WO2025186536A1

WO2025186536A1 - Aerosol provision systems, devices and methods

Info

Publication number: WO2025186536A1
Application number: PCT/GB2025/050340
Authority: WO
Inventors: Dean Cowan; Hongqiang LIU; Xiaofeng Xu; Guangnan ZOU
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-08
Filing date: 2025-02-21
Publication date: 2025-09-12
Anticipated expiration: 2026-09-08
Also published as: WO2025186536A8

Abstract

An aerosol provision device (2) for generating an aerosol from an aerosol-generating material for user inhalation, the aerosol provision device (2) comprising: an air hole (28) for air to enter or exit the aerosol provision device (2) during use; an inhalation sensor (16) for detecting user inhalation; and a channel (60) defined within the aerosol provision device (2) to provide fluid communication between the air hole (28) and the inhalation sensor (16), wherein the channel (60) comprises a first channel part (62) and a second channel part (64) held together to form the channel (60).

Description

AEROSOL PROVISION SYSTEMS, DEVICES AND METHODS

FIELD

The present disclosure relates to aerosol provision systems and devices.

BACKGROUND

Aerosol provision systems, such as electronic cigarettes (e-cigarettes) and tobacco-heating products, generally contain an aerosol-generating material, such as a source liquid or a tobacco rod, which may contain an active substance and / or a flavour, from which an aerosol or vapour is generated for inhalation by a user, for example through heat vaporisation or other means. Thus, an aerosol provision system will typically comprise an aerosol generator, such as a heater, arranged to vaporise or aerosolise a portion of aerosolgenerating material to generate a vapour or aerosol in an aerosol generation chamber.

When a user inhales on the system, air is drawn into the system through an air inlet and into the aerosol generation chamber where the air mixes with vaporised precursor material to form a condensation aerosol that is then drawn out of the system for user inhalation.

Many aerosol provision systems comprise an inhalation sensor for detecting when a user is inhaling on the system. The inhalation sensor will typically be housed in a cavity of a sensor housing having an opening coupled to an airflow path in the system so that changes in pressure when a user inhales on the system are communicated to the inhalation sensor. Signalling from the inhalation sensor may be used to actuate the aerosol generator and I or may be used to track usage.

SUMMARY

According to a first aspect of the disclosure there is provided an aerosol provision device for generating an aerosol from an aerosol-generating material for user inhalation, the aerosol provision device comprising: an air hole for air to enter or exit the aerosol provision device during use; an inhalation sensor for detecting user inhalation; and a channel defined within the aerosol provision device to provide fluid communication between the air hole and the inhalation sensor, wherein the channel comprises a first channel part and a second channel part held together to form the channel.

According to a second aspect of the disclosure there is provided a system comprising an aerosol provision device according to the first aspect of the disclosure and the aerosolgenerating material.

According to a third aspect of the disclosure there is provided a method of manufacturing an aerosol provision device for generating an aerosol from an aerosol-generating material for user inhalation, the method comprising: providing an air hole for air to enter or exit the aerosol provision device during use; providing an inhalation sensor for detecting user inhalation; and coupling a first channel part to a second channel part to provide a channel within the aerosol provision device to provide fluid communication between the air hole and the inhalation sensor.

In accordance with some examples, the first channel part and the second channel part may meet at an interface that extends in the same direction as the channel.

In accordance with some examples, the channel may have multiple branches to channel air from multiple holes to the inhalation sensor.

In accordance with some examples, the first channel part may extend in the same direction as the channel and have the form of a channel that is open on one side. The first channel part may in some examples be substantially U-shaped in cross-section.

In accordance with some examples, the second channel part may extend in the same direction as the channel and comprise a substantially planar surface.

In accordance with some examples, at least one of the first channel part and the second channel part may comprise a resilient material.

In accordance with some examples, the first channel part and the second channel part may have different stiffnesses. The first channel part may in some examples have a lower stiffness than the second channel part.

In accordance with some examples, the first channel part and the second channel part may be held together using a mechanical coupling.

In accordance with some examples, the mechanical coupling may be a snap-fit coupling.

In accordance with some examples, the first channel part and the second channel part may be releasably connected to each other.

In accordance with some examples, at least one of the first channel part and the second channel part may have at least one rib arranged to facilitate an interference fit between the first channel part and the second channel part. The at least one rib may, for example, comprise a series of protrusions extending at least partially around a perimeter of the first channel part and I or the second channel part.

In accordance with some examples, the first channel part and the second channel part may be held together using an adhesive.

In accordance with some examples, the aerosol provision device may further comprise first and second side walls extending away from the second channel part and arranged to accommodate at least a portion of the first channel part between the first and second side walls.

The first and second side walls and the second channel part may in some examples be integrally formed.

In accordance with some examples, the aerosol provision device may comprise a cover part arranged to engage with the first and second side walls and so hold the first channel part and the second channel part together I hold the first channel part against the second channel part.

The cover part may in some examples be arranged to engage with the first and second side walls with a mechanical coupling, for example a snap-fit coupling.

In some examples, the cover part may be integrally formed with the first channel part.

In accordance with some examples, the aerosol provision device may comprise a rechargeable power supply and charging circuitry for recharging the rechargeable power supply, wherein the charging circuitry and the inhalation sensor may be provided on a common circuit board assembly.

In accordance with some examples, the air hole and the inhalation sensor may be spaced apart. In some examples, the air hole and the inhalation sensor may be located towards opposite ends of the aerosol provision device. That is to say, the air hole may be located towards a first end of the aerosol provision device (i.e. the air hole is nearer to the first end of the aerosol device that it is to the second end of the aerosol device), and the inhalation sensor may be located towards a second end of the aerosol provision device (i.e. the inhalation sensor is nearer to the second end of the aerosol device that it is to the first end of the aerosol device).

In some examples, the aerosol provision device may comprise an electrical connection port for connecting an external power supply to the aerosol provision device, wherein the electrical connection port may be located towards the same end of the aerosol provision device (i.e. be in the same half of the device) as the inhalation sensor. In some examples, the aerosol provision device may comprise an interface for coupling with an article comprising the aerosol-generating material located towards the same end of the aerosol provision device (i.e. be in the same half of the device) as the air hole.

In accordance with some examples, the channel may be arranged to provide a sealed interface with the inhalation sensor.

In accordance with some examples, the inhalation sensor may comprise a pressure sensor for detecting pressure change during user inhalation. It will be appreciated that features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to, and may be combined with, embodiments of the invention according to other aspects of the invention as appropriate, and not just in the specific combinations described above.

BRIEF DESCRIPTION OF THE DRAWINGS

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

Figure 1 schematically represents an aerosol provision system according to some embodiments of the disclosure;

Figure 2 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some embodiments of the disclosure;

Figure 3 is a schematic cross-section view of the channel arrangement of the aerosol provision system taken at line I indicated in Figure 2;

Figure 4 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some other embodiments of the disclosure;

Figure 5 is a schematic cross-section view of the channel arrangement of the aerosol provision system taken at line III indicated in Figure 4;

Figure 6 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some further embodiments of the disclosure;

Figure 7 is a schematic cross-section view of the channel arrangement of the aerosol provision system taken at line IV indicated in Figure 6;

Figure 8 is a schematic cross-section view of the channel arrangement of the aerosol provision system taken at line II indicated in Figure 2 in accordance with some embodiments of the disclosure;

Figure 9, 10, 11 are schematic cross-section views of the first channel part in Figure 8 with alternative geometries;

Figures 12a to 12c respectively show schematic perspective 3D views of a second channel part, a first channel part and a cover part in accordance with some embodiments of the disclosure;

Figures 13a and 13b respectively shows schematic perspective 3D views the second channel part of Figure 12a and the first channel part of Figure 12b assembled together, and the second channel part of Figure 12a, the first channel part of Figure 12b and the cover part of Figure 12c assembled together; and Figures 14 and 15 show enlarged schematic views of the section marked as ‘A’ in Figure 1 in accordance with some further embodiments of the disclosure.

DETAILED DESCRIPTION

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

As used herein, the term “provision system” (which may also sometimes be referred to as a "delivery system") is intended to encompass systems that deliver / provide at least one substance to a user in use, and includes: non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosolgenerating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or 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 necessary. In some embodiments, the non- combustible aerosol provision system is a system for heating an aerosol-generating material, 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, gel and I or amorphous solid, and may or may not contain nicotine. In some embodiments, a hybrid system may, for example, comprise a liquid or gel aerosolgenerating 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, cartridges, or cartomizers throughout the disclosure, and these terms should be understood to be interchangeable herein. The "consumable" terminology reflects that this component will include material that is consumed during use. The consumable may be fully disposable and discarded in its entirety once the consumable material in the consumable has been consumed, or in other cases, the consumable material may be replenished after it has been consumed and the consumable retained for further use.

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.

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 aerosolgenerating 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 comprise one or more active constituents, one or more flavourants, one or more aerosol-former materials, and/or one or more other functional materials.

In some embodiments, the substance to be delivered may comprise 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, and I or 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.

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. 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 is 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 is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

As noted above, 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 eucalyptol, 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, gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

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

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

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

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

Thus, 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 (e.g. a wicking element), an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosolmodifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise a material heatable by electrical conduction, or 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 aerosolmodifying 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. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased or decreased pressure, or electrostatic energy. As is common in the technical field, the terms "aerosol" and "vapour", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably.

Aerosol provision systems often, though not always, comprise a modular assembly comprising a reusable device part and a replaceable (disposable/consumable) cartridge part. For systems that have a liquid aerosol-generating material, the consumable I cartridge will sometimes comprise a reservoir of the liquid aerosol-generating material and the aerosol generator (although the aerosol generator can in other examples be in the device), and for systems that have a solid aerosol-generating material, the consumable/cartridge will sometimes comprise a cigarette-like tobacco rod which is heated by a heater (aerosol generator) in the device (although the aerosol generator can in other examples be, at least in part, in the consumable, such as in the form of a susceptor (heating element) in a tobacco rod).

If a consumable comprises the aerosol-generating material and the vaporiser I atomizer I aerosol generator, it may sometimes be referred to as a ‘cartomizer’. The reusable device part may comprise the power supply (e.g. rechargeable power source) and control circuitry. It will be appreciated these different parts may comprise further elements depending on functionality. For example, the reusable device part will often comprise a user interface for receiving user input and displaying operating status characteristics, and the replaceable consumable device part in some cases comprises a temperature sensor for helping to control temperature. Consumables are often electrically and mechanically coupled to the control unit for use, for example using a screw thread, bayonet, or magnetic coupling with appropriately arranged electrical contacts, but in other examples a consumable may not include a mechanical coupling (e.g. it may simply be located in a predefined position for use - such as for a tobacco rod consumable) and I or may not include an electrical coupling (e.g. power may be transferred wirelessly, such as with induction heating, or by thermal conduction, or the aerosol generator might not be powered electrically or it might be located in the reusable device part). When the aerosol-generating material in a consumable is exhausted, or the user wishes to switch to a different consumable having a different aerosolgenerating material, the consumable may be removed from the reusable part (device) and a replacement consumable (cartridge) attached in its place. Systems conforming to this type of two-part modular configuration may generally be referred to as two-part systems. Aerosol provision systems may alternatively comprise a single unit which does not comprise a consumable part and separate reusable device part configured to be detachably coupled together by a user. Such an aerosol provision system may be referred to as a ‘single part’ aerosol provision system or device. In such a system I device, which may be intended to be disposed of after a supply of electrical power in a battery and / or a supply of aerosolgenerating material supplied with the system I device is exhausted, without refilling or recharging the device, components including a reservoir of aerosol-generating material, an aerosol generator, a power supply (e.g. a battery), and control circuitry, may all be housed within a single housing. Such an aerosol provision system or device may be referred to as ‘disposable’.

It is common for electronic cigarettes to have a generally elongate shape. For the sake of providing a concrete example, certain embodiments of the disclosure will be taken to comprise this kind of generally elongate two-part system employing disposable consumables. However, it will be appreciated that the underlying principles described herein may equally be adopted for different configurations, for example single-part systems or modular systems comprising more than two parts, refillable devices and single-use disposables, as well as other overall shapes, for example based on so-called box-mod high performance devices that typically have a boxier shape. More generally, it will be appreciated certain embodiments of the disclosure are based on aerosol provision systems which are operationally configured to provide new functionality in accordance with the principles described herein, and other constructional aspects of the systems configured to provide the new functionality are not of primary significance.

Figure 1 is a cross-sectional view through an example aerosol provision system 100 in accordance with certain embodiments of the disclosure. The system 100 comprises two main components, namely a device part 2 and a consumable part 4. The device part 2 may alternatively be referred to as a reusable part I control unit I aerosol provision device, and so on, and the consumable part 4 may alternatively be referred to as a replaceable part I disposable part I cartridge I cartomizer, and so on. The device part 2 and consumable part 4 together may be referred to as a system (e.g. an aerosol provision system I aerosol delivery system). The fact this example is a two-part device is not in itself directly significant to the system's functionality as described further herein.

In normal use the device 2 and the consumable 4 are releasably coupled together at an interface 6. When the consumable is exhausted or the user simply wishes to switch to a different consumable, the consumable may be removed from the device and a replacement consumable attached to the device in its place. The interface 6 provides a structural, electrical and airpath connection between the two parts and may be established in accordance with conventional techniques, for example based around a screw thread, latch mechanism, magnetic, friction or bayonet fixing, with appropriately arranged electrical contacts and openings for establishing the electrical connection and airflow path between the two parts as appropriate. The specific manner in which the consumable 4 couples to the device 2 is not significant to the principles described herein, but for the sake of a concrete example is assumed here to comprise a resilient latch mechanism, for example with a portion of the consumable being received in a corresponding receptacle in the device with cooperating latch engaging elements (not represented in Figure 1). It will also be appreciated the interface 6 in some implementations may not support an electrical connection between the respective parts. For example, in some implementations a vaporiser may be provided by the device rather than in the consumable, or the transfer of electrical power from the device to the consumable may be wireless (e.g. based on electromagnetic induction), so that an electrical connection between the device and the consumable is not needed.

The consumable 4 may in accordance with certain embodiments of the disclosure be broadly conventional. In Figure 1 , the consumable 4 comprises a consumable housing 42 formed of a plastics material. The consumable housing 42 supports other components of the consumable and provides the mechanical interface 6 with the device 2. The consumable housing in this example is generally circularly symmetric about a longitudinal axis along which the consumable couples to the device 2. In this example, the consumable has a length of around 4 cm and a diameter of around 2 cm. However, it will be appreciated the specific geometry, and more generally the overall shapes and materials used, may be different in different implementations.

Within the consumable housing 42 is a reservoir 44 that contains a liquid aerosol-generating material (vapour precursor material). The liquid aerosol-generating material may be conventional, and may be referred to as e-liquid. The liquid reservoir 44 in this example has an annular shape with an outer wall defined by the consumable housing 42 and an inner wall 58 that defines an airflow path 52 through the consumable 4. The reservoir 44 is closed at each end with end walls to contain the e-liquid. The reservoir 44 may be formed in accordance with conventional techniques, for example, it may comprise a plastics material and be integrally moulded with the consumable housing 42.

The consumable 4 further comprises a wick 46 and an aerosol generator (vaporiser) 48 in the form of a heater located, in this example, towards an end of the reservoir 44 opposite to a mouthpiece outlet 50. In this example, the wick 46 extends transversely across the consumable airflow path 52 with its ends extending into the reservoir 44 of e-liquid through openings in the inner wall of the reservoir 44. The openings in the inner wall of the reservoir 44 are sized to broadly match the dimensions of the wick 46 to provide a reasonable seal against leakage from the liquid reservoir into the consumable airflow path without unduly compressing the wick, which may be detrimental to its fluid transfer performance.

The wick 46 and aerosol generator 48 are arranged in the consumable airflow path 52 such that a region of the consumable airflow path 52 around the wick 46 and aerosol generator 48 in effect defines an aerosol generating region or vaporisation region for the consumable. The e-liquid in the reservoir 44 infiltrates the wick 46 through the ends of the wick extending into the reservoir 44 and is drawn along the wick by surface tension I capillary action (i.e. wicking). The aerosol generator 48 in this example comprises an electrically resistive wire coiled around the wick 46. In this example the aerosol generator 48 comprises a nickel chrome alloy (Cr20Ni80) wire and the wick 46 comprises a glass fibre bundle, but it will be appreciated the specific aerosol generator configuration is not significant to the principles described herein. For example, in some cases the aerosol generator may comprise a resistive heater track that is deposited on a porous ceramic block in fluid communication with the reservoir of liquid aerosol-generating material.

In use electrical power may be selectively, e.g. in response to detecting user inhalation, supplied to the aerosol generator 48 to vaporise an amount of e-liquid (aerosol-generating material) that is drawn to the vicinity of the aerosol generator 48 by the wick 46. Vaporised e- liquid may then become entrained in air drawn along the consumable airflow path from the vaporisation region and out the mouthpiece outlet 50 for user inhalation.

The rate at which aerosol-generating material is vaporised by the aerosol generator (heater) 48 will typically depend on the amount (level) of power supplied to the aerosol generator 48 during use (among other things). Thus electrical power can be applied to the aerosol generator to selectively generate vapour from the aerosol-generating material in the consumable 4, and furthermore, the rate of vapour generation can be changed by changing the amount of power supplied to the aerosol generator 48, for example through pulse width and/or frequency modulation techniques.

The device 2 comprises an outer housing 12 with an opening that defines an air inlet 28 for the system, a battery 26 for providing operating power, control circuitry 20 for controlling and monitoring the operation of the system, a user input button 14, an inhalation sensor (puff detector) 16, which in this example comprises a pressure sensor 16 located in a pressure sensor housing 18, and a visual display 24. The pressure sensor is configured to detect pressure change during user inhalation.

The outer housing 12 may be formed, for example, from a plastics or metallic material and in this example has a circular cross-sectional area generally conforming to the shape and size of the consumable 4 so as to provide a smooth transition between the two parts at the interface 6. In this example, the device has a length of around 6 cm so the overall length of the system when the consumable and device are coupled together is around 10 cm. However and as already noted, it will be appreciated that the overall shape and scale of a device implementing an embodiment of the disclosure is not significant to the principles described herein.

The air inlet 28 connects to an airflow path 30 through the device 2 and allows air to enter the device 2 during use. The device airflow path 30 in turn connects to the consumable airflow path 52 across the interface 6 when the device 2 and consumable 4 are connected together. The pressure sensor housing 18 containing the pressure sensor 16 is in fluid communication with the airflow path 30 in the device 2 (i.e. the pressure sensor housing 18 is on a branch from the airflow path 30 in the device 2). Thus, when a user inhales on the mouthpiece opening 50, there is a drop in pressure in the pressure sensor housing 18 that may be detected by the pressure sensor 16 and also air is drawn in through the air inlet 28, along the device airflow path 30, across the interface 6, through the vapour generation region in the vicinity of the aerosol generator 48 (where vaporised aerosol-generating material becomes entrained in the airflow when the aerosol generator is active), along the consumable airflow path 52, and out through the mouthpiece opening 50 for user inhalation. The battery 26 in this example is rechargeable and may be of a conventional type, for example of the kind normally used in systems and other applications requiring provision of relatively high currents over relatively short periods. In some implementations, the device 2 may comprise charging circuitry for recharging the rechargeable power source such as a rechargeable battery. The charging circuitry and the inhalation sensor may be provided on a common circuit board assembly (PCB) 31. The charging circuitry may be powered through a charging connector 22 in the device housing 12, for example a USB connector.

In some implementations, the air inlet 28 and the inhalation sensor 16 may be spaced apart within the device 2. For example, the air inlet 28 and the inhalation sensor 16 may be located towards opposite ends of the aerosol provision device 2 - that is to say, they may be located on opposite sides of a midpoint along the length of the device I in different halves of the device. Put another way, the air inlet may be nearer to the end of the aerosol device that couples to the consumable 4 than it is to the other end, and the inhalation sensor may be further from the end of the aerosol device that couples to the consumable 4 than it is from the other end. In some examples, the aerosol provision device 2 may comprise an electrical connection port or charging connector 22 for connecting an external power supply (not represented in Figure 1) to the aerosol provision device 2. In these examples, the electrical connection port may be located towards the same end of the aerosol provision device 2 as the inhalation sensor 16.

The user input button 14 in this example is a conventional mechanical button, for example comprising a spring mounted component which may be pressed by a user to establish an electrical contact. In this regard, the input button may be considered to provide a manual input mechanism for the terminal device, but the specific manner in which the button is implemented is not significant. For example, different forms of mechanical button or touch- sensitive button (e.g. based on capacitive or optical sensing techniques) may be used in other implementations. The specific manner in which the button is implemented may, for example, be selected having regard to a desired aesthetic appearance.

The display 24 is provided to give a user with a visual indication of various characteristics associated with the system, for example current power setting information, remaining battery power, and so forth. The display may be implemented in various ways. In this example the display 24 comprises a conventional pixilated LCD screen that may be driven to display the desired information in accordance with conventional techniques. In other implementations the display may comprise one or more discrete indicators, for example LEDs, that are arranged to display the desired information, for example through particular colours and I or flash sequences. More generally, the manner in which the display is provided and information is displayed to a user using the display is not significant to the principles described herein. Some embodiments may not include a visual display and may include other means for providing a user with information relating to operating characteristics of the system, for example using audio signalling or haptic feedback, or may not include any means for providing a user with information relating to operating characteristics of the system.

The control circuitry 20 is suitably configured I programmed to control the operation of the system in line with established techniques for controlling such devices. The control circuitry (processor circuitry) 20 may be considered to logically comprise various sub-units I circuitry elements associated with different aspects of the system's operation in accordance with the principles described herein and other conventional operating aspects of systems, such as display driving circuitry and user input detection. It will be appreciated the functionality of the control circuitry 20 can be provided in various different ways, for example using one or more suitably programmed programmable computer(s) and I or one or more suitably configured application-specific integrated circuit(s) I circuitry I chip(s) I chipset(s) configured to provide the desired functionality.

The control circuitry 20 is configured to receive signalling from the inhalation sensor 16 and to use this signalling to determine if a user is inhaling on the system and control the operation of the device 2, for example to supply power to the aerosol generator accordingly. This aspect of the operation of the system (i.e. the processing of signals from the inhalation sensor 16) may be performed in accordance with established techniques.

Although the example of Figure 1 is a two-part system, in other embodiments the aerosol provision system 100 may comprise a single-part device in which a power source, control circuitry, atomiser I aerosol generator, and aerosol-generating material may be provided in a single housing. It will be understood that aspects of the present disclosure not relating to the interface between the reusable device part 2 and a consumable part 4 apply equally for single-part device embodiments.

It will be appreciated that in a two-part device such as shown in the example of Figure 1 , the aerosol generator may be in either of the device part 2 or the consumable part 4. For example, an aerosol generator (e.g. a heater) may be located in the reusable device part and brought into proximity with a portion of aerosol-generating material in the consumable part when the consumable is engaged with the reusable device part. In some examples the aerosol generator may be in effect split across the device part and the consumable part. For example the aerosol generator may comprise an inductive drive coil in the device part that is configured to electromagnetically couple with a susceptor (heating element) within the consumable. As noted above, the reusable device part 2 comprises an inhalation sensor 16 which is electrically connected to the control circuitry 20. The inhalation sensor 16 may be referred to as a “puff sensor”, in that the inhalation sensor 16 is used to detect when a user is puffing on the system.

In some embodiments, the inhalation sensor may comprise a switch in an electrical path providing electrical power from the battery 26 to the aerosol generator 48. In such embodiments, the inhalation sensor 16 generally comprises a pressure sensor configured to close the switch when subjected to a particular level, or change in level, of pressure. Thus current can be supplied from the power source 26 to the aerosol generator 48 if the pressure in the vicinity of the inhalation sensor 16 drops below a threshold value or there is a downward change in pressure by more than a threshold value within a given time, depending on the specific implementation of the processing of the inhalation sensor signalling. In any event, a suitable threshold value can be empirically determined during a design phase for the system so as to correspond to a characteristic value associated with the initiation of a user puff. In other embodiments, rather than using a simple switch, the control circuitry 20 may be arranged to control the supply electrical power from the power source 26 to the aerosol generator 48 so that the amount of power depends on signal received from the inhalation sensor 16 by the control circuitry 20. However, as noted above, the specific manner in which the signal output from the inhalation sensor 16 (which may include a measure of capacitance, resistance or other characteristic of the inhalation sensor depending on its underlying technology) is used by the control circuitry 20 to control the supply of power from the battery 26 to the aerosol generator 48 can be carried out in accordance with any approach known to the skilled person.

In the example shown in Figure 1, the inhalation sensor 16 is mounted to a printed circuit board (PCB) 31 as described further herein, but this may not be the case in other examples. The inhalation sensor 16 may comprise any sensor which is able to detect when a user is inhaling on the system, for example the inhalation sensor 16 may be a pressure sensor or transducer (for example a membrane or solid-state pressure sensor), and may be a combined temperature and pressure sensor. In this example the inhalation sensor 16 is a microphone-type inhalation sensor (for example an electret-type microphone), which is sensitive to changes in air pressure. The inhalation sensor 16 is situated within the pressure sensor housing 18, and as noted above, the inhalation sensor 16 in this example is mounted to the PCB 31, and the PCB 31 in effect comprises a wall of the sensor housing 18.

For an aerosol provision system of the kind shown in Figure 1 , there can be constraints on where components can be placed within the system, for example resulting from a desire to achieve a particular external profile or from a desire to simplify the construction. As a consequence, it is possible that the inhalation sensor 16 may need to be located remotely from the air inlet 28 so that a dedicated channel is needed to provide for fluid communication between the inhalation sensor and the air inlet 28 so that the inhalation sensor 16 can respond to a drop in pressure when a user inhales on the system.

In the example of Figure 1 , the inhalation sensor 16 and the charging connector 22 are mounted to a common printed circuit board 31 , but the charging connector 22 is not adjacent to the air inlet 28. As a result the inhalation sensor 16 is spaced apart from the air inlet 28, and an air channel 60 is provided to provide fluid communication between the inhalation sensor 16 and the air inlet 28.

The channel 60 is defined, at least in part, by a first channel part 62 and a second channel part 64 held together to form the channel 60 as described further herein. By providing the channel in two separate parts, some of the limitations on the potential shapes for the channel that can arise for a one-part moulding can be overcome.

In the example shown in Figure 1 , the air inlet 28 is approximately halfway along the system 100 and generally towards one end of the device 2. The inhalation sensor 16, on the other hand, is disposed generally towards the other end of the device 2. The channel 60 in the device 2 provides fluid communication between the sensor housing 18 (containing the inhalation sensor 16) and the air inlet 28. As such, a pressure drop in the airflow path 30 through the device 2 resulting from a user inhaling on the mouthpiece opening 50 is transferred via the channel 60 to the sensor housing 18 and detected by the inhalation sensor 16. The channel 60 therefore enables user-inhalation to be detected with the inhalation sensor 16 disposed in the device 2 remotely (i.e. spaced apart) from the air inlet 28.

Figure 2 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some embodiments of the disclosure. Only a portion of the reusable part 2 of the aerosol provision system 100, proximal to the channel 60, is shown in Figure 2. Figure 3 is a schematic cross-section view of the channel arrangement of the aerosol provision system 100 taken at line I indicated in Figure 2.

As noted above, the channel 60 comprises a first channel part 62 and a second channel part 64. The first channel part 62 and the second channel part 64 meet at an interface 65 that extends in the same direction as the channel and the two parts are held together at this interface to form the channel 60. It has been recognized that by providing the channel 60 in two separate parts, manufacturing complexity can be reduced and design freedom can be increased for the channel 60, and hence for the aerosol provision device 2, for example in terms of the path the channel 60 follows within the device 2. In some implementations, the first channel part 62 and the second channel part 64 may be releasably connected to one another, for example to facilitate the cleaning, repairing or replacement of channel parts 62, 64.

The first channel part 62 is shaped to define an open channel (i.e. open on one side) that extends in the direction of the channel 60. Thus the first channel part 62 may be generally U-shaped in cross-section as seen in Figure 3 (the U-shape being upside down in this orientation). In this regard the first channel part 62 may be considered to form, for the orientation shown in Figures 2 and 3, an upside down trench extending along the channel 60. The first channel part 62 may be made from a resilient (i.e. compressible) material, and in this example is formed from silicone, although other resilient material may be used in other examples.

The second channel part 64 is formed from a plastics material and in that sense the second channel part 64 and the first channel part 62 have different stiffnesses, with, in this example, the first channel part 62 having a lower stiffness than the second channel part 64. The second channel part 64 includes a substantially planar surface extending in the same direction as the channel 60. First and second side walls 67 are integrally formed with the second channel part 64 so they extend away from the substantially planar surface of the second channel part 64 to form a receptacle for receiving at least a portion of the first channel part 62, as seen in Figure 3.

Thus, when the first channel part 62 and the second channel part 64 are assembled together, and as can be seen in Figure 3, the generally planar surface of the second channel part 64 meets the first channel part 62 at an interface 65 to seal the open side of the open channel provided by the first channel part 62, thereby forming the closed channel 60.

In this example the first channel part 62 and the second channel part 64 are held together, at least in part, by an interference fit caused by friction between the outer walls of the first channel part 62 and the sidewalls 67. The friction fit may be enhanced by the resilience of first channel part 62. For example, the first and second side walls 67 may be separated by a distance that is less than the width of the first channel part 62 so that when the resilient first channel part 62 is inserted into the space between the side walls 67 it will be in slight compression, thereby providing increased friction. In some cases the first channel part 62 may be provided with ribs 63 to enhance the interference fit between the first channel part 62 and the second channel part 64. If the ribs 63 are continuous, they may also help to provide an airtight seal between the first channel part 62 and side walls 67 to help with sealing the channel 60 from the interior of the device 2. More generally, at least one of the first channel part 62 and the second channel part 64 may include at least one rib 63 arranged to facilitate an interference fit between the first channel part 62 and the second channel part 64, and the at least one rib 63 may comprise series of protrusions extending at least partially around a perimeter (e.g. along a side) of the first channel part 62 and I or the second channel part 64.

As can be seen in Figure 3, the first channel part 62 in this example is provided with an overhang 61 along each of its edges which rests on the tops of the respective side walls 67. This can help with retaining the first channel part 62 in a desired position relative to the second channel part 64, and can also help with providing an air-tight seal for the channel 60. Indeed, in some cases the airtight seal for the channel 60 may be provided primarily by the overhang 61 and I or the ribs 63 such that the interface 65 between the first channel part 62 and the second channel part 64 does not itself form an airtight seal.

In other implementations, as discussed further below, the first channel part 62 and the second channel 64 part may be held together with a mechanical coupling, such as a snap-fit coupling. This may be instead of, or in addition to, providing for an interference fit between the first channel part 62 and the second channel part 64. In yet other examples, an adhesive may be used to hold the first channel part 62 and the second channel part 64 together. Again, this may be instead of, or in addition to, providing for an interference fit between the first channel part 62 and the second channel part 64, and indeed may be used with or without a mechanical coupling.

In the example of Figure 2, the channel 60 is generally L-shaped in the plane of the figure. A first end of the channel 60 (rightmost in Figure 2) forms a chamber 70 that is shaped to accommodate the sensor housing 18. A second end of the channel 60 (leftmost in Figure 2) couples to a nozzle section 68 that opens on to the airflow path 30 through the device so that pressure variations at the air inlet 28 are communicated via the nozzle section 68 to the channel 60, and ultimately to the inhalation sensor 16. The nozzle section 68 and the second channel part 64 may in some cases be integrally formed.

As noted above, the first channel part 62 is formed of a resilient material which is helpful for forming a sufficiently air-tight seal when the two channel parts 62, 64 are held together to form the channel 60. It will be appreciated, that in some examples the second channel part 64 may instead, or in addition, be formed of a resilient material to help with forming a seal between the two channel parts 62, 64 at their interface 65.

In some implementations, an end of the first channel part 62 shaped to accommodate the sensor housing 18 may be configured to comprise ribs 69 along an internal wall of the chamber 70. The resilient ribs 69 can thus help provide a sealing interference fit between the channel 60 and the sensor housing 18. Figure 4 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some further embodiments of the disclosure and Figure 5 is a schematic cross-section view of the channel arrangement of the aerosol provision system 100 taken at line III indicated in Figure 4. Elements and features of the arrangement represented in Figures 4 and 5 which are functionally similar to, and will be understood from, corresponding elements and features of the arrangement represented in Figures 2 and 3 are identified with corresponding reference numerals and are not discussed again in detail in the interests of brevity.

In the arrangement represented in Figures 4 and 5, the aerosol provision device comprises a cover part 66 that mechanically engages with the side walls 67 of the second channel part 64, in this example using snap-fit latches I tabs, so as to help hold the first channel part 62 and second channel part 64 together. Thus when the cover part 66 is engaged with the side walls 67, the first channel part is in effect sandwiched between the cover part 66 and the second channel part 64. The mechanical coupling between the cover part 66 and the side walls 67 may be a releasable coupling so the cover part 66, and hence also the first channel part 62, can be readily separated from the first channel part 62, for example to facilitate cleaning, repairing or replacement of the channel parts 62, 64 or cover part 66.

In the embodiment shown in Figures 4 and 5, the cover part 66 comprises a face portion 71, with tab portions 73 extending orthogonally from opposing edges of the face portion 71. The spacing of the tab portions 73 matches the separation of the side walls 67 of the second channel part 64, such that the planar tab portions 73 are aligned with, respectively, the outer surface of side walls 67. Latching elements 74 are provided on the side walls 67, which are shaped to engage corresponding latching elements 72 on the planar tab portions 73. The latching elements 72, 74 can comprise any geometry known to the skilled person, for example, an arrangement with lugs on a first one of the side walls 67 or cover part 66, which lock into matching recesses on a second one of the side walls 67 or cover part 66. For the sake of a concrete example, in Figure 5, a latching element 72 comprising a lug is shown on the outer surface of the side walls 67, into which a latching element 74 comprising a slot on the cover part 66 can be engaged. More than one pair of latching elements 72, 74 can be disposed on the side walls 67 and the tab portions 73 along the direction of the channel 60 to provide additional engagement and pressure at the interface 65 between the first channel part 62 and the second channel part 64. In some implementations, the cover part 66 and the first channel part 62 may be integrally formed to simplify the manufacturing and assembling process.

Figure 6 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some further embodiments of the disclosure and Figure 7 is a schematic cross-section view of the channel arrangement of the aerosol provision system 100 taken at line IV indicated in Figure 6. Elements and features of the arrangement represented in Figures 6 and 7 which are functionally similar to, and will be understood from, corresponding elements and features of the arrangements represented in Figures 2 to 5 are identified with corresponding reference numerals and are not discussed again in detail in the interests of brevity. In the configuration of Figures 6 and 7, the first channel part 62 and the second channel part 64 have cooperating interlocking features which may be used instead of, or in addition to the use of an interference fit and / or a cover part 66, to hold the two channel parts 62, 64 together.

Thus, as shown in the example of Figure 7, the second channel part 64 again has first and second side walls 167 extending away from a generally planar section to the second channel part 64 to form an open channel. However, in this example the sidewalls 167 do not form a space to receive the first channel part 62, but instead for walls for the channel 60 with the first channel part 62 arranged to sit on top of the side walls 167 so that an airtight seal is arranged at the interface 165 between the two channel parts 62, 64. The side walls 167 are provided with a rim portion 75 extending outwardly from the side walls 167. The first channel part 62 is again made from a resilient material and has a generally C-shape formed by a planar upper surface 76 and lips 77 along each edge arrange to clip over the rim portions 75 of the sidewalls 167 so as to hold the two channel parts 62, 64 together. When the first channel part 62 engages with the second channel part 64 in this way, the channel 60 is formed.

Figure 8 shows a schematic cross-section view of the channel arrangement of the aerosol provision system 100 taken at line II indicated in Figure 2 in accordance with some embodiments of the disclosure. In the cross-section of Figure 8, the channel 60 provided by the first and second channel parts 62, 64 follows a straight path. As noted above, the manufacture of a channel in this shape, and in other more complex shapes, can be facilitate using the disclosed approaches of forming a channel from two channel parts.

Figure 9 illustrates a schematic cross-section view of a first channel part 62 having an alternative, and more complex shape, as compared to that of Figure 8. In particular, the channel 60 provided by the first and second channel parts 62, 64 follows a path that has a right angle bend 78 to form a generally L-shaped channel. This may be desired, for example, in some implementations so that the channel 60 can route around other components in the device, and the approach of forming the channel from two separate channel parts allows this to be done in a simple and easy to manufacture way. Figure 10 illustrates a schematic cross-section view of a first channel part 62 having another alternative, and more complex shape, as compared to that of Figure 8. In particular, the channel 60 provided by the first and second channel parts 62, 64 follows a path that has two right angle bends 78 to form a generally zig-zag-shape. This may again be desired in some implementations so that the channel 60 can route around other components in the device, and as already noted, the approach of forming the channel from two separate channel parts allows this to be done in a simple and easy to manufacture way.

Figure 11 illustrates a schematic cross-section view of a first channel part 62 having another alternative, and more complex shape, as compared to that of Figure 8. The example of Figure 11 is in somewhat similar to the example of Figure 10 in comprising turns, but here the turns 79 are shallower than right angles. Yet again this may again be desired to allow the channel 60 to route around other components in the device 2.

Whilst various arrangements have been discussed above in relation to various schematic cross-sectional drawings, Figures 12a to 12c and Figures 13a and 13b schematically shows perspective 3D views of certain components to further aid an understanding of the relationship between the components.

Thus, Figure 12a shows an example of the second channel part 64, Figure 12b shows an example of the first channel part 62, and Figure 12c shows an example of the cover part 66. Figure 13a shows the second channel part 64 of Figure 12a and the first channel part 62 of Figure 12b assembled together, and Figure 13b shows the second channel part 64 of Figure 12a and the first channel part 62 of Figure 12b assembled together and with the cover part 66 of Figure 12c in positon.

There has also been described an aerosol provision device for generating an aerosol from an aerosol-generating material for user inhalation, the aerosol provision device comprising: an air inlet for air to enter the aerosol provision device during use; an inhalation sensor for detecting user inhalation; and a channel defined within the aerosol provision device to provide fluid communication between the air inlet and the inhalation sensor, wherein the channel comprises a first channel part and a second channel part held together to form the channel in combination with the aerosol forming substrate.

While the above description has largely focussed on configurations in which the channel extends between an inhalation sensor and an air hole for air to enter the device, i.e. an air inlet for the device, in other examples, such as discussed below, the channel extends between an inhalation sensor and an air hole for air to exit the device, i.e. an air outlet for the device. Figure 14 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some further embodiments of the disclosure. Elements and features of the arrangement represented in Figure 14 which are functionally similar to, and will be understood from, corresponding elements and features of the arrangements represented in Figures 2 to 7 are identified with corresponding reference numerals and are not discussed again in detail in the interests of brevity.

In the configuration of Figure 14, the air inlet 128 is arranged at the end of the aerosol provision device 2 opposite to the consumable 4, i.e. relatively closer to the inhalation sensor 16 compared to the examples discussed above. In the example of Figure 14, the air inlet 128 is arranged at an end wall 134 of the second channel part 64. An opening 132 is further arranged in the end of the first channel part 62 in a position that aligns with the air inlet 128 in the end wall 134 of the second channel part 64. In some implementations, the air channel 60 may be connected to multiple inlets 128 at the end of the device 2. The first channel part 62 may thus have multiple openings 132 corresponding to the positions of the multiple inlets 128. This can increase the amount of airflow into the device 2 and make it easier for the user to inhale on the system 100. Moreover, multiple air inlets having smaller diameters is more beneficial than a single air inlet with a larger diameter as the small air inlets can function as filter to prevent inhalation of dust particles and pollutants into the device 2, and particularly into the air channel 60.

When the user inhales on the mouthpiece opening of the consumable 4, air is drawn into the device 2 via the air inlet 128, travels through the airflow path 30 (represented by arrows in Figure 14) including the channel 60 and the nozzle section 68, and subsequently exits the device 2 at air hole 130. In the meantime, the user inhalation results in pressure drop which can be detected by the inhalation sensor 16 situated within the chamber 70.

Although Figure 14 illustrates an air inlet 128 arranged at the end of the device 2, it will be appreciated that the air inlet 128 may be disposed at any positions on the outer housing of the device along the air channel. In such cases, holes or openings can be configured on the bottom wall of the second channel part 64, or the side walls of the first and second channel parts 62, 64.

Figure 15 shows an enlarged schematic view of the section marked as ‘A’ in Figure 1 in accordance with some further embodiments of the disclosure. Elements and features of the arrangement represented in Figure 15 which are functionally similar to, and will be understood from, corresponding elements and features of the arrangements represented in Figures 2 to 7, and 14 are identified with corresponding reference numerals and are not discussed again in detail in the interests of brevity. In the example of Figure 15, the inhalation sensor 16 is disposed closer to midway between the air inlet 128 and air hole 130. A first air channel 160 is arranged to connect the chamber 70 to an air inlet 128. In addition, a second air channel 161 is arranged to connect the chamber 70 with the consumable 4 via the air hole 130, in a manner similar to the channel 60 in the embodiments described in Figures 2 to 7. The air inlet 128 is arranged at the end of the device 2 opposite to the consumable part, for example, at the end wall 134 of the second channel part 64.

The first air channel 160 and the second air channel 161 are respectively formed by the first and second channel parts 62, 64 in accordance with embodiments described in Figures 2 to 7. Specifically, the first channel part 62 may be substantially U-shaped in cross-section in the regions of the channels 160 and 161 , and the second channel part 64 may comprise a substantially planar surface. By means of mechanical coupling, adhesive or a cover part 66, the first channel part 62 and the second channel part 64 are held together to form the channels 160, 161. In the situation where the air inlet 128 is offset from the longitudinal axis of the nozzle section 68 and hence the second channel 161, an inclined first channel 160 may be configured to route the air path from the air inlet 128 to the second channel 161. For example, the first channel 160 may be formed by assembling a first channel part 62 having an inclined open channel and a second channel part 64 having a correspondingly ramped surface.

In some implementations, the first channel part 62 may be provided with ribs 169 to enhance the interference fit between the first channel part 62 and the second channel part 64.

The first channel part 62 and the second channel part 64 may be held together by mechanical coupling, adhesive, or a cover part 66 over the first channel 161, as in the embodiments illustrated by Figures 4 and 5. Additionally, the channel parts 62, 64 may be held together by a component, such as the charging port 22, pressing the first channel part 62 against the second channel part 64 over the region of the second channel 160.

In some implementations, the first channel 160 may be connected to multiple inlets 128 at the end of the device 2 to increase the airflow during user inhalation. Moreover, multiple air inlets 128 of smaller diameters can function as filter to prevent inhalation of dust particles and pollutants into the device 2, and particularly the air channels 160, 161.

When the user inhales on the mouthpiece opening of the consumable 4, air enters the device 2 via the air inlet 128, travels through the airflow path 30 (represented by arrows in Figure 15) which comprises the first channel 160, the second channel 161, the nozzle section 68, and subsequently exits the device 2 at air hole 130. In the meantime, air is sucked from the chamber 70 into the second channel 161, resulting in pressure drop which can be detected by the inhalation sensor 16 situated within the chamber 70.

In some respects, the arrangement of Figure 15 is very similar to the arrangement of Figure 14, except that there is a relatively longer air path between the air inlet 128 and the chamber 70 for the inhalation sensor 16. However, this relative longer air path between the air inlet 128 and the chamber 70 does not impact the manner in which the channel 161 between the inhalation sensor 16 and the air hole 130 (i.e. the air outlet for the device) can be arranged in accordance with the principles discussed above in relation to Figures 1 to 14.

Thus there has been described an aerosol provision device for generating an aerosol from an aerosol-generating material for user inhalation, the aerosol provision device comprising: an air hole for air to enter or exit the aerosol provision device during use; an inhalation sensor for detecting user inhalation; and a channel defined within the aerosol provision device to provide fluid communication between the air hole and the inhalation sensor, wherein the channel comprises a first channel part and a second channel part held together to form the channel.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. The delivery system described herein can be implemented as a combustible aerosol provision system, a non-combustible aerosol provision system or an aerosol-free delivery system.

Claims

1. An aerosol provision device for generating an aerosol from an aerosol-generating material for user inhalation, the aerosol provision device comprising: an air hole for air to enter or exit the aerosol provision device during use; an inhalation sensor for detecting user inhalation; and a channel defined within the aerosol provision device to provide fluid communication between the air hole and the inhalation sensor, wherein the channel comprises a first channel part and a second channel part held together to form the channel.

2. The aerosol provision device of claim 1, wherein the first channel part and the second channel part meet at an interface that extends in the same direction as the channel.

3. The aerosol provision device of claim 1 or 2, wherein the first channel part extends in the same direction as the channel and has the form of a channel that is open on one side.

4. The aerosol provision device of claim 3, wherein the first channel part is substantially U-shaped in cross-section.

5. The aerosol provision device of any of claims 1 to 4, wherein the second channel part extends in the same direction as the channel and comprises a substantially planar surface.

6. The aerosol provision device of any of claims 1 to 5, wherein at least one of the first channel part and the second channel part comprises a resilient material.

7. The aerosol provision device of any of claims 1 to 6, wherein the first channel part and the second channel part have different stiffnesses.

8. The aerosol provision device of claim 7, wherein the first channel part has a lower stiffness than the second channel part.

9. The aerosol provision device of any of claims 1 to 8, wherein the first channel part and the second channel part are held together using a mechanical coupling.

10. The aerosol provision device of claim 9, wherein the mechanical coupling is a snap-fit coupling.

11. The aerosol provision device of any of claims 1 to 10, wherein the first channel part and the second channel part are releasably connected to each other.

12. The aerosol provision device of any of claims 1 to 11, wherein at least one of the first channel part and the second channel part has at least one rib arranged to facilitate an interference fit between the first channel part and the second channel part.

13. The aerosol provision device of claim 12, wherein the at least one rib comprises a series of protrusions extending at least partially around a perimeter of the first channel part and I or the second channel part.

14. The aerosol provision device of any of claims 1 to 13, wherein the first channel part and the second channel part are held together using an adhesive.

15. The aerosol provision device of any of claims 1 to 14, further comprising first and second side walls extending away from the second channel part and arranged to accommodate at least a portion of the first channel part between the first and second side walls.

16. The aerosol provision device of claim 15, wherein the first and second side walls and the second channel part are integrally formed.

17. The aerosol provision device of claim 15 or 16, further comprising a cover part arranged to engage with the first and second side walls so as to hold the first channel part and the second channel part together.

18. The aerosol provision device of claim 17, wherein the cover part is arranged to engage with the first and second side walls with a mechanical coupling.

19. The aerosol provision device of claim 18, wherein the cover part is arranged to engage with the first and second side walls with a snap-fit coupling.

20. The aerosol provision device of any of claims 17 to 19, wherein the cover part and the first channel part are integrally formed.

21. The aerosol provision device of any of claims 1 to 20, wherein the air hole and the inhalation sensor are located towards opposite ends of the aerosol provision device.

22. The aerosol provision device of claim 21 , further comprising an interface for coupling with an article comprising the aerosol-generating material, wherein the interface is located towards the same end of the aerosol provision device as the air hole.

23. The aerosol provision device of any of claims 1 to 22, wherein the channel is arranged to provide a sealed interface with the inhalation sensor

24. The aerosol provision device of any of claims 1 to 23, wherein the inhalation sensor comprises a pressure sensor for detecting pressure change during user inhalation.

25. The aerosol provision device of any of claims 1 to 24, wherein the air hole is an air inlet for air to enter the device.

26. The aerosol provision device of any of claims 1 to 24, wherein the air hole is an air outlet for air to exit the device.

27. An aerosol provision system comprising the aerosol provision device of any of claims 1 to 26 and the aerosol-generating material.

28. A method of manufacturing an aerosol provision device for generating an aerosol from an aerosol-generating material for user inhalation, the method comprising: providing an air hole for air to enter or exit the aerosol provision device during use; providing an inhalation sensor for detecting user inhalation; and coupling a first channel part to a second channel part to provide a channel within the aerosol provision device to provide fluid communication between the air hole and the inhalation sensor.