Field of the Disclosure

The present disclosure relates to an aerosol delivery device and particularly, although not exclusively, an aerosol delivery device comprising a switching device configured to provide relative movement between an aerosol generator and an airflow passage. The present disclosure also relates to an aerosol delivery device and particularly, although not exclusively, an aerosol delivery device operable in a normal mode and a boost mode. The disclosure also relates to an aerosol delivery device and particularly, although not exclusively, to an aerosol delivery device comprising a supporting portion connecting a transfer element to a switch such that movement of the switch causes movement of the transfer element.

Background

A smoking-substitute device is an electronic device that permits the user to simulate the act of smoking by producing an aerosol mist or vapour that is drawn into the lungs through the mouth and then exhaled. The inhaled aerosol mist or vapour typically bears nicotine and/or other flavourings without the odour and health risks associated with traditional smoking and tobacco products. In use, the user experiences a similar satisfaction and physical sensation to those experienced from a traditional smoking or tobacco product, and exhales an aerosol mist or vapour of similar appearance to the smoke exhaled when using such traditional smoking or tobacco products.

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

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

Vaping smoking substitute devices can be configured in a variety of ways. For example, there are“closed system” vaping smoking substitute devices, which typically have a sealed tank and heating element. The tank is pre-filled with e liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute devices include a main body which includes the power source, wherein the main body is configured to be physically and electrically coupled to a consumable including the tank and the heating element. The consumable may also be referred to as a cartomizer. In this way, when the tank of a consumable has been emptied, that consumable is disposed of. The main body can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute devices are completely disposable, and intended for one-use only. There are also“open system” vaping smoking substitute devices which typically have a tank that is configured to be refilled by a user. In this way the device can be used multiple times.

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

For a smoking substitute device it is desirable to deliver nicotine into the user’s lungs, where it can be absorbed into the bloodstream. As explained above, in the so-called“vaping” approach,“e-liquid” is heated by a heating device to produce an aerosol vapour which is inhaled by a user. Many e-cigarettes also deliver flavour to the user, to enhance the experience. Flavour compounds are contained in the e- liquid that is heated. Heating of the flavour compounds may be undesirable as the flavour compounds are inhaled into the user’s lungs. Toxicology restrictions are placed on the amount of flavour that can be contained in the e-liquid. This can result in some e-liquid flavours delivering a weak and underwhelming taste sensation to consumers in the pursuit of safety.

In aerosol delivery devices, it is desirable to avoid large liquid droplets reaching a user’s mouth.

The present disclosure has been devised in light of the above considerations.

Summary

At its most general, the present disclosure relates to an aerosol delivery device comprising a switching device configured to provide relative movement between an aerosol generator and an airflow passage to vary a mass of first aerosol precursor per delivery event.

In a first aspect, there is provided an aerosol delivery device comprising an aerosol generator and a switching device, the aerosol generator comprising: an aerosol generator portion configured to receive an aerosol precursor; and an air flow passage configured to direct air past the aerosol generator portion to pick up the aerosol precursor from the aerosol generator portion to form an aerosol during a delivery event, wherein the switching device is configured to provide relative movement between the aerosol generator portion and the airflow passage to vary a mass of aerosol precursor per delivery event.

Optionally, the switching device may be configured to provide the relative movement to vary a surface area of the aerosol generator portion located in an aerosol generation region of the airflow passage and thereby vary the mass of aerosol precursor per delivery event. Advantageously, the switching device may be configured to provide the relative movement to vary a velocity of airflow past the aerosol generator portion and thereby vary the mass of aerosol precursor per delivery event.

Conveniently, the switching device may be configured to slide the aerosol generator portion to provide the relative movement.

Optionally, the aerosol delivery device may comprise a storage for storing the aerosol precursor.

Conveniently, the switching device may be further configured to slide the storage with the aerosol generator portion.

Advantageously, the switching device may be configured to provide a relative bias between the aerosol generator and the airflow passage towards a position in which the mass of aerosol precursor per delivery event is reduced.

Conveniently, the switching device may permit switching between a normal mode and a boost mode, wherein the aerosol generator is configured to: in the normal mode, produce aerosol comprising a first mass of aerosol precursor per delivery event; and in the boost mode, produce aerosol comprising a second mass of aerosol precursor per delivery event, wherein the second mass is greater than the first mass.

Optionally, the switching device may permit switching into an off mode, wherein in the off mode, the aerosol delivery device is configured not to produce aerosol during the delivery event.

Conveniently, the switching device may be configured to bias the aerosol generator from the boost mode towards the normal mode.

Advantageously, the switching device may permit continuous variation in mass of aerosol precursor per delivery event.

Conveniently, the aerosol generator may comprise a member, the member comprising the aerosol generator portion, wherein the member is configured to transfer the aerosol precursor to the aerosol generator portion.

Optionally, the aerosol may comprise a flavour component.

Advantageously, the aerosol may be sized to inhibit pulmonary penetration, and the aerosol is transmissible within at least one of a mammalian oral cavity and a mammalian nasal cavity.

Conveniently, the aerosol delivery device may be a consumable for a smoking substitute device.

Advantageously, the storage may comprise a reservoir, the reservoir formed of a first porous material.

Optionally, the storage may comprise a tank configured to store the first aerosol precursor as a free liquid.

Advantageously, the aerosol delivery device may be a consumable for a smoking substitute device. Conveniently, the aerosol delivery device may comprise an additional aerosol generator, the additional aerosol generator configured to produce an additional aerosol from an additional aerosol precursor during the delivery event.

Optionally, the additional aerosol generator may be configured to produce the additional aerosol comprising substantially the same mass of additional aerosol precursor per delivery event independently of the mass of aerosol precursor per delivery event.

Advantageously, the additional aerosol generator may be configured to heat the additional aerosol precursor to form the additional aerosol.

Conveniently, the second aerosol precursor may comprise an active component.

Optionally, the active component may be nicotine.

Advantageously, the additional aerosol may be sized for pulmonary penetration.

The present disclosure also relates to an aerosol delivery device which is switchable between: a normal mode in which an aerosol comprising a first mass of aerosol precursor is produced; and a boost mode in which an aerosol comprising a second mass of aerosol precursor is produced, wherein the second mass is greater than the first mass.

In a second aspect, there is provided an aerosol delivery device comprising: an aerosol generator configured to produce an aerosol from an aerosol precursor during a delivery event, wherein the aerosol comprises a flavour component; and a switching device permitting switching of the aerosol generator between a normal mode and a boost mode, wherein the aerosol generator is configured to: in the normal mode, produce aerosol comprising a first mass of aerosol precursor per delivery event; and in the boost mode, produce aerosol comprising a second mass of aerosol precursor per delivery event, wherein the second mass is greater than the first mass.

Optionally, the switching device may further permit switching of the aerosol generator into an off mode, wherein in the off mode, the aerosol generator is configured not to produce aerosol during the delivery event.

Advantageously, the switching device may permit continuous variation in mass of aerosol precursor per delivery event between the normal mode and the boost mode.

Conveniently, the switching device may be configured to bias the aerosol generator from the boost mode towards the normal mode.

Optionally, the switching device may comprise a sliding switching mechanism slidable to switch the aerosol generator between the normal mode and the boost mode.

Advantageously, the aerosol generator may comprise: an aerosol generator portion configured to receive the aerosol precursor; and an air flow passage configured to direct air past the aerosol generator portion to pick up the aerosol precursor from the aerosol generator portion to form the aerosol, wherein the switching device is configured to provide relative movement between the aerosol generator portion and the airflow passage to switch the aerosol generator between the normal mode and the boost mode.

Conveniently, the switching device may be configured to provide the relative movement to vary a surface area of the aerosol generator portion located in an aerosol generation region of the airflow passage to switch the aerosol generator between the normal mode and the boost mode.

Optionally, the switching device may be configured to provide the relative movement to vary a velocity of airflow past the aerosol generator portion to switch the aerosol generator between the normal mode and the boost mode.

Advantageously, the switching device may be configured to slide the aerosol generator portion to switch the aerosol generator between the normal mode and the boost mode.

Optionally, the aerosol delivery device may comprise a storage for storing the aerosol precursor.

Conveniently, the switching device may be further configured to slide the storage with the aerosol generator portion.

Advantageously, the switching device may be configured to provide a relative bias between the aerosol generator and the airflow passage towards the normal mode.

Optionally, the aerosol generator may comprise a member, the member comprising the aerosol generator portion, wherein the member is configured to transfer the aerosol precursor to the aerosol generator portion.

Optionally, the aerosol may comprise a flavour component.

Advantageously, the aerosol may be sized to inhibit pulmonary penetration, and the aerosol is transmissible within at least one of a mammalian oral cavity and a mammalian nasal cavity.

Conveniently, the aerosol delivery device may be a consumable for a smoking substitute device.

Advantageously, the storage may comprise a reservoir, the reservoir formed of a first porous material.

Optionally, the storage may comprise a tank configured to store the aerosol precursor as a free liquid.

Advantageously, the aerosol delivery device may be a consumable for a smoking substitute device.

Conveniently, the aerosol delivery device may comprise an additional aerosol generator, the additional aerosol generator configured to produce an additional aerosol from an additional aerosol precursor during the delivery event.

Optionally, the additional aerosol generator may be configured to produce the additional aerosol comprising substantially the same mass of additional aerosol precursor per delivery event independently of the mass of aerosol precursor per delivery event.

Advantageously, the additional aerosol generator may be configured to heat the additional aerosol precursor to form the additional aerosol.

Conveniently, the second aerosol precursor may comprise an active component. Optionally, the active component may be nicotine.

Advantageously, the additional aerosol may be sized for pulmonary penetration.

The present disclosure also relates to an aerosol delivery device comprising a supporting portion connecting a transfer element to a switch such that movement of the switch causes movement of the transfer element.

In a third aspect, there is provided aerosol delivery device comprising: a storage for storing an aerosol precursor; a transfer element for transferring aerosol precursor from the storage; a switch; and a supporting portion connecting the transfer element to the switch such that movement of the switch causes movement of the transfer element.

Such an aerosol delivery device can be used to easily transition from a deactivated to activated state whilst not hindering the flow of air through the aerosol delivery device. Further, by initially providing the aerosol delivery device in a deactivated state the risk of leakage can be minimised. The transfer element may be for transferring aerosol precursor from the storage to an aerosol generator. The switch may be referred to as an activation mechanism. The supporting portion may have the shape of an incomplete ring or collar, the transfer element being provided within the incomplete ring/collar and held therein through a friction fit. The supporting portion e.g. the ring/collar may be integrally formed with a mouthpiece of the aerosol delivery device.

Optionally, the aerosol delivery device may comprise a barrier arrangement for inhibiting flow of aerosol precursor from the storage, wherein the transfer element is movable with respect to the barrier arrangement to open the barrier arrangement so that the transfer element can transfer aerosol precursor from the storage on movement of the switch.

Advantageously, the aerosol delivery device may comprise an aerosol generator comprising an aerosol generator portion configured to receive the aerosol precursor from the transfer element; and an air flow passage configured to direct air past the aerosol generator portion to pick up the aerosol precursor from the aerosol generator portion to form an aerosol.

Conveniently, the aerosol delivery device may comprise a member, the member comprising the transfer element and the aerosol generator portion, wherein the member is movable from a first position to a second position to open the barrier arrangement.

Optionally, the member may be slidable from the first position to the second position to open the barrier arrangement.

Advantageously, the aerosol delivery device may comprise a mouthpiece and a body, wherein the mouthpiece is slidable relative to the body to provide the switch.

Conveniently, the barrier arrangement may be configured to open in response to sliding of the mouthpiece relative to the body.

Optionally, the barrier arrangement may be configured to remain permanently open after opening. Advantageously, the barrier arrangement may comprise a plug received in a tube, the plug configured to inhibit flow of aerosol precursor from the storage to the transfer element, wherein the plug is displaceable from the tube on movement of the transfer element so that the transfer element can transfer aerosol precursor from the storage.

Conveniently, the aerosol delivery device may comprise a guide for inhibiting return of the plug to the tube after the plug is displaced from the tube.

Optionally, the barrier arrangement may comprise a deformable barrier component, and the transfer element is configured to deform the barrier component to open the barrier arrangement.

Advantageously, the aerosol delivery device may comprise a pressure relief opening in the storage; and a blocking arrangement for inhibiting flow through the pressure relief opening, wherein the blocking arrangement is openable to permit air to flow through the pressure relief opening and into the storage as the storage empties of aerosol precursor.

Conveniently, the aerosol delivery device may be a consumable for a vaping device.

Optionally, the aerosol delivery device may comprise an additional aerosol generator, the additional aerosol generator configured to produce an additional aerosol from an additional aerosol precursor.

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

Summary of the Figures

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

Fig. 1 shows a schematic drawing of a smoking substitute system;

Fig. 2 shows a schematic drawing of a smoking substitute system;

Fig. 3 shows a schematic drawing of a smoking substitute system;

Fig. 4 shows a schematic drawing of a smoking substitute system;

Fig. 5 shows a cutaway view of a consumable;

Fig. 6 shows a cross-sectional view of a flavour pod portion of a consumable;

Fig. 7a shows a partial cutaway view of a consumable with an aerosol generator portion in a normal mode;

Fig. 7b shows a partial cutaway view of a consumable with an aerosol generator portion in a boost mode; Fig. 8 shows a cross-sectional view of a consumable in a deactivated state;

Fig. 9 shows a cross-sectional view of the consumable of Fig. 5 in an activated state; Fig. 10 a cross-sectional view of a flavour pod portion of a consumable;

Fig. 11a shows a top view of a flavour pod portion of a consumable; and

Fig. 11 b shows a cut away perspective view of a flavour pod portion of a consumable.

Detailed Description

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

Referring to Figures 1 and 2, there is shown a smoking substitute system comprising a smoking substitute device 100. The base unit 100 includes elements such as a battery, an electronic controller, and a pressure transducer. In this example, the substitute smoking system comprises a cartomiser 101 and a flavour pod 102. The cartomiser 101 may engage with the smoking substitute device 100 via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. A cartomiser may also be referred to as a“pod”. The smoking substitute system may be an aerosol delivery device according to the present disclosure.

The flavour pod 102 is configured to engage with the cartomiser 101 and thus with the substitute smoking device 100. The flavour pod 102 may engage with the cartomiser 101 via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. Fig. 2 illustrates the cartomiser 101 engaged with the substitute smoking device 100, and the flavour pod 102 engaged with the cartomiser 101 . As will be appreciated, in this example, the cartomiser 101 and the flavour pod 102 are distinct elements. Each of the cartomiser 101 and the flavour pod may be an aerosol delivery device according to the present disclosure.

As will be appreciated from the following description, the cartomiser 101 and the flavour pod 102 may alternatively be combined into a single component that implements the functionality of the cartomiser 101 and flavour pod 102. Such a single component may also be an aerosol delivery device according to the present disclosure. In other examples, the cartomiser may be absent, with only a flavour pod 102 present.

A“consumable” component may mean that the component is intended to be used once until exhausted, and then disposed of as waste or returned to a manufacturer for reprocessing.

Referring to Figures 3 and 4, there is shown a smoking substitute system comprising a smoking substitute device 100 and a consumable 103. The consumable 103 combines the functionality of the cartomiser 101 and the flavour pod 102. In Figure 3, the consumable 103 and the smoking substitute device 100 are shown separated from one another. In Figure 4, the consumable 103 and the smoking substitute device 100 are engaged with each other.

Referring to Figures 5 and 8, there is shown a consumable 103 engaged (in Figure 5) or engageable (Figure 8) with a smoking substitute device 100 via a push-fit engagement. The consumable 103 may be considered to have two portions - a cartomiser portion 104 and a flavour pod portion 105, both of which are located within a single component (as in Figures 3 and 4).

The consumable 103 includes an upstream airflow inlet 106 and a downstream airflow outlet 107. In other examples a plurality of inlets and/or outlets are included. Between and fluidly connecting the inlet 106 and the outlet 107 there is an airflow passage 108. The outlet 107 is located at the mouthpiece 109 of the consumable 103, and is formed by a mouthpiece aperture.

As above, the consumable 103 includes a flavour pod portion 105. The flavour pod portion 105 is configured to generate a first (flavour) aerosol for output from the outlet 107 of the mouthpiece 109 of the consumable 103. The flavour pod portion 105 of the consumable 103 includes a liquid transfer element int eh form of a member 1 15. The member 1 15 acts as a passive aerosol generator (i.e. an aerosol generator which does not use heat to form the aerosol, also referred to as an“aerosol generator” and a “first aerosol generator”), and is formed of a porous material. The member 1 15 comprises a supporting portion 1 17, which is located inside a housing, and an aerosol generator portion 1 18, which is located in the airflow passage 108. In this example, the aerosol generator portion 1 18 is a porous nib.

When activated, as discussed in more detail below, a first storage 1 16 (in this example a tank) for storing an aerosol precursor (i.e.“first aerosol precursor”, which is a flavour liquid) is fluidly connected to the member 1 15. The porous nature of the member 1 15 means that flavour liquid from the first storage 1 16 is drawn into the member 1 15. As the first aerosol precursor in the member 1 15 is depleted in use, further flavour liquid is drawn from the first storage 1 16 into the member 1 15 via a wicking action.

Before activation, the barrier arrangement 120 (see Figure 8) is closed and inhibits evaporation of aerosol precursor. In this example, this is achieved by the barrier arrangement inhibiting flow of aerosol precursor from the first storage 1 16 to the member 1 15. In order to inhibit flow of aerosol precursor, the barrier arrangement 120 substantially isolates the first storage 1 16 from the member 1 15. In this example, the barrier arrangement comprises a plug 120 (preferably formed from silicon) located at one end of a tube 122 containing the member 1 15 close to the first storage 1 16. In other examples, the plug may be replaced by a deformable and/or breakable barrier component, e.g. any one of: a duck bill valve; a split valve or diaphragm; or a sheet of foil, which may be pierced by the member 1 15 when opening the barrier arrangement.

The first storage 1 16 further includes a pressure relief opening 132, which in the deactivated state is sealed by blocking arrangement. In this example, the blocking arrangement comprises a pierceable cover (preferably made from foil). Piercing member 130, which is formed as a part of the mouthpiece 109 and may take the form of a blade, pierces the pierceable cover and opens the pressure relief opening 132 when the consumable is moved to the activated state (as is discussed in more detail below). This means that opening of the barrier arrangement also effects opening of the blocking arrangement.

As described above, the aerosol generator portion 1 18 is located within the airflow passage 108 through the consumable 103. The aerosol generator portion 1 18 therefore constricts or narrows the airflow passage 108. The aerosol generator portion 1 18 occupies some of the area of the airflow passage, resulting in constriction of the airflow passage 108. The airflow passage 108 is narrowest adjacent to the aerosol generator portion 1 18. Since the constriction results in increased air velocity and corresponding reduction in air pressure at the aerosol generator portion 1 18, the constriction is a Venturi aperture 1 19. The constriction is generally toroidal in shape, and may include one or more intersections where supports contact the aerosol generator portion 1 18.

The cartomiser portion 104 of the consumable 103 includes a second storage 1 10 (in this example a tank) for storing a second aerosol precursor (i.e. e-liquid, which may contain nicotine). Extending into the second storage 1 10 is a wick 1 1 1 . The wick 1 1 1 is formed from a porous wicking material (e.g. a polymer) that draws second aerosol precursor from the second storage 1 10 into a central region of the wick 1 1 1 that is located outside the e-liquid storage tank 1 10.

A heater 1 12 is a configured to heat the central region of the wick 1 1 1 . The heater 1 12 includes a resistive heating filament that is coiled around the central region of the wick 1 1 1 . The wick 1 1 1 , the heater 1 12 and the e-liquid storage tank 1 10 together act as an active aerosol generator (i.e. an aerosol generator which uses heat to form the aerosol, also referred to as an“additional aerosol generator” and a “second aerosol generator”).

As described above, the first and second aerosol generators are both at least partially located within the airflow passage 108, with the first aerosol generator downstream (with respect to air flow in use) of the second aerosol generator.

So that the consumable 103 may be supplied with electrical power for activation of the heater 1 12, the consumable 103 includes a pair of consumable electrical contacts 1 13. The consumable electrical contacts 1 13 are configured for electrical connection to a corresponding pair of electrical supply contacts 1 14 in the smoking substitute device 100. The consumable electrical contacts 1 13 are electrically connected to the electrical supply contacts 1 14 when the consumable 103 is engaged with the smoking substitute device 100. The smoking substitute device 100 includes an electrical power source (not shown), for example a battery.

Figure 9 shows the consumable 103 of Figure 8 in an activated state, like features are indicated by like reference numerals. To transition from the deactivated state to the activated state, mouthpiece 109 is moved along a central axis 150 towards cartomizer portion 104 (e.g. one along which the consumable extends, and along which member 1 15 extends). Moving the mouthpiece 109 in this way effects relative movement between the liquid transfer element (i.e. the member 1 15) and the barrier arrangement. This causes the barrier arrangement to open. In other examples, an activation switch is provided on an outer portion of the consumable for opening the barrier arrangement.

The mouthpiece 109, via supporting portion 1 17, is fixed to the member 1 15 and therefore member 1 15 moves with the mouthpiece 109. The mouthpiece 109, and member 1 15, is moved relative to the tank 1 16. This causes displacement of the plug 120 and opening of the barrier arrangement 1 16. The supporting portion 1 17 may be integrally formed with the mouthpiece 109. This helps facilitate assembly and also provides better concentricity with the member 1 15.

At the same time, movement of the mouthpiece 109 causes the piercing member 130 to contact and pierce pressure relief opening 132, thereby fluidly connecting the airflow passage 108 to an interior of the first storage 1 16. This permits air to flow into the first storage 1 16 as the first storage empties of aerosol precursor in use.

In the present example, once the barrier arrangement is open, the plug 120 is unconstrained within the first storage. However, in other cases, the plug 120 may be received by a guide for inhibiting return of the plug to the closed position after displacement of the plug. The guide may comprise a recess for receiving the plug 120.

In the present example, the barrier arrangement remains permanently open after opening, as the plug 120 does not return to the tube 122. However, in other examples, the barrier arrangement is selectively openable and closable by the user. This may be achieved by the plug (or another type of barrier arrangement) being fixed to an end portion of the member 1 15, such that the member 1 15 is selectively exposable to the first storage 1 16.

Once activated, and, in use, a user draws (or“sucks”, or“pulls”) on the mouthpiece 109 of the consumable 103, which causes a drop in air pressure at the outlet 107, thereby generating air flow through the inlet 106, along the airflow passage 108, out of the outlet 107 and into the user’s mouth.

When the heater 1 12 is activated (by passing an electric current through the heating filament in response to the user drawing on the mouthpiece 109) the e-liquid located in the wick 1 1 1 adjacent to the heating filament is heated and vaporised to form a vapour. The vapour condenses to form the second aerosol within the airflow passage 108. Accordingly, the second aerosol is entrained in an airflow along the airflow flow passage 108 to the outlet 107 and ultimately out from the mouthpiece 109 for inhalation by the user when the user 10 draws on the mouthpiece 109.

The substitute smoking device 100 supplies electrical current to the consumable electrical contacts 1 13. This causes an electric current flow through the heating filament of the heater 1 12 and the heating filament heats up. As described, the heating of the heating filament causes vaporisation of the e-liquid in the wick 1 1 1 to form the second aerosol.

As the air flows up through the airflow passage 108, it encounters the aerosol generator portion 1 18. The constriction of the airflow passage 108 caused by the aerosol generator portion 1 18 results in an increase in air velocity and corresponding decrease in air pressure in the airflow in the vicinity of the porous surface 1 18 of the aerosol generator portion 1 15. The corresponding low pressure region causes the generation of the first (flavour) aerosol from the porous surface 1 18 of the aerosol generator portion 1 18. The first (flavour) aerosol is entrained into the airflow and ultimately is output from the outlet 107 of the consumable 103 and thus from the mouthpiece 109 into the user’s mouth.

The first aerosol is sized to inhibit pulmonary penetration. The first aerosol is formed of particles with a mass median aerodynamic diameter that is greater than or equal to 15 microns, in particular, greater than 30 microns, more particularly greater than 50 microns, yet more particularly greater than 60 microns, and even more particularly greater than 70 microns.

The first aerosol is sized for transmission within at least one of a mammalian oral cavity and a mammalian nasal cavity. The first aerosol is formed by particles having a maximum mass median aerodynamic diameter that is less than 300 microns, in particular less than 200 microns, yet more particularly less than 100 microns. Such a range of mass median aerodynamic diameter will produce aerosols which are sufficiently small to be entrained in an airflow caused by a user drawing air through the flavour element and to enter and extend through the oral and or nasal cavity to activate the taste and/or olfactory receptors.

The second aerosol generated is sized for pulmonary penetration (i.e. to deliver an active ingredient such as nicotine to the user’s lungs). The second aerosol is formed of particles having a mass median aerodynamic diameter of less than or equal to 10 microns, preferably less than 8 microns, more preferably less than 5 microns, yet more preferably less than 1 micron. Such sized aerosols tend to penetrate into a human user’s pulmonary system, with smaller aerosols generally penetrating the lungs more easily. The second aerosol may also be referred to as a vapour.

The size of aerosol formed without heating is typically smaller than that formed by condensation of a vapour.

As a brief aside, it will be appreciated that the mass median aerodynamic diameter is a statistical measurement of the size of the particles/droplets in an aerosol. That is, the mass median aerodynamic diameter quantifies the size of the droplets that together form the aerosol. The mass median aerodynamic diameter may be defined as the diameter at which 50% of the particles/droplets by mass in the aerosol are larger than the mass median aerodynamic diameter and 50% of the particles/droplets by mass in the aerosol are smaller than the mass median aerodynamic diameter. The“size of the aerosol”, as may be used herein, refers to the size of the particles/droplets that are comprised in the particular aerosol.

Referring to Figs. 6 and 10 , there is shown a flavour pod portion 202 of a consumable, the consumable providing an aerosol delivery device. The consumable further comprises a cartomiser portion (not shown in Fig. 6/10) having all of the features of the cartomiser portion 104 described above with respect to Fig.

5. However, in other examples, the consumable does not comprise the cartomiser portion, and provides only flavour to the user.

The flavour pod portion 202 comprises an aerosol generator (also referred to as a“first aerosol generator”), which comprises an upstream (i.e. upstream with respect to flow of air in use) inlet 204 and a downstream (i.e. downstream with respect to flow of air in use) outlet 206. Between and fluidly connecting the inlet 204 and the outlet 206 the flavour pod portion 204 comprises an airflow passage 208. The airflow passage 208 comprises a first airflow branch 210 and a second airflow branch 212, each of the first airflow branch 210 and the second airflow branch 212 fluidly interconnecting the inlet 204 and the outlet 206. In other examples the airflow passage 208 may have an annular shape. The outlet 206 is located at the mouthpiece 209 of the consumable 103, and is also referred to as a mouthpiece aperture 206. The flavour pod portion 202 comprises a storage 214, which stores a first aerosol precursor (also referred to as an“aerosol precursor”. The storage 214 comprises a reservoir 216 located within a chamber 218. The reservoir 216 is formed of a first porous material.

The aerosol generator comprises a member 220, which comprises an aerosol generator portion 222 and a supporting portion 223. The aerosol generator portion 222 is located at a downstream end (an upper end in Fig. 6) of the member 220, while the supporting portion 223 makes up the rest of the member 220. The supporting portion 223 is elongate and substantially cylindrical. The aerosol generator portion 222 is bulb-shaped, and comprises a portion which is wider than the supporting portion 223. The aerosol generator portion 222 tapers to a tip at a downstream end of the aerosol generator portion 222.

The member 220 extends into and through the storage 214. The member 220 is in contact with the reservoir 216. More specifically, the supporting portion 223 extends into and through the storage 204 and is in contact with the reservoir 216. The member 220 is located in a substantially central position within the reservoir 216 and is substantially parallel to a central axis of the consumable. The member 220 is formed of a second porous material.

The first and second airflow branches 210, 212 are located on opposite sides of the member 220.

Additionally, the first and second airflow branches 210, 212 are located on opposite sides of the reservoir 216. The first and second airflow branches 210, 212 branch in a radial outward direction (with respect to the central axis of the consumable 200) downstream of the inlet 204 to reach the opposite sides of the reservoir 216.

The aerosol generator portion 222 is located in the airflow passage 208 downstream of the first and second airflow branches 210, 212. The first and second airflow branches 210, 212 turn in a radially inward direction to merge at the member 220, at a point upstream of the aerosol generator portion 222.

The aerosol generator portion 222 is located in a narrowing section 224 of the airflow passage 208. The narrowing section 224 is downstream of the point at which the first and second airflow branches 210 212 merge, but upstream of the mouthpiece aperture 207. The mouthpiece aperture 207 flares outwardly in the downstream direction, such that a width of the mouthpiece aperture 207 increases in the downstream direction.

In use, when a user draws on the mouthpiece 209, air flow is generated through the air flow passage 208. Air (comprising the second aerosol from the cartomiser portion as explained above with respect to Fig. 5) flows through the inlet 204 before the air flow splits to flow through the first and second airflow branches 210, 212. Further downstream, the first and second airflow branches 210, 212 provide inward airflow towards the member 220 and the aerosol generator portion 222.

As air flows past the aerosol generator portion in the narrowing section 224, the velocity of the air increases, resulting in a drop in air pressure. This means that the air picks up the first aerosol precursor from the aerosol generator portion 222 to form the first aerosol. The first aerosol has the particle size and other properties described above with respect to Fig. 5. As the first aerosol precursor is picked up by the air, the member 220 transfers further first aerosol precursor from the storage 214 to the aerosol generator portion 222. More specifically, the member 220 wicks the first aerosol precursor from the storage 214 to the aerosol generator portion 223.

In other examples, the storage 214 comprises a tank containing the first aerosol precursor as free liquid, rather than the reservoir 216 and the chamber 218. In such examples, the member 220 still extends into the tank to transfer first aerosol precursor from the tank to the aerosol generator portion 223.

Referring to Fig. 7a and 7b, there is shown a third consumable 300. The third consumable 300 comprises a flavour pod portion 302 and a cartomiser portion 304. The third consumable 300 comprises all of the features of the second consumable (and may also comprise all of the variations of the second consumable 200 described above), and only the differences are described here. For clarity many of the reference numerals are omitted from Fig. 7a and 7b.

The flavour pod portion 302 further comprises a switching device 306. The switching device 306 comprises a button 308 and a switching mechanism (not shown). The flavour pod portion 302 comprises a recess 309 for receiving the button 308. The button 308 is located on an in use front face of the third consumable 300. The button 308 is slidable within the recess 309 upwardly and downwardly (i.e. in a downstream direction towards and an upstream direction away from the mouthpiece 209).

In other examples, the button may be slidable in a horizontal plane or may be a rotary switch. These options may help to prevent accidental removal of the third consumable 300.

The switching mechanism connects the button 308 to the storage 214 and the member 222. The switching device 306 further comprises a bias device, which is a spring 310. The spring 310 is connected to the storage 214 and an underside of the mouthpiece 209. The spring 310 is configured to push the storage 214 (and hence the member 222) away from the mouthpiece 209.

The third consumable 300 comprises an aerosol generator, which comprises all of the features of the first aerosol generator described above. Fig. 7a shows the aerosol generator portion 223 of the aerosol generator in a normal mode, while Fig. 7b shows the aerosol generator portion 223 in a boost mode.

In the boost mode, a larger area of the aerosol generator portion 223 is located in an aerosol generation region of the air flow passage 208 than is the case in the normal mode. The aerosol generation region of the air flow passage 208 may be defined as a region in which the velocity of air flow is sufficiently high to generate the first aerosol in use. In the present example, the aerosol generation region of the air flow passage 208 is the narrowing section 224.

Additionally, in the boost mode, the aerosol generator portion 223 provides an increased area of constriction in the narrowing section 224 than is the case in the normal mode, which increases the velocity of airflow past the aerosol generator portion 223 in use compared to the normal mode.

Each of increasing the surface area of the aerosol generator portion 223 in the aerosol generation region and increasing the velocity of airflow past the aerosol generator portion 223 result in increased mass of first aerosol precursor in the first aerosol. The button 308 therefore allows the user to provide relative movement between the aerosol generator portion 223 and the airflow passage 208. This allows the user to vary/adjust a mass flow of aerosol precursor produced per delivery event (i.e. per puff taken by the user).

In the present example, the normal mode is the position in which the surface area of aerosol generator portion 223 located in the aerosol generation region is at a minimum. Additionally, the normal mode is the position in which the constriction in the narrowing section 224 is at a minimum.

In the present example, the boost mode is the position in which the surface area of aerosol generator portion 223 located in the aerosol generation region is at a maximum. Additionally, the boost mode is the position in which the constriction in the narrowing section 224 is at a maximum.

In use, to switch the aerosol generator portion 223 from the normal mode to the boost mode, the user slides the button 308 in an upward direction (i.e. in a downstream direction and towards the mouthpiece). This effects relative movement between the aerosol generator portion 223 and the airflow passage 208. More specifically, this effects sliding of the storage 214 and the member 222. As the button slides in the upward direction, the aerosol generator portion 223 slides further into the narrowing section 224 until the boost mode position is reached.

The user may slide the button 308 to any extent between the normal mode and the boost mode, permitting continuous variation in position of the aerosol generation portion 223 and continuous variation in mass of first aerosol precursor per delivery event between the normal mode and the boost mode. In general, as the user pushes the button 308 upwards, the surface area of the aerosol generator portion 223 in the aerosol generation region (in this case the narrowing section 224) increases. Additionally, as the user pushes the button 308 upwards, the aerosol generator portion 223 increases the area of constriction in the narrowing section 224, thereby increasing the velocity of airflow past the aerosol generator portion 223.

When the button 308 is released by the user, the spring 310 forces the aerosol generator portion 223 back into the normal mode.

In each of the normal mode and the boost mode (and any position of the aerosol generation portion 223 between the normal mode and the boost mode), the aerosol generator generally operates in the same way as the aerosol generator described above with respect to Fig. 6, with air flowing past the aerosol generator portion 223 to pick up aerosol precursor to generate aerosol during a delivery event when a user inhales.

In the present example, in the normal mode, the aerosol generator produces an aerosol comprises a first mass of aerosol precursor per delivery event. The first mass is less than 10 mg. More specifically, the first mass is less than 8 mg. More specifically, the first mass is less than 6 mg.

The first mass is at least 2 mg. More specifically, the first mass is at least 3 mg. More specifically, the first mass is at least 4 mg. More specifically, the first mass is substantially 5 mg. In the boost mode, the aerosol generator produces an aerosol which comprises a second mass of aerosol precursor per delivery event. The second mass is greater than the first mass. The second mass is at least 10 mg. More specifically, the second mass is at least 12 mg. More specifically, the second mass is at least 14 mg.

The second mass is not more than 20 mg. More specifically, the second mass is not more than 18 mg. More specifically, the second mass is not more than 16 mg. More specifically, the second mass is substantially 15 mg.

The second aerosol generator (or“additional aerosol generator”) of the cartomiser portion continues to produce second aerosol (or“additional aerosol”) comprising substantially the same mass of second aerosol precursor (or“additional aerosol precursor”) per delivery event regardless of the mode of the aerosol generator and the position of the aerosol generator portion 223.

In other examples, the switching device permits the aerosol generator portion 223 to be moved beyond the normal mode, to a position in which in the aerosol generator portion 223 has substantially zero surface area in the generation region. In this position, substantially zero aerosol precursor is produced during the delivery event, thereby providing an off mode.

Figs. 1 1 a and 1 1 b show further views of the flavour pod portion 202 which highlight features of the mouthpiece 209. Many of the reference numerals of Fig. 10 are omitted from Fig. 1 1 a and 1 1 b for clarity.

The mouthpiece aperture 206 comprises an inner surface 226, which is uneven. In the present example, the inner surface 226 has the form of a substantially frustoconical surface, but includes grooves or channels 228 to make the inner surface 226 somewhat uneven. In other examples, the inner surface 226 may have another form (for example, the form a substantially cylindrical surface), and may include any type of protrusion or groove to make the inner surface uneven.

The inner surface 226 is angled with respect to an axial direction (i.e. relative to a central axis extending from a base of the consumable to the mouthpiece) such that the width of the mouthpiece aperture 209 increases in the downstream direction. The inner surface 226 is immediately downstream of the narrowing section 224 of the airflow passage 108.

The grooves 228 are generally v-shaped in cross-sectional profile, and extend in the axial direction for the full length of the inner surface 226. Each groove 228 is formed from a pair of surfaces angled at between 30 and 90 degrees relative to each other. More specifically, each groove 228 is formed from a pair of surfaces angled at 60 degrees relative to each other.

The grooves 228 have a depth (measured normal to the inner surface 226) of at least 0.2 mm. More specifically, the grooves 228 have a depth of at least 0.3 mm. More specifically, the grooves 228 have a depth of at least 0.4 mm.

The grooves 228 have a depth of less than 0.8 mm. More specifically, the grooves have a depth of less than 0.7 mm. More specifically, the grooves have a depth of less than 0.6 mm.

More specifically, the grooves have a depth of substantially 0.5 mm. The grooves 228 are substantially equi-spaced in a circumferential manner around the inner surface 226. The inner surface 226 comprises at least 6 grooves. More specifically, the inner surface comprises at least 7 grooves. More specifically, the inner surface 226 comprises at least 8 grooves.

The inner surface 226 comprises at most 12 grooves 228. More specifically, the inner surface 226 comprises at most 1 1 grooves 228. More specifically, the inner surface 226 comprises at most 10 grooves 228.

More specifically, the inner surface 226 comprises 9 grooves 228.

The grooves 228 are spaced apart from each other by substantially 1 mm at the downstream end of the inner surface 226. In other examples, the spacing at the downstream end of grooves or protrusions may be selected such that it is equal to or less than the mass median diameter (as described above) of particles in the first aerosol.

The inner surface 226 comprises a smooth polished surface between the grooves 228. Polishing the surface in this way provides improved aerodynamic properties. However, in other examples, the inner surface 226 may be textured. In such examples, the texture of the surface may provide the uneven surface, and no grooves are required,

In use, the uneven nature of the inner surface 226 makes it easier for droplets to form on the inner surface 226, preventing large droplets from entering the user’s mouth. The grooves 228 help to channel the large droplets back into the consumable.

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

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

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

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

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words“have”,“comprise”, and“include”, and variations such as“having”,“comprises”,“comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. It must be noted that, as used in the specification and the appended claims, the singular forms“a,”“an,” and“the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from“about” one particular value, and/or to“about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent“about,” it will be understood that the particular value forms another embodiment. The term“about” in relation to a numerical value is optional and means, for example, +/- 10%.

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

The following numbered paragraphs may be useful in understanding the disclosure herein:

1 . An aerosol delivery device comprising:

an aerosol generator configured to produce an aerosol from an aerosol precursor during a delivery event, wherein the aerosol comprises a flavour component; and

a switching device permitting switching of the aerosol generator between a normal mode and a boost mode, wherein the aerosol generator is configured to:

in the normal mode, produce aerosol comprising a first mass of aerosol precursor per delivery event; and

in the boost mode, produce aerosol comprising a second mass of aerosol precursor per delivery event,

wherein the second mass is greater than the first mass.

2. An aerosol delivery device according to paragraph 1 , wherein the switching device further permits switching of the aerosol generator into an off mode, wherein in the off mode, the aerosol generator is configured not to produce aerosol during the delivery event.

3. An aerosol delivery device according to paragraph 1 or paragraph 2, wherein the switching device permits continuous variation in mass of aerosol precursor per delivery event between the normal mode and the boost mode.

4. An aerosol delivery device according to any one of the preceding paragraphs, wherein the switching device is configured to bias the aerosol generator from the boost mode towards the normal mode. 5. An aerosol delivery device according to any one of the preceding paragraphs, wherein the switching device comprises a sliding switching mechanism slidable to switch the aerosol generator between the normal mode and the boost mode.

6. An aerosol delivery device according to any one of the preceding paragraphs, wherein the aerosol generator comprises:

an aerosol generator portion configured to receive the aerosol precursor; and

an air flow passage configured to direct air past the aerosol generator portion to pick up the aerosol precursor from the aerosol generator portion to form the aerosol,

wherein the switching device is configured to provide relative movement between the aerosol generator portion and the airflow passage to switch the aerosol generator between the normal mode and the boost mode.

7. An aerosol delivery device according to paragraph 6, wherein the switching device is configured to provide the relative movement to vary a surface area of the aerosol generator portion located in an aerosol generation region of the airflow passage to switch the aerosol generator between the normal mode and the boost mode.

8. An aerosol delivery device according to paragraph 6 or paragraph 7, wherein the switching device is configured to provide the relative movement to vary a velocity of airflow past the aerosol generator portion to switch the aerosol generator between the normal mode and the boost mode.

9. An aerosol delivery device according to any one paragraphs 6 to 8, wherein the switching device is configured to slide the aerosol generator portion to switch the aerosol generator between the normal mode and the boost mode.

10. An aerosol delivery device according to paragraph 9, wherein the aerosol delivery device comprises a storage for storing the aerosol precursor, wherein the switching device is further configured to slide the storage with the aerosol generator portion.

1 1 . An aerosol delivery device according to paragraph any one of the preceding paragraphs, wherein the aerosol generator comprises a member, the member comprising the aerosol generator portion, wherein the member is configured to transfer the aerosol precursor to the aerosol generator portion.

12. An aerosol delivery device according to any preceding paragraph, wherein the aerosol delivery device is a consumable for a smoking substitute device.

13. An aerosol delivery device according to any preceding paragraph and further comprising an additional aerosol generator, the additional aerosol generator configured to produce an additional aerosol from an additional aerosol precursor during the delivery event. 14. An aerosol delivery device according to paragraph 13, wherein the additional aerosol generator is configured to produce the additional aerosol comprising substantially the same mass of additional aerosol precursor per delivery event in the normal mode and in the boost mode.

15. An aerosol delivery device according to paragraph 14, wherein the additional aerosol generator is configured to heat the additional aerosol precursor to form the additional aerosol.

16. An aerosol delivery device comprising:

a storage for storing an aerosol precursor;

a transfer element for transferring aerosol precursor from the storage;

a switch; and

a supporting portion connecting the transfer element to the switch such that movement of the switch causes movement of the transfer element.

17. An aerosol delivery device according to paragraph 16, and further comprising a barrier arrangement for inhibiting flow of aerosol precursor from the storage, wherein the transfer element is movable with respect to the barrier arrangement to open the barrier arrangement so that the transfer element can transfer aerosol precursor from the storage on movement of the switch.

18. An aerosol delivery device according to paragraph 17, and further comprising:

an aerosol generator comprising an aerosol generator portion configured to receive the aerosol precursor from the transfer element; and

an air flow passage configured to direct air past the aerosol generator portion to pick up the aerosol precursor from the aerosol generator portion to form an aerosol.

19. An aerosol delivery device according to paragraph 18 and further comprising a member, the member comprising the transfer element and the aerosol generator portion, wherein the member is movable from a first position to a second position to open the barrier arrangement.

20. An aerosol delivery device according to any one of paragraphs 16 to 19, wherein the member is slidable from the first position to the second position to open the barrier arrangement.

21 . An aerosol delivery device according to any one of paragraphs 16 to 20, and further comprising a mouthpiece and a body, wherein the mouthpiece is slidable relative to the body to provide the switch.

22. An aerosol delivery device according to claim 21 wherein the supporting portion is integrally formed with the mouthpiece.

23. An aerosol delivery device according to paragraph 21 or 22 when dependent on paragraph 17, wherein the barrier arrangement is configured to open in response to sliding of the mouthpiece relative to the body. 24. An aerosol delivery device according to any one of paragraphs 16 to 23, wherein the barrier arrangement is configured to remain permanently open after opening.

25. An aerosol delivery device according to any one of paragraphs 16 to 24, wherein the barrier arrangement comprises a plug received in a tube, the plug configured to inhibit flow of aerosol precursor from the storage to the transfer element,

wherein the plug is displaceable from the tube on movement of the transfer element so that the transfer element can transfer aerosol precursor from the storage.

26. An aerosol delivery device according to paragraph 25, and further comprising a guide for inhibiting return of the plug to the tube after the plug is displaced from the tube.

27. An aerosol delivery device according to any one of paragraphs 16 to 23, wherein the barrier arrangement comprises a deformable barrier component, and the transfer element is configured to deform the barrier component to open the barrier arrangement.

28. An aerosol delivery device according to any one of paragraphs 16 to 27, and further comprising: a pressure relief opening in the storage; and

a blocking arrangement for inhibiting flow through the pressure relief opening,

wherein the blocking arrangement is openable to permit air to flow through the pressure relief opening and into the storage as the storage empties of aerosol precursor.

29. An aerosol delivery device according to any one of paragraphs 16 to 28, wherein the aerosol delivery device is a consumable for a vaping device.

30. An aerosol delivery device according to any one of paragraphs 16 to 29 and further comprising an additional aerosol generator, the additional aerosol generator configured to produce an additional aerosol from an additional aerosol precursor.

31 . An aerosol delivery device according to paragraph 30, wherein the additional aerosol generator is configured to heat the additional aerosol precursor to form the additional aerosol.