Figure 1 shows a schematic diagram of an example aerosol/vapour delivery system in accordance with aspects of the present disclosure;
Figure 2 shows a cross-sectional view through an example aerosol delivery system in accordance with aspects of the present disclosure;
Figure 3 shows a cross-sectional view through an example aerosol delivery system in accordance with aspects of the present disclosure;
Figure 4 shows a cross-sectional view of the cartridge interface surface of a cartridge in accordance with aspects of the present disclosure;
Figure 5 shows a cross-sectional view of the cartridge interface surface of a cartridge in accordance with aspects of the present disclosure;
Figure 6 shows a schematic diagram of an example of a mouthpiece, cartridge and induction assembly for use in an aerosol/vapour delivery system in accordance with aspects of the present disclosure;
Figure 7 is shows a schematic diagram of an example of a mouthpiece, cartridge and induction assembly for use in an aerosol/vapour delivery system in accordance with aspects of the present disclosure; and
Figure 8 shows a flow diagram depicting a method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system in accordance with the present disclosure.

Detailed Description

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

In accordance with the present disclosure there is described a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate, the cartridge configured to connect and disconnect with a control unit of the aerosol delivery system via an interface. The cartridge comprises a heating element configured to aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element. The heating element providing at least a portion of a cartridge interface surface. The cartridge interface surface is configured to be adjacent to a control unit interface surface when the cartridge and the control unit are connected via the interface.

The provision of such a cartridge may be advantageous in that the cartridge configuration provides a relatively simple design in which the heating element provides a base of the cartridge. Such as system further allows for efficient aerosolisation due to the relatively large surface area of the heater, In particular, the system can be particularly advantageous for induction based heating where an induction element is provided substantially in a plane adjacent to the plane of the portion of the cartridge interface surface provided by heating element, because of the relative alignment and positioning of the heating element with respect to the plane of the induction element. In particular, there is a relatively increased magnetic flux density extending perpendicular to the plane of the planar induction element in contrast to the magnetic flux extending parallel to the plane of the planar induction element. Hence, aspects of the present disclosure describe a relatively simple design which allow for efficient heating.

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and

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

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

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

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

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

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

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

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source.

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

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

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

In some embodiments, the substance to be delivered comprises an active substance.

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

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

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

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

The active substance may be CBD or a derivative thereof.

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

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

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

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

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

In some embodiments, the substance to be delivered comprises a flavour.

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

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

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

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

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

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

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

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

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

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

Figure 1 is a highly schematic diagram (not to scale) of an example aerosol/vapour delivery system 10 in accordance with the present disclosure. The system 10 has a generally elongate shape in this example, extending along a longitudinal axis, and comprises two main components, namely a control or power component, section or unit 20 (sometimes also referred to as an aerosol/vapour delivery device), and a cartridge assembly or section 30 (sometimes referred to as a cartomiser or clearomiser) carrying aerosolisable substrate material and operating as a vapour-generating component.

The cartridge 30 includes a reservoir 33 containing a source liquid (sometimes called a liquid aerosol generating material) or other aerosolisable substrate material comprising a formulation such as liquid or gel from which an aerosol is to be generated, for example containing nicotine. As an example, the source liquid may comprise around 1 to 3% nicotine and 50% glycerol, with the remainder comprising roughly equal measures of water and propylene glycol, and possibly also comprising other components, such as flavourings. Nicotine-free source liquid may also be used, such as to deliver flavouring. A solid substrate (not illustrated), such as a portion of tobacco or other flavour element through which vapour generated from the liquid is passed, may also be included. The cartridge 30 is configured to supply liquid from the reservoir 33 to the heating element 34.

The reservoir 33 has the form of a storage tank, being a container or receptacle in which source liquid can be stored such that the liquid is free to move and flow within the confines of the tank. For a consumable cartridge, the reservoir 33 may be sealed after filling during manufacture so as to be disposable after the source liquid is consumed, otherwise, it may have an inlet port or other opening through which new source liquid can be added by the user. In some examples, the cartridge 30 also comprises a heating element 34 (sometimes called a heater) for generating the aerosol by vaporisation of the source liquid stored in the reservoir tank 33. In some examples, the heating element 34 is intended for heating via induction, which will be described further below. In the example shown inFigure 1, the heating element 34 is a susceptor (in examples where the heating element is a susceptor, the heating element may be called a susceptor heater, a susceptor heating element or a susceptor).

A liquid transfer or delivery arrangement (sometimes called a liquid transport element or liquid delivery element) such as a wick or other porous element 35 may be provided to deliver source liquid from the reservoir 33 to the heater 34. A wick 35 may have one or more parts located inside the reservoir 33, or otherwise be in fluid communication with the liquid in the reservoir 33, so as to be able to absorb source liquid and transfer it by wicking or capillary action to other parts of the wick 35 that are adjacent or in contact with the heater 34. This liquid is thereby heated and vaporised, to be replaced by new source liquid from the reservoir for transfer to the heater 34 by the wick 35. The wick may be thought of as a bridge, path or conduit between the reservoir 33 and the heater 34 that delivers or transfers liquid from the reservoir to the heater. Terms including conduit, liquid conduit, liquid transfer path, liquid delivery path, liquid transfer mechanism or element, and liquid delivery mechanism or element may all be used interchangeably herein to refer to a wick or corresponding component or structure.

A heater and wick (or similar) combination is sometimes referred to as an atomiser or atomiser assembly, and the reservoir with its source liquid plus the atomiser may be collectively referred to as an aerosol source. Other terminology may include a liquid delivery assembly or a liquid transfer assembly, where in the present context these terms may be used interchangeably to refer to a vapour-generating element (vapour generator) plus a wicking or similar component or structure (liquid transport element) that delivers or transfers liquid obtained from a reservoir to the vapour generator for vapour / aerosol generation. Various designs are possible, in which the parts may be differently arranged compared with the highly schematic representation ofFigure 1.

In some examples, the wick 35 may be an entirely separate element from the heater 34. In some other examples, the heater 34 may be configured to be porous and able to perform at least part of the wicking function directly (a metallic mesh or foam, for example). For example, the heating element 34 may comprise a capillary structure configured to wick a liquid aerosol generating substrate.

In some examples, the vapour generating element (i.e. the heating element 34) is an inductively heated susceptor element that operates by inductive heating to heat and vaporise an aerosol generating material. In other examples, the vapour generating element (i.e. the heating element 34) is heated by resistive heating (e.g. by causing a current to flow through a resistive wire, pathway or track to generate heat) to heat and vaporise an aerosol generating material. In general, therefore, an atomiser can be considered as one or more elements that implement the functionality of a vapour-generating or vaporising element able to generate vapour from source liquid delivered to it, and a liquid transport or delivery element able to deliver or transport liquid from a reservoir or similar liquid store to the vapour generator by a wicking action / capillary force. An atomiser is typically a component of a cartridge of a vapour generating system. In some designs, liquid may be dispensed from a reservoir directly onto a vapour generator with no need for a distinct wicking or capillary element. Embodiments of the disclosure are applicable to all and any such configurations which are consistent with the examples and description herein.

The liquid delivery element 35 may comprise any suitable wicking material. For example, it may be made from fibres which are grouped, bunched, wadded, woven or non-woven into a fabric or a fibrous mass, where interstices are present between adjacent fibres to provide a capillary effect for absorbency and wicking. Examples of fibre materials include cotton (including organic cotton), ceramic fibres and silica fibres. Other suitable materials are not excluded and will be apparent to the skilled person. In some examples (as an alternative to fibre based materials) the liquid delivery element 35 comprises a solid porous element, such as a porous ceramic material or a porous foam. For example, a porous ceramic material comprises a network of tiny pores or interstices which is able to support capillary action and hence provide a wicking capability to absorb liquid from a reservoir and deliver it to the vicinity of the heater for vaporisation.

Returning toFigure 1, the cartridge 30 comprises a housing 36 defining a mouthpiece or mouthpiece portion having an opening or air outlet 12 through which a user may inhale the aerosol generated by the heating element 34. In these examples, the outer surface of the housing 36 may be shaped to accommodate a user's lips to enable a user to more easily form a seal around the air outlet 12 with their mouth. In other examples (not shown), the cartridge 30 may not include or otherwise define a mouthpiece. Instead, in some examples, a mouthpiece may connect to the cartridge 30, or the cartridge 30 may be received within a cavity of the control unit 20 (e.g. defined by the induction assembly 40) such that the cartridge 30 is entirely enclosed by the control unit 20 which itself provides or is attached to a mouthpiece.

The power component or control unit 20 (sometimes called a device, device part or control part because it typically contains control circuitry) includes a power supply 25, such as a cell or battery, and which may be re-chargeable, to provide power for electrical components of the system 10, in particular to apply power to an induction element or work coil 42 (described in more detail below) to inductively heat a susceptor heating element 34 or to apply a current through a resistive pathway of a resistive heating element 34.

Additionally, there is a controller 28 such as a printed circuit board and/or other electronics or circuitry for generally controlling the aerosol delivery system 10. In some examples, the control electronics / circuitry 28 operates an induction element 42 using power from the power supply 25 when vapour is required, for example in response to a signal indicative of a user pressing a button (not shown) or from an air pressure sensor or air flow sensor (not shown) that detects an inhalation on the system 10 during which air enters through one or more air inlets 14 (e.g. provided at a junction between the control unit 20 and the cartridge 30).

When the induction element 42 is operated, the induction element 42 inductively heats the heating element 34 to a suitable temperature in order to vaporise source liquid delivered from the reservoir 33 by the liquid delivery element 35 to generate the aerosol, and this is then inhaled by a user through the opening 12 in the mouthpiece of the cartridge housing 36. The aerosol is carried from the aerosol source to the mouthpiece outlet 12 along one or more air channels defining an air pathway 16 (for example, see the arrows depicted inFigure 1) that connect the air inlet 14 to the aerosol source to the air outlet when a user inhales on the air outlet 12.

In some examples, the control unit 20 comprises a frame, or support structure 22 (sometimes called a device frame or support) which is configured to support, retain or position various components of the control unit 20, including the power supply 25 and the control circuitry 28. The frame 22 may also support other components not shown such as a wired connection port and PCB for charging (and optionally, communication), user interface elements (e.g. buttons, LEDs, display screens, haptic feedback units), and / or wireless communication components. The frame 20 can be provided by a single component, or may comprise a number of frame components which are combined to form the frame 20.

In some examples, the control unit 20 comprises an outer housing 24 and / or an end cap 26. For example, the outer housing 24 may be a tubular structure or wrap, which is configured to contain the components of the control unit 20. For example, the frame 22 containing the power supply 25 and the control circuitry 28 can be inserted into the outer housing 24, or the outer housing 24 can be provided around the outside of the frame 22. In some examples, an end cap 26 is provided at one end of the outer housing 24 (e.g. after insertion of the frame 20 containing the power supply 25 and the control circuitry 28) to seal the outer housing 24 (e.g. to protect the components on the inside of the outer housing 24 from the ingress of water and dust).

The induction element or work coil 42 may be provided as part of an induction assembly 40 which comprises a support structure or housing 44 which is configured to position or contain the induction element or work coil 42 (i.e. the support structure 44 supports the induction element 42). In some examples, the induction assembly 40 is formed by integrally molding the support structure 44 around the inductive work element 42, whereas in other examples the support structure 44 provides a scaffolding to which the inductive work element is attached or fixed.

In some examples, the support structure 44 provides the portion of the control unit interface surface. In some examples, the induction assembly 40 comprises a barrier layer providing the portion of the control unit interface surface 49. In some examples, the barrier layer comprises a coating on the surface of the induction element or a coating provided on a surface of the support structure 44. Said barrier layer may be configured to prevent or reduce corrosion or damage to components of the control unit 20 such as the induction element 42.

In some examples, the induction assembly 40 comprises a ferrite shield 48, such as a film, foil or sheet, which may be retained in position by the support structure 44. In some examples, the ferrite shield 48 is positioned adjacent to the induction element 42 on an opposite side of the induction element 42 to the control unit interface surface 49. For example, the ferrite shield may be inserted or embedded into the support structure 44, or provided on an underside of the support structure 44. A ferrite shield 48 can be used to inhibit magnetic flux in the direction of the shield from the induction element 42, when power is supplied to the induction element 42.

In some examples, the induction assembly 40 is a fixed or permanent component of the control unit 20. For example, the support structure 44 can be integrally formed with the frame 22 of the control unit 20. In other examples, the induction assembly 40 and the control unit 20 are separate connectable parts detachable from one another by separation in a direction parallel to the longitudinal axis of aerosol delivery system 10. For example, the components 20, 40 are joined together when the system 10 is in use by cooperating engagement elements (for example, a screw or bayonet fitting) which provide mechanical and electrical connectivity between the power section 20 and the induction assembly 40. The electrical connectivity can be required in order to provide electrical power to the induction element 42 when the control circuitry 28 determines that power should be supplied to the induction element 42. The control circuitry is at least for controlling the supply of power to the induction element, wherein the control circuitry is configured to drive the induction element to induce current flow in the susceptor to inductively heat the susceptor and so vaporise a portion of the aerosol generating substrate in the vicinity of the susceptor.

The use of an interchangeable induction assembly 40 improves the ease of replacing the induction assembly 40 in the case of damage or wear, as well as potentially also allowing for customisation of a system 10 by allowing a user to replace an induction assembly with a different induction assembly with an alternate configuration for operation with a different heating element 34 arrangement (e.g. provided by a cartridge 30 having a different configuration).

In some examples, the induction assembly 40 may seal an end of the outer housing 24 (e.g. to protect the components on the inside of the outer housing 24 from the ingress of water and dust). For example, the induction assembly 40 may be provided at the opposite end of the outer housing 24 to the end having the end cap 26. The induction assembly 40 may connect to the frame 22 and / or the outer housing 24 in such a way that a liquid seal is formed preventing liquid from flowing into the cavity formed by the outer housing 24, end cap 26 and the induction assembly 40. Alternatively in some examples, the control unit comprises a second end cap which is fixed to the outer housing 24 and / or frame 22 between the frame 22 and the induction assembly 40. In some of these examples, a second end cap may be configured to facilitate the attachment of the induction assembly 40 to the control unit 20.

The control unit (power section) 20 and the cartridge (cartridge assembly) 30 are separate connectable parts detachable from one another by separation in a direction parallel to the longitudinal axis of aerosol delivery system 10. In some examples, the components 20, 30 are joined together when the system 10 is in use by cooperating engagement elements (for example, a screw or bayonet fitting) which provide mechanical connectivity (and in some examples electrical connectivity) between the power section 20 and the cartridge assembly 30. For example, a portion of the outer housing 24 can be an engagement element (not shown) configured to engage with a corresponding engagement (not shown) of the cartridge 30 provided by a portion of the cartridge housing 36.

In some other examples, the induction assembly 40 may facilitate the connection between the control unit 20 and the cartridge 30. For example the induction assembly 40 and the cartridge 30 may include cooperating engagement elements (for example, a screw or bayonet fitting) which provide mechanical (and optionally electrical) connectivity between the induction assembly 40 and the cartridge 30 to indirectly connect the cartridge 30 to the control unit 20 (including electrical connectivity if necessary) via the induction assembly 40.

In systems that use inductive heating, electrical connectivity can be omitted from the connection between the cartridge 30 and the control unit 20 if no parts requiring electrical power are located in the cartridge 30.

In some examples, the cartridge 30 and induction assembly 40 are shaped (e.g. the cartridge housing 36 and the induction support structure 44, respectively) so that when they are connected, there is an appropriate exposure of the heating element 34 to flux generated by the induction element 42 for the purpose of generating current flow in the material of the heater. For example, the heating element 34 can be configured to provide at least a portion of a cartridge interface surface 39 and the induction assembly 40 can be configured to provide at least a portion of a control unit interface surface 49, with the induction element 42 provided adjacent to the control unit interface surface 49. In these examples, the cartridge interface surface 39 is adjacent to the control unit interface surface when the cartridge and the control unit are connected via the interface which therefore causes the induction element 42 to be provided proximally to heating element 34. Inductive heating arrangements are discussed further below.

In some examples, the heating element 34 comprises a planar surface providing at least the portion of the cartridge interface surface 39. For example, the heating element 34 is a planar element such as a sheet of material, or the heating element 34 is a block having a planar surface on one side.

As described above, aspects of the disclosure relate to inductive heating. This is a process by which an electrically conducting item, typically made from metal, is heated by electromagnetic induction via eddy currents flowing in the item which generates heat. An induction element 42 (e.g. work coil) operates as an electromagnet when a high-frequency alternating current from an oscillator is passed through it; this produces a magnetic field. When the conducting item

(i.e. susceptor) is placed in the flux of the magnetic field, the field penetrates the item and induces electric eddy currents. These flow in the item, and generate heat according to current flow against the electrical resistance of the item via Joule heating, in the same manner as heat is produced in a resistive electrical heating element by the direct supply of current.

An attractive feature of induction heating is that no electrical connection to the conducting item is needed; the requirement instead is that a sufficient magnetic flux density is created in the region occupied by the item. In the context of vapour provision systems, where heat generation is required in the vicinity of liquid, this is beneficial since a more effective separation of liquid and electrical current can be effected. Assuming no other electrically powered items are placed in a cartomiser, there is no need for any electrical connection between a cartridge and its power section, and a more effective liquid barrier can be provided by the cartomiser wall, reducing the likelihood of leakage.

Induction heating is effective for the direct heating of an electrically conductive item, as described above, but can also be used to indirectly heat non-conducting items. In a vapour provision system, the need is to provide heat to liquid in the porous wicking part of the atomiser in order to cause vaporisation. For indirect heating via induction, the electrically conducting item is placed adjacent to or in contact with the item in which heating is required, and between the work coil and the item to be heated. The work coil heats the conducting item directly by induction heating, and heat is transferred by thermal radiation or thermal conduction to the non-conducting item. In this arrangement, the conducting item is termed a susceptor. Hence, in an atomiser, the heating component can be provided by an electrically conductive material (typically metal) which is used as an induction susceptor to transfer heat energy to a liquid proximal to the atomiser (e.g. held by a wick 35 and / or the heating element 34 itself).

A susceptor may usefully be formed from a suitable material, which is electrically resistive/conductive, in other words able to carry an electrical current. This enables the heater to have its temperature increased by exposure to a magnetic field generated by a high frequency alternating current in a work coil, by induction effects as noted above, where the magnetic flux induces eddy currents in the heater material.

In some examples, the heating element 34 comprises a planar element such as a sheet of an appropriate material, suitably dimensioned and shaped for making into a heater. A planar element such as a sheet inherently provides a (first) planar surface on one face of the planar element and a second planar surface on the opposing side of the planar element. In some examples, the planar element may be a flat planar element.

In some examples, the planar element may be a flat planar element. In some of these examples, a susceptor in the form of a flat planar element is positioned to be offset from, and parallel to, a plane of an induction element 42 (e.g. they each provide a parallel plane of a pair of parallel, adjacent, planes). The portion of the planar element forming the heating element 34 which is offset from, and parallel to, a plane of the induction element 42 will be exposed to the magnetic field generated by the high frequency alternating current in the induction element 42. Without being bound by theory, this field will typically be strongest towards the centre of the plane of the induction element 42 for a spirally wound two-dimensional coil. Hence, the portion of the heating element 34 which is offset and parallel to the plane of the induction element 42 will be heated more relative to portions of the heating element 34 which are additionally or alternatively offset or displaced laterally with respect to the plane of the induction element 42.

In some examples, a heating element 34 is formed from a planar element such as a sheet may be curved or bent into a non-flat shape (the heating element 34 no longer occupies a single plane). The curving may be formed by rolling or folding. In some examples, by curving or bending the heating element 34, the heating element 34 is configured to provide a nearly or substantially flat surface (rather than a flat surface) which comprises a curvature taking the planar surface out of a single plane. Said surfaces are considered nearly or substantially planar surfaces because the curvature of the planar surface is relatively small. For example, the curvature of the surface may be up to 10 degrees with respect to an abstract origin of a circle located on the opposing side of the plane of the induction element 42 to the heating element 34 (in contrast to the separation of the susceptor and the planar element which may be in the range of up to 2 mm; the separation of the susceptor and the abstract origin may be in the range of a few cm or more, such that the surface of the susceptor is substantially planar with respect to the plane of the induction element). In some examples, a suitable induction element 42 for use with a susceptor heating element 34 may be similarly curved to the heating element 34, which may act to increase the magnetic flux towards a middle of the heating element 34.

A suitable element for a susceptor heating element 34 is an electrically conductive material, with adequate resistance to enable heating by induction effects via induced eddy currents. In some examples, the heating element 34 is provided by a planar element such as a sheet. For example, the heating element 34 is a sheet or foil of a metallic material, where suitable metals include mild steel, ferritic stainless steel, aluminium, nickel, cupro-nickel, nichrome (nickel chrome alloy), and alloys of these materials. In some examples, the sheet may be laminate of layers of two or more materials.

The sheet thickness can be balanced against the requirement to provide a sufficient volume of resistive material to provide sufficient heating (recalling that in some examples the amount of material is reduced by perforations). Accordingly in some examples, the susceptor comprises a planar element, the planar element having a thickness in the range of one or more of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm. These values may be the total thickness of the sheet including any supporting elements or coatings. If the thickness is insufficient, the heater may lack adequate structural integrity, although this may be compensated by additional components (e.g. support components).

In some examples, a planar element for a heater 34 has a simple rectangular or oval shape or profile. In other examples, a planar element for a heater 34 may have an alternative shape such as a non-rectangular, polygonal shape, or a circular or elliptical shape. This may be particularly useful where heating is intended to be focussed at particular zones or portions within the cartridge 30.

In some of these examples where the heating element 34 is a susceptor, a planar element providing the heating element 34 can be provided with a shape that corresponds to zones which are incident with relatively large magnetic flux from the planar element.

In some other examples, the heating element 34 is not provided by a planar element (i.e. defined by two relatively larger dimensions and a thickness of a relatively small order of magnitude) and is instead provided by an block element having a thickness of a similar order of magnitude to the two dimensions defining the planar surface of the heating element 34.

In some examples, the element or block formed of a suitable electrically conductive material, with adequate resistance to enable heating by induction effects via induced eddy currents. For example, the susceptor heating element 34 may comprise an inductively heatable material such as wire wool or mesh (e.g. a (ferritic) stainless steel mesh) or a metal foam (e.g. nickel foam or cupro-nickel foam) formed into an appropriate shape.

In some other examples, the element or block formed of a base material upon which a resistive track can be printed. For example, the base material may be a ceramic material or similar.

In contrast to a planar element, a block (e.g. provided by stainless steel mesh or nickel foam) may have a thickness in the range of 0.1 to 3 mm. In some examples, the stainless steel mesh or nickel foam may have a thickness in the range of 0.2 to 1 mm. In some examples, the stainless steel mesh or nickel foam may have a thickness in the range of 0.25 to 0.6 mm. The thicknesses extending in a direction normal to or away from the planar surface defining the cartridge interface surface.

In some examples, a block element for a heater 34 has a simple cuboid shape (such as a flat slab). In some examples, a block can be formed into a particular configuration (e.g. by curving the surface of the shape). In other examples, a block element may have an alternative shape such as a circular or elliptical disc shape with a thickness as described above. A suitable block element provides a substantially planar surface by one face of the block element (e.g. a surface providing a portion of the cartridge interface surface 39).

In some of these examples where the heating element 34 is a susceptor, the block element can be configured with a shape that corresponds to zones which are incident with relatively large magnetic flux from the planar element. In some examples, a suitable block element may be formed by pressing a steel mesh into a required shape or by forming a nickel foam within a mould having a required shape.

In some examples, where the heating element is a resistive heating element, the heating element can comprise a substrate sheet upon which a resistive track is provided. In some examples the substrate sheet has a thickness in the range of one or more of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm.

In some examples, the heating element 34 (sometimes called heater 34) comprises a plurality of apertures extending through the heating element 34. Said apertures may be called perforations or holes. In some examples, the plurality of perforations may be holes cut or punched through the material of a heating element 34 formed from a planar element (e.g. a sheet of material). Each hole is small compared to the total external surface area of the heating element 34 (e.g. the plane of a sheet). In some examples, the holes are relatively closely packed and evenly distributed over the surface of the heating element 34 so that many holes are included. The holes may be circular, for example, or may be elongated or slot-shaped. The purpose of the holes is to enable the generated vapour to more easily escape from the atomiser (e.g. wick and susceptor) into the aerosol chamber to be collected by the airflow through the aerosol chamber. For example, when liquid in the wick 35 within the atomiser is vaporised by the heat from the heater 34, the generated vapour can flow outwardly through the perforations into the free space of the air pathway 16 adjacent to the heater 34.

When designing the heater 34, it may be necessary to balance the increased ease of vapour flow afforded by additional perforations with the decreased amount of heater material available for heating. Accordingly, one can consider an optimum total area for the perforations compared to the area of the heater material which generates heat and provides it for vaporisation. If we define the total heater material area without any holes, a range for the total area then taken up the perforations may be in the range of about 5% to 30%, for example about 20% of the total heater material area, for example. In any case, it is useful that the total area of the perforations does not exceed about 50%, due to manufacturing restrictions. Also, too large an open area (total area of the perforations) may lead to poor inductive coupling in the event that induction heating is used, while too small an open area makes it difficult for generated vapour to escape from the wick 35.

In some examples, the number density of the plurality of apertures increases or decreases along the width (and / or length) from edges of the planar surface towards a centre of the planar surface. In other words, the number density of the plurality of apertures increases from a peripheral edge of the planar surface of the heating element 34 towards a centre of the planar surface of the heating element 34.

In some examples, the density of the plurality of apertures varying from a peripheral edge of the portion of the cartridge interface surface 39 towards a centre of the portion of the cartridge interface surface 39. In some examples, the density of the plurality of apertures increases from a peripheral edge of the portion of the cartridge interface surface 39 towards a centre of the portion of the cartridge interface surface 39.

While not shown, in some examples, the cartridge 30 comprises a removable cover adjacent to the portion of the cartridge interface surface 39. Said removable cover is removed prior to connecting the cartridge 30 to the control unit 20. The removable cover may cover the surface of the heating element 34, and may in some examples, comprise protrusions which plug the plurality of apertures. The removable cover can prevent or inhibit leakage from the reservoir 30 and may be formed of a material which is non-reactive with liquid aerosol generating substrate, such as silicon.

In some examples, the heating element 34 is shaped to provide an opening for a portion of the air pathway 16. For example the heating element 34 can comprise an opening that is configured to receive a tube defining a portion of the air pathway 16 leading to the mouth end outlet 12. In some example, the opening is towards or at a centre of portion of the cartridge interface surface 39 defined by the heating element 34.

In some examples, the wick 35 comprises an inductively heatable material such as a stainless steel mesh or a nickel foam. Said wick 35 formed of an inductively heatable material may also provide the heater 34 component (e.g. a combined wick-heater atomiser) or may be in addition to the heater 34 (e.g. the wick part of an atomiser formed of a wick 35 and heater 34). When the wick 35 is placed in the flux of the magnetic field, the field penetrates the item and induces electric eddy currents. These flow in the item, and generate heat according to current flow against the electrical resistance of the item via Joule heating, in the same manner as heat is produced in a resistive electrical heating element by the direct supply of current. In some examples, particularly where the wick 35 is used in conjunction with a separate susceptor heating element 34, the wick 35 is able to contribute to the heating of the liquid and may also retain residual or latent heat between puffs, which can act to reduce the amount of energy or time required to heat the susceptor heating element 34 to a vaporisation temperature on a subsequent puff. In particular, the wick 35 may have a large mass, in comparison to the susceptor heating element 34, which acts to store latent heat, while the relatively low mass of the susceptor heating element 34 allows for rapid heating of the susceptor heating element 34.

In some examples, a stainless steel mesh or nickel foam providing a wick 35 has a shape corresponding to the heating element 34. For example, a wick 35 and a heating element 34 may comprise abutting surfaces which are configured to ensure reasonable contact between the wick 35 and the heating element 34. For examples, the wick 35 may comprise a cuboid shape having a same length and width as the heating element 34. Where the heating element 34 is a curved planar element, the wick 35 can optionally be manipulated into a particular configuration to (e.g. by curving the surface of the shape).

In other examples, a planar element may have an alternative shape such as a circular, or elliptical shape. This may be particularly useful where heating is intended to be focussed at particular zones or portions within the cartridge 30. In some examples, the wick 35 may or may not have a corresponding shape.

In some examples, the wick 35 can aid in positioning the heating element 34 by, for example, exerting a retaining force on the heating element 34 caused by compression of the wick 34 between the heater 35 and an element of the housing 36 which is in contact with the wick 35.

In some examples, the liquid transport element 35 (sometimes called a wick) provides liquid to a second heater surface (e.g. an abutting surface) on an opposing side of the heating element 34 to the cartridge interface surface 39. In some examples, liquid can be supplied to the heating element 34 via the liquid transport element 35 and then when the liquid is vaporised and the liquid is able to pass through the heating element 34 (e.g. by one or more apertures extending through the heating element 34) from the second heater surface to the cartridge interface surface 39 provided by the heating element 34.

Returning toFigure 1 in more detail, in the example shown, the an induction assembly 40 comprises an induction element 42 operable to induce current flow in a heating element 34 of the cartridge 30 to inductively heat the heating element 34 and so aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element 34. The induction assembly provides at least a portion of a control unit interface surface 49, wherein the induction element 42 is provided adjacent to the control unit interface surface 49. For example the induction element 42 is defined by a plane which is parallel and adjacent to a plane of the control unit interface surface 49, or which defines the control unit interface surface 49.

The cartridge 30 and induction assembly 40 are shaped so that a cartridge interface surface 39 and a control unit interface surface 49, provided by an induction assembly 40, are parallel and adjacent to each other with an air gap provided between the two in which generated aerosol joins the air pathway 16.

In particular, in examples in accordance withFigure 1, the induction element 42 is provided in the form of a planar induction element, the induction could being formed substantially in a plane around an axis. In examples such as those in accordance withFigure 1, the axis around which the planar induction element is formed is parallel to the longitudinal axis of the system 10. In some examples, the planar induction element 42, and the control unit interface surface 49 which it is provided adjacent to, are formed in a plane perpendicular to a longitudinal extension of the system 10.

In some examples, the planar induction element 42 is formed by a resistive wire, such as a nickel or cupronickel wire, which is configured or arranged into a shape such as a flat spiral. In some examples, the induction element is a litz coil. In some examples, a resistive wire providing the planar induction element 42 is provided in a support structure 44 which acts to retain the resistive wire in a particular shape (e.g. a two-dimensional spiral). In some of these examples, the resistive wire may be embedded in the support structure. In other examples, a resistive wire providing the planar induction element 42 is substantially free-standing in that the resistive wire is able to support an orientation and configuration with respect to an anchor location (i.e. where the resistive wire engages a support structure 44). For example, the resistive wire may be a suitably rigid material (e.g. a suitably thick wire) that it is able to maintain a configuration throughout continued use.

In some examples, the planar induction element 42 may be printed or deposited on a portion of a substrate or support structure 44 which is configured to be inserted into the recess 38 when the cartridge 30 is attached to the induction assembly 40 and / or device 20. In some examples, a laser is used to activate the surface of the support structure 44, which may comprises a thermoplastic material such as polyetheretherketone (PEEK) which may have been doped with a metallic inorganic compound. The laser creates one or more laser activated regions upon the support structure 44 which can then be further metallised using e.g. an electroless plating process to build up one or more conductive layers of e.g. copper. For example, an inductor coil 42 may be deposited upon a support structure 44 so as to form a spiral inductor coil 42. However, other embodiments are also contemplated wherein the inductor coil 42 may be formed upon the support structure 44 so as to have a different configuration.

Forming a planar induction element 42 by printing or depositing a conductive layer on a support structure 44, such as by utilising a laser direct structuring process as described above, results in a induction element 42 being formed which is integrated with or into the support structure 44. This advantageously can reduce the size of the support structure 44 required compared to a support structure 44 which is suitable for retaining a resistive wire providing a planar induction element 42 and can therefore enable the induction assembly 40 to be provided in a more compact arrangement.

In some examples, the planar induction element 42 is a planar induction coil. For example, the planar induction element 42 is a flat spiral coil (sometimes called a pancake coil). By a flat coil it is meant that the coil spirals in a two dimensional plane from an outer most point of the spiral to an inner most point of the spiral (not necessarily at the geometric centre of the spiral). In some examples, the coil may project out of the two dimensional plane to some extent, and may be considered folded or curved. In these examples, the flat spiral coil is a substantially flat spiral coil in that the extent of any curving or folding out of the plane is relatively small, and preferably less than 5 degrees out of the plane. In other examples, the spiral coil does not project out of the two dimensional plane of the spiral configuration, other than by way of the three-dimensional thickness of the element providing the spiral coil (e.g. wire thickness or deposition thickness).

In some examples, the spiral coil increases regularly or consistently from a centremost point to an outermost point (e.g. constant radial increase per change in angle), and may be considered a substantially circular spiral coil. In some other examples, the spiral coil has a substantially elliptical shape or an irregular shape caused by, for example, varying the radial increase as a function of the change in angle and distance from the axis from a centremost point to an outermost point.

In the example ofFigure 1, the portion of the induction assembly 40 containing the induction element 42 is part of the support structure 44 or housing of the induction assembly 40. This part of the support structure 44 may have a planar shape corresponding or related to the plane of the planar induction coil. The support structure 44 may be defined by first and second planar surfaces on respective sides of the planar induction coil 42 (i.e. intersecting with the axis around which the planar induction coil is formed), and also one or more peripheral surfaces radially outward from the spiral (i.e. not intersecting with the axis around which the spiral coil is formed). The support structure 44 may surround the planar induction element 42 in the to provide a protective housing for the planar induction element and / or to support or maintain the position of the induction element 42 within the induction assembly 40. In some other examples, not shown, at least a portion of the planar induction element 42 may not be covered by the support structure 44. In such examples, the planar induction element 42 may be exposed to ambient air.

At least a part of the susceptor heating element 34 (i.e. the part providing the cartridge interface surface 39) is provided adjacent the surface of the induction assembly 40 proximal to the induction element 42 (i.e. the control unit interface surface 49). The susceptor heating element 34 portion defining the cartridge interface surface 39 is provided parallel and adjacent to the plane of the planar induction element 42 (and parallel to the control unit interface surface 49).

By providing a (planar) susceptor heating element 34 defining a cartridge interface surface 39 parallel and adjacent to the plane of the planar induction element 42 there is an appropriate exposure of the susceptor heating element 34 to flux generated by the induction element 42 provided at or adjacent to the control unit interface surface 49 for the purpose of generating current flow in the material of the heater. In this way, the susceptor heating element 34 is responsive to the magnetic field generated by the planar induction element 42. If the susceptor heating element 34 is located so that the separation of the susceptor heating element 34 from the planar induction element 42 is minimised, the flux experienced by the susceptor heating element 34 can be higher and the heating effect made more efficient.

The distance separating the susceptor heating element 34 from the induction element 42 is sometimes called the coupling distance. Without being bound by theory, a susceptor heating element 34 and the induction element 42 effectively form a pair in which the induction element 42 is inductively coupled to the susceptor heating element 34 and is able to transmit or transfer energy to the susceptor heating element 34 when a current is applied to the induction element 42. The coupling distance relates to the distance across which energy is transferred from the induction element 42 to the susceptor heating element 34. The further away the susceptor heating element 34 is (i.e. the larger the coupling distance), the greater the loss in energy. In some examples, in order to reduce energy losses to a suitable proportion, the coupling distance is in the range of less than 2 mm. In some examples, the coupling distance is in the range of less than 1.5 mm. In some examples, the coupling distance is in the range of less than 1 mm.

The coupling distance can alternatively be described by the offset distance relating to the distance separating the planar surface from the planar induction coil (e.g. the difference between abstract parallel planes relating to the cartridge interface surface 39 and the planar induction coil 42). In some examples, the cartridge interface surface 39 defined by the susceptor heating element 39 is offset from the planar induction element 42 by an offset distance in a range of less than 2 mm. In some examples, the cartridge interface surface 39 is offset from the planar induction element 42 by an offset distance in a range of less than 1.5 mm. In some examples, the cartridge interface surface 39 is offset from the planar induction element 42 by an offset distance in a range of less than 1 mm.

As shown inFigure 1, in some examples, the aerosol delivery system 10 comprises an air pathway 16 defined in part by a volume between the heating element 34 and the control unit interface surface 49 (e.g. defined by the induction assembly 40). The separation of the cartridge interface surface 39 and the control unit interface surface 49 is set at least in part by the width or size of the portion of the air pathway 16 formed between the cartridge interface surface 39 and the control unit interface surface 49, with the air pathway 16 in this region of the system 10 needing to be sized to allow adequate air flow. In some examples, the separation of the cartridge interface surface 39 and the control unit interface surface 49 is in the range of more than 0.5 mm. In some examples, the separation of the cartridge interface surface 39 and the control unit interface surface 49 is in the range of more than 1 mm. The separation of cartridge interface surface 39 and the control unit interface surface 49 can sometimes be called a thickness of the air pathway 16.

In some examples, the separation distance of the cartridge interface surface 39 and the control unit interface surface 49 is in the range of 0.3 mm to 2.5 mm. In some examples, the separation distance of the cartridge interface surface 39 and the control unit interface surface 49 is in the range of 0.5 mm to 1.5 mm. The minimum distance is dependent on the requirement for the airflow resistance though the gap between the cartridge interface surface 39 and the control unit interface surface 49, while the maximum distance is dependent on ensuring the coupling distance is not too great (thereby reducing the efficiency of the inductive heating). In some examples, the thickness of any barrier layer and/or support structure 44 separating the induction element 42 from the cartridge interface surface 39 is no more than 1 mm.

While not shown inFigure 1, in some examples, the cartridge 30 comprises a spacer (or multiple spacers) protruding outwardly from the cartridge interface surface 39. In some examples, the gap or volume between the cartridge interface surface 39 and the control unit interface surface 49 is maintained by the presence of one or more spacers (or protrusions) extending from the plane defining the cartridge interface surface 39 and / or the control interface surface 49. Each spacer (or protrusion) may have a height (out of the plane of the relevant surface) corresponding to the required air gap such that the spacer contacts the opposing surface, thereby maintaining a gap between the surfaces corresponding to the height of the spacer. In some examples, one or more spacers are provided around at least a portion of the periphery of the cartridge interface surface 39 and / or the control unit interface surface 49.

In some examples where the heating element 34 is a susceptor heating element 34 the requirements of the aerosol pathway 16 and the coupling distance need to be balanced against one another when determining the sizing and positioning of the various items. In some examples, the coupling distance is in the range of 0.75 mm to 2 mm, and the separation of the cartridge interface surface 39 and the control unit interface surface 49 (thickness of the air pathway 16) is in the range of more than 0.5 mm to 1.5 mm, where the separation of the cartridge interface surface 39 and the control unit interface surface 49 is less than or equal to the coupling distance. In some examples, the coupling distance may be equal or substantially equal to the separation of the cartridge interface surface 39 and the control unit interface surface 49. For example, there may be no further features between the cartridge interface surface 39 and the control unit interface surface 49 (e.g. the support structure 44 may not encompass the induction element 42, which instead extends from the induction element 42). In some other examples, the coupling distance may be less than the separation of the cartridge interface surface 39 and the control unit interface surface 49 due to the presence of a protective layer or housing layer (e.g. provided by the support structure 44 to protect the induction element 42).

In some examples where the heating element 34 is either a resistive heating element or a susceptor heating element 34, the provision of an air pathway 16 defined in part by a volume between the heating element 34 and the control unit interface surface 49 provides a system 10 comprising a large vaporisation surface (e.g. corresponding to the portion of the cartridge interface surface 39 provided by the heating element 34) which allows for significant aerosol generation, whilst also comprising a relatively simple to manufacture system in which the heating element 34 provides a base portion (or surface) of the cartridge 30.

TheFigure 1 design is merely an example arrangement, and the various parts and features may be differently distributed between the power section 20 and the cartridge assembly section 30, and other components and elements may be included. The two sections may connect together end-to-end in a longitudinal configuration as inFigure 1, or in a different configuration such as a parallel, side-by-side arrangement. The system may or may not be generally cylindrical and/or have a generally longitudinal shape. Either or both sections or components may be intended to be disposed of and replaced when exhausted (the reservoir is empty or the battery is flat, for example), or be intended for multiple uses enabled by actions such as refilling the reservoir and recharging the battery. In other examples, the system 10 may be unitary, in that the parts of the control unit 20 (e.g. including an induction assembly 40) and the cartridge 30 are comprised in a single housing and cannot be separated. Embodiments and examples of the present disclosure are applicable to any of these configurations and other configurations of which the skilled person will be aware.

Figure 2 is a cross-sectional view through an example aerosol delivery system 10 in accordance with the present disclosure, where the cross-section intersects a support structure or housing 44 of an induction assembly 40 and an outer housing 24 of the control unit 20. The housing 44 comprise a recess 47 for an induction element 42. Aspects of the support structure 44 (and related components for use with the support structure) may be understood as described in relation toFigure 1.

The outer housing 24 surrounds the induction assembly support structure 44. In some examples, as per the example ofFigure 2, the outer housing 24 and the support structure 44 both have a rounded rectangular outer peripheral shape with at least a pair of substantially parallel sides, and rounded corners connecting the parallel sides. It will be appreciated that the outer housing 24 and support the support structure 44 can have different outer peripheral shapes such as a circular or elliptical shape.

The recess 47 comprises a pair of counter-rotating spiral recesses 47 each of which is configured to receive a spiral coil of a single induction element 42. In particular, in some examples, the induction assembly comprises a pair of adjacent counter rotating coils in a single plane. In other words, the induction element 42 comprises a first portion comprising a first spiral coil and a second portion connected to the first portion which comprises a second spiral coil which spirals inwardly in the opposite direction to the first spiral coil. In some examples, each of the spiral recesses comprise a plurality of parallel sections provided towards the centre of the support structure 44, where the first spiral recess is adjacent to the second spiral recess. This can advantageously allow for focussed heating centrally to each counter rotating coil (i.e. due to the concentration of magnetic flux centrally).

The first spiral recess is provided in a first portion (e.g. half) of the support structure 44 and the second spiral recess is provided in an adjacent, second portion (e.g. half) of the support structure 44. The provision of two spiral recesses may be advantageous for systems having an elongated cross-section (e.g. an ellipse rather than a circle, such as a substantially elliptical shape with a major axis that is 2-3 times the size of the minor axis). In other examples, the recess 47 can comprise a single spiral recess.

The induction assembly 40 is created by providing an suitable planar induction element 42 (e.g. a wire that can be spirally wound) in the recess 47. It will be appreciated that in other examples, where the induction element 42 is not provided by a pair of connected spiral coils, the insertion portion 45 may have an alternative to the recess 47 which is suitable for receiving the alternate induction element 42.

The recess 47 of the support structure 44 may be open in that it is visible on a surface of the support structure 44, or the recess 47 may be internal to the housing 44 (i.e. to encapsulate an induction element 42). In some examples, the recess 47 is provided at the surface of the support structure 44 which provides the control unit interface surface 49 (e.g. the cross-section shown inFigure 2 may depict the control unit interface surface 49). In some examples where recess 47 is provided at the surface of the support structure 44 providing the control unit interface surface 49, an induction element 42 provided in the recess 47 defines a portion of the control unit interface surface 49.

An induction element 42 may be provided by a resistive wire, or by a conductive track, as discussed above in relation toFigure 1.

Figure 3 is a cross-sectional view through an further example aerosol delivery system 10 in accordance with the present disclosure, where the cross-section intersects a support structure or housing 44 of an induction assembly 40 and an outer housing 24. Aspects of the support 44 (and related components for use with the support structure) may be as understood as described in relation toFigure 1 or2.

In contrast to the example ofFigure 2, the example induction assembly 40 ofFigure 3 comprises a first recess 471 and a second recess 472 each of which is configured to receive an induction element 42 (e.g. a separate and distinct induction element). As such the induction assembly 40 ofFigure 3 can be considered to provide a two induction element system.

In some examples, as shown inFigure 3, the first recess 471 and the second recess 472 are counter-rotating spiral recesses. For example, the first recess comprises a first spiral recess, and the second recess comprises a second spiral recess which spirals inwardly in the opposite direction to the first spiral coil.

The induction assembly 40 is created by providing suitable planar induction elements 42 (e.g. a wire that can be spirally wound) in each of the recesses 47. As such, in some examples, the induction assembly comprises a first induction element second induction element. The first induction element is provided adjacent to a first portion of the control unit interface surface, wherein the first induction element is operable to induce current flow in the first portion of the heating element of the cartridge to inductively heat the first portion of the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the first portion of the heating element. The second induction element is provided adjacent to a second portion of the control unit interface surface, wherein the second induction element is operable to induce current flow in the second portion of the heating element of the cartridge to inductively heat the second portion of the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the second portion of the heating element. In some examples, the first induction element and the second induction element comprise counter rotating coils. In some examples, the first and second induction elements are a pair of adjacent counter rotating coils in a single plane.

In some examples, a system 10 comprising two induction elements 42 is advantageous in that each induction element 42 can be powered separately, and importantly power can be alternatively supplied to each induction element 42 in turn. For example, a first induction element 42 in the first recess 471 can be powered for a period of time, and then a second induction element 42 in the second recess 472 can be powered for a period of time (e.g. alternating at a frequency of around 50 Hz).

In some examples, in a system 10 comprising two induction elements 42, one of the induction elements 42 to be operated without operating the other of the induction elements 42. As such, the operated induction element 42 can heat an adjacent portion of a heating element 42, while the portion of the heating element adjacent to the other induction element 42 is substantially not heated (e.g. not heated to a vaporisation temperature).

In some examples, the cartridge 30 comprises a first reservoir for a first liquid aerosol generating substrate, the cartridge 30 configured to supply liquid from the first reservoir to a first portion of the heating element 34, and the cartridge 30 comprises a second reservoir for a second liquid aerosol generating substrate, the cartridge 30 is configured to supply liquid from the second reservoir to a second portion of the heating element 34. In some examples, the cartridge 30 comprises the first liquid aerosol generating substrate and the second liquid aerosol generating substrate, wherein the first liquid aerosol generating substrate is different to the second liquid aerosol generating substrate.

Advantageously, where a cartridge 30 comprises first and second reservoirs each holding an aerosol generating substrate (which may be different to each other), selectively operating one or both of the induction elements 42 allows for the aerosol produced by the system 10 to be altered. For example, in some examples where the aerosol generating substrates in different reservoirs are different, a flavour can be selected and / or an active substance introduced by aerosolising a reservoir having said flavour or active substance. In other examples, where the aerosol generating substrates in the different reservoirs are the same, a strength or concentration of the aerosol generated by the system 10 can be changed.

Figure 4 is a cross-sectional view of the cartridge interface surface 39 of a cartridge 30 in accordance with the present disclosure. Aspects of cartridge 30 not described in detail below may be as understood as described in relation toFigure 1.

The cartridge interface surface 39 ofFigure 4 is defined by a susceptor heating element 34 which provides a base (e.g. bottom plate) of the cartridge 30 and a portion of the housing 36 surrounding a periphery of the susceptor heating element 34. In some examples, the susceptor heating element 34 can be a planar element comprising a planar surface defining at least a portion of the cartridge interface surface 39.

The portion of the housing 36 comprises a rim or edge or the cartridge interface surface 39. In some examples, the heating element 34 can be retained as part of the cartridge 30 by the rim. For example, the rim can comprise a shelf or ledge which contacts the heating element 34 to retain the heating element 34 in the cartridge 30.

The rim comprises a series of spacers 366 (or protrusions) and airflow gaps 368 (or openings). The spacers of the rim are configured (or otherwise provided) to engage with a corresponding portion of the control unit interface surface 49 (not shown) such that a void is formed between the cartridge interface surface 39 and the control unit interface surface 49, when the cartridge 30 is connected to the induction assembly 40 of the control unit 20. In some examples, there are at least two spacers 366. In some examples, two spacers of the at least two spacers 366 are provided on opposite sides of the heating element 34 providing the cartridge interface surface 39. In some examples, the spacers 366 additionally are configured to retain the heating element 34 as part to the cartridge 30 by extending inwardly over the surface of the heating element 34.

The airflow gaps 368 are provided around the rim of the housing 36 between the spacers 366 such that air if able to flow into the void between the cartridge interface surface 39 and control unit interface surface 49 via the airflow gaps 368. Each airflow gap 366 is formed between a respective pair of spacers 368. In some examples, there may be at least two airflow gaps 368.

The cartridge 30 comprises an airflow passage 364 which extends through the heating element 34. The airflow passage 364 provides a portion of the air pathway 16 of the system 10. The heating element 34 comprises an opening which allows air and / or aerosol to flow from the void between the cartridge interface surface 39 and the control unit interface surface 49, and into the airflow passage 364. The central passage can extend from the void, to the mouth end of the cartridge 30 (e.g. to the outlet 12). As such, air may flow into the system 10 via an inlet 14, towards and through airflow gaps 368, across the surface of the heating element 34 which provides a portion of the cartridge interface surface 39 and into the airflow passage 364 and out of the mouth-end outlet 12.

The opening in the heating element may be a circular aperture (or cutout) or may be a different shape such as an elongated slots (e.g. rectangular or elliptical). In some examples, the airflow passage 364 can be considered a central passage 364 because it is provided centrally to the surface of the heating element 34 and the cartridge 30. In some other examples, not shown, the passageway is not a central passageway (i.e. not disposed centrally in the cartridge 30) and is instead displaced to one side of the cartridge 30.

The wall defining the airflow passage through the cartridge 30 may also define a boundary of a reservoir 33. In some of these examples the reservoir 33 may be provided by an annular cavity between the wall defining the airflow passage 364 and the outer wall of the housing 36. The reservoir 33 can be filled with a liquid transport element 35 which is configured to retain a liquid aerosol generating material in contact with the heating element 34.

In some examples, as shown inFigure 4, the heating element 34 comprises a plurality of apertures 345 extending through the heating element 34. Said apertures 345 may be called perforations or holes. In some examples, the plurality of perforations 345 may be holes cut or punched through the material of a heating element 34 (e.g. a sheet of a susceptor material). Each hole 345 is small compared to the total external surface area of the heating element 34 (e.g. the plane of a sheet). The holes 345 may be circular, for example, or may be elongated or slot-shaped. The purpose of the holes 345 is to enable the generated vapour to more easily escape from the atomiser (e.g. wick and susceptor) into the aerosol chamber to be collected by the airflow through the aerosol chamber. For example, when liquid in the wick 35 within the atomiser is vaporised by the heat from the heater 34, the generated vapour can flow outwardly through the perforations into the free space of the air pathway 16 adjacent to the heater 34.

In some examples, the holes 345 are relatively closely packed in one or more regions of the heating element 34. For example the holes 345 may be provided in a regions in which airflow is primarily expected or in regions corresponding to relatively greater magnetic flux generated by an induction element 42. In some examples, where the induction element 42 comprises two spiral portions (e.g. distinct coils or a single interconnected pair of counter-rotating coils), the apertures 345 can be provided adjacent to an approximate centre of each spiral portion. In some examples, the apertures 345 may be provided between the airflow passage 364 and the rim of the housing 36 substantially along an axis where the cartridge 30 is relatively wider. In some examples the apertures 345 in a grouping fan out from the airflow passage 364 towards an airflow gap 368.

Figure 5 is a cross-sectional view of the cartridge interface surface 39 of a cartridge 30 in accordance with the present disclosure. Aspects of cartridge 30 not described in detail below may be as understood as described in relation toFigure 1.

In contrast to the example cartridge ofFigure 4, the example cartridge ofFigure 5 comprises a resistive track 62 provided on the surface of the heating element 34 (the surface providing the cartridge interface surface 39). The heating element 34 ofFigure 5 is a resistive heating element 34 which is configured to be heated by passing a current through the resistive track 62 in order to generate thermal energy. In other words, the temperature of the resistive heating element 34 is increased by the passage of an electric current through the resistive track 62 to produce heat. While heat is generated by the resistive track 62, the substrate of the heating element 34 upon which the resistive track 62 is provided can also be heated by thermal conduction from the resistive track. In general the substrate for a resistive heating element comprises a material which is a good thermal conductor and a poor electrical conductor, and which can also be heated to a high temperature without damage, such as a ceramic material.

In some examples, the resistive track 62 comprises a single conductive pathway which extends between two electrical contacts 64. The electrical contacts 64 can be provided at either end of the resistive track 62 and are each configured to provide electrical contact with a respective electrode of a suitable control unit 20 when the cartridge 30 is attached to the control unit 20. For example, the control unit 20 can comprise a pair of electrodes which protrude from the control unit interface surface 49 in order to engage the electrical contacts 64. In some examples, the electrodes are configured to have a height equivalent to that of a spacer 366. In some examples, the resistive track 62 can be formed from a conductive material (e.g. copper) by printing or depositing a conductive layer on to the substrate material of the heating element 34.

In some examples, the resistive track 62 is configured as a sinuous or meandering pathway, with apertures 345 provided adjacent to the resistive track 62. The resistive heating of the portion of the heating element 34 in which the apertures 345 are provided, allows for the aerosolisation of the aerosol generating material adjacent to the heating element 34, into the air pathway 16 via the apertures 345.

Figure 6 is a highly schematic diagram (not to scale) of an example of a mouthpiece 50, cartridge 30 and induction assembly 40 for use in an aerosol/vapour delivery system 10 in accordance with the present disclosure. The cartridge 30 differs from the cartridge 30 shown inFigure 1, in that the cartridge 30 is configured to be received in a cavity 51 defined at least in part by a separate mouthpiece component 50 (called a mouthpiece 50 herein). The heating element 34, the liquid transport element 35, the reservoir 33 of the cartridge 30, as well as the induction assembly 40 ofFigure 6 are as described in relation toFigure 1 and will not be described again in detail. Alternate embodiments of a cartridge 30 and induction assembly 40, which are suitable for use with a mouthpiece 50 as disclosed inFigure 6, may include aspects described in relation toFigures 2 to 4. Furthermore, while not shown, in some examples a cartridge 30 having a resistive heating element 34 as shown inFigure 5 could be used with a mouthpiece 50 as detailed below, in combination with a control unit 20 comprising a pair of electrodes for creating a resistive circuit with a resistive track 62, rather than an induction assembly 40.

The cartridge 30 ofFigure 6 may be termed a pod or capsule and is configured to be received inside a cavity 51 or void defined in part by the mouthpiece 50. For example, the housing 36 of the cartridge 30 is not configured to define a mouthpiece shape, but is instead configured to define a structure which can be contained within the system 10 by the mouthpiece 50, and which can accommodate components such as the reservoir 33, a susceptor 34, and a liquid transport element 35.

In the example ofFigure 6, the cavity 51 for receiving the cartridge 30 is defined at one end by the induction assembly 40 providing the control unit interface surface 49 and at an opposing end by the mouthpiece 50. The periphery of the cavity 51 is defined by the outer housing 24 which comprises a peripheral wall extending from the control unit 20. In use the cartridge 30 is received within the cavity 51 defined by the outer housing 24 and induction assembly 40 such that the cartridge interface surface 39 is adjacent to the control unit interface surface 49, and subsequently an control unit-end of the mouthpiece 50 is inserted into the outer housing 24 to retain the cartridge 30 in place. In such a system 10, the mouthpiece 50 may form an interference fit with the outer housing 24 which retains the mouthpiece 50 in contact with the outer housing 24. Such an attachment can be considered a push-fit mechanism. When a user wishes to replace a cartridge 30, the user can pull (i.e. apply a force to overcome the interference fit) the mouthpiece 50 from the outer housing 24 in order to allow the cartridge 30 to be extracted.

In some examples, the cavity 51 has a shape and size which corresponds to the outer shape defined by the cartridge 30 but which is larger, (e.g. slightly larger such as 1 % larger) than the outer shape defined by the cartridge 30. This allows the cartridge 30 to be inserted or placed into cavity 51, such that the cartridge 30 is retained in the cavity 51. In some examples, the size of the cartridge 30 and the size of the cavity 51 may be substantially similar such that an interference fit is formed between the housing 52 defining the cavity 51 and the housing 36 defining the cartridge 30.

As depicted inFigure 6, the housing 36 may be a body having a central airflow passage 364 extending between two openings in opposing end faces of the body. The airflow passage 364 provides a portion of the air pathway 16 of the system 10. The heating element 34 provides an opening at one end of the airflow passage 364. The opening may be a circle, or a different shape such as an elongated slots (e.g. rectangular or elliptical).

The walls of the airflow passage 364 further define an inner wall of the reservoir 33. The reservoir 33 is provided by a cavity 51 defined by the housing 36 and the walls of the airflow passage 364 (e.g. an annular cavity). The cartridge 30 includes a liquid transport element 35 which is provided in the reservoir 33. In contrast toFigure 1 the liquid transport element 35 fills the entirety of the reservoir 33. It will be appreciated that in other examples having a mouthpiece 50 as described in relation toFigure 6, the liquid transport element 35 may only comprise a section adjacent to the heating element 34 and does not fill the whole of the reservoir 33.

As also depicted inFigure 6, in some examples, the support structure 44 of the induction assembly 40 comprises attachment features 441 configured to facilitate the connection of the housing 44 to a control unit 20 having corresponding attachment features 221. In these examples, the induction assembly 40 is releasably attached to the control unit 20. In some examples, the attachment features 441 allow an induction assembly 40 to be reversibly connected to a control unit 20, such that the induction assembly 40 can be removed and replaced without damaging the control unit 20 or the induction assembly 40. This may allow the control unit 20 to be used with different types of cartridges having different susceptor arrangements. In some other examples, the induction assembly 40 is an integral component of a control unit 20, the attachment features 441 and corresponding attachment features 221 may be omitted 48 (e.g. the housing 44 may be integrally formed with a housing of the control unit), or the attachment features 441 may be configured to provide a permanent attachment which is not intended to be reversed (i.e. disconnected).

Figure 7 is a highly schematic diagram (not to scale) of an example of a mouthpiece 50, cartridge 30 and induction assembly 40 for use in an aerosol/vapour delivery system 10 in accordance with the present disclosure. Similar to the example cartridge 30 ofFigure 6, the example cartridge 30 ofFigure 7 is configured to be received in a separate mouthpiece component 50 (called a mouthpiece 50 herein).

In contrast toFigure 6, the housing 52 of the mouthpiece 50 comprises two portions; a first, upper, downstream or mouth-end portion 52 and a second, lower, upstream or device-end portion 54. The cavity 51 may be formed by one or both of the upper and lower portions 52,54.

In the example ofFigure 7, the cavity 51 is an internal space or volume defined by the upper and lower housing portions 52,54, with the upper housing portion 52 also defining the external shape of the mouthpiece 50. For example, the upper housing portion 52 defines an outlet 12 of the air pathway 16 through which a user can inhale. In some examples, the upper and lower housing portions 52,54 are formed from a metal or plastic material (for example, the housing may be formed by plastic injection moulding process). Additionally, the mouthpiece 50 ofFigure 7 comprises an opening mechanism 56 and a locking mechanism 58.

The opening mechanism 56 is configured to allow for movement of the first portion 52 with respect to the second portion 54, or vice versa. In some examples, the opening mechanism 56 is a hinge or flexible connector. Where the opening mechanism 56 is a hinge, the opening mechanism 56 can allow for rotation of the first portion 54 with respect to the second portion 52. In some examples, the rotation can be with respect to an axis which is perpendicular to the longitudinal axis of the system 1, while in some other examples the rotation with respect to an axis which is parallel to the longitudinal axis of the system 1.

The opening mechanism 56 allows the mouthpiece 50 to be moved between a first configuration in which the cavity 51 is at least partially exposed in order to allow a cartridge 30 to be inserted and / or removed, and a second configuration in which the cavity 51 is substantially closed (except for via openings for the air pathway 16) in order to retain and / or protect a cartridge 30 provided within the cavity 51. The first configuration may be termed an open or accessible configuration because the cavity 51 is open and accessible to a user, and the second configuration may be termed a closed or inaccessible configuration because the cavity 51 is closed and inaccessible to a user.

As such, in some examples, a mouthpiece comprises an opening mechanism configured to allow the mouthpiece to be moved between a first configuration and a second configuration, wherein in the first configuration the cavity is at least partially exposed in order to allow a cartridge to be inserted and / or removed, and wherein the second configuration is configured to retain a cartridge provided within the cavity.

Advantageously, the opening mechanism 56 allows a user to open the cavity 51 without a full disconnection of the first portion 52 from the second portion 54, thereby improving user accessibility because a user does not have to hold each portion 52,54 separately whilst inserting or removing a cartridge 30 from the cavity 51. However, it will be appreciated that in some other examples, an opening mechanism 56 may not be included and instead the first portion 52 and the second portion 54 may fully detach from each other when changing the mouthpiece configuration from the second configuration to the first configuration.

The connection mechanism 58 acts to retain the first portion 52 in contact with the second portion 54 of the housing. For example, the connection mechanism 58 may be a latch or lock which prevents or inhibits the first portion 52 from moving relative to the second portion 54, or vice versa. The connection mechanism 58 is configured to prevent or inhibit the mouthpiece 50 from moving from the closed configuration to the open configuration in order to prevent a cartridge 30 from inadvertently being leaving the cavity 51 prior to a user intending to remove the cartridge 30.

In some examples, the connection mechanism 58 is provided in one or both of the first portion 52 and the second portion 54. For example, the connection mechanism 58 can comprise a corresponding component in each of the first and second portions 52,54 which are configured to engage with each other to prevent or inhibit movement of the first and second portion 52,54 with respect to each other. In some examples, the connection mechanism 58 comprises a mechanical mechanism including a latch or clip in one of the first portion 52 and the second portion 54, and a corresponding component (e.g. a second clip or a ridge) in the other of the first portion 52 and the second portion 54 for retaining the latch or clip. In some examples, the connection mechanism 58 comprises a first magnet in the first portion 52, and a second magnet (attractive to the first magnet) in the second portion 54, the two magnets generating a force that needs to be overcome to move the first portion 52 relative to the second portion 54.

In some examples, the connection mechanism 58 is user actuatable such that a user can interact directly with the connection mechanism 58 to inhibit the connection mechanism 58 from retaining the mouthpiece in the second configuration. In other words, the connection mechanism 58 is user actuatable such that a user can interact directly with the connection mechanism 58 to allow the first portion 52 to move relative to the second portion 54 (e.g. the user may move or bend a latch out of a position with respect to a corresponding clip, or may apply force to overcome the attraction between two magnets).

In some examples, the connection mechanism 58 is electronically controlled (e.g. electrically operated by the control circuitry 28). For example, while not shown, at least a part of the connection mechanism 58 may be electrically connected to the control circuitry 28 and may be operable (e.g. in response to electrical signals) by the control circuitry 28 to activate or deactivate the connection mechanism 58. In some examples, the connection mechanism 58 may comprise an electromagnet and a permanent magnet, where the electromagnet is configured to generate a magnetic field when a current is supplied through the electromagnet, which causes an attractive force to be generated between the permanent magnet and electromagnet. In some examples, the connection mechanism 58 comprises an actuator which is movable in response to an electric signal to engage a latch or similar (such a latch and actuator may be positioned to not be visible to a user when the mouthpiece 50 is in the second configuration).

Advantageously, the connection mechanism 58 can be used to slow down a user, when a user is seeking to change a cartridge 30. For example, when a heating element 34 is heated to high temperature. Particularly in cases where a user heats the heating element 34 a number of times in a short period (e.g. 10 puffs in 1 minute), elements of the cartridge 30 can become hot (particularly, heating element 34 and the components close to the heating element 34). If the user were to remove the cartridge 30 immediately after puffing the user (or their clothing or nearby item such as a table) could be burned.

The provision of connection mechanism 58 delays the user from accessing the cartridge 30 immediately, and instead allows heat (thermal energy) to dissipate throughout the cartridge 30 and surrounding elements of the system 10. It will be appreciated that even where the connection mechanism 58 is a simple mechanical mechanism such as a latch, this may still delay the user from accessing the cartridge by a few seconds (e.g. at least 2 to 3 seconds). In some examples, where the connection mechanism 58 is electronically controlled, the control circuitry 28 may implement a timer preventing the connection mechanism 58 from being disengaged for a period of time after a most recent activation of the induction element 42 (e.g. the period of time is in a range of greater than 3 seconds, and preferably greater than 5 seconds). In some examples the period of time may be fixed, whereas in other examples the period of time may be calculated based on the usage of the system up to the last puff (e.g. increased usage prior to the last activation causing the period of time to be greater).

In some examples, not shown, the lower portion 54 may not be a component of the mouthpiece 50. Instead in these examples, the induction assembly 40 or the device 20 define or otherwise provide at least a portion of the cavity 51 for the cartridge 50 (for example, at a minimum the induction assembly 40 or the device 20 may define an end surface of the cavity with the remaining surfaces defined by a single mouthpiece housing component). In these examples, the connection mechanism 58 and / or the opening mechanism 56, as described above, can be provided by the induction assembly 40 or device 20. For example, the mouthpiece 50 may be connected by a hinge (opening mechanism 56) to the induction assembly 40 or to the device 20 (e.g. the housing 24 of the device 20). As such, in some examples, the mouthpiece 50 comprises at least a component of an connection mechanism, wherein the connection mechanism is configured to retain the mouthpiece in the second configuration.

Furthermore, in some examples, a connection mechanism 58 as described above is provided to connect a cartridge 30 directly to the control unit 20 and/or the induction assembly 40 without the presence of a separate mouthpiece 50. For example, the connection mechanism 58 may engage or lock the cartridge 30 on to the control unit 20 and/or the induction assembly 40 to prevent the cartridge from inadvertently disconnecting.

Figure 8 is a flow diagram depicting a method 100 of generating an aerosol from an aerosol generating substrate in an aerosol delivery system 10 in accordance with the present disclosure. The aerosol delivery system 10 comprises a cartridge 30 and a control unit 20, wherein the cartridge 30 comprises a heating element 34 providing at least a portion of a cartridge interface surface 39; and the control unit 20 comprises a control unit interface surface 29. The system 10 and its components (e.g. induction assembly 40, cartridge 30 and control unit 20) may be as described in relation to any ofFigures 1 to 7 and will not be described again in detail.

The method 100 starts with a first step 110 of connecting the cartridge 30 with the control unit 20 via an interface. The cartridge interface surface 39 is adjacent to the control unit interface surface 29 when the cartridge 30 and the control unit 20 are connected via the interface. The cartridge interface surface 39 and the control unit interface surface 49 can be defined by substantially parallel planes, between which an air gap is provided which forms part of the air pathway 16 of the system 10 leading from the inlet 14 to the outlet 12.

In some examples, the heating element 34 comprises a susceptor, and the control unit 20 comprises an induction assembly 40 providing the portion of the control unit interface surface 49. The induction assembly 40 comprises an induction element 42 operable to induce current flow in the heating element 34 of the cartridge 30 to inductively heat the heating element 34 and so aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element 34. The induction element 42 is provided adjacent to the control unit interface surface 49, such that the induction element 42 is also adjacent to the susceptor 34 because the susceptor 34 provides at least a part of the cartridge interface surface 30 (e.g. they both define planes which are parallel to one another).

The induction element 42 can be a planar induction element defined by a plane. By a plane defining the planar induction element 38, it is meant the plane in which the planar induction element 38 is substantially arranged (e.g. for a two dimensional spiral coil, the plane of the spiral). The planar induction element 42 is offset from the susceptor 34 in a direction perpendicular to the plane (e.g. to form the air gap). The planar surface of the susceptor 34 is provided in a direction which is displaced perpendicular to the plane of the planar induction element 42 (e.g. for a two dimensional spiral coil, the susceptor 34 may be displaced from the spiral coil 42 with respect to an axis which passes through the centre point or origin of the spiral coil 42). In some examples the offset distance is equal to the distance separating the cartridge interface surface 39 and the control unit interface surface 49 (e.g. because the induction element 42 is provided on the surface of the induction assembly 40), whereas in other examples the offset distance is greater than the distance separating the cartridge interface surface 39 and the control unit interface surface 49 (e.g. because a support structure 44 or barrier layer defining the control unit interface surface 49 is provided between the induction element 42 and the heating element 34).

In some examples, the heating element 34 is a resistive heating element 34 comprising a resistive track 62 provided on a portion of the cartridge interface surface 39. In these examples, the control unit 20 comprises a pair of electrical contacts (e.g. electrodes) configured to provide an electrical connection with respective portions 64 of the resistive track 62 when the cartridge 30 and the control unit 20 are connected via the interface.

In some examples, the method 100 continues with a step 120 of causing a current to flow in the heating element to heat the heating element to a first temperature, so as to vaporise a portion of the aerosol generating substrate in the vicinity of the heating element 34.

In some examples where the control unit 20 comprises an induction element and the heating element 34 is a susceptor, causing a current to flow in the heating element to heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element 34 comprises driving an induction element 42 to induce current flow in the heating element to inductively heat the heating element 34. In these examples, an induction element 42 may be driven to heat the susceptor heating element 34 to at least a vaporisation temperature of an aerosol forming component of the aerosol generating substrate (e.g. a liquid from a reservoir 33).

In some examples where the control unit 20 comprises a pair of electrical contacts for forming an electrical circuit with a resistive track of a heating element, causing a current to flow in the heating element to heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element 34 comprises supplying current through a resistive track between respective portions of the resistive track. In these examples, a current can be supplied through the resistive track 62 to heat the resistive heating element 34 to at least a vaporisation temperature of an aerosol forming component of the aerosol generating substrate (e.g. a liquid from a reservoir 33).

The temperature to which the heating element 34 is driven to vaporise a portion of the aerosol generating substrate in the vicinity of the heating element 34 can be considered a first temperature or a vaporisation or aerosolisation temperature. In some examples, the first temperature is in the range of between 150°C and 300°C. In some examples, the first temperature is in the range of between 190°C and 220°C.

In some examples, step 120 is triggered by a user input. For example, the user may engage a user input element. For example, the user may interact with a user actuatable element, such as a button, or the user may inhale on the system (e.g. via the outlet 12) to trigger a puff sensor. In addition to the user input element being a user actuatable element such as a button, or a puff sensor, the user input element could also be any sensor capable of identifying a user interaction (e.g. a capacitance sensor, a motion sensor, or an optical sensor). The user input element can be configured to send a signal to the control circuitry 28 indicating that a user input has occurred, and the control circuitry 28 can trigger step 120 (i.e. drive the planar induction element 42). For example, a user inhales on the outlet 12, a puff sensor sends a signal to the control circuitry identifying a user input corresponding to an inhalation (e.g. a signal identifying a pressure drop), and the control circuitry 28 causes a current to flow in the heating element 34 (e.g. by applying a current directly or via induction) to heat the heating element 34 in response to a signal indicating that a user is interacting with a user input element.

In some examples, the system 10 comprises a temperature sensor for measuring a temperature of the heating element 34. The temperature sensor may be configured to measure a value indicative of the temperature of the heating element 34 rather than directly measuring the heating element 34 directly. For example, a suitable temperature sensor may be able to determine the temperature of the heating element 34 based on resistance of an element close to the heating element 34 (e.g. a thermocouple in the vicinity of the heating element 34). In some examples, the induction element 42 may be used to measure the temperature of the heating element 34 based on a strength and frequency of the inductive coupling between the susceptor and the induction element 42. Measurements or signals relating (directly or indirectly) to the temperature of the heating element 34 can be sent to the control circuitry 28, and used to control how the induction element 42 is driven (i.e. to achieve or maintain a temperature).

In some examples, the method ends after causing a current to flow in the heating element 34 to heat the heating element 34 to a first temperature. For example, the control circuitry 120 can cease to cause a current to flow in a heating element 34 after a period of time corresponding to a user's puff, and / or corresponding to a predicted amount of aerosol generation (e.g. based on knowledge of the energy input to the system and energy required to vaporise the aerosol generating substrate, and either actively calculated during use or based on predetermined data, such as a look-up table, for a particular system 10 configuration). In some examples, the control circuitry 28 can cease to cause a current to flow in a heating element 34 by ceasing to drive an induction element 42 to induce current flow in the heating element 34 to inductively heat the heating element 34 to a first temperature.

In some examples, the method ends after causing a current to flow in the heating element 34 to heat the heating element 34 to a first temperature for a fixed period of time. In some examples, the fixed period of time may be a period of time in the range of 1.5 to 5 seconds. In some examples, the fixed period of time may be a period of time in the range of 2.5 to 4 seconds.

In some examples, the method ends after causing a current to flow in the heating element 34 to heat the heating element 34 to a first temperature when a user input (e.g. inhalation, button press, or similar as described above) ceases to be provided. For example, a user ceases to inhale of the system 10, the puff sensor sends a signal indicating that air pressure has increased, and the control circuitry 28 ceases to cause the current to flow (e.g. by ceasing to drive an induction element 42). Alternatively, a user ceases to press a button of the system 10, the button sends a signal indicating that the button is not being pressed, and the control circuitry 28 ceases to cause the current to flow. In some examples, the control circuitry 28 implements a maximum activation period even where the user continues to trigger a user input mechanism. This may prevent overheating of the system 10, if for example the user input element has malfunctioned. In some examples, the maximum activation period is a period in the range of 6 to 15 seconds. In some examples, the maximum activation period is a period in the range of 7 to 12 seconds. The method 100 may, in some examples, end after step 120.

In some examples, the method 100 comprises a further step 115 of causing a current to flow in the heating element 34 to heat the heating element 34 to a second temperature that is a lower temperature than the first temperature, and which is not sufficient to vaporise a portion of the aerosol generating substrate in the vicinity of the heating element 34. In other words, the second temperature is lower than a temperature required to vaporise the portion of the aerosol generating substrate in the vicinity of the heating element 34. The second temperature may be considered a preheat temperature. In some examples, the second temperature is in the range of 80°C to 200°C. In some examples, the second temperature is in the range of 120°C to 170°C. The heating element 34 can be a resistive heating element or a susceptor heating element as discussed above in relation to step 120.

As such, in some examples in accordance with step 115, the method 100 comprises causing a current to flow in the heating element 34 to heat the heating element 34 to a first temperature so as to vaporise the portion of the aerosol generating substrate in the vicinity of the susceptor, and wherein the method further comprises causing a current to flow in the heating element 34 to heat the heating element 34 to a second temperature which is lower than the first temperature and lower than a temperature required to vaporise the portion of the aerosol generating substrate in the vicinity of the heating element 34.

It will be appreciated that the control circuitry 28 is able to heat the heating element 34 to a particular temperature by, for example, modifying the power supplied through the planar induction element 42 or, for example, by applying the power supplied through a resistive track 62.. For example, the control circuitry 28 can monitor the temperature of the heating element 34 by a suitable sensor (e.g. thermocouple or based on a shift in resonant frequency detectable by the planar induction element 42), and can turn alter the power supplied through the planar induction element 42 or resistive track 62. As an example, the control circuitry 28 can supply power (to a resistive track 62 or an induction element 42) in periodic pulses at a set frequency (e.g. 500-50Hz) until a required temperature is reached. As long as the heating element 34 is at or above the required temperature the control circuitry 28 can prevent the supply of power during the next scheduled pulse. When the heating element 34 falls below the required temperature, the control circuitry 28 can resume supplying pulses.

In some examples, the control circuitry is configured to cause a current to flow in the heating element 34 to heat the heating element 34 to a second temperature to a second temperature in response to a stimulus, wherein the stimulus comprises one or more of a signal indicative of the connection of a cartridge 30 to the control unit 20, and a signal indicative of a user's intention to begin a session of usage.

In some examples, a stimulus may be the detection of the connection of a cartridge 30 to the control unit 20. In some examples, the control circuitry 28 may be able to determine that a cartridge 30 has already been attached (i.e. is currently attached) based on a measurement or sensor reading (e.g. from a sensor for detecting attachment of a cartridge 30 such as an optical sensor, a signal indicating that a circuit has been formed with the resistive track 62, or based on a signal from an induction element 42 indicating that an inductively heatable element has been moved towards the induction element 42). In some examples, a stimulus may be the user pressing a button of the device 20, or the user taking a first puff on the device 20 (triggering a puff sensor, if present).

A stimulus may be indicative of a user's intention to begin a session of usage (e.g. a user's intention to take a series of puffs on the system 10 (by puff it is meant a user will inhale on the outlet 12 of the system 10). In some examples, the method 100 comprises (the control circuitry 28) causing a current to flow in the heating element 34 to heat the heating element 34 to a second temperature in response to a stimulus, wherein the stimulus comprises one or more of a signal indicative of the connection of a cartridge 30 to the control unit 20, and a signal indicative of a user's intention to begin a session of usage.

In some examples, the control circuitry 28 is configured to maintain the heating element 34 at the second temperature prior to raising the temperature to the first temperature during an activation of the device 20 by a user (e.g. a puff), and / or the control circuitry 28 is configured to maintain the heating element 34 at the second temperature between activations of the device 20 by a user. In other words, the control circuitry 28 is configured to maintain the heating element 34 at the second temperature prior to raising the temperature to the first temperature in response to a signal indicating that a user is interacting with a user input element, and / or the control circuitry is configured to maintain the heating element 34 at the second temperature between signals indicating that a user is interacting with a user input element. By maintaining the temperature of the heating element 34 at the second temperature, the time taken to ramp the temperature up to the first temperature can be decreased, thereby leading to the quicker production of a vapor (if an aerosol generating substrate is present). As discussed above, a user input element may comprise one or more of a button, a capacitance sensor, a motion sensor, an optical sensor and a pressure sensor, or any other suitable input mechanism.

As such, in some examples, the method 100 comprises causing a current to flow in the heating element 34 to heat the heating element 34 from the second temperature to the first temperature in response to a signal indicating that a user is interacting with a user input element. For example, while the control circuitry 28 is causing a current to flow in the heating element to heat the heating element 34 to the second temperature, a user may press a button or inhale on the system 10, and the control circuitry 28 may switch to causing a current to flow in the heating element 34 to heat the heating element 34 from the second temperature to the first temperature.

In some examples, the control circuitry 28 is configured to perform step 115 (e.g. causing a current to flow in the heating element 34 to heat the heating element to a second temperature lower than the first temperature), after performing step 120 (causing a current to flow in the heating element to heat the heating element to a first temperature). In some examples, this is in addition to causing a current to flow in the heating element 34 to heat the heating element 34 to a second temperature that is a lower temperature than the first temperature prior to a first puff (e.g. in response to a stimulus).

As such, in some examples the method comprises maintaining the heating element 34 at the second temperature after a signal indicating that a user is interacting with the user input element has stopped, and / or between signals indicating that a user is interacting with the user input element.

In some examples, where the method comprises step 115, the method 100 additionally comprises a step 125 of Ceasing to cause a current to flow in the heating element 34 after a period of inactivity. The control circuitry 28 may be configured to maintain the heating element 34 at the second temperature for a period of time in response to a stimulus, and to cease causing a current to flow in the heating element 34 if an input from the user is not received before the end of the period of time. In other words, in some examples, the control circuitry is configured to cease causing a current to flow in the heating element 34 to maintain the heating element 34 at the second temperature after a period of inactivity. As above, the input (i.e. action indicating activity) may be a button press or a puff (measured by a puff sensor) indicating that the user is inhaling, or intends to inhale) on the system 10. In some examples, the period of inactivity is in the range of 10 seconds to 120 seconds. In some examples, the period of inactivity is in the range of between 20 seconds to 60 seconds. The method 100 may, in some examples, end after step 125.

When the method 100 ends, the system 10 may enter a standby mode or a low power sleep mode. For example, after step 120 or after step 125, the control circuitry 28 may enter a standby mode where the control circuitry 28 periodically interrogates any user input elements for indications that the user is inhaling or intending to inhale on the device (or for other interactions relation to control of the system such as checking battery levels, changing heater temperature and turning off or resetting the device). In some examples, if no user inputs are received for a period of time (e.g. 5 to 10 minutes), the control circuitry 28 may turn the system 10 off or place the system 10 in a low power sleep mode.

In some examples, there is a connection mechanism 58 (e.g. as described in relation tofigure 8) configured to retain a cartridge 30 as part of the aerosol delivery system 10. The method can additionally comprise engaging and disengaging the connection mechanism 58, wherein the connection mechanism 58 is electronically operable (e.g. by the control circuitry 28). In some examples, the connection mechanism 58 connects different portions of a mouthpiece 50 which define a cavity 51, the connection mechanism 58 connects a mouthpiece 50 to the control unit 20 and/or the induction assembly 40 (a cavity 51 for the cartridge 30 being provided by one or more of the mouthpiece 50, control unit 20 and induction assembly 40), or the connection mechanism 58 connects the cartridge directly to the control unit 20 and/or the induction assembly 40 (e.g. there is no separate mouthpiece 50).

In some examples, the method 100 further comprises (not shown) engaging a connection mechanism 58 configured to retain a cartridge as part of an aerosol delivery system, and disengaging the connection mechanism. By disengaging the connection mechanism, a user is able to remove and / or attach a cartridge 30 (e.g. by inserting a cartridge 30 into a cavity 51). By implementing such a connection mechanism 58 a risk to a user of injury or a risk of damage to the surroundings can be reduced, because disabling or disengaging the connection mechanism can delay the user from removing the cartridge for a few seconds; in which time the heating element 34 can cool to a lower temperature.

In some examples, the method comprises engages the connection mechanism 58 in response to the control circuitry 28 determining that a cartridge has been attached to the system. In some examples, the method comprises engages the connection mechanism 58 in response to the control circuitry 28 receiving an input from a user indicating the connection mechanism 58 should be engaged. For example the connection mechanism 58 may be engaged in response to a first activation of the aerosol delivery system 10.

In some examples, the method comprises disengaging the connection mechanism 58 in response to the control circuitry 28 receiving an input from a user indicating the connection mechanism 58 should be disengaged (e.g. a button press or combination of button presses). In some examples, the method comprises disengaging the connection mechanism 58 in response to the control circuitry 28 entering a standby mode or a low power sleep mode. In some examples, the method comprises disengaging the connection mechanism 58 in response to the control circuitry 28 ceasing to drive the induction element 42 after a period of inactivity. In some examples, the method comprises disengaging the connection mechanism 58 in response to the control circuitry 28 determining that an amount of time has passed since a last activation (e.g. the time since the control circuitry 28 caused the susceptor to be heated to the first temperature). In some of these examples, the amount of time since a last activation may be in the range of 2 to 10 seconds or 3 to 5 seconds. In some examples, the method comprises disengaging the connection mechanism 58 in response to the control circuitry 28 determining that the heating element 34 is below a threshold temperature.

Thus, there has been described a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate. The cartridge is configured to connect and disconnect with a control unit of the aerosol delivery system via an interface. The cartridge comprises a heating element configured to aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element, the heating element providing at least a portion of a cartridge interface surface. The cartridge interface surface is configured to be adjacent to a control unit interface surface when the cartridge and the control unit are connected via the interface.

There has also been described a mouthpiece for use in an aerosol delivery system. The mouthpiece is configured to retain a cartridge in accordance with the first aspect in a cavity. The mouthpiece comprises: an outlet for the aerosol delivery system; and an opening mechanism configured to allow the mouthpiece to be moved between a first configuration and a second configuration. In the first configuration the cavity is at least partially exposed in order to allow a cartridge to be inserted and / or removed. In the second configuration the mouthpiece is configured to retain a cartridge provided within the cavity.

There has further been described an induction assembly for use with a cartridge in accordance with the first aspect. The induction assembly comprising: an induction element operable to induce current flow in a heating element of the cartridge to inductively heat the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element. The induction assembly provides at least a portion of a control unit interface surface. The induction element is provided adjacent to the control unit interface surface.

There has further been described a control unit for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate. The control unit comprising: the induction assembly of the third aspect; a power supply for supplying power to the induction element; and control circuitry for controlling the supply of power to the induction element. The control circuitry is configured to drive the induction element to induce current flow in a heating element to inductively heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element.

There has further been described an aerosol delivery system for generating an aerosol from an aerosol generating substrate. The aerosol delivery system comprising: the cartridge of the first aspect; the control unit of the fourth aspect, wherein an air pathway is provided between the cartridge interface surface and the control unit interface surface;

There has further been described a method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system, the aerosol delivery system comprising a cartridge and a control unit, wherein the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; and the control unit comprises a control unit interface surface. The method comprising: connecting the cartridge with the control unit via an interface, wherein the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected via the interface; causing a current to flow in the heating element to heat the heating element so as to vaporise a portion of the aerosol generating substrate in the vicinity of the heating element.

As noted, a heating element in accordance with the disclosure can be a susceptor for inductive heating or a resistive heater for heating of a liquid aerosol generating material, as described with regard to cartridges shown inFigures 1 and4 to 7. In some other examples, a heating in accordance with the disclosure may be used for heating of an alternate aerosol generating material such as a gel aerosol generating material (e.g. a thermo-reversible gel).

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

Furthermore, there is a great degree of flexibility in the design/configuration of the aerosol provision system as a whole, as is exemplified at least by the various possibilities of features as outlined in the set of clauses following this paragraph. For the avoidance of any doubt, it will be commensurately appreciated that any features from these clauses may be combined as required in any combination beyond those as expressly set out in these clauses, noting the great flexibility and interchangeability in the usage of such features which the present disclosure clearly provides for.

Clauses

Clause 1. A cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate, the cartridge configured to connect and disconnect with a control unit of the aerosol delivery system via an interface, the cartridge comprising:

a heating element configured to aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element, the heating element providing at least a portion of a cartridge interface surface;
wherein the cartridge interface surface is configured to be adjacent to a control unit interface surface when the cartridge and the control unit are connected via the interface.

Clause 2. The cartridge of any clause 1, wherein the heating element comprises a planar surface providing at least the portion of the cartridge interface surface.

Clause 3. The cartridge of any preceding clause, wherein the cartridge comprises a spacer protruding outwardly from the cartridge interface surface.

Clause 4. The cartridge of clause 3, wherein the spacer protrudes outwardly from the cartridge interface surface by a distance in the range of 0.3 mm to 2 mm.

Clause 5. The cartridge of any preceding clause, wherein the heating element comprises a capillary structure configured to wick a liquid aerosol generating substrate.

Clause 6. The cartridge of an preceding clause, wherein the heating element comprises a plurality of apertures extending through the heating element.

Clause 7. The cartridge of clause 6, wherein the plurality of apertures are arranged in a pattern, the density of the plurality of apertures varying from a peripheral edge of the portion of the cartridge interface surface towards a centre of the portion of the cartridge interface surface.

Clause 8. The cartridge of clause 7, wherein the density of the plurality of apertures increases from a peripheral edge of the portion of the cartridge interface surface towards a centre of the portion of the cartridge interface surface.

Clause 9. The cartridge of any preceding clause, wherein the cartridge comprises a reservoir for a liquid aerosol generating substrate, wherein the cartridge is configured to supply liquid from the reservoir to the heating element.

Clause 10. The cartridge of clause 9, wherein the cartridge comprises a liquid transport element configured to wick the liquid aerosol generating substrate towards the heating element.

Clause 11. The cartridge of clause 10, wherein the liquid transport element is formed of a susceptor material.

Clause 12. The cartridge of any of clauses 9 to 11, wherein the reservoir is a first reservoir for a first liquid aerosol generating substrate, and wherein the cartridge comprises a second reservoir for a second liquid aerosol generating substrate, the cartridge is configured to supply liquid from the second reservoir to a second portion of the heating element.

Clause 13. The cartridge of clause 12, wherein the cartridge comprises the first liquid aerosol generating substrate and the second liquid aerosol generating substrate, wherein the first liquid aerosol generating substrate is different to the second liquid aerosol generating substrate.

Clause 14. The cartridge of any preceding clause, wherein the heating element comprises a resistive track provided on the cartridge interface surface.

Clause 15. The cartridge of any of clauses 1 to 13, wherein the heating element comprises a susceptor.

Clause 16. The cartridge of clause 15, wherein the susceptor is formed of a material having a capillary structure configured to wick the liquid aerosol generating substrate.

Clause 17. The cartridge of clause 16, wherein the susceptor is formed of one of a wire wool, mesh or metal foam.

Clause 18. The cartridge of clause 17, wherein the susceptor comprises a nickel foam or a cupro-nickel foam.

Clause 19. The cartridge of clause 18, wherein the susceptor comprises a stainless steel mesh.

Clause 20. The cartridge of any of clauses 15 to 19, wherein the susceptor comprises a planar element, the planar element having a thickness in the range of one or more of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm.

Clause 21. The cartridge of clause 18, wherein the planar element comprises a sheet or foil.

Clause 22. The cartridge of clause 20 or clause 21, wherein the planar element comprises one or more of mild steel, ferritic stainless steel, aluminium, nickel, cupro-nickel, and nichrome.

Clause 23. The cartridge of any preceding clause, where the cartridge comprises a removable cover adjacent to the portion of the cartridge interface surface.

Clause 24. The cartridge of any preceding clause, wherein the cartridge is configured to provide a mouthpiece for a user to inhale an aerosol generated from an aerosol-generating substrate.

Clause 25. A mouthpiece for use in an aerosol delivery system, wherein the mouthpiece is configured to retain a cartridge in accordance with any of clauses 1 to 23 in a cavity, the mouthpiece comprising an outlet for the aerosol delivery system.

Clause 26. The mouthpiece of clause 25, wherein the mouthpiece comprises an opening mechanism configured to allow the mouthpiece to be moved between a first configuration and a second configuration, wherein in the first configuration the cavity is at least partially exposed in order to allow a cartridge to be inserted and / or removed, and wherein in the second configuration the mouthpiece is configured to retain a cartridge provided within the cavity.

Clause 27. The mouthpiece of clause 26, wherein the mouthpiece comprises at least a component of an connection mechanism, wherein the connection mechanism is configured to retain the mouthpiece in the second configuration.

Clause 28. The mouthpiece of clause 27, wherein the connection mechanism is user actuatable such that a user can interact directly with the connection mechanism to inhibit the connection mechanism from retaining the mouthpiece in the second configuration.

Clause 29. An induction assembly for use with a cartridge in accordance with any of clauses 1 to 24, the induction assembly comprising:

an induction element operable to induce current flow in a heating element of the cartridge to inductively heat the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element,
wherein the induction assembly provides at least a portion of a control unit interface surface, wherein the induction element is provided adjacent to the control unit interface surface.

Clause 30. The induction assembly of clause 29, wherein the induction assembly comprises a support structure configured to retain the induction element.

Clause 31. The induction assembly of clause 30, wherein the support structure provides the portion of the control unit interface surface.

Clause 32. The induction assembly of clause 29 or 30, wherein the induction assembly comprises a barrier layer providing the portion of the control unit interface surface.

Clause 33. The induction assembly of clause 32, wherein the barrier layer comprises a coating on the surface of the induction element.

Clause 34. The induction assembly of any of clauses 29 to 33, wherein the induction element is formed from a resistive wire.

Clause 35. The induction assembly of any of clauses 29 to 33, wherein the induction element comprises one or more conductive layers deposited upon a support structure.

Clause 36. The induction assembly of clause 35, wherein the one or more conductive layers comprise a metal or a metal alloy.

Clause 37. The induction assembly of clause 36, wherein the one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminium, platinum, tungsten or zinc.

Clause 38. The induction assembly of any of clauses 34 to 37, wherein the induction element comprises a flat spiral coil.

Clause 39. The induction assembly of any of clauses 34 to 37, wherein the induction element comprises a pair of adjacent counter rotating coils in a single plane.

Clause 40. The induction assembly of clauses 29 to 39, wherein the induction assembly comprises a ferrite shield, wherein the ferrite shield is positioned adjacent to the induction element on an opposite side of the induction element to the control unit interface surface.

Clause 41. The induction assembly of clauses 29 to 40, wherein the induction element is a first induction element and wherein the induction assembly comprises a second induction element;

wherein the first induction element is provided adjacent to a first portion of the control unit interface surface, wherein the first induction element is operable to induce current flow in the first portion of the heating element of the cartridge to inductively heat the first portion of the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the first portion of the heating element; and
wherein the second induction element is provided adjacent to a second portion of the control unit interface surface, wherein the second induction element is operable to induce current flow in the second portion of the heating element of the cartridge to inductively heat the second portion of the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the second portion of the heating element.

Clause 42. The induction assembly of clause 41, wherein the first induction element and the second induction element comprise counter rotating coils.

Clause 43. A control unit for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate, the control unit comprising:

the induction assembly of any of clauses 29 to 42;
a power supply for supplying power to the induction element; and
control circuitry for controlling the supply of power to the induction element, wherein the control circuitry is configured to drive the induction element to induce current flow in a heating element to inductively heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element.

Clause 44. The control unit of clause 43, wherein the induction assembly is releasably attached to the control unit.

Clause 45. The control unit of clause 43 or 44, wherein the control circuitry is configured to drive the induction element to induce current flow in the heating element to inductively heat the heating element to a first temperature so as to vaporise the portion of the aerosol generating substrate in the vicinity of the heating element, and wherein the control circuitry is configured to drive the induction element to induce current flow in a heating element to inductively heat the heating element to a second temperature which is lower than the first temperature and lower than a temperature required to vaporise the portion of the aerosol generating substrate in the vicinity of the heating element.

Clause 46. The control unit of clause 45, wherein the second temperature is a temperature in the range of 80°C to 200°C.

Clause 47. The control unit of clause 45 or 46, wherein the control circuitry is configured to drive the induction element to induce current flow in the heating element to inductively heat the heating element to a second temperature in response to a stimulus, wherein the stimulus comprises one or more of a signal indicative of the connection of a cartridge to the induction assembly and / or control unit, and a signal indicative of a user's intention to begin a session of usage.

Clause 48. The control unit of any of clauses 45 to 47, wherein the control circuitry is configured to drive the induction element to induce current flow in the heating element to inductively heat the heating element from the second temperature to the first temperature in response to a signal indicating that a user is interacting with a user input element.

Clause 49. The control unit of clause 48, wherein the control circuitry is configured to maintain the heating element at the second temperature after a signal indicating that a user is interacting with the user input element has stopped, and / or between signals indicating that a user is interacting with the user input element.

Clause 50. The control unit of clause 48 or 49, wherein the control unit comprises the user input element, the user input element comprising one or more of a button, a capacitance sensor, a motion sensor, an optical sensor and a pressure sensor.

Clause 51. The control unit of any of clauses 45 to 50, wherein the control circuitry is configured to cease driving the induction element to induce current flow in the heating element to maintain the heating element at the second temperature after a period of inactivity.

Clause 52. The control unit of clause 51, wherein the period of inactivity is in the range of 10 seconds to 120 seconds.

Clause 53. An aerosol delivery system for generating an aerosol from an aerosol generating substrate, the aerosol delivery system comprising:

the cartridge of clause 24, or the cartridge of any of clauses 1 to 23 and, optionally, the mouthpiece of any of clauses 25 to 28; and
the control unit of any of clauses 43 to 52, wherein an air pathway is provided between the cartridge interface surface and the control unit interface surface.

Clause 54. The aerosol delivery system of clause 53, wherein the separation distance of the cartridge interface surface and the control unit interface surface is in the range of 0.3 mm to 2 mm.

Clause 55. The aerosol delivery system of clause 54, wherein the separation distance of the cartridge interface surface and the control unit interface surface is in the range of 0.5 mm to 1.5 mm.

Clause 56. A method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system, the aerosol delivery system comprising a cartridge and a control unit, wherein the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; and the control unit comprises a control unit interface surface, the method comprising:

connecting the cartridge with the control unit via an interface, wherein the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected via the interface;
causing a current to flow in the heating element to heat the heating element so as to vaporise a portion of the aerosol generating substrate in the vicinity of the heating element.

Clause 57. The method of clause 56, wherein causing a current to flow in the heating element to heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element comprises:

driving an induction element to induce current flow in the heating element to inductively heat the heating element;
wherein the heating element comprises a susceptor, and wherein the control unit comprises an induction assembly providing the portion of the control unit interface surface, the induction assembly comprising the induction element operable to induce current flow in the heating element of the cartridge to inductively heat the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element, wherein the induction element is provided adjacent to the control unit interface surface.

Clause 58. The method of clause 56, wherein causing a current to flow in the heating element to heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element comprises:

supplying current through a resistive track between respective portions of the resistive track;
wherein the heating element comprises the resistive track provided on the portion of the cartridge interface surface, and wherein the control unit comprises a pair of electrical contacts configured to provide an electrical connection with respective portions of the resistive track when the cartridge and the control unit are connected via the interface.

Clause 59. The method of any of clauses 56 to 58, wherein the method comprises causing a current to flow in the heating element to heat the heating element to a first temperature so as to vaporise the portion of the aerosol generating substrate in the vicinity of the heating element, and wherein the method further comprises causing a current to flow in the heating element to heat the heating element to a second temperature which is lower than the first temperature and lower than a temperature required to vaporise the portion of the aerosol generating substrate in the vicinity of the heating element.

Clause 60. The method of clause 59, wherein the second temperature is a temperature in the range of 80°C to 200°C.

Clause 61. The method of clause 59 or 60, wherein the method comprises causing a current to flow in the heating element to heat the heating element to a second temperature in response to a stimulus, wherein the stimulus comprises one or more of a signal indicative of the connection of a cartridge to the control unit, and a signal indicative of a user's intention to begin a session of usage.

Clause 62. The method of any of clauses 59 to 61, wherein the method comprises causing a current to flow in the heating element to heat the heating element from the second temperature to the first temperature in response to a signal indicating that a user is interacting with a user input element.

Clause 63. The method of clause 62, wherein the method comprises maintaining the heating element at the second temperature after a signal indicating that a user is interacting with the user input element has stopped, and / or between signals indicating that a user is interacting with the user input element.

Clause 64. The method of any of clauses 59 to 63, wherein the method comprises causing a current to flow in the heating element ceasing to maintain the heating element at the second temperature, and ceasing to cause a current to flow in the heating element to maintain the heating element at the second temperature after a period of inactivity.

Clause 65. The method of clause 64, wherein the period of inactivity is in the range of 10 seconds to 120 seconds.

Clause 66. The method of any of clauses 59 to 65, wherein the method comprises engaging a connection mechanism configured to retain a cartridge as part of an aerosol delivery system, and disengaging the connection mechanism, wherein the connection mechanism is electronically operable.

Claims

A cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate, the cartridge configured to connect and disconnect with a control unit of the aerosol delivery system via an interface, the cartridge comprising:
a heating element configured to aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element, the heating element providing at least a portion of a cartridge interface surface;
wherein the cartridge interface surface is configured to be adjacent to a control unit interface surface when the cartridge and the control unit are connected via the interface.
The cartridge of claim 1, wherein the heating element comprises a planar surface providing at least the portion of the cartridge interface surface.
The cartridge of any preceding claim, wherein the cartridge comprises a spacer protruding outwardly from the cartridge interface surface; and optionally, wherein the spacer protrudes outwardly from the cartridge interface surface by a distance in the range of 0.3 mm to 2 mm.
The cartridge of any preceding claim, wherein the heating element comprises a plurality of apertures extending through the heating element.
The cartridge of claim 4, wherein the plurality of apertures are arranged in a pattern, the density of the plurality of apertures varying from a peripheral edge of the portion of the cartridge interface surface towards a centre of the portion of the cartridge interface surface; and optionally, wherein the density of the plurality of apertures increases from a peripheral edge of the portion of the cartridge interface surface towards a centre of the portion of the cartridge interface surface.
The cartridge of any preceding claim, wherein the heating element comprises a resistive track provided on the cartridge interface surface.
The cartridge of any of claims 1 to 5, wherein the heating element comprises a susceptor; and optionally, wherein the susceptor comprises a planar element having a thickness in the range of one or more of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm.
The cartridge of any preceding claim, where the cartridge comprises a removable cover adjacent to the portion of the cartridge interface surface.
A mouthpiece for use in an aerosol delivery system, wherein the mouthpiece is configured to retain a cartridge in accordance with any of claims 1 to 8 in a cavity, wherein the mouthpiece comprises:
an outlet for the aerosol delivery system; and
an opening mechanism configured to allow the mouthpiece to be moved between a first configuration and a second configuration, wherein in the first configuration the cavity is at least partially exposed in order to allow a cartridge to be inserted and / or removed, and wherein in the second configuration the mouthpiece is configured to retain a cartridge provided within the cavity; and optionally,
at least a component of an connection mechanism, wherein the connection mechanism is configured to retain the mouthpiece in the second configuration.
An induction assembly for use with a cartridge in accordance with any of claims 1 to 8, the induction assembly comprising:
an induction element operable to induce current flow in a heating element of the cartridge to inductively heat the heating element and so aerosolise a portion of the aerosol generating substrate in the vicinity of the heating element,
wherein the induction assembly provides at least a portion of a control unit interface surface, wherein the induction element is provided adjacent to the control unit interface surface.
The induction assembly of claim 10, wherein the induction element comprises a pair of adjacent counter rotating coils in a single plane.
A control unit for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate, the control unit comprising:
the induction assembly of claim 10 or 11;
a power supply for supplying power to the induction element; and
control circuitry for controlling the supply of power to the induction element, wherein the control circuitry is configured to drive the induction element to induce current flow in a heating element to inductively heat the heating element and so vaporise a portion of the aerosol generating substrate in the vicinity of the heating element.
An aerosol delivery system for generating an aerosol from an aerosol generating substrate, the aerosol delivery system comprising:
the cartridge of any of claims 1 to 8;
the control unit of claim 12, wherein an air pathway is provided between the cartridge interface surface and the control unit interface surface; and optionally
the mouthpiece of claim 9.
The aerosol delivery system of claim 13, wherein the separation distance of the cartridge interface surface and the control unit interface surface is in the range of 0.3 mm to 2 mm; and optionally wherein the separation distance of the cartridge interface surface and the control unit interface surface is in the range of 0.5 mm to 1.5 mm.
A method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system, the aerosol delivery system comprising a cartridge and a control unit, wherein the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; and the control unit comprises a control unit interface surface, the method comprising:
connecting the cartridge with the control unit via an interface, wherein the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected via the interface;
causing a current to flow in the heating element to heat the heating element so as to vaporise a portion of the aerosol generating substrate in the vicinity of the heating element.