AEROSOL DELIVERY DEVICE

Abstract

An aerosol delivery device comprises: a flow passage configured to provide fluid communication between a vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising an aerosol vapor formed from liquid vaporized by the vaporizer in use; and a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to turn the flow towards a circumferential direction of the aerosol delivery device.

Claims

1. An aerosol delivery device comprising: a flow passage configured to provide fluid communication between a vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising an aerosol vapor formed from liquid vaporized by the vaporizer in use; and a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to turn the flow towards a circumferential direction of the aerosol delivery device.

2. An aerosol delivery device according to claim 1 further comprising the vaporizer.

3. An aerosol delivery device according to claim 2, wherein the aerosol delivery device comprises a vaporizer chamber containing the vaporizer, and wherein the turbulence inducing element is at least partially located in the vaporizer chamber.

4. An aerosol delivery device according to claim 1, wherein the turbulence inducing element is located at least 1 mm downstream of the vaporizer.

5. An aerosol delivery device comprising: a vaporizer configured to form an aerosol vapor from e-liquid; a flow passage configured to provide fluid communication between the vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising the aerosol vapor in use; a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to induce turbulence in the flow; and a vaporizer chamber containing the vaporizer and the turbulence inducing element, wherein the turbulence inducing element is at least 1 mm downstream of the vaporizer.

6. An aerosol delivery device according to claim 5, wherein the turbulence inducing element is at least partially located within the vaporizer chamber.

7. An aerosol delivery device according to claim 4, wherein the turbulence inducing element is at least 2 mm downstream of the vaporizer.

8. An aerosol delivery device according to claim 7, wherein the turbulence inducing element is at least 2.5 mm downstream of the vaporizer.

9. An aerosol delivery device according to claim 4, wherein the turbulence inducing element is at most 5 mm downstream of the vaporizer.

10. An aerosol delivery device according to claim 9, wherein the turbulence inducing element is at most 4 mm downstream of the vaporizer.

11. An aerosol delivery device according to claim 4, wherein the turbulence inducing element is substantially 3 mm downstream of the vaporizer.

12. An aerosol delivery device according to claim 5, wherein the turbulence inducing element is configured to turn the flow towards a circumferential direction.

13. An aerosol delivery device according to claim 5, wherein the turbulence inducing element is further configured to turn the flow towards a radial direction of the aerosol delivery device.

14. An aerosol delivery device according to claim 13, wherein the turbulence inducing element comprises a baffle across the flow passage, the baffle forming a first flow obstacle to turn the flow towards the radial direction.

15. An aerosol delivery device according to claim 14, wherein the baffle is configured to effect branching of the flow.

16. An aerosol delivery device according to claim 5, wherein the turbulence inducing element comprises an upstand, and the flow passage comprises an outlet tube, wherein the outlet tube and the upstand are configured to together form a second flow obstacle to turn the flow towards the circumferential direction.

17. An aerosol delivery device according to claim 16, wherein the second flow obstacle is configured to effect additional branching of the flow.

18. An aerosol delivery device according to claim 5, wherein the turbulence inducing element comprises an outlet, the turbulence inducing element further configured to turn the flow such that the flow is in a substantially axial direction at the outlet.

19. An aerosol delivery device according to claim 18, wherein the turbulence inducing element comprises a protrusion forming a third flow obstacle to turn the flow towards the axial direction.

20. An aerosol delivery device according claim 5, further comprising a reservoir for storing a liquid, the reservoir in fluid communication with the vaporizer to pass liquid to the vaporizer for vaporization.

21.-92. (canceled)

Description

SUMMARY OF THE FIGURES

[0261] So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

[0262] FIG. 1A is a side view of a smoking substitute device of the first mode.

[0263] FIG. 1B is a side view of main body of the smoking substitute device of the first mode.

[0264] FIG. 1B is a side view of consumable of the smoking substitute device of the first mode.

[0265] FIG. 2A is a schematic drawing of the main body of the first mode.

[0266] FIG. 2B is a schematic drawing of the consumable of the first mode.

[0267] FIG. 3 is a cross-sectional view of the consumable of the first mode.

[0268] FIG. 4 is a cross-sectional view of a manufacturing assembly of the first mode.

[0269] FIG. 5A is a cross-sectional view of a portion of a second consumable of the first mode.

[0270] FIG. 5B is a bottom view of the portion of the second consumable of the first mode.

[0271] FIG. 6A is a vertical sectional view of a portion of a third consumable of the first mode.

[0272] FIG. 6B is a horizontal sectional view of a portion of the third consumable of the first mode.

[0273] FIG. 7A is a front schematic view of a smoking substitute system of the second mode.

[0274] FIG. 7B is a front schematic view of a main body of the system of the second mode.

[0275] FIG. 7C is a front schematic view of a consumable of the system of the second mode.

[0276] FIG. 8A is a schematic of the components of the main body of the second mode.

[0277] FIG. 8B is a schematic of the components of the consumable of the second mode.

[0278] FIG. 9A is a section view of the consumable of the second mode.

[0279] FIG. 9B is a detailed section view of a vaporizing chamber of the consumable of the second mode.

[0280] FIG. 10 is a section view of a manufacturing assembly for manufacturing the consumable of the second mode.

[0281] FIG. 11A is a front schematic view of a smoking substitute system of the third mode.

[0282] FIG. 11B is a front schematic view of a main body of the system of the third mode.

[0283] FIG. 11C is a front schematic view of a consumable of the system of the third mode.

[0284] FIG. 12A is a schematic of the components of the main body of the third mode.

[0285] FIG. 12B is a schematic of the components of the consumable of the third mode.

[0286] FIG. 13A is a section view of the consumable of the third mode.

[0287] FIG. 13B is a detailed section view of a vaporizing chamber of the consumable of the third mode.

[0288] FIG. 14 is a section view of a manufacturing assembly for manufacturing the consumable of the third mode.

[0289] FIG. 15A is a front schematic view of a smoking substitute system of the fourth mode.

[0290] FIG. 15B is a front schematic view of a main body of the system of the fourth mode.

[0291] FIG. 15C is a front schematic view of a consumable of the system of the fourth mode.

[0292] FIG. 16A is a schematic of the components of the main body of the fourth mode.

[0293] FIG. 16B is a schematic of the components of the consumable of the fourth mode.

[0294] FIG. 17A is a section view of the consumable of the fourth mode.

[0295] FIG. 17B and FIG. 17C are detailed section views of a vaporizing chamber of the consumable of the fourth mode.

[0296] FIG. 18 is a section view of a manufacturing assembly for manufacturing the consumable of the fourth mode.

[0297] FIG. 19A is a front schematic view of a smoking substitute system of the fifth mode.

[0298] FIG. 19B is a front schematic view of a main body of the system of the fifth mode.

[0299] FIG. 19C is a front schematic view of a consumable of the system of the fifth mode.

[0300] FIG. 20A is a schematic of the components of the main body of the fifth mode.

[0301] FIG. 20B is a schematic of the components of the consumable of the fifth mode.

[0302] FIG. 21 is a section view of the consumable of the fifth mode.

[0303] FIG. 22A is a perspective view of a base insert of the consumable of the fifth mode.

[0304] FIG. 22B is an alternative perspective view of the base insert of FIG. 22A.

[0305] FIG. 22C is a section view of the base insert of FIG. 22A.

[0306] FIG. 23A is a front schematic view of a smoking substitute system of the sixth mode.

[0307] FIG. 23B is a front schematic view of a device of the system of the sixth mode.

[0308] FIG. 23C is a front schematic view of a consumable of the system of the sixth mode.

[0309] FIG. 24A is a schematic of the components of the device of the sixth mode.

[0310] FIG. 24B is a schematic of the components of the consumable of the sixth mode.

[0311] FIG. 25A is a schematic section view of the device of the sixth mode.

[0312] FIG. 25B is a section view of the consumable engaged with the device of the sixth mode.

[0313] FIG. 26 is a section view of a manufacturing assembly for manufacturing the consumable of the sixth mode.

DETAILED DESCRIPTION OF THE FIGURES

[0314] First Mode: An Aerosol Delivery Device in which a Turbulence Inducing Element is Configured to Turn Flow Towards a Circumferential Direction

[0315] Aspects and embodiments of the first mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0316] FIG. 1A shows an aerosol delivery device, which is a smoking substitute device 110. In this example, the smoking substitute device 110 includes a main body 120 and a consumable 150. The consumable 150 may alternatively be referred to as a “pod”. The consumable may also be referred to as a cartridge or cartomizer. In other examples, the term “aerosol delivery device” may apply to the consumable 150 alone rather than the smoking substitute device 110.

[0317] In this example, the smoking substitute device 110 is a closed system vaping device, wherein the consumable 150 includes a liquid reservoir or sealed tank 156 and is intended for one-use only.

[0318] FIG. 1A shows the smoking substitute device 110 with the main body 120 physically coupled to the consumable 150.

[0319] FIG. 1B shows the main body 120 of the smoking substitute device 110 without the consumable 150.

[0320] FIG. 1C shows the consumable 150 of the smoking substitute device 110 without the main body 120.

[0321] The main body 120 and the consumable 150 are configured to be physically coupled together, in this example by pushing the consumable 150 into an aperture in a top end 122 of the main body 120, such that there is an interference fit between the main body 120 and the consumable 150. In other examples, the main body 120 and the consumable could be physically coupled together by screwing one onto the other, or through a bayonet fitting, for example. An optional light 126, e.g., an LED, located behind a small translucent cover, is located a bottom end 124 of the main body 120. The optional light 126 may be configured to illuminate when the smoking substitute device 110 is activated.

[0322] The consumable 150 includes a mouthpiece (not shown in FIG. 1A-1C) at a top end 152 of the consumable 150, as well as one or more air inlets (not shown) so that air can be drawn into the smoking substitute device 110 when a user inhales through the mouthpiece. At a bottom end 154 of the consumable 150, there is located a tank 156 that contains e-liquid. The tank 156 may be a translucent body, for example.

[0323] The tank 156 preferably includes a window 158, so that the amount of e-liquid in the tank 156 can be visually assessed. The main body 120 includes a slot 128 so that the window 158 of the consumable 150 can be seen whilst the rest of the tank 156 is obscured from view when the consumable 150 is inserted into the aperture in the top end 122 of the main body 120.

[0324] The tank 156 may be referred to as a “clearomizer” if it includes a window 158, or a “cartomizer” if it does not.

[0325] The consumable 150 may identify itself to the main body 120, via an electrical interface, RFID chip, or barcode.

[0326] FIG. 2A is a schematic drawing of the main body 120 of the smoking substitute device 110.

[0327] FIG. 2B is a schematic drawing of the consumable 150 of the smoking substitute device 110.

[0328] As shown in FIG. 2A, the main body 120 includes a power source 118, a control unit 130, a memory 132, a wireless interface 134, an electrical interface 136, and, optionally, one or more additional components 138.

[0329] The power source 118 is preferably a battery, more preferably a rechargeable battery.

[0330] The control unit 130 may include a microprocessor, for example.

[0331] The memory 132 is preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the control unit 130 to perform certain tasks or steps of a method.

[0332] The wireless interface 134 is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 134 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 134 may also be configured to communicate wirelessly with a remote server.

[0333] The electrical interface 136 of the main body 120 may include one or more electrical contacts. The electrical interface 136 may be located in, and preferably at the bottom of, the aperture in the top end 122 of the main body 120. When the main body 120 is physically coupled to the consumable 150, the electrical interface 136 may be configured to pass electrical power from the power source 118 to (e.g., a heating device of) the consumable 150 when the smoking substitute device 110 is activated, e.g., via the electrical interface 160 of the consumable 150 (discussed below). The electrical interface may be configured to receive power from a charging station, when the main body 120 is not physically coupled to the consumable 150 and is instead coupled to the charging station. The electrical interface 136 may also be used to identify the consumable 150 from a list of known consumables. For example, the consumable may be a particular flavor and/or have a certain concentration of nicotine. This can be identified to the control unit 130 of the main body 120 when the consumable is connected to the main body. Additionally, or alternatively, there may be a separate communication interface provided in the main body 120 and a corresponding communication interface in the consumable 150 such that, when connected, the consumable can identify itself to the main body 120.

[0334] The additional components 138 of the main body 120 may comprise the optional light 126 discussed above.

[0335] The additional components 138 of the main body 120 may, if the power source 118 is a rechargeable battery, comprise a charging port configured to receive power from the charging station. This may be located at the bottom end 124 of the main body 120. Alternatively, the electrical interface 136 discussed above is configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0336] The additional components 138 of the main body 120 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 the charging station (if present).

[0337] The additional components 138 of the main body 120 may include an airflow sensor for detecting airflow in the smoking substitute device 110, e.g., caused by a user inhaling through a mouthpiece 166 (discussed below) of the smoking substitute device 110. The smoking substitute device 110 may be configured to be activated when airflow is detected by the airflow sensor. This optional sensor could alternatively be included in the consumable 150 (though this is less preferred where the consumable 150 is intended to be disposed of after use, as in this example). 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.

[0338] The additional components 138 of the main body 120 may include an actuator, e.g., a button. The smoking substitute device 110 may be configured to be activated when the actuator is actuated. This provides an alternative to the airflow sensor noted, as a mechanism for activating the smoking substitute device 110.

[0339] As shown in FIG. 2B, the consumable 150 includes the tank 156, an electrical interface 160, a heating device 162, one or more air inlets 164, a mouthpiece 166, and, optionally, one or more additional components 168. The consumable 150 includes a heater chamber 170, which contains the heating device 162.

[0340] The electrical interface 160 of the consumable 150 may include one or more electrical contacts. The electrical interface 136 of the main body 120 and an electrical interface 160 of the consumable 150 are preferably configured to contact each other and thereby electrically couple the main body 120 to the consumable 150 when the bottom end 154 of the consumable 150 is inserted into the top end 122 of the main body 120 (as shown in FIG. 1A) to physically coupled the consumable 150 to the main body 120. 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 main body 120 to the heating device 162 in the consumable 150.

[0341] The heating device 162 is preferably configured to heat e-liquid contained in the tank 156, e.g., using electrical energy supplied from the power source 118, in order to vaporize the e-liquid. In one example, the heating device 162 includes a heating filament and a wick, wherein a first portion of the wick extends into the tank 156 in order to draw e-liquid out from the tank 156, and wherein the heating filament coils around a second portion of the wick located outside the tank 156. In this example, the heating filament is configured to heat up e-liquid drawn out of the tank 156 by the wick to produce an aerosol vapor.

[0342] The one or more air inlets 164 are preferably configured to allow air to be drawn into the smoking substitute device 110, when a user inhales through the mouthpiece 166. When the consumable 150 is physically coupled to the main body 120, the air inlet 164 receives air which flows from the top end 122 of the main body 120, between the main body 120 and the bottom end 154 of the consumable 150.

[0343] In use, a user activates the smoking substitute device 110, e.g., through actuating an actuator included in the main body 120 or by inhaling through the mouthpiece 166 as described above. Upon activation, the control unit 130 may supply electrical energy from the power source 118 to the heating device 162 (via electrical interfaces 136, 160), which may cause the heating device 162 to heat e-liquid drawn from the tank 156 to produce a vapor which is inhaled by a user through the mouthpiece 166.

[0344] As an example of one of the one or more additional components 168, an interface for obtaining an identifier of the consumable may be provided. As discussed above, this interface may be, for example, an RFID reader, a barcode or QR code reader, or an electronic interface which is able to identify the consumable to the main body. The consumable 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 main body.

[0345] Of course, a skilled reader would readily appreciate that the smoking substitute device 110 shown in FIG. 1 and FIG. 2 shows just one example implementation of a smoking substitute device, and that other forms of smoking substitute device could be used.

[0346] As another example, an entirely disposable (one use) smoking substitute device could be used as the smoking substitute device.

[0347] FIG. 3 shows a cross-sectional view of a consumable 150. The consumable comprises a tank 156 for storing e-liquid, a mouthpiece 166 and an outlet tube 306, which in this example is a chimney or tube. The tank 156 surrounds the outlet tube 306, with the outlet tube extending through a central portion of the tank 156. The outlet tube 306 has a substantially circular cross-section.

[0348] The tank 156 is provided by an outer casing of the consumable 150. The outer casing of the consumable 150 comprises a tank wall 304. The tank wall 304 extends completely around the outlet tube 306 to define the tank 156 in the form of an annulus between the outlet tube 306 and the tank wall 304. The tank wall 304 extends from the bottom of the consumable up to the mouthpiece 166. Where the tank wall 304 meets the mouthpiece 166, the mouthpiece 166 has a larger outer width than the tank 156, which means that there is a lip 168 around the bottom of the mouthpiece 166.

[0349] The tank wall 304 tapers, which means that it has a thickness which decreases. The thickness of the tank wall 304 decreases along a first demolding direction, as defined below with respect to FIG. 4. The first demolding direction is a downward direction in FIG. 3, which is a direction away from the mouthpiece 166. This means that, aside from a small number of indents (for example, to provide physical connection between the consumable 150 and the main body 120), the thickness of the tank wall 304 generally decreases with increasing distance along the first demolding direction.

[0350] The thickness of the tank wall 304 decreases due to internal surfaces of the tank wall 304 being angled to the first demolding direction at a first tank draft angle. Additionally, the thickness of the tank wall 304 decreases due to external surfaces of the tank wall 304 being angled to the first demolding direction at a second tank draft angle.

[0351] The first tank draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

[0352] The second tank draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

[0353] The first tank draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

[0354] The second tank draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

[0355] It will be appreciated that the first tank draft angle and the second tank draft angle need not be the same as each other, and may be selected independently according to the above draft angles. In fact, one of the first tank draft angle and the second tank draft angle may be substantially 0 degrees, while the other may vary as described above.

[0356] Similarly, the outlet tube 306 comprises an outlet wall 307. The outlet wall 307 extends fully around the circular cross-section of the outlet tube 306 to provide the outlet tube 306. The outlet wall 307 tapers, which means that it has a thickness which decreases. The thickness of the outlet wall 307 decreases along the first demolding direction, as defined below with respect to FIG. 4. As before, the first demolding direction is a downward direction in FIG. 3, which is a direction away from the mouthpiece 166. This means that the thickness of the outlet wall 307 generally decreases along the first demolding direction. The thickness of the outlet wall 307 decreases due to an inner surface of the outlet wall 307 being angled to the first demolding direction at a first outlet draft angle. Additionally, the thickness of the outlet wall 307 decreases due to an external surface of the outlet wall 307 being angled to the first demolding direction at a second outlet draft angle.

[0357] The first outlet draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

[0358] The second outlet draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0, preferably at least 3.5.

[0359] The first outlet draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

[0360] The second outlet draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

[0361] It will be appreciated that the first outlet draft angle and the second outlet draft angle need not be the same as each other, and may be selected independently according to the above draft angles. In fact, one of the first outlet draft angle and the second outlet draft angle may be substantially 0 degrees, while the other may vary as described above.

[0362] Similarly, the outlet draft angles and tank draft angles may be selected independently from each other according to the above draft angles.

[0363] The outlet tube 306 has an internal width (i.e., a width/diameter of a passage through the outlet tube 306) which generally decreases in a downstream direction (i.e., downstream with respect to the fluid flow when a user inhales, which is an upward direction in FIG. 3). The downstream direction is a direction towards the mouthpiece 166 and, in this example, is an opposite direction to the first demolding direction. This decrease in width occurs due to the second outlet draft angle described above.

[0364] A difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.10 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.12 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.14 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.16 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.18 mm.

[0365] The difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.30 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.28 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.26 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.24 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.22 mm.

[0366] More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is substantially 0.20 mm. The outlet tube 306 is substantially 30 mm long. In other examples, the outlet tube 306 may have a length less than 30 mm.

[0367] The airway has an internal width less than 5.0 mm at an upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.5 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.2 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.8 mm at the upstream end of the outlet tube 306.

[0368] The airway has an internal width greater than 2.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.5 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.2 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.4 mm at the upstream end of the outlet tube 306.

[0369] More specifically, the airway has an internal width of substantially 3.6 mm at the upstream end of the outlet tube 306.

[0370] The airway has an internal width less than 4.8 mm at a downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.3 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.0 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.6 mm at the downstream end of the outlet tube 306.

[0371] The airway has an internal width greater than 1.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.3 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.0 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.2 mm at the downstream end of the outlet tube 306.

[0372] More specifically, the airway has an internal width of substantially 3.4 mm at a downstream end of the outlet tube 306.

[0373] The mouthpiece 166 comprises a mouthpiece aperture 314. The outlet tube 306 fluidly connects the heating device 162 to the mouthpiece 166, and, more specifically, the outlet tube 306 fluidly connects the heating device 162 to the mouthpiece aperture 314.

[0374] The mouthpiece aperture 314 has a radially inwardly directed inner surface 316. The inner surface 316 of the mouthpiece aperture 314 joins an outer surface 318 of the mouthpiece 166 (i.e., a surface which the user inserts into their mouth in use) at an outer edge 320 of the mouthpiece aperture 314. The outer edge 320 surrounds the mouthpiece aperture 314.

[0375] At the outer edge 320, the angle between the inner surface 316 of the mouthpiece aperture 314 and the outer surface 318 of the mouthpiece 166 (i.e., the “mouthpiece angle”) is less than 90 degrees. In the present example, this is due to the outer edge 320 being rounded to define a substantially smooth curve. For the purposes of this disclosure, the rounded portion is considered to be part of the inner surface 316. In this case, where the outer edge 320 is rounded, the mouthpiece angle is substantially 0 degrees. The smooth curve extends between the outer surface 318 and a lower portion of the inner surface 316, the lower portion extending in a substantially downward direction in FIG. 3 (i.e., normal to the outer surface 318 at the outer edge 320 and parallel to the direction of fluid flow in the outlet tube 306).

[0376] In the present example, the curve followed by the rounded portion is substantially an arc of a circle. The radius of the rounded portion is preferably less than 1.0 mm. More specifically, the radius of the rounded portion is less than 0.8. More specifically, the radius of the rounded portion is less than 0.6 mm.

[0377] The radius of the rounded portion is greater than 0.2 mm. More specifically, the radius of the rounded portion is greater than 0.4 mm.

[0378] However, in other examples, the radius of the rounded portion is less than 0.4 mm, and may be less than 0.2 mm. However, the rounded portion need not follow such a curve, and could be any substantially smooth curve.

[0379] In other examples, the outer edge 320 is not rounded, and is instead chamfered or beveled, such that the inner surface 316 comprises an angled portion, which extends at constant angle from the outer edge 320. Such a portion may extend the full depth of the mouthpiece aperture 314 (i.e., up to an inner edge 322, where the mouthpiece aperture 314 meets an inner surface of the mouthpiece 166), or may extend only part of the depth of the mouthpiece aperture 314, up to a lower portion extending in the substantially downward direction as described above.

[0380] The mouthpiece angle is preferably less than 75 degrees, preferably less than 60 degrees, preferably less than 45 degrees, preferably less than 30 degrees, preferably less than 15 degrees, preferably substantially 0 degrees.

[0381] In other examples, the inner surface 316 may comprise a combination of rounded portions and angled portions, and may include several angled portions angled at different angles.

[0382] Within the tank 156 there is a heating device 162, which in this example is a coil and wick assembly. The heating device 162 comprises an outer shell with one or more apertures. These apertures are filled with a wick material, so that e-liquid may only ingress the heating device 162 from the tank 156 via capillary action. The wick material passes through or proximal to a coil, which is connected to one or more electrical contacts.

[0383] The consumable 150 further comprises a tank seal 308, which seals a bottom portion of the tank 156 beneath the heating device 162. The tank seal 308 is connected to the heating device 162, and the tank seal 308 comprises an air inlet 164, such that air flow is permitted from outside the tank through the air inlet 164 to the heating device 162.

[0384] The tank 156, the outlet tube 306 and the mouthpiece 166 are integrally formed with each other. The tank 156, the outlet tube 306 and the mouthpiece 166 make up a single component formed from a continuous piece of material. The tank 156, the outlet tube 306 and the mouthpiece 166 are formed in an injection molding process as described below with respect to FIG. 4. The tank 156, the outlet tube 306 and the mouthpiece 166 are made of a thermoplastic material. More specifically, the tank 156, the outlet tube 306 and the mouthpiece 166 are made of polypropylene.

[0385] The outlet tube 306 comprises a filter 310 located within the outlet tube 306. The filter 310 is tubular with an annular cross-section, and an outer surface of the filter 310 is in contact with an inner surface of the outlet tube 306. The outlet tube 306 comprises a void 312, and the filter 310 does not extend into the void 312. The void 312 is a portion of the outlet tube 306 in which no filter is present.

[0386] The void 312 comprises a downstream void portion 313 downstream of the filter 310. The downstream portion is located above the filter 310 and below the mouthpiece aperture 314 in FIG. 3. In other examples, the filter 310 extends to the mouthpiece aperture 314. The void 312 further comprises an upstream void portion 315 upstream of the filter 310. The void 312 occupies preferably at least 5% of a total length of the outlet tube 306, preferably at least 10% of the total length of the outlet tube 306, preferably at least 15% of the total length of the outlet tube 306, preferably at least 20% of the total length of the outlet tube 306, preferably at least 25% of the total length of the outlet tube 306.

[0387] The void 312 occupies preferably not more than 30% of a total length of the outlet tube 306, preferably not more than 25% of the total length of the outlet tube 306, preferably not more than 20% of the total length of the outlet tube 306, preferably not more than 15% of the total length of the outlet tube 306, preferably not more than 10% of the total length of the outlet tube 306. In this example, the filter 310 has a length of substantially 25 mm.

[0388] The outlet tube 306 comprises a retainer (not shown) which retains the filter 310 in position in the outlet tube 306. The retainer comprises a rib, which extends inwardly from an inner surface of the outlet tube to retain the filter in position in the outlet tube by an interference fit.

[0389] The filter 310 is made from a fabric, which may be cotton or another fiber. The filter may be formed of a mesh. The filter permits flow of vaporized e-liquid through the filter 310, but prevents flow of un-vaporized e-liquid through the filter 310. This reduces leakage of un-vaporized e-liquid into the user's mouth. The filter 310 may be a gas-permeable and liquid-impermeable membrane.

[0390] In use, when the consumable 150 is connected to the main body 120, the user inserts the mouthpiece 166 into their mouth. The user inhales through the mouthpiece aperture 314, which draws air through the air inlet 164 and into the heating device 162.

[0391] At the same time, an electrical current is provided to the one or more contacts, which causes heating of the coil, and consequent vaporization of the e-liquid within the wick material. The air flow passes through the coil and wick assembly, drawing with it vaporized e-liquid to form the aerosol vapor. The aerosol vapor flows up the outlet tube 306, before exiting the consumable 150 via mouthpiece aperture 314. The e-liquid only enters the coil and wick assembly via the one or more apertures and then, only via the wick.

[0392] As the aerosol vapor flows through the outlet tube 306, it passes the filter 310, which filters un-vaporized e-liquid out of the aerosol vapor. The void 312 provides a portion of the outlet tube 306 for condensation settling. The void 312 provides an unobstructed portion of the inner surface of the outlet tube 306 at which un-vaporized e-liquid which remains in the aerosol vapor downstream of the filter 310 can condense and flow down the inner surface of the outlet tube 306 into the filter 310. This further reduces leakage of un-vaporized e-liquid into the user's mouth.

[0393] FIG. 4 shows a drawing of a manufacturing assembly 400 which is used to manufacture the consumable 150. The manufacturing assembly 400 comprises a first mold 402 and a second mold 404.

[0394] The first mold 402 has a shape which complements that of a first end (a lower end in FIG. 3) of the integrally formed tank 156, mouthpiece 166 and outlet tube 306. The first mold 402 therefore has a shape which matches the inner surfaces of the tank 156, and the inner and outer surfaces of the outlet tube 306.

[0395] The second mold 404 has a shape which complements that of a second end (an upper end in FIG. 4) of the integrally formed tank 156, mouthpiece 166 and outlet tube 306. The second mold 404 therefore has a shape which matches the outer surface 318 of the mouthpiece 166 and the inner surface 316 of the mouthpiece aperture 314.

[0396] When the first mold 402 and the second mold 404 are brought together, they define a closed cavity which has the shape of the tank 156, the mouthpiece 166 and the outlet tube 306.

[0397] To manufacture the tank 156, the mouthpiece 166 and the outlet tube 306, heated material is injected into the cavity between the first mold 402 and the second mold 404. At this point, the first mold 402 and the second mold 404 meet at a boundary between external surfaces of the mouthpiece 166 and the tank 156.

[0398] The material is subsequently cooled, and the first mold 402 and the second mold 404 are separated, with the first mold 402 travelling in the first demolding direction 406 (i.e., away from the second mold 404) and the second mold 404 travelling in a second demolding direction 408 (i.e., away from the first mold 402 and opposite to the first demolding direction 406). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

[0399] The filter 310 is then inserted into the outlet tube 306, and the heating device 162, tank seal 308 and any additional components are inserted into the tank 156. The filter 310 is pushed into the outlet tube 306 through the upstream end of the outlet tube 306. Since the filter 310 is shorter than the outlet tube 306, the outlet tube 306 comprises the void 312.

[0400] In some examples (particularly where the void comprises the downstream void portion 313), the filter 310 is pushed into the outlet tube 306 using an insertion tool (not shown), with the insertion tool sized so that the filter 310 is inserted such that the filter 310 does not extend to the downstream end of the outlet tube 306, thereby providing the downstream void portion 313. In other examples, the filter 310 is pushed fully up to the mouthpiece aperture 314, with the filter 310 abutting against the mouthpiece aperture 314, which is narrower than the outlet tube 306.

[0401] Referring to FIG. 5A and FIG. 5B, there is shown a portion of a second consumable 500. For clarity, the heating device 162, the tank seal 308 and the filter 310 are omitted from FIG. 5A and FIG. 5B. However, the portion of the second consumable 250 is for use with the heating device 162, tank seal 308, filter 310 and any additional components described above.

[0402] The second consumable 500 comprises all of the features of the consumable 150 as described above. Many of the reference numerals relating to those features are omitted from FIG. 5A and FIG. 5B for clarity. However, like reference numerals are used in FIG. 5A and FIG. 5B where features referred to previously are referred to again.

[0403] In addition to the features which are common with the consumable 150, the second consumable 500 comprises a support 502. The support 502 comprises a first rib 504 and a second rib 506.

[0404] Each of the first and second ribs 504, 506 extends in a radially outward direction (with respect to the central axis of the outlet tube) from an external surface of the outlet wall 307 to an inner surface of the tank wall 304. More specifically, each of the first and second ribs 504, 506 extends to the inner surface of the tank wall 304 at a downstream end of the second consumable 500, where the tank wall 304 is also a wall of the mouthpiece 166.

[0405] Each of the first and second ribs 504, 506 also extends from an external surface of a wall of the mouthpiece aperture 314. Since the external surface of the wall of the mouthpiece aperture 314 is continuous with the external surface of the outlet wall 307, each of the first and second ribs 504, 506 connects to the external surfaces of the wall of the mouthpiece aperture and the outlet tube up to the downstream end of the second consumable 500.

[0406] As best illustrated in FIG. 5B, the first and second ribs 504, 506 are substantially equally spaced around the outlet tube 306. More specifically, the first and second ribs 504, 506 are spaced from each other by 180 degrees around the central axis of the outlet tube 306. The first and second ribs 504, 506 are substantially aligned with a horizontal (as shown in FIG. 5B) line of symmetry of the outlet tube, and extend along a line equidistant between front and rear portions of the second consumable 500.

[0407] The support 502 is formed of the same material as the outlet tube 306 and the tank 156. The support 502 is integrally formed with the tank 156 and the outlet tube 306.

[0408] The second consumable 500 operates in the same way as the consumable 150, with the support 502 providing structural support to maintain the outlet tube 306 in alignment with the heating device in use.

[0409] The second consumable 500 is manufactured through the same process as that described in FIG. 4, with the manufacturing assembly 400 modified so that the closed cavity formed when the first and second molds 402, 404 are brought together further defines the shape of the support 502. The support 502 provides structural support to the outlet tube 306 during demolding and subsequent assembly of the second consumable 500.

[0410] Referring to FIG. 6A and FIG. 6B, there is shown a portion of a third consumable 600. The third consumable 600 comprises all of the features of the second consumable 500 as described above. Many of the reference numerals relating to those features are omitted from FIG. 6A and FIG. 6B for clarity. However, like reference numerals are used in FIG. 6A and FIG. 6B where features referred to previously are referred to again. The third consumable 600 functions in generally the same manner as the second consumable 500, and only the differences are described here.

[0411] In addition to the features which are common with the second consumable 500, the third consumable 600 comprises turbulence inducing element 602. The turbulence inducing element 602 is partially located in an end portion of the outlet tube 306. The turbulence inducing element 602 is partially located in the heater chamber 170. The turbulence inducing element 602 is formed from silicone. The turbulence inducing element 602 is held in position by a friction fit with the end portion of the outlet tube 306.

[0412] The turbulence inducing element 602 is at least 1 mm downstream of the heating device 162 (i.e., the “vaporizer”). It has been found that positioning the turbulence inducing element 602 at least this distance downstream of the heating device 162 permits the aerosol to fully form before the turbulence inducing element 602 is reached. This means that the turbulence induced by the turbulence inducing element 602 is more effective in breaking up any large droplets formed in the aerosol, which reduces leakage of liquid to the user's mouth.

[0413] More specifically, the turbulence inducing element is at least 1.5 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at least 2 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at least 2.5 mm downstream of the vaporizer.

[0414] The turbulence inducing element is at most 5 mm downstream of the vaporizer. It has been found that positioning the turbulence inducing element 602 beyond this distance from the vaporizer has little effect on the leakage to the user's mouth. It is therefore desirable to have the turbulence inducing element at most this distance from the vaporizer to provide a more compact consumable. More specifically, the turbulence inducing element is at most 5 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at most 4 mm downstream of the vaporizer. More specifically, the turbulence inducing element is substantially 3 mm downstream of the vaporizer.

[0415] The turbulence inducing element 602 comprises a baffle 604. The baffle 604 provides a substantially planar surface positioned normal to a longitudinal axis of the third consumable 600 in a flow path from the heating device 162 to the outlet tube 306. The baffle 604 is a first flow obstacle. The baffle 604 is provided by an in-use lowermost surface of the turbulence inducing element 602.

[0416] The turbulence inducing element 602 comprises first and second inlets 606, 608 downstream of the baffle 604. The first and second inlets 606, 608 are in side portions of the turbulence inducing element 602. The first and second inlets 606, 608 are formed by apertures between the baffle 604 and the end portion of the outlet tube 306. The first and second inlets 606, 608 are substantially diametrically opposed. In other examples only one inlet is provided.

[0417] The turbulence inducing element 602 comprises first and second upstands 610, 612. Each of the first and second upstands 610, 612 is provided downstream of a respective one of the first and second inlets 606, 608. The first and second upstands 610, 612 extend in a direction substantially normal to the plane of the baffle 604 in a substantially axial direction. The first and second upstands 610, 612 provide substantially circumferential surfaces (i.e., surfaces which extend in a circumferential direction). The circumferential directions are normal to the longitudinal axis of the third consumable 600. The circumferential directions are parallel to the circumference of the outlet tube 306. Each upstand 610, 612 is a second flow obstacle. The first and second upstands 610, 612 are substantially diametrically opposed with respect to the outlet tube 306. The first and second upstands contact the internal surface of the outlet tube 306 to provide the friction fit between the turbulence inducing element 602 and the outlet tube 306.

[0418] The turbulence inducing element 602 comprises a protrusion 614. The protrusion 614 extends across a diameter of the outlet tube 306. The protrusion 614 extends along a direction substantially normal to a diameter extending between the first and second upstands 610, 612. The protrusion 614 protrudes parallel to the longitudinal axis of the third consumable 600 to contact the outlet tube 306. The protrusion 614 is a third flow obstacle. The protrusion is of substantially uniform height (measured along the axial direction).

[0419] In use, the aerosol vapor flows through the heater chamber 170 and contacts the turbulence inducing element 60. The position of the baffle 604 means that the flow of aerosol contacts the baffle 604 and is turned towards a radial direction. More specifically, the flow branches (i.e., splits into two flow streams) at the baffle 604, with the flow streams turned towards substantially opposite radially outward directions. The radial directions are normal to the longitudinal axis of the third consumable 600. The radial directions are parallel to radii of the outlet tube 306.

[0420] The effect of turning towards the radial direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. In the present example, the flow is turned such that it flows in a substantially radial direction, but, in other examples, this is not the case.

[0421] As such, after the flow branches at the baffle 604 to form two flow streams, each flow stream flows through a respective one of the first and second inlets 606, 608. Since the first and second inlets 606, 608 are in side portions of the turbulence inducing element 602, the flow turns from radially outward to radially inward to flow through the first and second inlets 606, 608.

[0422] In the present example, substantially all of the flow passes through turbulence inducing element 602, and substantially all of the flow is turned by the turbulence inducing element 602 as described.

[0423] The first and second upstands 610, 612 cooperate with the end portion of the outlet tube 306 to turn the flow streams towards circumferential directions. The substantially radially inward flow streams contact the circumferential surface of the upstands 610, 612, causing the flow streams to turn towards the circumferential direction. More specifically, each of the flow streams branches again, with each stream splitting into two further flow streams turned towards circumferential directions.

[0424] The effect of turning towards the circumferential direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. However, in the present example, the flow is turned such that it is in a substantially radial direction.

[0425] The protrusion 614 is therefore configured to turn the flow towards the axial direction within the outlet tube 306, where the flow streams recombine to flow through the outlet tube 306 as before.

[0426] The effect of turning towards the axial direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. However, in the present example, the flow is turned such that it flows substantially parallel to a circumferential direction.

[0427] Second Mode: An Aerosol Delivery Device with an Airflow Path Around an Airflow-Directing Member

[0428] Aspects and embodiments of the second mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0429] FIG. 7A shows a first embodiment of a smoking substitute system 100b. In this example, the smoking substitute system 100b includes a main body 102b and an aerosol delivery device in the form of a consumable 104b. The consumable 104b may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

[0430] In this example, the smoking substitute system 100b is a closed system vaping system, wherein the consumable 104b includes a sealed tank 106b and is intended for single-use only. The consumable 104b is removably engageable with the main body 102b (i.e., for removal and replacement). FIG. 7A shows the smoking substitute system 100b with the main body 102b physically coupled to the consumable 104b, FIG. 7B shows the main body 102b of the smoking substitute system 100b without the consumable 104b, and FIG. 7C shows the consumable 104b of the smoking substitute system 100b without the main body 102b.

[0431] The main body 102b and the consumable 104b are configured to be physically coupled together by pushing the consumable 104b into a cavity at an upper end 108b of the main body 102b, such that there is an interference fit between the main body 102b and the consumable 104b. In other examples, the main body 102b and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

[0432] The consumable 104b includes a mouthpiece (not shown in FIG. 7A, 1B or 1C) at an upper end 109b of the consumable 104b, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104b when a user inhales through the mouthpiece. The tank 106b containing e-liquid is located at the lower end 111b of the consumable 104b.

[0433] The tank 106b includes a window 112b, which allows the amount of e-liquid in the tank 106b to be visually assessed. The main body 102b includes a slot 114b so that the window 112b of the consumable 104b can be seen whilst the rest of the tank 106b is obscured from view when the consumable 104b is inserted into the cavity at the upper end 108b of the main body 102b.

[0434] The lower end 110b of the main body 102b also includes a light 116b (e.g., an LED) located behind a small translucent cover. The light 116b may be configured to illuminate when the smoking substitute system 100b is activated. Whilst not shown, the consumable 104b may identify itself to the main body 102b, via an electrical interface, RFID chip, or barcode.

[0435] FIG. 8A and FIG. 8B are schematic drawings of the main body 102b and consumable 104b. As is apparent from FIG. 8A, the main body 102b includes a power source 118b, a controller 120b, a memory 122b, a wireless interface 124b, an electrical interface 126b, and, optionally, one or more additional components 128b.

[0436] The power source 118b is preferably a battery, more preferably a rechargeable battery. The controller 120b may include a microprocessor, for example. The memory 122b preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120b to perform certain tasks or steps of a method.

[0437] The wireless interface 124b is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124b could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124b may also be configured to communicate wirelessly with a remote server.

[0438] The electrical interface 126b of the main body 102b may include one or more electrical contacts. The electrical interface 126b may be located in a base of the aperture in the upper end 108b of the main body 102b. When the main body 102b is physically coupled to the consumable 104b, the electrical interface 126b is configured to transfer electrical power from the power source 118b to the consumable 104b (i.e., upon activation of the smoking substitute system 100b).

[0439] The electrical interface 126b may be configured to receive power from a charging station when the main body 102b is not physically coupled to the consumable 104b and is instead coupled to the charging station. The electrical interface 126b may also be used to identify the consumable 104b from a list of known consumables. For example, the consumable 104b may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126b). This can be indicated to the controller 120b of the main body 102b when the consumable 104b is connected to the main body 102b. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102b and a corresponding communication interface in the consumable 104b such that, when connected, the consumable 104b can identify itself to the main body 102b.

[0440] The additional components 128b of the main body 102b may comprise the light 116b discussed above.

[0441] The additional components 128b of the main body 102b may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118b is a rechargeable battery). This may be located at the lower end 110b of the main body 102b. Alternatively, the electrical interface 126b discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0442] The additional components 128b of the main body 102b may, if the power source 118b 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 the charging station (if present).

[0443] The additional components 128b of the main body 102b may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100b, e.g., caused by a user inhaling through a mouthpiece 136b of the consumable 104b. The smoking substitute system 100b may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104b. 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.

[0444] The additional components 128b of the main body 102b may include a user input, e.g., a button. The smoking substitute system 100b may 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 100b.

[0445] As shown in FIG. 8B, the consumable 104b includes the tank 106b, an electrical interface 130b, a vaporizer 132b, one or more air inlets 134b, a mouthpiece 136b, and one or more additional components 138b.

[0446] The electrical interface 130b of the consumable 104b may include one or more electrical contacts. The electrical interface 126b of the main body 102b and an electrical interface 130b of the consumable 104b are configured to contact each other and thereby electrically couple the main body 102b to the consumable 104b when the lower end 111b of the consumable 104b is inserted into the upper end of the main body 102b (as shown in FIG. 7A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118b in the main body 102b to the vaporizer 132b in the consumable 104b.

[0447] The vaporizer 132b is configured to heat and vaporize e-liquid contained in the tank 106b using electrical energy supplied from the power source 118b. As will be described further below, the vaporizer 132b includes a heating filament and a wick. The wick draws e-liquid from the tank 106b and the heating filament heats the e-liquid to vaporize the e-liquid.

[0448] The one or more air inlets 134b are preferably configured to allow air to be drawn into the smoking substitute system 100b, when a user inhales through the mouthpiece 136b. When the consumable 104b is physically coupled to the main body 102b, the air inlets 134b receive air, which flows to the air inlets 134b along a gap between the main body 102b and the lower end 111b of the consumable 104b.

[0449] In operation, a user activates the smoking substitute system 100b, e.g., through interaction with a user input forming part of the main body 102b or by inhaling through the mouthpiece 136b as described above. Upon activation, the controller 120b may supply electrical energy from the power source 118b to the vaporizer 132b (via electrical interfaces 126b, 130b), which may cause the vaporizer 132b to heat e-liquid drawn from the tank 106b to produce a vapor which is inhaled by a user through the mouthpiece 136b.

[0450] An example of one of the one or more additional components 138b of the consumable 104b is an interface for obtaining an identifier of the consumable 104b. 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 consumable. The consumable 104b 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 main body 102b.

[0451] It should be appreciated that the smoking substitute system 100b shown in FIG. 7A to FIG. 8B 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).

[0452] FIG. 9A is a section view of the consumable 104b described above. The consumable 104b comprises a tank 106b for storing e-liquid, a mouthpiece 136b and a passage 140b extending along a longitudinal axis of the consumable 104b. In the illustrated embodiment the passage 140b is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106b surrounds the passage 140b, such that the passage 140b extends centrally through the tank 106b.

[0453] A tank housing 142b of the tank 106b defines an outer casing of the consumable 104b, whilst a passage wall 144b defines the passage 140b. The tank housing 142b extends from the lower end 111b of the consumable 104b to the mouthpiece 136b at the upper end 109b of the consumable 104b. At the junction between the mouthpiece 136b and the tank housing 142b, the mouthpiece 136b is wider than the tank housing 142b, so as to define a lip 146b that overhangs the tank housing 142b. This lip 146b acts as a stop feature when the consumable 104b is inserted into the main body 102b (i.e., by contact with an upper edge of the main body 102b).

[0454] The tank 106b, the passage 140b and the mouthpiece 136b are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 10, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

[0455] Although not immediately apparent from the figures, the tank housing 142b tapers, such that the thickness of the tank housing 142b decreases in a first demolding direction (as will be discussed further with respect to FIG. 10). In FIG. 9A the first demolding direction is in a downward direction away from the mouthpiece 136b. This means that, aside from a small number of indents (which provide physical connection between the consumable 104b and the main body 102b), the thickness of the tank housing 142b decreases with increasing distance away from the mouthpiece 136b. In particular, the tank housing 142b tapers in this way, because internal and external surfaces of the tank housing 142b are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142b and passage wall 144b as a single (i.e., unitary) component.

[0456] Like the tank housing 142b, the passage wall 144b is also tapered such that the thickness of the passage wall 144b decreases along the first demolding direction. Again, the thickness of the passage wall 144b decreases due to internal and external surfaces of the passage wall 144b being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144b, the passage 140b has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 9A). For example, the passage 140b has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140b (e.g., approximately 3.6 mm). On the other hand, the passage 140b has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140b (e.g., approximately 3.4 mm).

[0457] The mouthpiece 136b comprises a mouthpiece aperture 148b defining an outlet of the passage 140b. The mouthpiece aperture 148b has a radially inwardly directed inner surface 150b, which joins an outer surface 152b of the mouthpiece 136b (i.e., a surface which contacts a user's lips in use) at an outer edge 154b of the mouthpiece aperture 148b. At this outer edge 154b, the included angle between the inner surface 150b of the mouthpiece aperture 148b and the outer surface 152b of the mouthpiece 136b (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154b being rounded. This outer edge 154b may otherwise be chamfered or beveled.

[0458] The vaporizer 132b is located in a vaporizing chamber 156b of the consumable 104b. This is best shown in FIG. 9B, which provides a detailed view of the vaporizing chamber 156b. The vaporizing chamber 156b is downstream of the air inlet 134b of the consumable 104b and is fluidly connected to the mouthpiece aperture 148b (i.e., outlet) by the passage 140b. In particular, the passage 140b extends between the mouthpiece aperture 148b and a passage opening 158b from the chamber 156b. This passage opening 158b is formed in a downstream (i.e., upper) wall 160b of the chamber 156b.

[0459] The vaporizer 132b comprises a porous wick 162b and a heater filament 164b coiled around the porous wick 162b. As is apparent from FIG. 9A and FIG. 9B, the porous wick 162b extends transversely across the chamber 156b between sidewalls 166b of the chamber 156b which form part of an inner sleeve 168b of an insert 170b that defines the lower end 111b of the consumable 104b that connects with the main body 102b. The insert 170b is inserted into an open lower end of the tank 106b so as to seal against the tank housing 142b.

[0460] In this way, the inner sleeve 168b projects into the tank 106b and seals with the passage 140b (around the passage wall 144b) so as to separate the chamber 156b from the e-liquid in the tank 106b. Ends of the porous wick 162b project through apertures in the inner sleeve 168b and into the tank 106b so as to be in contact with the e-liquid in the tank 106b. In this way, e-liquid is transported along the porous wick 162b (e.g., by capillary action) to a central portion of the porous wick 162b. The transported e-liquid is heated by the heater filament 164b (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing in the vaporizing chamber 156b. This vaporized liquid may cool to form an aerosol in the passage 140b, which may then be inhaled by a user.

[0461] In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156b. This may be undesirable for a user. To reduce or avoid this, the consumable 104b comprises a baffle 172b, which is shown in more detail in FIG. 9B. The baffle 172b extends across the chamber 156b so as to be interposed between the vaporizer 132b and the passage opening 158b. In this way, un-vaporized liquid from the porous wick 162b may collect on an upstream (i.e., lower) planar surface 174b of the baffle 172b rather than entering the passage opening 158b. The baffle 172b also causes airflow from the vaporizer 132b to the passage opening 158b to be redirected around the baffle 172b. The baffle 172b comprises two opposing upstream edges 176b around which the airflow is redirected. These upstream edges 176b and the sidewalls 166b of the chamber 156b define two respective apertures 178b spaced either side of the baffle 172b. The baffle further comprises two downstream edges 179b.

[0462] The chamber air flow path, i.e., the airflow through the vaporizing chamber 156b from proximal the vaporizer 132b to the passage opening 158b extends is bifurcated and has two branches extending through the apertures 178b in a generally longitudinal direction between the upstream edges 176b and the downstream edges 179b. The transverse cross-sectional area of the chamber air flow path as it passes between the upstream and downstream edges 176b, 179b is constant within each branch and equal between the two branches. Furthermore, the transverse cross-sectional area of the chamber airflow path between the upstream and downstream edges 176b, 179b in each branch is equal to the minimum (smallest) cross-sectional area of the chamber airflow path downstream of the downstream edges 179b, i.e., between the downstream edges 179b and the passage opening 158b. In fact, the chamber airflow path between the apertures 178b and the passage opening 158b is constant. The chamber airflow path will deflect radially towards the passage opening 158b at the downstream edges 179b.

[0463] Although not clear from FIG. 9B, the transverse width of the apertures 178b equals the longitudinal spacing between the downstream edges 179b of the baffle 172b and the end wall 160b of the vaporizing chamber 156b. Furthermore, the transverse width of the end wall 160b of the vaporizing chamber 156b between the passage opening 158b and the sidewall 166b of the vaporizing chamber 156b (measured between the radially outermost limit of the passage opening 158b and the proximal sidewall 166b) is less than the length of the chamber airflow path between the upstream edges 176b and the downstream edges 179b of the baffle 172b.

[0464] Upon inhalation by a user at the mouthpiece aperture 148b, air flows along the bifurcated chamber airflow path around the porous wick 162b, through the apertures 178b and into the passage 140b via the passage opening 158b.

[0465] FIG. 10 shows a drawing of a manufacturing assembly 282b which is used to manufacture the consumable 104b. The manufacturing assembly 282b comprises a first mold 284b and a second mold 286b.

[0466] The first mold 284b has a shape which complements that of a first end of the integrally formed tank housing 142b and mouthpiece 136b. The first mold 284b therefore has a shape which matches the inner surfaces defining the tank 106b.

[0467] The second mold 286b has a shape which complements that of a second end of the integrally formed tank housing 142b and mouthpiece 136b. The second mold 286b has a shape which matches the outer surface of the mouthpiece 136b and the inner surface of the mouthpiece aperture 148b.

[0468] When the first mold 284b and the second mold 286b are brought together, they define a closed cavity which has the shape of the tank housing 142b, the mouthpiece 136b and the passage walls 144b.

[0469] To manufacture these components, heated material is injected into the cavity between the first mold 284b and the second mold 286b. At this point, the first mold 284b and the second mold 286b meet at a boundary between external surfaces of the mouthpiece 136b and the tank housing 142b.

[0470] The material is subsequently cooled, and the first mold 284b and the second mold 286b are separated, with the first mold 284b travelling in the first demolding direction 288b (i.e., away from the second mold 286b) and the second mold 286b travelling in a second demolding direction 290b (i.e., away from the first mold 284b and opposite to the first demolding direction 288b). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

[0471] The insert 170b and any additional components are subsequently inserted into the tank 106b.

[0472] Third Mode: An Aerosol Delivery Device with an Airflow-Directing Member Having a Sloped Surface

[0473] Aspects and embodiments of the third mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0474] FIG. 11A shows a first embodiment of a smoking substitute system 100c. In this example, the smoking substitute system 100c includes a main body 102c and an aerosol delivery device in the form of a consumable 104c. The consumable 104c may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

[0475] In this example, the smoking substitute system 100c is a closed system vaping system, wherein the consumable 104c includes a sealed tank 106c and is intended for single-use only. The consumable 104c is removably engageable with the main body 102c (i.e., for removal and replacement). FIG. 11A shows the smoking substitute system 100c with the main body 102c physically coupled to the consumable 104c, FIG. 11B shows the main body 102c of the smoking substitute system 100c without the consumable 104c, and FIG. 11C shows the consumable 104c of the smoking substitute system 100c without the main body 102c.

[0476] The main body 102c and the consumable 104c are configured to be physically coupled together by pushing the consumable 104c into a cavity at an upper end 108c of the main body 102c, such that there is an interference fit between the main body 102c and the consumable 104c. In other examples, the main body 102c and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

[0477] The consumable 104c includes a mouthpiece (not shown in FIG. 11A, 1B or 1C) at an upper end 109c of the consumable 104c, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104c when a user inhales through the mouthpiece. The tank 106c containing e-liquid is located at the lower end 111c of the consumable 104c.

[0478] The tank 106c includes a window 112c, which allows the amount of e-liquid in the tank 106c to be visually assessed. The main body 102c includes a slot 114c so that the window 112c of the consumable 104c can be seen whilst the rest of the tank 106c is obscured from view when the consumable 104c is inserted into the cavity at the upper end 108c of the main body 102c.

[0479] The lower end 110c of the main body 102c also includes a light 116c (e.g., an LED) located behind a small translucent cover. The light 116c may be configured to illuminate when the smoking substitute system 100c is activated. Whilst not shown, the consumable 104c may identify itself to the main body 102c, via an electrical interface, RFID chip, or barcode.

[0480] FIG. 12A and FIG. 12B are schematic drawings of the main body 102c and consumable 104c. As is apparent from FIG. 12A, the main body 102c includes a power source 118c, a controller 120c, a memory 122c, a wireless interface 124c, an electrical interface 126c, and, optionally, one or more additional components 128c.

[0481] The power source 118c is preferably a battery, more preferably a rechargeable battery. The controller 120c may include a microprocessor, for example. The memory 122c preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120c to perform certain tasks or steps of a method.

[0482] The wireless interface 124c is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124c could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124c may also be configured to communicate wirelessly with a remote server.

[0483] The electrical interface 126c of the main body 102c may include one or more electrical contacts. The electrical interface 126c may be located in a base of the aperture in the upper end 108c of the main body 102c. When the main body 102c is physically coupled to the consumable 104c, the electrical interface 126c is configured to transfer electrical power from the power source 118c to the consumable 104c (i.e., upon activation of the smoking substitute system 100c).

[0484] The electrical interface 126c may be configured to receive power from a charging station when the main body 102c is not physically coupled to the consumable 104c and is instead coupled to the charging station. The electrical interface 126c may also be used to identify the consumable 104c from a list of known consumables. For example, the consumable 104c may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126c). This can be indicated to the controller 120c of the main body 102c when the consumable 104c is connected to the main body 102c. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102c and a corresponding communication interface in the consumable 104c such that, when connected, the consumable 104c can identify itself to the main body 102c.

[0485] The additional components 128c of the main body 102c may comprise the light 116c discussed above.

[0486] The additional components 128c of the main body 102c may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118c is a rechargeable battery). This may be located at the lower end 110c of the main body 102c. Alternatively, the electrical interface 126c discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0487] The additional components 128c of the main body 102c may, if the power source 118c 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 the charging station (if present).

[0488] The additional components 128c of the main body 102c may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100c, e.g., caused by a user inhaling through a mouthpiece 136c of the consumable 104c. The smoking substitute system 100c may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104c. 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.

[0489] The additional components 128c of the main body 102c may include a user input, e.g., a button. The smoking substitute system 100c may 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 100c.

[0490] As shown in FIG. 12B, the consumable 104c includes the tank 106c, an electrical interface 130c, a vaporizer 132c, one or more air inlets 134c, a mouthpiece 136c, and one or more additional components 138c.

[0491] The electrical interface 130c of the consumable 104c may include one or more electrical contacts. The electrical interface 126c of the main body 102c and an electrical interface 130c of the consumable 104c are configured to contact each other and thereby electrically couple the main body 102c to the consumable 104c when the lower end 111c of the consumable 104c is inserted into the upper end 108c of the main body 102c (as shown in FIG. 11A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118c in the main body 102c to the vaporizer 132c in the consumable 104c.

[0492] The vaporizer 132c is configured to heat and vaporize e-liquid contained in the tank 106c using electrical energy supplied from the power source 118c. As will be described further below, the vaporizer 132c includes a heating filament and a wick. The wick draws e-liquid from the tank 106c and the heating filament heats the e-liquid to vaporize the e-liquid.

[0493] The one or more air inlets 134c are preferably configured to allow air to be drawn into the smoking substitute system 100c, when a user inhales through the mouthpiece 136c. When the consumable 104c is physically coupled to the main body 102c, the air inlets 134c receive air, which flows to the air inlets 134c along a gap between the main body 102c and the lower end 111c of the consumable 104c.

[0494] In operation, a user activates the smoking substitute system 100c, e.g., through interaction with a user input forming part of the main body 102c or by inhaling through the mouthpiece 136c as described above. Upon activation, the controller 120c may supply electrical energy from the power source 118c to the vaporizer 132c (via electrical interfaces 126c, 130c), which may cause the vaporizer 132c to heat e-liquid drawn from the tank 106c to produce a vapor which is inhaled by a user through the mouthpiece 136c.

[0495] An example of one of the one or more additional components 138c of the consumable 104c is an interface for obtaining an identifier of the consumable 104c. 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 consumable. The consumable 104c 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 main body 102c.

[0496] It should be appreciated that the smoking substitute system 100c shown in FIG. 11A to FIG. 12B 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).

[0497] FIG. 13A is a section view of the consumable 104c described above. The consumable 104c comprises a tank 106c for storing e-liquid, a mouthpiece 136c and a passage 140c extending along a longitudinal axis of the consumable 104c. In the illustrated embodiment the passage 140c is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106c surrounds the passage 140c, such that the passage 140c extends centrally through the tank 106c.

[0498] A tank housing 142c of the tank 106c defines an outer casing of the consumable 104c, whilst a passage wall 144c defines the passage 140c. The tank housing 142c extends from the lower end 111c of the consumable 104c to the mouthpiece 136c at the upper end 109c of the consumable 104c. At the junction between the mouthpiece 136c and the tank housing 142c, the mouthpiece 136c is wider than the tank housing 142c, so as to define a lip 146c that overhangs the tank housing 142c. This lip 146c acts as a stop feature when the consumable 104c is inserted into the main body 102c (i.e., by contact with an upper edge of the main body 102c).

[0499] The tank 106c, the passage 140c and the mouthpiece 136c are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 14, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

[0500] Although not immediately apparent from the figures, the tank housing 142c tapers, such that the thickness of the tank housing 142c decreases in a first demolding direction (as will be discussed further with respect to FIG. 14). In FIG. 13A the first demolding direction is in a downward direction away from the mouthpiece 136c. This means that, aside from a small number of indents (which provide physical connection between the consumable 104c and the main body 102c), the thickness of the tank housing 142c decreases with increasing distance away from the mouthpiece 136c. In particular, the tank housing 142c tapers in this way, because internal and external surfaces of the tank housing 142c are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142c and passage wall 144c as a single (i.e., unitary) component.

[0501] Like the tank housing 142c, the passage wall 144c is also tapered such that the thickness of the passage wall 144c decreases along the first demolding direction. Again, the thickness of the passage wall 144c decreases due to internal and external surfaces of the passage wall 144c being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144c, the passage 140c has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 13A). For example, the passage 140c has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140c (e.g., approximately 3.6 mm). On the other hand, the passage 140c has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140c (e.g., approximately 3.4 mm).

[0502] The mouthpiece 136c comprises a mouthpiece aperture 148c defining an outlet of the passage 140c. The mouthpiece aperture 148c has a radially inwardly directed inner surface 150c, which joins an outer surface 152c of the mouthpiece 136c (i.e., a surface which contacts a user's lips in use) at an outer edge 154c of the mouthpiece aperture 148c. At this outer edge 154c, the included angle between the inner surface 150c of the mouthpiece aperture 148c and the outer surface 152c of the mouthpiece 136c (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154c being rounded. This outer edge 154c may otherwise be chamfered or beveled.

[0503] The vaporizer 132c is located in a vaporizing chamber 156c of the consumable 104c. This is best shown in FIG. 13B, which provides a detailed view of the vaporizing chamber 156c. The vaporizing chamber 156c is downstream of the air inlet 134c of the consumable 104c and is fluidly connected to the mouthpiece aperture 148c (i.e., outlet) by the passage 140c. In particular, the passage 140c extends between the mouthpiece aperture 148c and a passage opening 158c from the chamber 156c. This passage opening 158c is formed in a downstream (i.e., upper) wall 160c of the chamber 156c.

[0504] The vaporizer 132c comprises a porous wick 162c and a heater filament 164c coiled around the porous wick 162c. As is apparent from FIG. 13A and FIG. 13B, the porous wick 162c extends transversely across the chamber 156c between sidewalls 166c of the chamber 156c which form part of an inner sleeve 168c of an insert 170c that defines the lower end 111c of the consumable 104c that connects with the main body 102c. The insert 170c is inserted into an open lower end of the tank 106c so as to seal against the tank housing 142c.

[0505] In this way, the inner sleeve 168c projects into the tank 106c and seals with the passage 140c (around the passage wall 144c) so as to separate the chamber 156c from the e-liquid in the tank 106c. Ends of the porous wick 162c project through apertures in the inner sleeve 168c and into the tank 106c so as to be in contact with the e-liquid in the tank 106c. In this way, e-liquid is transported along the porous wick 162c (e.g., by capillary action) to a central portion of the porous wick 162c that is exposed to airflow through the chamber 156c. The transported e-liquid is heated by the heater filament 164c (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing past the porous wick 162c. This vaporized liquid may cool to form an aerosol in the passage 140c, which may then be inhaled by a user.

[0506] In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156c. This may be undesirable for a user. To reduce or avoid this, the consumable 104c comprises a baffle 172c, which is shown in more detail in FIG. 13B. The baffle 172c extends transversely across the chamber 156c so as to be interposed between the vaporizer 132c and the passage opening 158c. In this way, un-vaporized liquid from the porous wick 162c may collect on an upstream (i.e., lower) planar surface 174c of the baffle 172c rather than entering the passage opening 158c. The baffle 172c also causes airflow from the vaporizer 132c to the passage opening 158c to be redirected around the baffle 172c. The baffle 172c comprises two opposing transverse edges 176c around which the airflow is redirected. These transverse edges 176c and the sidewalls 166c of the chamber 156c define two respective apertures 178c spaced either side of the baffle 172c. Upon inhalation by a user at the mouthpiece aperture 148c, air flows along a bifurcated airflow path around the porous wick 162c, through the apertures 178c and into the passage 140c via the passage opening 158c.

[0507] In order to reduce the velocity of the air flowing around the baffle 172c, the baffle 172c comprises two sloped surfaces 180c, which are disposed at a downstream side of the baffle 172c. Each sloped surface 180c slopes inwardly (towards the longitudinal axis and the passage opening 158c) from a respective transverse edge 176c. The sloped surfaces 180c are connected by a downstream (i.e., upper) planar surface 182c of the baffle 172c such that the baffle 172c has a generally trapezoidal cross-section (i.e., taken along a longitudinally oriented plane as shown in FIG. 13B).

[0508] The presence of the sloped surfaces 180c provides an increased gap between the baffle 172c and the sidewalls 166c when compared to a similar baffle having perpendicular (i.e., non-sloped) edge surfaces. This increased gap lowers the velocity of the air, which results in reduced propensity for the air to carry un-vaporized liquid (e.g., that has collected on the upstream surface of the baffle 172c) into the passage 140c. As such, a larger baffle 172c may be used (so as to provide greater protection to the passage opening 158c). In the illustrated embodiment, the baffle 172c has a transverse width that is substantially the same as an inner diameter of the passage 140c.

[0509] FIG. 14 shows a drawing of a manufacturing assembly 282c which is used to manufacture the consumable 104c. The manufacturing assembly 282c comprises a first mold 284c and a second mold 286c.

[0510] The first mold 284c has a shape which complements that of a first end of the integrally formed tank housing 142c and mouthpiece 136c. The first mold 284c therefore has a shape which matches the inner surfaces defining the tank 106c.

[0511] The second mold 286c has a shape which complements that of a second end of the integrally formed tank housing 142c and mouthpiece 136c. The second mold 286c has a shape which matches the outer surface of the mouthpiece 136c and the inner surface of the mouthpiece aperture 148c.

[0512] When the first mold 284c and the second mold 286c are brought together, they define a closed cavity which has the shape of the tank housing 142c, the mouthpiece 136c and the passage walls 144c.

[0513] To manufacture these components, heated material is injected into the cavity between the first mold 284c and the second mold 286c. At this point, the first mold 284c and the second mold 286c meet at a boundary between external surfaces of the mouthpiece 136c and the tank housing 142c.

[0514] The material is subsequently cooled, and the first mold 284c and the second mold 286c are separated, with the first mold 284c travelling in the first demolding direction 288c (i.e., away from the second mold 286c) and the second mold 286c travelling in a second demolding direction 290c (i.e., away from the first mold 284c and opposite to the first demolding direction 288c). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

[0515] The insert 170c and any additional components are subsequently inserted into the tank 106c.

[0516] Fourth Mode: An Aerosol Delivery Device in which an Airflow Path Through a Vaporizing Chamber is a Single, Deflected Path

[0517] Aspects and embodiments of the fourth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0518] FIG. 15A shows a first embodiment of a smoking substitute system 100d. In this example, the smoking substitute system 100d includes a main body 102d and an aerosol delivery device in the form of a consumable 104d. The consumable 104d may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

[0519] In this example, the smoking substitute system 100d is a closed system vaping system, wherein the consumable 104d includes a sealed tank 106d and is intended for single-use only. The consumable 104d is removably engageable with the main body 102d (i.e., for removal and replacement). FIG. 15A shows the smoking substitute system 100d with the main body 102d physically coupled to the consumable 104d, FIG. 15B shows the main body 102d of the smoking substitute system 100d without the consumable 104d, and FIG. 15C shows the consumable 104d of the smoking substitute system 100d without the main body 102d.

[0520] The main body 102d and the consumable 104d are configured to be physically coupled together by pushing the consumable 104d into a cavity at an upper end 108d of the main body 102d, such that there is an interference fit between the main body 102d and the consumable 104d. In other examples, the main body 102d and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

[0521] The consumable 104d includes a mouthpiece (not shown in FIG. 15A, 1B or 1C) at an upper end 109d of the consumable 104d, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104d when a user inhales through the mouthpiece. The tank 106d containing e-liquid is located at the lower end 111d of the consumable 104d.

[0522] The tank 106d includes a window 112d, which allows the amount of e-liquid in the tank 106d to be visually assessed. The main body 102d includes a slot 114d so that the window 112d of the consumable 104d can be seen whilst the rest of the tank 106d is obscured from view when the consumable 104d is inserted into the cavity at the upper end 108d of the main body 102d.

[0523] The lower end 110d of the main body also includes a light 116d (e.g., an LED) located behind a small translucent cover. The light 116d may be configured to illuminate when the smoking substitute system 100d is activated. Whilst not shown, the consumable 104d may identify itself to the main body 102d, via an electrical interface, RFID chip, or barcode.

[0524] FIG. 16A and FIG. 16B are schematic drawings of the main body 102d and consumable 104d. As is apparent from FIG. 16A, the main body 102d includes a power source 118d, a controller 120d, a memory 122d, a wireless interface 124d, an electrical interface 126d, and, optionally, one or more additional components 128d.

[0525] The power source 118d is preferably a battery, more preferably a rechargeable battery. The controller 120d may include a microprocessor, for example. The memory 122d preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120d to perform certain tasks or steps of a method.

[0526] The wireless interface 124d is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124d could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124d may also be configured to communicate wirelessly with a remote server.

[0527] The electrical interface 126d of the main body 102d may include one or more electrical contacts. The electrical interface 126d may be located in a base of the aperture in the upper end 108d of the main body 102d. When the main body 102d is physically coupled to the consumable 104d, the electrical interface 126d is configured to transfer electrical power from the power source 118d to the consumable 104d (i.e., upon activation of the smoking substitute system 100d).

[0528] The electrical interface 126d may be configured to receive power from a charging station when the main body 102d is not physically coupled to the consumable 104d and is instead coupled to the charging station. The electrical interface 126d may also be used to identify the consumable 104d from a list of known consumables. For example, the consumable 104d may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126d). This can be indicated to the controller 120d of the main body 102d when the consumable 104d is connected to the main body 102d. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102d and a corresponding communication interface in the consumable 104d such that, when connected, the consumable 104d can identify itself to the main body 102d.

[0529] The additional components 128d of the main body 102d may comprise the light 116d discussed above.

[0530] The additional components 128d of the main body 102d may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118d is a rechargeable battery). This may be located at the lower end 110d of the main body 102d. Alternatively, the electrical interface 126d discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0531] The additional components 128d of the main body 102d may, if the power source 118d 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 the charging station (if present).

[0532] The additional components 128d of the main body 102d may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100d, e.g., caused by a user inhaling through a mouthpiece 136d of the consumable 104d. The smoking substitute system 100d may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104d. 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.

[0533] The additional components 128d of the main body 102d may include a user input, e.g., a button. The smoking substitute system 100d may 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 100d.

[0534] As shown in FIG. 16B, the consumable 104d includes the tank 106d, an electrical interface 130d, a vaporizer 132d, one or more air inlets 134d, a mouthpiece 136d, and one or more additional components 138d.

[0535] The electrical interface 130d of the consumable 104d may include one or more electrical contacts. The electrical interface 126d of the main body 102d and an electrical interface 130d of the consumable 104d are configured to contact each other and thereby electrically couple the main body 102d to the consumable 104d when the lower end 111d of the consumable 104d is inserted into the upper end 108d of the main body 102d (as shown in FIG. 15A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118d in the main body 102d to the vaporizer 132d in the consumable 104d.

[0536] The vaporizer 132d is configured to heat and vaporize e-liquid contained in the tank 106d using electrical energy supplied from the power source 118d. As will be described further below, the vaporizer 132d includes a heating filament and a wick. The wick draws e-liquid from the tank 106d and the heating filament heats the e-liquid to vaporize the e-liquid.

[0537] The one or more air inlets 134d are preferably configured to allow air to be drawn into the smoking substitute system 100d, when a user inhales through the mouthpiece 136d. When the consumable 104d is physically coupled to the main body 102d, the air inlets 134d receive air, which flows to the air inlets 134d along a gap between the main body 102d and the lower end 110d of the consumable 104d.

[0538] In operation, a user activates the smoking substitute system 100d, e.g., through interaction with a user input forming part of the main body 102d or by inhaling through the mouthpiece 136d as described above. Upon activation, the controller 120d may supply electrical energy from the power source 118d to the vaporizer 132d (via electrical interfaces 126d, 130d), which may cause the vaporizer 132d to heat e-liquid drawn from the tank 106d to produce a vapor which is inhaled by a user through the mouthpiece 136d.

[0539] An example of one of the one or more additional components 138d of the consumable 104d is an interface for obtaining an identifier of the consumable 104d. 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 consumable. The consumable 104d 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 main body 102d.

[0540] It should be appreciated that the smoking substitute system 100d shown in FIG. 15A to FIG. 16B 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).

[0541] FIG. 17A is a section view of the consumable 104d described above. The consumable 104d comprises a tank 106d for storing e-liquid, a mouthpiece 136d and a passage 140d extending along a longitudinal axis of the consumable 104d. In the illustrated embodiment the passage 140d is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106d surrounds the passage 140d, such that the passage 140d extends centrally through the tank 106d.

[0542] A tank housing 142d of the tank 106d defines an outer casing of the consumable 104d, whilst a passage wall 144d defines the passage 140d. The tank housing 142d extends from the lower end 111d of the consumable 104d to the mouthpiece 136d at the upper end 109d of the consumable 104d. At the junction between the mouthpiece 136d and the tank housing 142d, the mouthpiece 136d is wider than the tank housing 142d, so as to define a lip 146d that overhangs the tank housing 142d. This lip 146d acts as a stop feature when the consumable 104d is inserted into the main body 102d (i.e., by contact with an upper edge of the main body 102d).

[0543] The tank 106d, the passage 140d and the mouthpiece 136d are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 18, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

[0544] Although not immediately apparent from the figures, the tank housing 142d tapers, such that the thickness of the tank housing 142d decreases in a first demolding direction (as will be discussed further with respect to FIG. 18). In FIG. 17A the first demolding direction is in a downward direction away from the mouthpiece 136d. This means that, aside from a small number of indents (which provide physical connection between the consumable 104d and the main body 102d), the thickness of the tank housing 142d decreases with increasing distance away from the mouthpiece 136d. In particular, the tank housing 142d tapers in this way, because internal and external surfaces of the tank housing 142d are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142d and passage wall 144d as a single (i.e., unitary) component.

[0545] Like the tank housing 142d, the passage wall 144d is also tapered such that the thickness of the passage wall 144d decreases along the first demolding direction. Again, the thickness of the passage wall 144d decreases due to internal and external surfaces of the passage wall 144d being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144d, the passage 140d has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 17A). For example, the passage 140d has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140d (e.g., approximately 3.6 mm). On the other hand, the passage 140d has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140d (e.g., approximately 3.4 mm).

[0546] The mouthpiece 136d comprises a mouthpiece aperture 148d defining an outlet of the passage 140d. The mouthpiece aperture 148d has a radially inwardly directed inner surface 150d, which joins an outer surface 152d of the mouthpiece 136d (i.e., a surface which contacts a user's lips in use) at an outer edge 154d of the mouthpiece aperture 148d. At this outer edge 154d, the included angle between the inner surface 150d of the mouthpiece aperture 148d and the outer surface 152d of the mouthpiece 136d (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154d being rounded. This outer edge 154d may otherwise be chamfered or beveled.

[0547] The vaporizer 132d is located in a vaporizing chamber 156d of the consumable 104d. This is best shown in FIG. 17B, which provides a detailed view of the vaporizing chamber 156d. The vaporizing chamber 156d is downstream of the air inlet 134d of the consumable 104d and is fluidly connected to the mouthpiece aperture 148d (i.e., outlet) by the passage 140d. In particular, the passage 140d extends between the mouthpiece aperture 148d and a passage opening 158d from the vaporizing chamber 156d. This passage opening 158d is formed in a downstream (i.e., upper) wall 160d of the vaporizing chamber 156d.

[0548] The vaporizer 132d comprises a porous wick 162d and a heater filament 164d coiled around the porous wick 162d. As is apparent from FIG. 17A and FIG. 17B, the porous wick 162d extends transversely across the vaporizing chamber 156d between sidewalls 166ad, 166b of the vaporizing chamber 156d which form part of an inner sleeve 168d of a silicone insert 170d that defines the lower end 111d of the consumable 104d that connects with the main body 102d. The insert 170d is inserted into an open lower end of the tank 106d so as to seal against the internal surface of the tank housing 142d.

[0549] In this way, the inner sleeve 168d projects into the tank 106d and seals with the passage 140d (around the passage wall 144d) so as to separate the vaporizing chamber 156d from the e-liquid in the tank 106d. Ends of the porous wick 162d project through apertures in the inner sleeve 168d and into the tank 106d so as to be in contact with the e-liquid in the tank 106d. In this way, e-liquid is transported along the porous wick 162d (e.g., by capillary action) to a central portion of the porous wick 162d. The transported e-liquid is heated by the heater filament 164d (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing in the vaporizing chamber 156d. This vaporized liquid may cool to form an aerosol in the passage 140d, which may then be inhaled by a user.

[0550] In some cases, un-vaporized liquid can be carried by air flowing through the vaporizing chamber 156d. This may be undesirable for a user. To reduce or avoid this, the consumable 104d comprises a baffle 172d, which is shown in more detail in FIG. 17B. The baffle 172d extends across the vaporizing chamber 156d so as to be interposed between the vaporizer 132d and the passage opening 158d. In this way, un-vaporized liquid from the porous wick 162d may collect on an upstream (i.e., lower) planar surface 174d of the baffle 172d rather than entering the passage opening 158d. The baffle 172d also causes the chamber airflow path from the vaporizer 132d to the passage opening 158d to be redirected around the baffle 172d.

[0551] The baffle 172d depends from and is integral with a (second) side wall 166b of the vaporizing chamber 156d, i.e., the baffle 172d is integral with the silicone insert 170d. The baffle 172d comprises an upstream edge 176d around which the airflow is redirected. This upstream edge 176d and the (first) sidewall 166a of the vaporizing chamber 156d define a single aperture 178d at a lateral edge of the baffle 172d. The aperture 178d is laterally offset from the longitudinal axis of the passage opening 158d. The baffle 172d further comprises a downstream edge 179d.

[0552] As shown in FIG. 17C, first portion 182d of the chamber airflow path extends in a generally longitudinal direction to the vaporizer 132d from the air inlet 134d and is aligned with the axial center of the device (i.e., aligned with the longitudinal axis of the passage 140d). A second portion 183d of the chamber airflow path then extends generally radially from the vaporizer 132d to the aperture 178d. Thus, there is a first lateral deflection in the chamber airflow path as it passes from the vaporizer 132d to the aperture 178d.

[0553] A third portion 184d of the chamber airflow path from the aperture 178d (i.e., the upstream edge 176d of the baffle 179d) to the downstream edge 179d of the baffle 172d is generally longitudinal and is laterally offset from the axial center of the device. Thus, there is a first axial deflection between the second and third portions 183d, 184d of the chamber air flow path. The transverse cross-sectional area of the third portion 184d of the chamber air flow path as it passes between the upstream and downstream edges 176d, 179d is substantially constant.

[0554] A fourth portion 185d of the chamber airflow path between the third portion 184d and the passage 140d extends generally radially (laterally) parallel to a planar upper surface of the baffle 172d, such that there is a second lateral deflection between the third and fourth portions 184d, 185d of the chamber airflow path.

[0555] The chamber airflow path may then comprise a second axial deflection from the lateral direction (of the fourth portion) to a longitudinal direction as it leaves the vaporizing chamber 156d at the passage opening 158d.

[0556] Upon inhalation by a user at the mouthpiece aperture 148d, air flows along the single, unified chamber airflow path around the porous wick 162d, through the aperture 178d and into the passage 140d via the passage opening 158d.

[0557] FIG. 18 shows a drawing of a manufacturing assembly 282d which is used to manufacture the consumable 104d. The manufacturing assembly 282d comprises a first mold 284d and a second mold 286d.

[0558] The first mold 284d has a shape which complements that of a first end of the integrally formed tank housing 142d and mouthpiece 136d. The first mold 284d therefore has a shape which matches the inner surfaces defining the tank 106d.

[0559] The second mold 286d has a shape which complements that of a second end of the integrally formed tank housing 142d and mouthpiece 136d. The second mold 286d has a shape which matches the outer surface of the mouthpiece 136d and the inner surface of the mouthpiece aperture 148d.

[0560] When the first mold 284d and the second mold 286d are brought together, they define a closed cavity which has the shape of the tank housing 142d, the mouthpiece 136d and the passage walls 144d.

[0561] To manufacture these components, heated material is injected into the cavity between the first mold 284d and the second mold 286d. At this point, the first mold 284d and the second mold 286d meet at a boundary between external surfaces of the mouthpiece 136d and the tank housing 142d.

[0562] The material is subsequently cooled, and the first mold 284d and the second mold 286d are separated, with the first mold 284d travelling in the first demolding direction 288d (i.e., away from the second mold 286d) and the second mold 286d travelling in a second demolding direction 290d (i.e., away from the first mold 284d and opposite to the first demolding direction 288d). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

[0563] The insert 170d and any additional components are subsequently inserted into the tank 106d.

[0564] Fifth Mode: An Aerosol Delivery Device with an Airflow Path Circumventing a Vaporizer

[0565] Aspects and embodiments of the fifth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0566] FIG. 19A shows a first embodiment of a smoking substitute system 100e. In this example, the smoking substitute system 100e includes a main body 102e and an aerosol delivery device in the form of a consumable 104e. The consumable 104e may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

[0567] In this example, the smoking substitute system 100e is a closed system vaping system, wherein the consumable 104e includes a sealed tank 106e and is intended for single-use only. The consumable 104e is removably engageable with the main body 102e (i.e., for removal and replacement). FIG. 19A shows the smoking substitute system 100e with the main body 102e physically coupled to the consumable 104e, FIG. 19B shows the main body 102e of the smoking substitute system 100e without the consumable 104e, and FIG. 19C shows the consumable 104e of the smoking substitute system 100e without the main body 102e.

[0568] The main body 102e and the consumable 104e are configured to be physically coupled together by pushing the consumable 104e into a cavity at an upper end 108e of the main body 102e, such that there is an interference fit between the main body 102e and the consumable 104e. In other examples, the main body 102e and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

[0569] The consumable 104e includes a mouthpiece (not shown in FIG. 19A, 18 or 1C) at an upper end 109e of the consumable 104e, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104e when a user inhales through the mouthpiece. The tank 106e containing e-liquid is located at the lower end 111e of the consumable 104e.

[0570] The tank 106e includes a window 112e, which allows the amount of e-liquid in the tank 106e to be visually assessed. The main body 102e includes a slot 114e so that the window 112e of the consumable 104e can be seen whilst the rest of the tank 106e is obscured from view when the consumable 104e is inserted into the cavity at the upper end 108e of the main body 102e.

[0571] The lower end 111e of the main body 102e also includes a light 116e (e.g., an LED) located behind a small translucent cover. The light 116e may be configured to illuminate when the smoking substitute system 100e is activated. While not shown, the consumable 104e may identify itself to the main body 102e, via an electrical interface, RFID chip, or barcode.

[0572] FIG. 20A and FIG. 20B are schematic drawings of the main body 102e and consumable 104e. As is apparent from FIG. 20A, the main body 102e includes a power source 118e, a controller 120e, a memory 122e, a wireless interface 124e, an electrical interface 126e, and, optionally, one or more additional components 128e.

[0573] The power source 118e is preferably a battery, more preferably a rechargeable battery. The controller 120e may include a microprocessor, for example. The memory 122e preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120e to perform certain tasks or steps of a method.

[0574] The wireless interface 124e is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124e could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124e may also be configured to communicate wirelessly with a remote server.

[0575] The electrical interface 126e may be located in a base of the aperture in the upper end 108e of the main body 102e. When the main body 102e is physically coupled to the consumable 104e, the electrical interface 126e is configured to transfer electrical power from the power source 118e to the consumable 104e (i.e., upon activation of the smoking substitute system 100e).

[0576] The electrical interface 126e may be configured to receive power from a charging station when the main body 102e is not physically coupled to the consumable 104e and is instead coupled to the charging station. The electrical interface 126e may also be used to identify the consumable 104e from a list of known consumables. For example, the consumable 104e may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126e). This can be indicated to the controller 120e of the main body 102e when the consumable 104e is connected to the main body 102e. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102e and a corresponding communication interface in the consumable 104e such that, when connected, the consumable 104e can identify itself to the main body 102e.

[0577] The additional components 128e of the main body 102e may comprise the light 116e discussed above.

[0578] The additional components 128e of the main body 102e may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118e is a rechargeable battery). This may be located at the lower end 110e of the main body 102e. Alternatively, the electrical interface 126e discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0579] The additional components 128e of the main body 102e may, if the power source 118e 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 the charging station (if present).

[0580] The additional components 128e of the main body 102e may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100e, e.g., caused by a user inhaling through a mouthpiece 136e of the consumable 104e. The smoking substitute system 100e may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104e. 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.

[0581] The additional components 128e of the main body 102e may include a user input, e.g., a button. The smoking substitute system 100e may 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 100e.

[0582] As shown in FIG. 20B, the consumable 104e includes the tank 106e, an electrical interface 130e, a vaporizer 132e, one or more air inlets 134e, a mouthpiece 136e, and one or more additional components 138e.

[0583] The electrical interface 126e of the main body 102e and an electrical interface 130e of the consumable 104e are configured to contact each other and thereby electrically couple the main body 102e to the consumable 104e when the lower end 110e of the consumable 104e is inserted into the upper end of the main body 102e (as shown in FIG. 19A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118e in the main body 102e to the vaporizer 132e in the consumable 104e.

[0584] The vaporizer 132e is configured to heat and vaporize e-liquid contained in the tank 106e using electrical energy supplied from the power source 118e. As will be described further below, the vaporizer 132e includes a heating filament and a wick. The wick draws e-liquid from the tank 106e and the heating filament heats the e-liquid to vaporize the e-liquid.

[0585] The one or more air inlets 134e are preferably configured to allow air to be drawn into the smoking substitute system 100e, when a user inhales through the mouthpiece 136e. When the consumable 104e is physically coupled to the main body 102e, the air inlets 134e receive air, which flows to the air inlets 134e along a gap between the main body 102e and the lower end 110e of the consumable 104e.

[0586] In operation, a user activates the smoking substitute system 100e, e.g., through interaction with a user input forming part of the main body 102e or by inhaling through the mouthpiece 136e as described above. Upon activation, the controller 120e may supply electrical energy from the power source 118e to the vaporizer 132e (via electrical interfaces 126e, 130e), which may cause the vaporizer 132e to heat e-liquid drawn from the tank 106e to produce a vapor which is inhaled by a user through the mouthpiece 136e.

[0587] An example of one of the one or more additional components 138e of the consumable 104e is an interface for obtaining an identifier of the consumable 104e. 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 consumable. The consumable 104e 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 main body 102e.

[0588] It should be appreciated that the smoking substitute system 100e shown in FIG. 19A to FIG. 20B 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).

[0589] FIG. 21 is a section view of the consumable 104e described above. The consumable 104e comprises a tank 106e for storing e-liquid, a mouthpiece 136e and a passage 140e extending along a longitudinal axis of the consumable 104e. In the illustrated embodiment the passage 140e is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106e surrounds the passage 140e, such that the passage 140e extends centrally through the tank 106e.

[0590] A tank housing 142e of the tank 106e defines an outer casing of the consumable 104e, whilst a passage wall 144e defines the passage 140e. The tank housing 142e extends from the lower end 111e of the consumable 104e to the mouthpiece 136e at the upper end 109e of the consumable 104e. At the junction between the mouthpiece 136e and the tank housing 142e, the mouthpiece 136e is wider than the tank housing 142e, so as to define a lip 146e that overhangs the tank housing 142e. This lip 146e acts as a stop feature when the consumable 104e is inserted into the main body 102e (i.e., by contact with an upper edge of the main body 102e).

[0591] The tank 106e, the passage 140e and the mouthpiece 136e are integrally formed with each other so as to form a single unitary component. This component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

[0592] Although not immediately apparent from the figures, the tank housing 142e tapers, such that the thickness of the tank housing 142e decreases in a downward direction away from the mouthpiece 136e. This means that, aside from a small number of indents (which provide physical connection between the consumable 104e and the main body 102e), the thickness of the tank housing 142e decreases with increasing distance away from the mouthpiece 136e. In particular, the tank housing 142e tapers in this way, because internal and external surfaces of the tank housing 142e are angled with respect to the downward direction away from the mouthpiece 136e. This tapering assists in forming the tank housing 142e and passage wall 144e as a single (i.e., unitary) component.

[0593] The mouthpiece 136e comprises a mouthpiece aperture 148e defining an outlet of the passage 140e.

[0594] The vaporizer 132e is located in a vaporizing chamber 156e of the consumable 104e. The vaporizing chamber 156e is downstream of the air inlets 134e (discussed later with references to FIG. 22A-FIG. 22C) of the consumable 104e and is fluidly connected to the mouthpiece aperture 148e (i.e., outlet) by the passage 140e. In particular, the passage 140e extends between the mouthpiece aperture 148e and an opening 158e from the chamber 156e. This opening 158e is formed in a downstream (i.e., upper) wall 160e of the chamber 156e.

[0595] The lower end 111e (i.e., base) of the consumable 104e that connects with the main body 102e is defined by a base insert 170e. The base insert 170e is inserted into an open lower end of the tank 106e so as to seal against an internal surface of the tank housing 142e.

[0596] The vaporizer 132e comprises a porous wick 162e and a heater filament 164e (not shown in FIG. 21, but described in more detail below in relation to FIG. 22A to FIG. 22C) coiled around the porous wick 162e. The porous wick 162e extends transversely across the chamber 156e between sidewalls of the chamber 156e which form part of an inner sleeve 168e of the base insert 170e.

[0597] The inner sleeve 168e projects into the tank 106e and seals with the passage 140e (around the passage wall 144e) so as to separate the chamber 156e from the e-liquid in the tank 106e. Transverse ends of the porous wick 162e project into the tank 106e so as to be in contact with the e-liquid in the tank 106e. In this way, e-liquid is transported along the porous wick 162e (e.g., by capillary action) to a central portion of the porous wick 162e that is exposed to airflow through the chamber 156e. The transported e-liquid is heated by the heater filament 164e (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing within the vaporizing chamber 156e. This vaporized liquid may cool to form an aerosol in the passage 140e, which may then be inhaled by a user.

[0598] FIG. 22A illustrates the base insert 170e of the consumable 104e. FIG. 22A also illustrates the coiled heater filament 164e but does not show the porous wick 162e. A pair of contact pins 200e having a circular cross section in the longitudinal direction are embedded in the base portion 170e. As is more clearly shown in FIG. 22C, the contact pins 200e extend through the base portion 170e in a direction substantially parallel to the longitudinal axis of the consumable 104e.

[0599] An upper (downstream) face 202e of each of the pair of contact pins 200e is electrically connected to respective ends of the heater filament 164e. The upper face 202e of each of the pair of contact pins 200e is also physically connected to respective ends of the heater filament 164e. The upper faces 202e of the contact pins 200e may be connected to the heater filament 164e by crimping, welding or compressing.

[0600] As shown in FIG. 22B, a lower (upstream) face 204e of each of the contact pins 200e comprises the electrical interface 130e for interfacing with the corresponding electrical interface 126e on the main body 102e. Thus, when the consumable 104e is engaged with the main body 102e, the lower faces 204e of the contact pins 200e contact corresponding electrical contacts on the main body 102e. As the main body electrical contacts are electrically connected to the power source 118e, power can be supplied by the main body 102e, via the contact pins 200e, to the heater filament 164e in order to heat the heater filament 164e.

[0601] The contact pins 200e are aligned with each other in a transverse direction perpendicular to the longitudinal direction of the device. The contact pins 200e are also transversely aligned parallel to the transversely extending porous wick 162e.

[0602] Furthermore, as shown more clearly in FIG. 22C, the connection between the upper face 202e of each contact pin 200e and the heater filament 164e is located upstream of the heater filament 164e and porous wick 162e.

[0603] As shown in FIG. 22C, the heater filament 164e and the porous wick 162e are positioned to overlie the axial center of the base insert 170e. Accordingly, the heater filament 164e and porous wick 162e are centrally positioned in the consumable 104e in the transverse plane relative to the longitudinal axis of the consumable 104e, such that the central longitudinal axis 210e of the consumable 104e intersects the heater filament 164e and porous wick 162e.

[0604] Each contact pin 200e is spaced in the transverse direction from the central longitudinal axis 210e of the consumable 104e. Specifically, each contact pin 200e is spaced from the central longitudinal axis 210e of the consumable 104e by a same distance on either side of the central longitudinal axis 210e.

[0605] Each of the contact pins 200e is substantially cylindrical. However, as shown in FIG. 22A-FIG. 22C, each contact pin 200e tapers towards the upper face 202e, which is connected to the heater filament 164e.

[0606] The contact pins 200e may be formed from a metal/metal alloy with high electrical conductivity. The contact pins 200e may be formed from one or more of silver, copper, gold, platinum, palladium, tungsten, nickel, graphite, molybdenum, for example.

[0607] As previously mentioned, the heater filament 164e and porous wick 162e are positioned within a vaporizing chamber 156e. As shown in FIG. 22A-FIG. 22C, a pair of inlet channels 220e extend through the base insert 170e into the vaporizing chamber 156e. The inlet channels extend in a generally longitudinal direction of the device. They allow air to flow through the base insert 170e from air inlets 134e at the lowermost surface 111e of the consumable 104e (i.e., lowermost surface of the base portion 170e), through openings 224e into the vaporizing chamber 156e. Thus, by drawing on the mouthpiece 136e, a user may draw air through the air inlets 134e, the inlet channels 220e, the vaporizing chamber 156e, the passage 140e, and out through the outlet defined by the mouthpiece aperture 148e in the mouthpiece 136e.

[0608] In FIG. 22A-FIG. 22C, the two openings 224e of the inlet channels 220e are transversely offset from the central longitudinal axis 210e of the consumable 104e on either side of the central longitudinal axis 210e in the front to back direction. The two openings 224e of the inlet channels 220e are equally spaced from the central longitudinal axis 210e of the aerosol delivery device on either side of the central longitudinal axis 210e. They are aligned with each other in the front to rear direction.

[0609] The openings 224e of the inlet channels 220e are formed in perpendicular stepped portions 230e in the front and rear walls of the vaporizing chamber 156e. The stepped portions 230e in the front and rear walls, and therefore the openings 224e of the inlet channels 220e, are axially downstream of the heater filament 164e and the porous wick 162e.

[0610] The openings 224e of the inlet channels 220e are elongated in the transverse direction such that they extend substantially parallel to the transversely-extending porous wick 162e. The air inlets 134e at the lowermost surface 111e of the base portion 170e are also elongated in the transverse direction such that they extend substantially parallel to the transverse axis aligning the lower faces 204e of the contact pins 200e on the lowermost surface of the base portion.

[0611] Sixth Mode: A Smoking Substitute Device Having an Air Inlet

[0612] Aspects and embodiments of the sixth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0613] FIG. 23A shows a first embodiment of a smoking substitute system 100f. In this example, the smoking substitute system 100f includes a device 102f and a consumable 104f. The consumable 104f 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 consumable. In such (open) systems, a tank of the aerosol delivery device may be accessible for refilling the device.

[0614] In this example, the smoking substitute system 100f is a closed system vaping system, wherein the consumable 104f includes a sealed tank 106f and is intended for single-use only. The consumable 104f is removably engageable with the device 102f (i.e., for removal and replacement). FIG. 23A shows the smoking substitute system 100f with the device 102f physically coupled to the consumable 104f, FIG. 23B shows the device 102f of the smoking substitute system 100f without the consumable 104f, and FIG. 23C shows the consumable 104f of the smoking substitute system 100f without the device 102f.

[0615] The device 102f and the consumable 104f are configured to be physically coupled together by pushing the consumable 104f into a cavity (not shown in FIG. 23A-FIG. 23C) at an upper end 108f of the device 102f, such that there is an interference fit between the device 102f and the consumable 104f. In other examples, the device 102f and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

[0616] The consumable 104f includes a mouthpiece (not shown in FIG. 23A-1C) at an upper end 109f of the consumable 104f, and one or more air inlets (again, not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104f when a user inhales through the mouthpiece. The tank 106f containing e-liquid is located at the lower end 111f of the consumable 104f.

[0617] The tank 106f includes a window 112f, which allows the amount of e-liquid in the tank 106f to be visually assessed. The device 102f includes a slot 114f so that the window 112f of the consumable 104f can be seen whilst the rest of the tank 106f is obscured from view when the consumable 104f is inserted into the cavity at the upper end 108f of the device 102f.

[0618] The lower end 110f of the device 102f also includes a light 116f (e.g., an LED) located behind a small translucent cover. The light 116f may be configured to illuminate when the smoking substitute system 100f is activated. Whilst not shown, the consumable 104f may identify itself to the device 102f, via an electrical interface, RFID chip, or barcode.

[0619] FIG. 24A and FIG. 24B are schematic drawings of the device 102f and consumable 104f. As is apparent from FIG. 24A, the device 102f includes a power source 118f, a controller 120f, a memory 122f, a wireless interface 124f, an electrical interface 126f, and, optionally, one or more additional components 128f.

[0620] The power source 118f is preferably a battery, more preferably a rechargeable battery. The controller 120f may include a microprocessor, for example. The memory 122f preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120f to perform certain tasks or steps of a method.

[0621] The wireless interface 124f is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124f could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124f may also be configured to communicate wirelessly with a remote server.

[0622] The electrical interface 126f of the device 102f may include one or more electrical contacts. The electrical interface 126f may be located at a base of the cavity in the upper end 108f of the device 102f. When the device 102f is physically coupled to the consumable 104f, the electrical interface 126f is configured to transfer electrical power from the power source 118f to the consumable 104f (i.e., upon activation of the smoking substitute system 100f).

[0623] The electrical interface 126f may be configured to receive power from a charging station when the device 102f is not physically coupled to the consumable 104f and is instead coupled to the charging station. The electrical interface 126f may also be used to identify the consumable 104f from a list of known consumables. For example, the consumable 104f may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126f). This can be indicated to the controller 120f of the device 102f when the consumable 104f is connected to the device 102f. Additionally, or alternatively, there may be a separate communication interface provided in the device 102f and a corresponding communication interface in the consumable 104f such that, when connected, the consumable 104f can identify itself to the device 102f.

[0624] The additional components 128f of the device 102f may comprise the light 116f discussed above.

[0625] The additional components 128f of the device 102f may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118f is a rechargeable battery). This may be located at the lower end 110f of the device 102f. Alternatively, the electrical interface 126f discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0626] The additional components 128f of the device 102f may, if the power source 118f 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 the charging station (if present).

[0627] The additional components 128f of the device 102f may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the substitute system 100f, e.g., caused by a user inhaling through a mouthpiece 136f of the consumable 104f. The smoking substitute system 100f may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104f. 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.

[0628] The additional components 128f of the device 102f may include a user input, e.g., a button. The smoking substitute system 100f may 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 100f.

[0629] As shown in FIG. 24B, the consumable 104f includes the tank 106f, an electrical interface 130f, a vaporizer 132f, one or more air inlets 134f, a mouthpiece 136f, and one or more additional components 138f.

[0630] The electrical interface 130f of the consumable 104f may include one or more electrical contacts. The electrical interface 126f of the device 102f and an electrical interface 130f of the consumable 104f are configured to contact each other and thereby electrically couple the device 102f to the consumable 104f when the lower end 111f of the consumable 104f is inserted into the cavity at the upper end of the device 102f (as shown in FIG. 23A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118f of the device 102f to the vaporizer 132f of the consumable 104f.

[0631] The vaporizer 132f is configured to heat and vaporize e-liquid contained in the tank 106f using electrical energy supplied from the power source 118f. As will be described further below, the vaporizer 132f includes a heating filament and a wick. The wick draws e-liquid from the tank 106f and the heating filament heats the e-liquid to vaporize the e-liquid.

[0632] The one or more air inlet(s) 134f are preferably configured to allow air to be drawn into the consumable 104f, when a user inhales through the mouthpiece 136f. As will be discussed further below, when the consumable 104f is physically coupled to the device 102f air flows along an airflow path between the device 102f and the lower end 111f of the consumable 104f to the air inlet(s) of the consumable 104f.

[0633] In operation, a user activates the smoking substitute system 100f, e.g., through interaction with a user input forming part of the device 102f or by inhaling through the mouthpiece 136f as described above. Upon activation, the controller 120f may supply electrical energy from the power source 118f to the vaporizer 132f (via electrical interfaces 126f, 130f), which may cause the vaporizer 132f to heat e-liquid drawn from the tank 106f to produce a vapor which is inhaled by a user through the mouthpiece 136f.

[0634] An example of one of the one or more additional components 138f of the consumable 104f is an interface for obtaining an identifier of the consumable 104f. 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 consumable. The consumable 104f 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 102f.

[0635] It should be appreciated that the smoking substitute system 100f shown in FIG. 23A to FIG. 24B 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).

[0636] FIG. 25A is a schematic section view of an upper end of the device 102f. The device 102f comprises a body 174f accommodating the power source 118f, and side walls 176f. The side walls 176f extend (upwardly) from an end surface 184f of the body 174f in a longitudinal direction so as to define a cavity 178f for receipt of the consumable 104f. In order to facilitate engagement with the consumable 104f, two of the side walls 176f include two inwardly extending projections 180f. These projections 180f engage with recesses of the consumable 104f when received in the cavity 178f, so as to help retain the consumable 104f in the cavity 178f. When engaged in this manner (as shown in FIG. 25B), the consumable 104f interfaces with the electrical interface 130f (in the form of electrical contacts) of the device 102f such that power is supplied to the consumable 104f from the power source 118f of the device 102f.

[0637] Each of the side walls 176f comprises an air inlet aperture 182f formed therein. Each air inlet aperture 182f is formed in its respective side wall 176f at a (longitudinal) position that is adjacent the end surface 184f of the cavity 178f. That is, a lower edge of each aperture 182f is aligned with the end surface 184f of the cavity 178f. As will be discussed further below with response to FIG. 25B, this positioning of the apertures 182f allows air (i.e., that is external to the device 102f) to be directed into the cavity 178f in a substantially transverse direction and between body 174f (i.e., the end surface 184f) and the consumable 104f.

[0638] FIG. 25B is a section view of the device 102f engaged with the consumable 104f. The consumable 104f comprises a tank 106f for storing e-liquid, a mouthpiece 136f and a passage 140f extending along a longitudinal axis of the consumable 104f. In the illustrated embodiment the passage 140f is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106f surrounds the passage 140f, such that the passage 140f extends centrally through the tank 106f.

[0639] A tank housing 142f of the tank 106f defines an outer casing of the consumable 104f, whilst a passage wall 144f defines the passage 140f. The tank housing 142f extends from the lower end 111f of the consumable 104f to the mouthpiece 136f at the upper end 109f of the consumable 104f. At the junction between the mouthpiece 136f and the tank housing 142f, the mouthpiece 136f is wider than the tank housing 142f, so as to define a lip 146f that overhangs the tank housing 142f. This lip 146f acts as a stop feature when the consumable 104f is inserted into the device 102f (i.e., by contact with an upper end of the side walls 176f of the device 102f).

[0640] The tank 106f, the passage 140f and the mouthpiece 136f are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 26, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

[0641] Although not immediately apparent from the figures, the tank housing 142f tapers, such that the thickness of the tank housing 142f decreases in a first demolding direction (as will be discussed further with respect to FIG. 26). In FIG. 25A the first demolding direction is in a downward direction away from the mouthpiece 136f. This means that, aside from a small number of indents (which provide physical connection between the consumable 104f and the device 102f), the thickness of the tank housing 142f decreases with increasing distance away from the mouthpiece 136f. In particular, the tank housing 142f tapers in this way, because internal and external surfaces of the tank housing 142f are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142f and passage wall 144f as a single (i.e., unitary) component.

[0642] Like the tank housing 142f, the passage wall 144f is also tapered such that the thickness of the passage wall 144f decreases along the first demolding direction. Again, the thickness of the passage wall 144f decreases due to internal and external surfaces of the passage wall 144f being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144f, the passage 140f has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 25B). For example, the passage 140f has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140f (e.g., approximately 3.6 mm). On the other hand, the passage 140f has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140f (e.g., approximately 3.4 mm).

[0643] The mouthpiece 136f comprises a mouthpiece aperture 148f defining an outlet of the passage 140f. The mouthpiece aperture 148f has a radially inwardly directed inner surface 150f, which joins an outer surface 152f of the mouthpiece 136f (i.e., a surface which contacts a user's lips in use) at an outer edge 154f of the mouthpiece aperture 148f. At this outer edge 154f, the included angle between the inner surface 150f of the mouthpiece aperture 148f and the outer surface 152f of the mouthpiece 136f (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154f being rounded. This outer edge 154f may otherwise be chamfered or beveled.

[0644] The vaporizer 132f is located in a vaporizing chamber 156f of the consumable 104f. The vaporizing chamber 156f is fluidly connected to the mouthpiece aperture 148f (i.e., outlet) by the passage 140f. In particular, the passage 140f extends between the mouthpiece aperture 148f and a passage opening 158f from the chamber 156f. This passage opening 158f is formed in a downstream (i.e., upper) wall 160f of the chamber 156f.

[0645] The air inlet 134f of the consumable 104f (as discussed above) is an air inlet 134f to the vaporizing chamber. This air inlet 134f is fluidly connected to each of the air inlet apertures 182f via respective airflow paths that extend transversely across the end surface 184f of the body 174f. In particular, these airflow paths are defined between the body 174f (i.e., the end surface 184f) and the consumable 104f (i.e., the insert 170f). That is, when the consumable 104f is received in the cavity 178f, a gap is maintained between the insert 170f and the end surface 184f. This gap is aligned with the air inlet apertures 182f to permit transverse airflow therethrough. Whilst not shown, the end surface 184f or the consumable 104f may comprise guide surfaces (e.g., ribs) that project therefrom so as to at least partly define the airflow path (e.g., to define the transverse path that the airflow takes).

[0646] The vaporizer 132f comprises a porous wick 162f and a heater filament 164f coiled around the porous wick 162f. The porous wick 162f extends transversely across the chamber 156f between sidewalls 166f of the chamber 156f which form part of an inner sleeve 168f of an insert 170f that defines the lower end 111f of the consumable 104f (i.e., that connects with the device 102f). The insert 170f is inserted into an open lower end of the tank 106f so as to seal against the tank housing 142f.

[0647] In this way, the inner sleeve 168f projects into the tank 106f and seals with the passage 140f (around the passage wall 144f) so as to separate the chamber 156f from the e-liquid in the tank 106f. Ends of the porous wick 162f project through apertures in the inner sleeve 168f and into the tank 106f so as to be in contact with the e-liquid in the tank 106f. In this way, e-liquid is transported along the porous wick 162f (e.g., by capillary action) to a central portion of the porous wick 162f that is exposed to airflow through the chamber 156f. The transported e-liquid is heated by the heater filament 164f (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing past the porous wick 162f. This vaporized liquid may cool to form an aerosol in the passage 140f, which may then be inhaled by a user.

[0648] In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156f. This may be undesirable for a user. To reduce this, the consumable 104f comprises a baffle 172f. The baffle 172f extends across the chamber 156f so as to be interposed between the vaporizer 132f and the passage opening 158f. In this way, un-vaporized liquid from the porous wick 162f may collect on an upstream (i.e., lower) planar surface of the baffle 172f rather than entering the passage opening 158f.

[0649] FIG. 26 shows a drawing of a manufacturing assembly 286f which is used to manufacture the consumable 104f described above. The manufacturing assembly 286f comprises a first mold 288f and a second mold 290f.

[0650] The first mold 288f has a shape which complements that of a first end of the integrally formed tank housing 142f and mouthpiece 136f. The first mold 288f therefore has a shape which matches the inner surfaces defining the tank 106f.

[0651] The second mold 290f has a shape which complements that of a second end of the integrally formed tank housing 142f and mouthpiece 136f. The second mold 290f has a shape which matches the outer surface of the mouthpiece 136f and the inner surface of the mouthpiece aperture 148f.

[0652] When the first mold 288f and the second mold 290f are brought together, they define a closed cavity which has the shape of the tank housing 142f, the mouthpiece 136f and the passage walls 144f.

[0653] To manufacture these components, heated material is injected into the cavity between the first mold 288f and the second mold 290f. At this point, the first mold 288f and the second mold 290f meet at a boundary between external surfaces of the mouthpiece 136f and the tank housing 142f.

[0654] The material is subsequently cooled, and the first mold 288f and the second mold 290f are separated, with the first mold 288f travelling in a first demolding direction 292f (i.e., away from the second mold 290f) and the second mold 290f travelling in a second demolding direction 294f (i.e., away from the first mold 288f and opposite to the first demolding direction 292f). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

[0655] Subsequently, the insert 170f (e.g., including the vaporizer) and any additional components are inserted into the tank 106f to form the consumable 104f.

CONCLUSION

[0656] The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the disclosure in diverse forms thereof.

[0657] While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure.

[0658] For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

[0659] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0660] 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.

[0661] 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%.

[0662] The words “preferred” and “preferably” are used herein refer to embodiments of the disclosure 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.