may be spaced from the airflow sensor by a distance (e.g. along a transverse axis) that is greater than 2 mm, or greater than e.g. 5 mm, or 10 mm, or 15 mm.

The device may comprise a partition wall that (e.g. substantially) partitions the chamber into a first chamber portion comprising the opening, and a second chamber portion in which the airflow sensor is disposed. The partition wall may substantially (but not completely) seal the first chamber portion from the second chamber portion. The partition wall may at least partly define the retaining recess. Thus, at least one of the retaining protrusions may form part of the partition wall.

The device may comprise an air exchange aperture fluidly connecting the first and second chamber portions. The air exchange aperture may be configured (e.g. sized and/or shaped) to permit airflow between the chamber portions, but restrict liquid flow therebetween. The air exchange aperture may be configured, in particular, to restrict flow of liquid aerosol precursor between the first and second chamber portions.

The air exchange aperture may be defined by the partition wall. The air exchange aperture may be formed in the partition wall (i.e. may extend through the partition wall from the first to second chamber).

The air exchange aperture may alternatively be defined between a distal edge of the partition wall and a surface defining the chamber. The distal edge of the partition wall may be tapered (e.g. pointed). This may facilitate restricting the passage of fluid into the second chamber portion (e.g. due to surface tension of the liquid).

The partition wall may project from the second side of the interface wall. The partition wall may extend across an interior of the skirt (i.e. from one portion of the skirt to another portion of the skirt on an opposing side of the skirt). The partition wall may be integrally formed with the skirt and/or the interface wall.

The device may comprise a device body defining an internal cavity. At least a portion of the socket member may be received in the internal cavity. Thus, for example, at least a portion of the skirt may extend into the internal cavity. An external surface of the skirt may form an interference fit with an internal surface of the device body. In this way, the socket member may be in the form of a cap, capping the device body (or may be in the form of a plug or insert).

The device may comprises a source of power which may be a battery. The source of power may be a capacitor. The power source may be a rechargeable power source. The device may comprise a charging connection for connection to an external power supply for recharging of the power source within the device. The power source may be adjacent to the separator element.

The device body may house the power source and/or other electrical components (e.g. in the internal cavity). The device body may be an elongate body i.e. with a greater length than depth/width. It may have a greater width than depth. The interface wall may accommodate one or more device electrical contacts for engagement (e.g. abutment) with one or more corresponding component electrical contacts of the component. The device electrical contacts may be electrically connected to the power source. In this way, power may be supplied to the component from the power source, via the electrical contacts.

The device body may have a length of between 5 and 30 cm e.g. between 10 and 20 cm such as between 10 and 13 cm. The maximum depth of the device body may be between 5 and 30 mm e.g. between 10 and 20 mm.

The device body may have a front surface that is curved in the transverse dimension. The device body may have a rear surface that is curved in the transverse dimension. The curvatures of the front surface and rear surface may be of the opposite sense to one another. Both front and rear surfaces may be convex in the transverse dimension. They may have an equal radius of curvature.

The radius of curvature of the front surface may be between 10 and 50 mm, preferably between 10 and 40 mm, preferably between 10 and 30 mm, preferably been 10 and 20 mm, more preferably between 10 and 15 mm, more preferably substantially 13.5 mm.

The front and rear surfaces may meet at opposing transverse edges of the device body. This leads to a mandorla-Zlemon-Zeye-shaped cross sectional shape of the device body.

The transverse edges may have a radius of curvature that is significantly smaller than the radius of curvature of either the front or rear surface. This leads to the transverse edges being substantially “pointed” or “sharp”. The transverse edges may have a radius of curvature in the transverse dimension of less than 10 mm, preferably less than 5 mm, preferably less than 2 mm, preferably less than 1 mm.

The transverse edges may extend substantially the full longitudinal length of the device body. However, in some embodiments, the transverse edges may only extend along a longitudinal portion of the device body.

The device body may have a curved longitudinal axis i.e. curved in a direction between the front and rear faces.

The front and/or rear surface of the device body may include at least one visual user feedback element, for example one or more lights e.g. one or more LEDs.

In some embodiments, the device body may include an illumination region configured to allow light provided by the visual user feedback element (e.g. one or more lights/LEDs) within the device body to shine through.

The device may comprise a movement detection unit (e.g. an accelerometer) for detecting a movement of the device, and a haptic feedback generation unit (e.g. an electric motor and a weight mounted eccentrically on a shaft of the electric motor). The controller may be configured to identify an operation of the device; and control the one or more lights contained within the device body, (e.g. to illuminate the illumination region) based on the operation of the device identified.

The controller may be configured to control the haptic feedback generation unit to generate the haptic feedback in response to the detection of movement of the device by the movement detection unit.

A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

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

The airflow sensor may be configured to detect a puff (i.e. inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e. puffing or not puffing).

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

The device may comprise an electrical connection (e.g. one or more contact pins) for connection of the power source to the heating element.

The device may comprise a chassis within the device body and one or more of the electrical components of the device (e.g. one or more of the power source, charging connection, visual feedback element, movement detection unit, haptic feedback generation unit, controller, memory, wireless interface, puff sensor and/or electrical connection) may be mounted on or affixed to the chassis.

In a third aspect, there is provided an aerosol delivery kit comprising a device according to the first or second aspect and a pin for receipt through the opening of the device to actuate the user input device.

The aerosol delivery kit may further comprise a component for containing an aerosol precursor.

In a fourth aspect, there is provided an aerosol delivery system comprising a device according to the first or second aspect and a component for containing an aerosol precursor.

The system may further comprise a pin for receipt through the opening of the device to actuate the user input device. The pin may comprise an enlarged portion. The enlarged portion may facilitate gripping of the pin by a user. For the avoidance of doubt, the term “pin” (as used in the context of the present specification), does not necessarily require a sharpened end or point. Rather, the term is used to describe an elongate tool. The pin may have a width/diameter that is less than 3 mm, or e.g. less than 2 mm, or less than 1 mm.

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

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

The component cavity (into which the component is received) may be configured such that, when the component is received therein, a space or channel is formed between the component and the device for airflow. Air may flow into an inlet of the component from the space or channel. The airflow passage may form at least part of this space or channel.

Thus, the consumable component may comprise one or more engagement portions for engaging with the device.

The consumable component may comprise an electrical interface for interfacing with a corresponding electrical interface of the device (i.e. the device electrical contacts). When the device is engaged with the consumable component, the electrical interface may be configured to transfer electrical power from the power source to a heating element of the consumable component. The electrical interface may also be used to identify the consumable component from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable component is connected to the device.

The device may alternatively or additionally be able to detect information about the consumable component via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of the consumable. In this respect, the consumable component may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

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

In such embodiments, the aerosol former (e.g. e-liquid) may be replenished by re-filling a tank that is integral with the device (rather than replacing the consumable). Access to the tank (for re-filling of the e-liquid) may be provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap). The smoking substitute system may comprise an airflow path therethrough, the airflow path extending from an air inlet to an outlet. The air inlet may be provided in the device body. The outlet may be at a mouthpiece portion of the component. In this respect, a user may draw fluid (e.g. air) into and along the airflow path by inhaling at the outlet (i.e. using the mouthpiece portion). In other embodiments, and as mentioned above, the inlet may be formed between the device and the component.

The airflow path passes a vaporiser between the air inlet and the outlet. The vaporiser may be provided in the component.

The airflow path may comprise a first portion extending from the air inlet towards the vaporiser. A second portion of the airflow path passes through the vaporising chamber to a conduit that extends to the outlet. The conduit may extend along the axial centre of the component. At least part of the first portion may extend through the airflow passage (i.e. partly defined by the interface wall) defined between the component and the device.

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

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

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

At least a portion of one of the walls defining the tank may be translucent or transparent.

The conduit may extend through the tank with the conduit walls defining an inner region of the tank. In this respect, the tank may surround the conduit e.g. the tank may be annular. An inlet to the conduit may be at an end of the component proximate the interface wall.

As discussed above, the air flow path passes the vaporiser between the air inlet and the outlet. The vaporiser may comprise a wick e.g. an elongate wick which may have a cylindrical shape.

The wick may be oriented so as to extend in the direction of the width dimension of the component (perpendicular to the longitudinal axis of the component). Thus the wick may extend in a direction perpendicular to the direction of airflow in the airflow path.

The vaporiser may be disposed in the vaporising chamber. The vaporising chamber may form part of the airflow path. The wick may comprise a porous material. A portion of the wick may be exposed to airflow in the airflow path. The wick may also comprise one or more portions in contact with liquid aerosol precursor stored in the tank. For example, opposing ends of the wick may protrude into the tank and a central portion (between the ends) may extend across the airflow path so as to be exposed to airflow. Thus, fluid may be drawn (e.g. by capillary action) along the wick, from the tank to the exposed portion of the wick.

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

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

In a sixth aspect there is provided a method of forming an aerosol delivery device according to the first or second aspect, the method comprising injection moulding the socket member, sealing a PCB to the skirt of the socket member and inserting the socket member into an open end of the device body.

The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

BRIEF DESCRIPTION OF THE DRAWINGS

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

• Fig. 1 A is a front schematic view of a smoking substitute system;

• Fig. 1 B is a front schematic view of a device of the system;

• Fig. 1 C is a front schematic view of a component of the system;

• Fig. 2A is a schematic of the electrical components of the device;

• Fig. 2B is a schematic of the parts of the component;

• Fig. 3 is a section view of the component;

• Fig. 4 is a perspective view of an embodiment of the device;

• Fig. 5 is a schematic transverse cross-section view of the device body of Figure 4; Fig. 6 is a schematic section view of an interior of the device of Figure 4; and

Fig. 7 is a section view of a socket member of the device of Figure 4.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Aspects and embodiments will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

Fig. 1A shows a first embodiment of a smoking substitute system 100. In this example, the smoking substitute system 100 includes a device 102 and a component 104. The component 104 may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e. open systems), the device may be integral with the component. In such systems, a tank of the aerosol delivery system may be accessible for refilling the device.

In this example, the smoking substitute system 100 is a closed system vaping system, wherein the component 104 includes a sealed tank 106 and is intended for single-use only. The component 104 is removably engageable with the device 102 (i.e. for removal and replacement). Fig. 1A shows the smoking substitute system 100 with the device 102 physically coupled to the component 104, Fig. 1 B shows the device 102 of the smoking substitute system 100 without the component 104, and Fig. 1 C shows the component 104 of the smoking substitute system 100 without the device 102.

The device 102 and the component 104 are configured to be physically coupled together by pushing the component 104 into a cavity at an upper end 108 of the device 102, such that there is an interference fit between the device 102 and the component 104. In other examples, the device 102 and the component 104 may be coupled by screwing one onto the other, or through a bayonet fitting.

The component 104 includes a mouthpiece portion at an upper end 109 of the component 104, and one or more air inlets (not shown) in fluid communication with the mouthpiece portion such that air can be drawn into and through the component 104 when a user inhales through the mouthpiece portion. The tank 106 containing e-liquid is located at the lower end 111 of the component 104.

The tank 106 includes a window 112, which allows the amount of e-liquid in the tank 106 to be visually assessed. The device 102 includes a slot 114 so that the window 112 of the component 104 can be seen whilst the rest of the tank 106 is obscured from view when the component 104 is inserted into the cavity at the upper end 108 of the device 102.

The lower end 110 of the device 102 also includes a light 116 (e.g. an LED) located behind a small translucent cover. The light 116 may be configured to illuminate when the smoking substitute system 100 is activated. Whilst not shown, the component 104 may identify itself to the device 102, via an electrical interface, RFID chip, or barcode. The lower end 110 of the device 102 also includes a charging connection 115, which is usable to charge a battery within the device 102. The charging connection 115 can also be used to transfer data to and from the device, for example to update firmware thereon.

Figs. 2A and 2B are schematic drawings of the device 102 and component 104. As is apparent from Fig. 2A, the device 102 includes a power source 1 18, a controller 120, a memory 122, a wireless interface 124, an electrical interface 126, and, optionally, one or more additional components 128.

The power source 118 is preferably a battery, more preferably a rechargeable battery. The controller 120 may include a microprocessor, for example. The memory 122 preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 to perform certain tasks or steps of a method.

The wireless interface 124 is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface 124 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface 124 may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 of the device 102 may include one or more electrical contacts. The electrical interface 126 may be located in a base of the aperture in the upper end 108 of the device 102. When the device 102 is physically coupled to the component 104, the electrical interface 126 is configured to transfer electrical power from the power source 118 to the component 104 (i.e. upon activation of the smoking substitute system 100).

The electrical interface 126 may also be used to identify the component 104 from a list of known components. For example, the component 104 may be a particular flavour and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126). This can be indicated to the controller 120 of the device 102 when the component 104 is connected to the device 102. Additionally, or alternatively, there may be a separate communication interface provided in the device 102 and a corresponding communication interface in the component 104 such that, when connected, the component 104 can identify itself to the device 102.

The additional components 128 of the device 102 may comprise the light 116 discussed above.

The additional components 128 of the device 102 also comprises the charging connection 1 15 configured to receive power from the charging station (i.e. when the power source 118 is a rechargeable battery). This may be located at the lower end 110 of the device 102.

The additional components 128 of the device 102 may, if the power source 118 is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in a charging station (if present).

The additional components 128 of the device 102 include an airflow (i.e. puff) sensor for detecting airflow in the smoking substitute system 100, e.g. caused by a user inhaling through a mouthpiece portion 136 of the component 104. The smoking substitute system 100 may be configured to be activated when airflow is detected by the airflow sensor. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 of the device 102 includes a user input device, which may include a user input, e.g. a button. As will be described further below, the user input device can be actuated so as to provide a control signal to the controller 120. The smoking substitute system 100 may comprise further user input means, and may, for example, be configured to be activated when a user interacts with the user input (e.g. presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100.

As shown in Fig. 2B, the component 104 includes the tank 106, an electrical interface 130, a vaporiser 132, one or more air inlets 134, a mouthpiece portion 136, and one or more additional components 138.

The electrical interface 130 of the component 104 may include one or more electrical contacts. The electrical interface 126 of the device 102 and an electrical interface 130 of the component 104 are configured to contact each other and thereby electrically couple the device 102 to the component 104 when the lower end 1 11 of the component 104 is inserted into the upper end 108 of the device 102 (as shown in Fig. 1 A). In this way, electrical energy (e.g. in the form of an electrical current) is able to be supplied from the power source 118 in the device 102 to the vaporiser 132 in the component 104.

The vaporiser 132 is configured to heat and vaporise e-liquid contained in the tank 106 using electrical energy supplied from the power source 118. As will be described further below, the vaporiser 132 includes a heating filament and a wick. The wick draws e-liquid from the tank 106 and the heating filament heats the e-liquid to vaporise the e-liquid.

The one or more air inlets 134 are preferably configured to allow air to be drawn into the smoking substitute system 100, when a user inhales through the mouthpiece portion 136. When the component 104 is physically coupled to the device 102, the air inlets 134 receive air, which flows to the air inlets 134 along a gap between the device 102 and the lower end 1 11 of the component 104.

In operation, a user activates the smoking substitute system 100, e.g. through interaction with a user input forming part of the device 102 or by inhaling through the mouthpiece portion 136 as described above. Upon activation, the controller 120 may supply electrical energy from the power source 1 18 to the vaporiser 132 (via electrical interfaces 126, 130), which may cause the vaporiser 132 to heat e- liquid drawn from the tank 106 to produce a vapour which is inhaled by a user through the mouthpiece portion 136.

An example of one of the one or more additional components 138 of the component 104 is an interface for obtaining an identifier of the component 104. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the component. The component 104 may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the device 102.

It should be appreciated that the smoking substitute system 100 shown in figures 1A to 2B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

Fig. 3 is a section view of an example of the component 104 described above. The component 104 comprises a tank 106 for storing e-liquid, a mouthpiece portion 136 and a conduit 140 extending along a longitudinal axis of the component 104. In the illustrated embodiment the conduit 140 is in the form of a tube having a substantially circular transverse cross-section (i.e. transverse to the longitudinal axis). The tank 106 surrounds the conduit 140, such that the conduit 140 extends centrally through the tank 106.

A tank housing 142 of the tank 106 defines an outer casing of the component 104, whilst a conduit wall 144 defines the conduit 140. The tank housing 142 extends from the lower end 111 of the component 104 to the mouthpiece portion 136 at the upper end 109 of the component 104. At the junction between the mouthpiece portion 136 and the tank housing 142, the mouthpiece portion 136 is wider than the tank housing 142, so as to define a lip 146 that overhangs the tank housing 142. This lip 146 acts as a stop feature when the component 104 is inserted into the device 102 (i.e. by contact with an upper edge of the device 102).

The tank 106, the conduit 140 and the mouthpiece portion 136 are integrally formed with each other so as to form a single unitary component and may e.g. be formed by way of an injection moulding process. Such a component may be formed of a thermoplastic material such as polypropylene.

The mouthpiece portion 136 comprises a mouthpiece aperture 148 defining an outlet of the conduit 140. The vaporiser 132 is fluidly connected to the mouthpiece aperture 148 and is located in a vaporising chamber 156 of the component 104. The vaporising chamber 156 is downstream of the inlet 134 of the component 104 and is fluidly connected to the mouthpiece aperture 148 (i.e. outlet) by the conduit 140.

The vaporiser 132 comprises a porous wick 150 and a heater filament 152 coiled around the porous wick 150. The wick 150 extends transversely across the chamber vaporising 156 between sidewalls of the chamber 156 which form part of an inner sleeve 154 of an insert 158 that defines the lower end 111 of the component 104 that connects with the device 102. The insert 158 is inserted into an open lower end of the tank 106 so as to seal against the tank housing 142.

In this way, the inner sleeve 154 projects into the tank 106 and seals with the conduit 140 (around the conduit wall 144) so as to separate the vaporising chamber 156 from the e-liquid in the tank 106. Ends of the wick 150 project through apertures in the inner sleeve 154 and into the tank 106 so as to be in contact with the e-liquid in the tank 106. In this way, e-liquid is transported along the wick 150 (e.g. by capillary action) to a central portion of the wick 150 that is exposed to airflow through the vaporising chamber 156. The transported e-liquid is heated by the heater filament 152 (when activated e.g. by detection of inhalation), which causes the e-liquid to be vaporised and to be entrained in air flowing past the wick 150. This vaporised liquid may cool to form an aerosol in the conduit 140, which may then be inhaled by a user.

Fig. 4 shows a perspective view of an embodiment of the device 102 engaged with the component 104 at the upper end 108. The device 102 includes a charging connection 1 15 at the lower end 1 10.

The front surface 201 of the device body 200 is curved in the transverse dimension. The rear surface 202 of the device body 200 is curved in the transverse dimension. The curvatures of the front surface

201 and rear surface 202 are of the opposite sense to one another. Both front and rear surfaces 201 ,

202 are convex in the transverse dimension. This leads to a mandorla-Zlemon-Zeye-shaped cross sectional shape of the device body 200.

The front surface 201 and rear surface 202 meet at two transverse edges 205. The transverse edges 205 have a radius of curvature that is significantly smaller than the radius of curvature of either the front 201 or rear surface 202. This leads to the transverse edges being substantially “pointed” or “sharp”. The transverse edges may have a radius of curvature in the transverse dimension of less than 1 millimetre.

As illustrated in Fig. 4, the transverse edges 205 extend substantially the full longitudinal length of the device body 200.

The front surface 201 of the device body 200 may include an illumination region through which at least one light source may be visible.

Fig. 5 illustrates a schematic transverse cross section through the device 102 of Fig. 4, in accordance with an embodiment. The front surface 201 and rear surface 202 are shown meeting at the transverse edges 205 on either side of the device body 200. The radius of curvature in the transverse dimension of the front surface 201 is equal to the radius of curvature in the transverse dimension of the rear surface 202.

The radius of curvature of the front surface 201 may be between 10 and 15 mm.

Figure 6 shows the internal components of the device 102. The controller 120 and charging connection 115 of the device 102 are disposed at the lower end 110 of the device 102. The component 104 is engaged at the opposing upper end 108 of the device 102. In particular, the component 104 is engaged in a cavity 206 at the upper end 108 of the device 102. A socket member 207 is inserted into the device body 200 and extends transversely across the device body 200. The socket member 207 defines the base of the cavity 206, such that a lower end 1 11 of the component 104 abuts (i.e. so as to be supported on) the socket member 207. The power source, in the form of a battery 118, of the device 102 is located between the socket member 207 and the controller 120. Although not apparent from the figure, the battery 1 18 is electrically connected to the component 104 so as to provide power to a vaporiser of the component 104.

Figure 7 illustrates the socket member 207 in more detail. The socket member 207 comprises a transversely extending interface wall 208 having a first side 209 for interfacing with the component 104, and a second side 210 at least partly defining an internal chamber 211 of the device 102. An opening

212 is formed in the interface wall 208 for airflow into and/or out of the chamber 211 . An airflow sensor

213 (in the form of a differential pressure sensor) is concealed in the chamber 211 and spaced in a transverse direction (in Figure 7 extending laterally across the page) from the opening 212. The spacing is such that the airflow sensor 213 is not aligned with the opening 212.

The proximity of the airflow sensor 213 to the component 104 facilitates accurate detection or measurement of airflow entering the component 104. The airflow sensor 213 is supported on a separator element in the form of a printed circuit board (PCB) 222 that defines a lower surface of the chamber 211 . That is, a lower opening of the socket member 207 is sealed by the PCB 222 (separator element).

Also mounted to the PCB 222 is a switch 226 that, along with an actuator (in the form of an actuating arm 227), defines a user input device of the device 102. The switch 226 and actuating arm 227 are both concealed within the chamber 221 of the device 102. The switch 226 is in the form of a press button that, when pressed, is configured to provide a control signal to the controller 120. The controller 120 is configured to, in response to the control signal, revert the device 102 to a state representative of a factory setting state.

The actuating arm 227 extends over the switch 226 such that a portion of the actuating arm 227 is disposed between the opening 212 and the switch 226. In other words, a portion of the actuating arm 227 is directly below the opening 212 so as to lie on an axis extending through a centre of the opening 212. In this way, the opening 212 is arranged such that the switch 226 is actuatable by insertion of a pin through the opening to move the actuating arm 227 towards the switch 226.

Thus, the opening 212 serves two purposes: a Venturi aperture for the measurement of airflow and to provide access to the concealed switch 226. This simplifies construction of the device 102 and maximises efficient use of space within the device 102.

The opening 212 is configured (i.e. sized and shaped) to prevent access to the actuating arm 227 by a user’s finger. This ensures that a user is unable to inadvertently actuate the switch 226 (which could cause unwanted irreversible changes to the device 102).

The actuating arm 227 comprises a proximal end 228 mounted in the chamber 211 and an opposing distal end 229 extending over, and overlying, the switch 226 (such that an underside of the distal end 229 is in contact with the switch 226). The actuating arm 226 is moveable (i.e. by a pin received through the opening 212) between an activated position, in which it presses the switch 226, and a deactivated position, in which the switch 226 is not pressed by the actuating arm 226. The actuating arm 227 is formed of a resilient material such that it returns to the deactivated position upon removal of any force (i.e. from a pin) that moves it into the activated position. This flexibility is somewhat facilitated by a recess 230 formed in an upper side of the actuating arm 227 proximate to the proximal end 228.

The distal end 229 of the actuating arm 227 is cantilevered from the proximal end 228 so as to be a free end. An end-stop 231 , in the form of a protrusion, is provided on an underside of the distal end 229 of the actuating arm 227 (i.e. the side of the actuating arm 227 facing the switch 226). The end-stop 231 contacts an upper surface of the PCB 222 upon movement of the distal end 229 of the actuating arm 227 by e.g. a pin. In this way, the end-stop 231 restricts further movement of the actuating arm 227 (i.e. beyond the activated position).

The proximal end 228 of the actuating arm 227 comprises a mounting portion formed of upper 232 and lower 233 projections that respectively project from the upper side and underside of the actuating arm 227. The upper projection 232 has a tapered distal end portion, while the lower projection 233 is tapered from its base to its distal end. Each of the projections 232, 233 has a circular cross-sectional shape.

The lower projection 233 abuts an upper surface of the PCB 222. The upper projection 233 is received (and retained) in a retaining portion, in the form of a recess 234. The recess 234 is partly defined by a retaining protrusion 235 that protrudes downwardly from the second side 210 the interface wall 208. In this way, the actuating arm 227 is somewhat retained (i.e. in a vertical direction as shown) by contact of the upper side of the actuating arm 227 with a distal end of the retaining protrusion 235 and contact of the lower projection 232 with the PCB 222.

The recess 234 is also partly defined by a partition wall 216 that partitions the chamber 211 into a first chamber portion 217 (at a first transverse end 214 of the chamber 21 1) comprising the opening 212 and a second chamber portion 218 (at a second transverse end 215 of the chamber 211) in which the airflow sensor 213 is disposed. Receipt of the upper projection 233 between the partition wall 216 and the retaining projection 232 restricts movement of the actuating arm 227 in the transverse direction.

The opening 212 is disposed at the first transverse end 214 of the chamber 21 1 and the airflow sensor 213 is disposed at the second transverse end 215 of the chamber 211 that is opposite to the first transverse end 214. This spacing of the airflow sensor 213 from the opening 212 helps to ensure that the airflow sensor 213 is not fouled (e.g. damaged) by any aerosol precursor that leaks from the component 104 and into the chamber 211 through the aperture 212.

The partition wall 216 projects downwardly from the second side 210 of the interface wall 208 so as to substantially seal the first chamber portion 217 from the second chamber portion 218. The projection of the partition wall 216 is such that it doesn’t extend the entire way across the chamber 211 . Thus, an air exchange aperture 219 (in the form of an elongate gap) is partly defined by a distal edge 220 of the partition wall 216, which allows air exchange between the first 217 and second 218 chamber portions. The air exchange aperture 219 is sized so as to permit airflow between the chamber portions 217, 218, but restrict liquid flow therebetween. The distal edge 220 of the partition wall 216 is tapered (to a point), which helps to restrict passage of fluid into the second chamber 218 (i.e. due to surface tension of the liquid).

The socket member 207 further comprises a skirt 221 depending from a periphery of the interface wall 208. In this way an inner surface of the skirt 221 and the second side of the interface wall 208 partly define the chamber 211. In particular, the interface wall 208 defines a top of the chamber 211 and the skirt 221 defines an elliptical side wall of the chamber 21 1 . The partition 216 extends (i.e. in the direction into the page) across an interior of the skirt 221 (so as to extend from one portion of the skirt 221 to an opposing portion).

The interface wall 208 is integrally formed with the skirt 221 . The partition wall 216 is integrally formed with both the skirt 221 and the interface wall 208. In this way, the socket member 207 is unitary (i.e. a single piece). As should be apparent from the figure, the socket member 207 is configured so as to be formable by injection moulding, and may be formed by way of a straight-pull moulding process (i.e. without any need for side-actions).

The opening 212 formed in the interface wall 208 is the only opening to the chamber 211. Thus, the chamber 211 is sealed, other than for the opening 212. This facilitates measurement of airflow to the component 104 by way of pressure changes in the chamber 211 .

The PCB 222 extends transversely and separates the chamber from an internal cavity of the device 102 that comprises the power source 118 and the controller 120. The PCB 222 is parallel to, and spaced from, the interface wall 208 such that the chamber 211 is defined therebetween.

As noted above, the airflow sensor 213 is supported on the PCB 222. A portion of the sensor 213 extends through the PCB 222 so as to measure air pressure on the opposing side of the PCB 222 to the chamber 211 . This allows the airflow sensor 213 to measure a differential pressure.

The airflow sensor 213 is electronically connected to the PCB 222 so as to exchange signals with the PCB 222. The PCB 222 is, in turn, electronically connected to the controller 120 such that the sensor 213 is able to communicate with the controller 120. As an example, the airflow sensor 213 may indicate, to the controller 120, when an airflow entering the component 104 is detected (e.g. detection of a puff). The controller 120 may, in response, control the heater 152 of the component 104 (e.g. activate the heater 152).

The entire periphery of the PCB 222 is sealed against an overhanging lip 223 of the skirt 223. In particular the seal is provided by an adhesive layer 224 between the periphery of the PCB 222 and the overhanging lip 224.

The first side 209 of the interface wall 208 comprises a plurality of spacers in the form of protrusions 225 projecting upwardly from the first side 209. The distal ends of the protrusions 225 abut the underside of the component 104 (as shown in Figure 6), when received in the cavity 206 of the device 102. In this way, the protrusions 225 space the component 104 (the underside of the component 104) from the first side 209 of the interface wall 208. This space defines an airflow passage 236 for airflow into the component 104. The airflow path extends past the opening 212, which enables the airflow sensor 213 to detect the airflow.

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

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/- 10%.

The words "preferred" and "preferably" are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

Further aspects and embodiments are described with reference to the following numbered paragraphs:

1 . An aerosol delivery device (102), engageable with a component (104) for containing an aerosol precursor, the device (102) comprising: a transversely extending interface wall (208) having a first side (209) at least partly defining an airflow passage when the device (102) is engaged with the component (104), and a second side (210) at least partly defining an internal chamber (211) of the device (102); an opening (212) formed in the interface wall (208) for airflow into and/or out of the chamber (211); and an airflow sensor (213) concealed in the chamber (211) and spaced in a transverse direction from the opening (212). 2. An aerosol delivery device (102) according to paragraph 1 wherein the opening (212) is disposed at a first transverse end (214) of the chamber (211) and the airflow sensor (213) is disposed at a second transverse (215) end of the chamber (211) that is opposite to the first transverse end (214).

3. An aerosol delivery device (102) according to paragraph 1 or 2 comprising a partition wall (216) that partitions the chamber (211) into a first chamber portion (217) comprising the opening (212) and a second chamber portion (218) in which the airflow sensor (213) is disposed.

4. An aerosol delivery device (102) according to paragraph 3 comprising an air exchange aperture (219) fluidly connecting the first (217) and second chamber portions (218).

5. An aerosol delivery device (102) according to paragraph 4 wherein the air exchange aperture (219) is configured to permit airflow between the chamber portions (217, 218) but restrict liquid flow therebetween.

6. An aerosol delivery device (102) according to any one of paragraphs 3 to 5 wherein the air exchange aperture (219) is partly defined by a distal edge (220) of the partition wall (216).

7. An aerosol delivery device (102) according to paragraph 6 wherein the distal edge (220) of the partition wall (216) is tapered.

8. An aerosol delivery device (102) according to any one of paragraphs 3 to 7 wherein the partition wall (216) is integrally formed with the interface wall (208).

9. An aerosol delivery device (102) according to any one of paragraphs 1 to 8 wherein the interface wall (208) forms part of a socket member (207) of the device (102), the socket member (207) further comprising a skirt (221) depending from a periphery of the interface wall (208).

10. An aerosol delivery device (102) according to any one of paragraphs 1 to 9 comprising a separator element (222) separating the chamber (211) from an internal cavity of the device (102).

11. An aerosol delivery device (102) according to paragraph 10 wherein the separator element (222) is a printed circuit board (PCB).

12. An aerosol delivery device (102) according to paragraph 11 wherein the airflow sensor (213) is supported on, and electrically connected to, the PCB (222).

13. An aerosol delivery device (102) according to any one of paragraphs 10 to 12, when dependent on paragraph 9, wherein the separator element (222) is sealed to the skirt (221) of the socket member (207).

14. An aerosol delivery device (102) according to any one of paragraphs 1 to 13 wherein the first side (209) of the interface wall (208) comprises a spacer (225) for spacing the component (104) from the first side (209) of the interface wall (208) when the component (104) is engaged with the device (102). An aerosol delivery system (100) comprising a device (102) according to any one of paragraphs 1 to 14 and a component (104) for containing an aerosol precursor.

Claims

1 . An aerosol delivery device (102), engageable with a component (104) for containing an aerosol precursor, the device (102) comprising: a controller (120) for controlling an operation of the device (102); an airflow sensor (213) and a user input device (227, 226) concealed within a chamber (211) of the aerosol delivery device (102), the user input device (227, 226) configured to provide, when actuated, a control signal to the controller (120), and an opening (212) to the chamber (211) providing fluid communication between the chamber (211) and an airflow passage (236), the opening (212) arranged such that the user input device (227, 226) is actuatable by insertion of a pin through the opening (212).

2. An aerosol delivery device (102) according to claim 1 wherein the opening (212) is configured to prevent access to the user input device (227, 226) through the opening (212) by a user’s finger.

3. An aerosol delivery device (102) according to claim 1 or 2 wherein the opening (212) has a width that is less than 5 mm.

4. An aerosol delivery device (102) according to any one of the preceding claims wherein the user input device (227, 226) is aligned on a line of sight extending through the opening (212).

5. An aerosol delivery device (102) according to claim 4 wherein the user input device (227, 226) is arranged such that an axis extending through the opening (212), and that is normal to the opening (212), extends through the user input device (227, 226).

6. An aerosol delivery device (102) according to any one of the preceding claims wherein the controller (120) is configured, upon receipt of the control signal from the user input device (227, 226), to adjust one or more device settings, for example, to revert the one or more device settings to a previous state.

7. An aerosol delivery device (102) according to any one of the preceding claims wherein the user input device (227, 226) comprises a switch (226).

8. An aerosol delivery device (102) according to claim 7 wherein the switch (226) is a press button.

9. An aerosol delivery device (102) according to claim 7 or 8 wherein the user input device (227, 226) comprises an actuating arm (227) for actuating the switch (226).

10. An aerosol delivery device (102) according to claim 9 wherein the actuating arm (227) comprises a proximal end (228) mounted in the chamber (211) and a distal end (229) extending over the switch (226).

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11. An aerosol delivery device (102) according to claim 10 wherein the distal end (229) is cantilevered from the proximal end (228).

12. An aerosol delivery device (102) according to any one of claims 9 to 11 wherein the actuating arm (227) is formed of a resilient material.

13. An aerosol delivery device (102) according to any one of the preceding claims comprising a transversely extending interface wall (208) having a first side (209) at least partly defining the airflow passage (236) and a second side (210) at least partly defining the chamber (211), the opening (212) to the chamber (211) being formed in the interface wall (208).

14. An aerosol delivery device (102) according to any one of the preceding claims comprising a transversely extending printed circuit board (PCB) (222) defining a base of the chamber (211), the switch (226) supported on the PCB.

15. An aerosol delivery system (100) comprising a device (102) according to any one of the preceding claims and a component (104) for containing an aerosol precursor.