JP7499283B2 - Vapor Delivery Systems - Google Patents

Description

The present disclosure relates to vapor delivery systems, such as nicotine delivery systems (e.g., e-cigarettes and the like).

Electronic vapor delivery systems, such as electronic cigarettes (e-cigarettes), generally include a reservoir of feedstock liquid containing a formulation typically including nicotine, or a vapor precursor material, such as a solid material like a tobacco-based product, from which vapor is generated, e.g., by thermal vaporization, for inhalation by the user. To this end, a vapor delivery system will typically comprise a vapor generation chamber, which includes a vaporizer, e.g., a heating element, arranged to vaporize a portion of the precursor material to generate vapor in the vapor generation chamber. When a user inhales from the device and the vaporizer is powered, air is drawn into the device through an intake hole and enters the vapor generation chamber, where the air and the vaporized precursor material mix to form a condensation aerosol. There is a flow path between the vapor generation chamber and the mouthpiece opening, such that the incoming air drawn through the vapor generation chamber continues along this flow path to the mouthpiece opening, carrying with it a portion of the vapor/condensation aerosol and exiting the mouthpiece opening for inhalation by the user. Some e-cigarettes include flavoring materials in the flow path through the device to impart additional flavoring. Such devices are sometimes referred to as hybrid devices, and the flavouring material may include, for example, a quantity of tobacco that is disposed in an air path between the vapour generating chamber and the mouthpiece, where the vapour/condensation aerosol drawn through the device passes through the quantity of tobacco before exiting the mouthpiece for inhalation by the user.

This specification describes various techniques that seek to achieve the improved performance of the devices discussed above.

According to a first aspect of a particular embodiment, there is provided an aerosol delivery system comprising: an apparatus for generating an inhalable medium, the apparatus comprising a receptacle for a flavoring material for imparting flavor to the inhalable medium generated by the apparatus, the receptacle comprising a wall portion for holding the flavoring material, the wall portion comprising a plurality of openings for airflow and a non-planar region, the plurality of openings being disposed within the non-planar region.

According to another aspect of certain embodiments, there is provided an aerosol providing means comprising: a means for generating an inhalable medium, the means comprising a receptacle means for flavoring material means for imparting flavor to the inhalable medium generated by the means for generating an inhalable medium, the receptacle means comprising wall portion means for holding the flavoring material means, the wall portion means comprising a plurality of opening means for airflow and a non-planar region, the plurality of opening means being disposed within the non-planar region.

According to another aspect of certain embodiments, there is provided a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the receptacle comprising a wall portion for holding the flavoring material, the wall portion comprising a plurality of openings for airflow and a non-planar region, the plurality of openings being disposed within the non-planar region.

According to another aspect of certain embodiments, there is provided a method of flavoring an inhalable medium produced by an apparatus for generating an inhalable medium, the method comprising the steps of providing a receptacle for flavoring material for flavoring the inhalable medium, the receptacle having a wall portion for holding the flavoring material, the wall portion having a plurality of openings for airflow and a non-planar region, the plurality of openings being disposed within the non-planar region, the method further comprising passing the inhalable medium through the receptacle to flavor the inhalable medium.

According to another aspect of certain embodiments, there is provided an aerosol delivery system comprising: an apparatus for generating an inhalable medium, the apparatus comprising a receptacle for a flavoring material for imparting flavor to the inhalable medium generated by the apparatus, the receptacle comprising a side wall portion, an outlet wall portion, and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall portion and the outlet wall portion being attached to the side wall portion to compress the flavoring material in the cavity between the inlet wall portion and the outlet wall portion.

According to another aspect of certain embodiments, there is provided a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall portion and the outlet wall portion being attached to the side wall portion to compress the flavoring material in the cavity between the inlet wall portion and the outlet wall portion.

According to another aspect of certain embodiments, there is provided a means for generating an inhalable medium, the means comprising a receptacle means for a flavoring material means for imparting flavor to the inhalable medium generated by the means for generating an inhalable medium, the receptacle means comprising a sidewall means, an outlet wall means and an inlet wall means, the sidewall means defining a cavity for the flavoring material, the inlet wall means and the outlet wall means each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall means and the outlet wall means attached to the sidewall means for compressing the flavoring material in the cavity between the inlet wall means and the outlet wall means.

According to another aspect of certain embodiments, there is provided a method of imparting flavoring to an inhalable medium produced by an apparatus for producing an inhalable medium, the method comprising the steps of providing a receptacle for the flavoring material, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall portion and the outlet wall portion being attached to the side wall portion to compress the flavoring material in the cavity between the inlet wall portion and the outlet wall portion, the method further comprising passing the inhalable medium through the receptacle to impart flavoring to the inhalable medium.

According to another aspect of certain embodiments, there is provided a method of manufacturing a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the method comprising the steps of providing a side wall portion to which one of the inlet wall portion and the outlet wall portion is attached, placing the flavoring material within the cavity, and attaching the other of the inlet wall portion and the outlet wall portion to the side wall portion such that the flavoring material is compressed between the inlet wall portion and the outlet wall portion.

According to another aspect of certain embodiments, there is provided an aerosol delivery system comprising: a device for generating an inhalable medium, the device comprising a receptacle for a flavoring material for flavoring the inhalable medium generated by the device, the receptacle comprising a housing comprising a mouthpiece portion, a sidewall portion, and an outlet wall portion of the mouthpiece portion having a plurality of openings for airflow, the mouthpiece portion, the sidewall portion, and the outlet wall portion being integrally formed.

According to another aspect of certain embodiments, there is provided a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the receptacle comprising a housing having a mouthpiece portion, a sidewall portion, and an outlet wall portion of the mouthpiece portion having a plurality of openings for airflow, the mouthpiece portion, the sidewall portion, and the outlet wall portion being integrally formed.

According to another aspect of certain embodiments, there is provided a means for generating an inhalable medium, the means comprising a receptacle means for flavoring material means for imparting flavor to the inhalable medium generated by the means for generating an inhalable medium, the receptacle means comprising housing means comprising a mouthpiece means, sidewall means, and outlet wall means for the mouthpiece means having a plurality of opening means for airflow, the mouthpiece means, sidewall means, and outlet wall means being integrally formed.

According to another aspect of certain embodiments, there is provided a method of imparting flavoring to an inhalable medium produced by an apparatus for producing an inhalable medium, the method comprising the steps of: providing an apparatus comprising a receptacle for flavoring material for imparting flavoring to an inhalable medium produced by the apparatus for producing an inhalable medium, the receptacle comprising a housing comprising a mouthpiece portion, a sidewall portion, and an outlet wall portion of the mouthpiece portion having a plurality of openings for airflow, the mouthpiece portion, the sidewall portion, and the outlet wall portion being integrally formed, the method further comprising passing the inhalable medium through the receptacle to impart flavoring to the inhalable medium.

According to another aspect of certain embodiments, there is provided a method of manufacturing a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the method comprising integrally forming a mouthpiece portion, a sidewall portion, and an outlet wall portion of the mouthpiece portion having a plurality of openings for airflow.

Further aspects and features of the present invention are defined in the appended claims.

The above paragraphs have been provided by way of general introduction and are not intended to limit the scope of the claims which follow. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

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

FIG. 1 is a schematic cross-sectional view of an aerosol delivery system according to certain embodiments of the present disclosure. FIG. 2 is a perspective view of a receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. FIG. 2 is a perspective view of a receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. FIG. 2 is a perspective view of a receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. 1A and 1B are perspective and cross-sectional views, respectively, of a receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. 1A and 1B are perspective and cross-sectional views, respectively, of a receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. 1A and 1B are perspective and cross-sectional views, respectively, of a further receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. 1A and 1B are perspective and cross-sectional views, respectively, of a further receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. A schematic cross-sectional view of a further exemplary receptacle for use with an aerosol delivery system according to certain embodiments of the present disclosure. FIG. 2 is a schematic cross-sectional view of a receptacle containing a fragrance material for use with an aerosol delivery system according to certain embodiments of the present disclosure. 15A-15C are schematic diagrams illustrating a method of filling the receptacle according to the example of FIG. 14 with a fragrance material, according to certain embodiments of the present disclosure. 15A-15C are schematic diagrams illustrating a method of filling the receptacle according to the example of FIG. 14 with a fragrance material, according to certain embodiments of the present disclosure. 15A-15C are schematic diagrams illustrating a method of filling the receptacle according to the example of FIG. 14 with a fragrance material, according to certain embodiments of the present disclosure. FIG. 2 is a schematic cross-sectional view of a receptacle containing a fragrance material for use with an aerosol delivery system according to certain embodiments of the present disclosure. FIG. 2 is a schematic representation of a method for manufacturing a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium according to a particular embodiment of the present disclosure.

Aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and embodiments may be implemented in a conventional manner and, for the sake of brevity, will not be discussed/described in detail. Thus, it will be appreciated that aspects and features of the devices and methods discussed herein that are not described in detail may be implemented in accordance with any conventional technique for implementing such aspects and features.

The present disclosure relates to vapor delivery systems, sometimes referred to as aerosol delivery systems, such as e-cigarettes, including hybrid devices. Throughout the following description, the term "e-cigarette" or "electronic cigarette" may be used, but it will be appreciated that the terms may be used interchangeably with vapor delivery system/device, electronic vapor delivery system/device, vapor delivery system/device, electronic vapor delivery system/device, aerosol delivery system/device, electronic aerosol delivery system/device, aerosol delivery system/device, and electronic aerosol delivery system/device. Furthermore, as is common in the art, the terms "vapor" and "aerosol," and the related terms "vaporize," "volatilize," and "aerosolize" may generally be used interchangeably.

Aerosol delivery systems often, but not always, comprise a modular assembly that includes both a reusable part (also called a control unit) and a replaceable/disposable cartridge part (also called a consumable part). In many cases, the replaceable cartridge part will include the aerosolizable material and the vaporizer, and the reusable part will include the power source (e.g., a rechargeable battery), the actuation mechanism (e.g., a button or puff sensor), and the control circuitry. However, it will be appreciated that these different parts may include further elements depending on their functionality. For example, in the case of so-called hybrid devices, the cartridge part may also include additional flavoring materials or aerosol modifiers. For example, the flavoring material may be a quantity of tobacco provided as an insert ("pod") to add flavor to the aerosol generated elsewhere in the system. The flavoring material or aerosol modifier may be a substance that can modify the aerosol when used. The modifier may modify the aerosol to produce a physiological or sensory effect on the human body. Exemplary aerosol modifiers are actives, flavors, and sensates. Sensates produce an organoleptic sensation that can be sensed through the senses, such as a cool sensation or a sour sensation.

The flavoring material may be removable for replacement, for example to change flavors or because the flavoring material has a shorter usable life than the aerosol generating components of the cartridge. Reusable device portions will often also include additional components, such as a user interface for accepting user input and displaying operating status characteristics.

As used herein, the terms "flavor" and "flavoring" refer to materials that can be used to produce a desired taste or aroma in products for adult consumers, to the extent permitted by local regulations. In some examples, the flavoring materials can include tobacco materials or materials containing tobacco extracts, and/or nicotine. In some examples, the flavoring materials can include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, mint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, iuca, linseed ... such as orchid, sage, fennel, pepper, ginger, anise, coriander, coffee, or peppermint oil from any species of the genus Mentha), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. These may be imitation, synthetic or natural, or mixtures thereof.

In the case of a modular device, the cartridge and control unit may be electrically and mechanically coupled together in use, for example using threads, latching or bayonet fastening means with suitable mating electrical contacts. When the vapor precursor material in the cartridge is depleted, or when the user desires to replace it with a different cartridge having a different vapor precursor material, the cartridge may be removed from the control unit and a replacement cartridge may be installed in its place.

It is relatively common for aerosol delivery systems including multi-part devices to have a generally elongated shape, and to provide a concrete example, certain embodiments of the present disclosure described herein will be interpreted as including a generally elongated multi-part device that utilizes a disposable cartridge containing an aerosolizable material, a flavoring medium, and an electric heater to vaporize the aerosolizable material to form a condensed aerosol that is inhaled by the user during use. These vapor delivery systems may be referred to, for example, as hybrid systems or hybrid e-cigarettes. In some cases, the flavoring material insert itself may be removable from the disposable cartridge portion so that the flavoring material insert can be replaced separately from the cartridge or reusable portion, for example, to change flavors or because the usable life of the flavoring material insert is different from the usable life of the vapor generating components of the cartridge. The flavoring material insert may be housed in a receptacle. Throughout the following description, the terms "pod," "receptacle," "container," or "insert" may be used, but it will be appreciated that these terms may be used interchangeably. In some examples, the pod may be reusable and the user may have access to the perfume insert in the pod to replace the perfume insert. In other examples, the pod may be disposable and the user is prevented from accessing or attempting to replace the perfume insert. The use of the pod may enhance the user experience, for example, by ensuring optimal placement of the perfume insert in the airflow path and/or by limiting the properties of the perfume insert (e.g., volume, viscosity, density, etc.).

It will be appreciated that the underlying principles described herein may equally be employed in aerosol delivery systems of different configurations, such as devices following other overall shapes, for example based on so-called box-mod high performance devices, which typically have a more box-like shape, or smaller form factor devices, such as so-called pod-mod devices. More generally, it will be appreciated that embodiments of the present disclosure may be based on aerosol delivery systems configured to incorporate the principles described herein, regardless of the particular form of other aspects of such aerosol delivery systems.

1 is a cross-sectional view through an exemplary e-cigarette 1 according to certain embodiments of the present disclosure. The e-cigarette 1 comprises three main components: a reusable portion 2, a replaceable/disposable cartridge portion 4, and a flavoring means 8 containing a quantity of flavoring material 36 (e.g., shredded tobacco, reconstituted tobacco, or extruded tobacco) provided within an insertion housing, such as a removable receptacle. However, the fact that this example is a multi-part hybrid device is not directly critical to the device's operational functionality as described further herein.

During normal use, the reusable part 2 and the cartridge part 4 are removably coupled together at the interface 6. When the cartridge part is depleted (i.e., when the aerosolizable material in the cartridge part, such as a liquid, is depleted or substantially depleted), or simply when the user desires to replace it with a different cartridge part, the cartridge part can be removed from the reusable part and a replacement cartridge part can be attached to the reusable part instead. The interface 6 provides a structural, electrical, and air path connection between the two parts, and can be established by conventional techniques, for example, based on threads, latching mechanisms, or bayonet fastening means, with electrical contacts and openings appropriately positioned to appropriately establish the electrical connection and air path between the two parts. The particular manner in which the cartridge part 4 is mechanically attached to the reusable part 2 is not important to the principles described herein, but for the sake of concreteness of the example, it is assumed here that a portion of the cartridge includes a latching mechanism (not shown in FIG. 1) that is received in a corresponding receptacle with a cooperating latch-engaging element of the reusable part. It will also be appreciated that interface 6 may not support electrical connection between the respective portions in some implementations. For example, in some implementations, a vaporizer may be provided by the reusable portion rather than within the cartridge portion, or the transfer of power from the reusable portion to the cartridge portion may be wireless (e.g., based on electromagnetic induction) such that no electrical connection between the reusable portion and the cartridge portion is required.

The cartridge portion 4 is generally conventional according to certain embodiments of the present disclosure. In FIG. 1, the cartridge portion 4 comprises a cartridge housing 42 formed of a plastic material. The cartridge housing 42 supports the other components of the cartridge portion and provides a mechanical joint 6 to the reusable portion 2. The cartridge housing is circularly symmetric about a longitudinal axis along which the cartridge portion couples to the reusable portion 2. In this example, the cartridge portion has a length of about 4 cm and a diameter of about 3 cm. However, it will be appreciated that the detailed geometry, as well as the more commonly used overall shapes and materials, may vary in different implementations.

Within the cartridge housing 42 is a reservoir 44 containing a liquid vapor precursor material. The liquid vapor precursor material may be conventional and may be referred to as e-liquid. The liquid reservoir 44 has an annular shape in this example with an outer wall defined by the cartridge housing 42 and an inner cartridge wall 58 that defines an air passage 52 through the cartridge portion 4. The reservoir 44 is closed at each end by end walls to contain the e-liquid. The reservoir 44 may be formed by conventional techniques, for example it may comprise a plastic material and may be molded integrally with the cartridge housing 42.

During normal use, the cartridge part 4 and the receptacle 8 are removably coupled together at the joint 1. When the scented material 36 in the receptacle 8 is exhausted, or simply when the user desires to switch to a different receptacle and/or scented material, the receptacle can be removed from the cartridge part and the scented material in the receptacle can be replaced, or a different receptacle can be installed in the cartridge part instead. The joint 10 provides a structural connection of the air path between these two parts, and can be established by conventional techniques, for example, based on threads, latching mechanisms, or bayonet fastening means, with electrical contacts and openings appropriately positioned to appropriately establish an electrical connection and air path between the two parts. The particular manner in which the cartridge part 4 is mechanically attached to the receptacle 8 is not critical to the principles described herein, but in these and other examples, retention and positioning of the receptacle 8 can be due to friction and/or can be facilitated by clips, ledges, and other features in the air path 52. For example, the insert portion 38 of the receptacle 8 may be inserted into a receiver 54 provided at an open end of the air passage 52 opposite the end of the cartridge 4 that couples to the control unit 2. The insert portion 38 and/or the receiver 54 may have surface protrusions (e.g., ridges or ridges) to help retain the receptacle 8 within the cartridge portion 4 by friction.

It will also be appreciated that the joint 10 may, in some implementations, support electrical connections between the respective portions. For example, the receptacle 8 may include a heater for heating the scented material 36.

In the illustrated example, the receptacle 8 includes a housing or sidewall portion 32 that defines a channel or cavity 34 in which a flavoring agent 36 can be contained or held. The sidewall portion 32 of the receptacle 8 may also include two open ends. In normal use, air or other inhalable medium can flow from one end of the cavity to the other (e.g., during a puff), allowing air drawn along the air path 52 during use to pass through the flavoring material 36 and thereby become loaded with flavoring agent (e.g., tobacco flavoring) before exiting the receptacle through the mouthpiece outlet 50 (i.e., the opening or aperture) and being inhaled by the user. To hold or place the flavoring agent 36, the receptacle may include a channel inlet wall portion 40 (i.e., a lower or upstream wall) attached to the channel wall portion 32, and a channel outlet wall portion 70 (i.e., an upper or downstream wall), each of which is adapted to cover an open end, respectively. The channel inlet wall portion 40 and the channel outlet wall portion 70 each have a plurality of holes, openings, or apertures for air flow. For example, the channel inlet wall portion 40 and the channel outlet wall portion 70 may be formed by a mesh, a perforated wall portion, or an air permeable screen. The channel inlet wall portion 40 and the channel outlet wall portion 70 may be provided toward opposite ends of the channel wall portion 34. For example, one or both may be disposed at the end of the channel wall portion 34, or one or both may be disposed inset (e.g., 2-20% of the length of the channel wall portion 34, preferably 5-15% of the length of the channel wall portion 34) from the end of the channel wall portion 34.

The channel inlet wall portion 40 (i.e., the lower or upstream wall) and the channel outlet wall portion 70 (i.e., the upper or downstream wall) may be replaceably attached to the channel wall portion 32 or may be fixedly attached to the channel wall outlet portion 70. By replaceably attached, it is meant that the receptacle 8 is configured such that the wall portions can be separated as needed (e.g., to allow replacement or refilling of the scent material in the receptacle 8). By fixedly attached, it is meant that the receptacle 8 is configured such that the wall portions cannot be separated (e.g., any separation would require destruction of components of the receptacle 8). It will be appreciated that in some instances it may be advantageous to have one wall portion (e.g., the inlet wall portion 40) fixedly attached to the side wall portion 32 and the other wall portion (e.g., the outlet wall portion 70) replaceably attached to the side wall portion 32.

The inlet wall portion 40 and/or the outlet wall portion 70 may be attached to the sidewall portion by a particular engagement mechanism, for example, using a latch, bayonet, push fit, and threaded connection. The sidewall portion 32 may have corresponding features to allow connection. It will be appreciated that the use of latches, bayonet, push fit, and threaded connections typically represent reversible engagement mechanisms, while adhesive bonding and/or ultrasonic welding may be used to create a permanent connection after initial connection via the engagement mechanism to create a fixed attachment or engagement. In other examples, one or both of the wall portions 40, 70 may be fixedly attached to the sidewall portion 32 using ultrasonic welding, adhesive bonding, or other methods without any of the engagement mechanisms described above. In some other examples, one of the wall portions 40, 70 may be formed integrally with the sidewall portion 32 such that the selected one of the wall portions 40, 70 is originally fixedly attached to the sidewall portion 32. Other methods of attaching either the inlet wall portion 40 or the outlet wall portion 70 are described in more detail below.

It will be appreciated that the channel inlet wall portion 40 and the channel outlet wall portion 70 do not necessarily need to be symmetrically disposed about the center point of the receptacle 8. In some examples, the channel inlet wall portion 40 and the channel outlet wall portion 70 may be configured to be substantially different from each other. For example, as shown in FIG. 1, the channel inlet wall portion 40 may be configured to have a flat or planar shape, while the channel outlet wall portion 70 may be configured to have a curved or non-planar shape. Furthermore, the channel inlet wall portion 40 and the channel outlet wall portion 70 may be constructed from different materials. For example, the channel inlet wall portion 40 may be constructed from a metal material and the channel outlet wall portion 70 may be constructed from a plastic material, or vice versa. In some examples, the channel inlet wall portion 40 and/or the channel outlet wall portion 70 may be constructed from the same material as the sidewall portion 32. For example, the channel inlet wall portion 40 and/or the channel outlet wall portion 70 may be constructed from the same plastic material as the sidewall portion 32. In some examples, one of the channel inlet wall portion 40 or the channel outlet wall portion 70 may be integrally formed with the receptacle sidewall portion 32 (e.g., by integrally molding the components). The receptacle sidewall portion 32, the channel inlet wall portion 40, and/or the channel outlet wall portion 70 may include or consist of a plastic material. Exemplary materials include copolyester (Tritan®), polybutylene terephthalate, polycarbonate, polyphthalamide (Grivory®), and polypropylene.

In some examples, the sidewall portion 32 of the receptacle 8 may define or otherwise incorporate a mouthpiece element. For example, the sidewall portion 32 may be configured to provide an outer surface shaped to assist in forming a seal with the user's lips during use. In other examples, a mouthpiece may be attached downstream of the receptacle 8 (not shown).

The cartridge portion further includes a wick 46 and a heater (vaporizer) 48 disposed toward the end of the reservoir 44 opposite the receptacle 8. In this example, the wick 46 extends across the cartridge air path 52 and ends into the e-liquid reservoir 44 through an opening in the inner wall of the reservoir 44. The opening in the inner wall of the reservoir 44 is sized to generally match the dimensions of the wick 46 to provide a reasonable seal against leakage from the liquid reservoir into the cartridge air path without excessive compression of the wick, which may be detrimental to the fluid transport capabilities of the wick.

The wick 46 and heater 48 are disposed within the cartridge air path 52 such that the area of the cartridge air path 52 around the wick 46 and heater 48 effectively defines a vapor generation or vaporization area for the cartridge portion. The e-liquid in the reservoir 44 penetrates the wick 46 through the end of the wick that extends into the reservoir 44 and is drawn along the wick by surface tension/capillary action (i.e., wicking). The heater 48 in this example comprises an electrically resistive wire coiled around the wick 46. In this example, the heater 48 comprises a nickel-chromium alloy (Cr20Ni80) wire and the wick 46 comprises a fiberglass bundle, although it will be appreciated that the particular configuration of the vaporizer is not critical to the principles described herein. In use, power can be supplied to the heater 48 to vaporize a quantity of e-liquid (vapor precursor material) drawn by the wick 46 to the vicinity of the heater 48. The vaporized e-liquid can then be entrained in the air that is drawn along the cartridge air path from the vaporization region through the channel wall portion 34 of the receptacle 8 and out the mouthpiece outlet 50 for inhalation by the user.

The rate at which e-liquid is vaporized by the vaporizer (heater) 48 is determined by the amount (level) of power supplied to the heater 48 during use. Thus, power can be applied to the heater to selectively generate vapor from the e-liquid in the cartridge portion 4, and further, the rate of vapor production can be varied by varying the amount of power supplied to the heater 48, for example, by pulse width modulation and/or frequency modulation techniques.

The particular manner in which the various aspects of the vapor delivery system function is not directly related to the principles underlying the examples described herein. For example, while the embodiments described above have focused primarily on devices having electrically heated vaporizers for heating liquid vapor precursor material, the same principles can be employed in devices based on vaporizers based on other technologies, such as, for example, piezoelectric vibrator-based vaporizers or optically heated vaporizers, and also on other aerosol precursor materials, such as solid materials, including plant-derived materials, such as tobacco-derived materials, or other forms of vapor precursor materials, such as gel-, paste-, or foam-based vapor precursor materials.

The reusable portion 2 comprises an outer housing 12 having an opening defining an air inlet 28 for the e-cigarette, a battery 26 for providing operating power to the e-cigarette, control circuitry 20 for controlling and monitoring operation of the e-cigarette, a user input button 14, a puff sensor (puff detector) 16, which in this example comprises a pressure sensor located within a pressure sensor chamber 18, and a visual display 24.

The outer housing 12 may be formed, for example, from a plastic or metal material, and in this example has a circular cross-sectional area that generally follows the shape and size of the cartridge portion 4 so as to provide a smooth transition between the two portions at the junction 6. In this example, the reusable portion has a length of about 6 cm, and therefore the overall length of the e-cigarette when the cartridge portion and the reusable portion are joined together is about 10 cm. However, it will be appreciated (as previously noted) that the overall shape and scale of an electronic cigarette embodying an embodiment of the present disclosure is not critical to the principles described herein.

The air inlet 28 connects to an air path 30 through the reusable part 2. The reusable part air path 30 then connects through the junction 6 to the cartridge air path 52 when the reusable part 2 and the cartridge part 4 are connected together. The pressure sensor chamber 18 containing the pressure sensor 16 is in fluid communication with the air path 30 of the reusable part 2 (i.e., the pressure sensor chamber 18 branches off from the air path 30 of the reusable part 2). Thus, when the user inhales through the mouthpiece opening 50, a pressure drop is created in the pressure sensor chamber 18 that can be detected by the pressure sensor 16, and air is drawn along the reusable part air path 30 through the air inlet 28, through the junction 6, through the vapor generating region adjacent the atomizer 48 (vaporized e-liquid is entrained in the air stream during vaporizer operation), along the cartridge air path 52, and out through the mouthpiece opening 50 for inhalation by the user.

The battery 26 in this example is rechargeable and may be of a conventional type, such as the type typically used in e-cigarettes and other applications requiring relatively high current for a relatively short period of time. The battery 26 may be recharged through a charging connector, such as a USB connector, in the housing 12 of the reusable portion.

The user input buttons 14 in this example are conventional mechanical buttons, e.g., spring-loaded components that a user can press to establish electrical contact. In this regard, the input buttons can be thought of as providing a manual input mechanism for the terminal device, although the particular manner in which the buttons are implemented is not critical. For example, in other implementations, different forms of mechanical buttons or touch-sensitive buttons (e.g., based on capacitive or optical sensing technologies) may be used. The particular manner in which the buttons are implemented may be selected based on, for example, a desired aesthetic consideration.

A display 24 is provided to provide the user with visual indications of various features associated with the e-cigarette, such as current power setting information, remaining battery power, and the like. The display may be implemented in a variety of ways. In this example, the display 24 comprises a conventional pixelated LCD screen that may be driven to display the desired information by conventional techniques. In other implementations, the display may comprise one or more separate indicators, such as LEDs, configured to display the desired information, for example by a particular color and/or blinking sequence. More generally, the manner in which a display is provided and information is displayed to the user using the display is not critical to the principles described herein. Some embodiments may not include a visual display, may include other means for providing information to the user regarding the operational characteristics of the e-cigarette, such as using audio signaling or haptic feedback, or may not include any means for providing information to the user regarding the operational characteristics of the e-cigarette.

The control circuitry 20 is suitably configured/programmed to control the operation of the electronic cigarette to provide functionality according to embodiments of the present disclosure as further described herein, as well as to provide conventional operational functions of electronic cigarettes, consistent with established techniques for controlling such devices. The control circuitry (processor circuitry) 20 can be considered to logically comprise various subunits/circuit elements associated with various aspects of the operation of the electronic cigarette in accordance with the principles described herein, such as display driver circuitry and user input detection, and other conventional operational aspects of electronic cigarettes. It will be appreciated that the functionality of the control circuitry 20 can be provided in a variety of different ways, for example, using one or more suitably programmed programmable computer(s) and/or one or more suitably configured application specific integrated circuit(s)/circuitry/chip(s)/chipset(s) to provide the desired functionality.

In this example, the vapor delivery system 1 includes a user input button 14 and an inhalation sensor 16. The control circuitry 20 may be configured to receive signaling from the inhalation sensor 16 and use this signaling to determine whether the user is inhaling on the e-cigarette, and also to receive signaling from the input button 14 and use this signaling to determine whether the user is pressing (i.e., actuating) the input button. These aspects of the operation of the e-cigarette (i.e., puff detection and button press detection) may be performed by themselves according to off-the-shelf techniques (e.g., using conventional inhalation sensors and inhalation sensor signal processing techniques, and using conventional input buttons and input button signal processing techniques). Other example vapor delivery systems may have only one of the user input button 14 and the inhalation sensor 16. In further examples, the vapor delivery system may have neither the user input button nor the inhalation sensor, depending on the configuration and operation of the system.

According to embodiments of the present disclosure, the cross-sectional area of an air path at a location may be defined as the area perpendicular or lateral to the central or medial axis of the air path at that location. This area may be bounded by at least one wall, such as the inner cartridge wall 58 or side wall portion 32, or other structural feature. In use, air flows in the direction of the central axis from the air inlet 28 towards the air outlet 50. The cross-sectional area thus provides a dimension of the lateral area available for air to flow through during use. In some examples, the cross-section of the air path may have a substantially circular shape, an elliptical shape, a polygonal shape, or a polygonal shape with rounded corners. The cross-sectional area of the air path is the area of that shape at that location. In some examples, the shape of the cross-section may vary at different locations.

2A, 2B, and 2C show perspective views of a receptacle according to the exemplary vapor delivery system of FIG. 1. The receptacle 8 is formed by a sidewall portion 32. The outer surface of the sidewall portion 32 is configured to provide a mouthpiece outlet 50 and an insertable portion 38 for insertion into a corresponding receptacle 54 (not shown) of the cartridge portion 4. The sidewall portion 32 has a rounded, flaring shape adjacent the mouthpiece outlet 50 and configured to receive the lips of a user during use. It will be appreciated that in other examples not shown, the sidewall portion 32 may have a different shape. For example, the sidewall portion 32 may include a flat surface rather than a rounded surface. Still further, in other examples, the sidewall portion 32 may not be flared.

The sidewall portion 32 defines a channel 34 in which a flavoring 36 may be contained or retained. The housing for the receptacle 8 also includes two ends that define an inlet and an outlet for the channel 34, allowing an inhalable medium (e.g., vapor, aerosol, and/or air) drawn along the air path 52 during use to pass through the flavoring material 36 and thereby to be loaded with flavoring (e.g., tobacco flavoring) before exiting the receptacle through the mouthpiece outlet 50 and being inhaled by the user. The housing is further configured to provide a plurality of protrusions 64 for providing contact with a surface of the receiver 54. The housing is further configured to provide a recess 62 for a user to grasp when removing or engaging the receptacle 8 from the cartridge portion.

2A, 2B, and 2C, the receptacle 8 includes a mouthpiece, a sidewall portion 32, and an outlet wall portion 70, which are provided as a single integrally formed component. The integrally formed component may be formed by integrally molding the mouthpiece, the sidewall portion 32, and the outlet wall portion 70 using a single mold. The components may be formed using injection molding or any other conventional process. For example, the components may be integrally formed by an additive manufacturing process, such as top-down or bottom-up 3D printing of a suitable material. In some examples, a casting process may be used.

The outlet wall portion 70 has a plurality of holes that allow air to pass from one side of the outlet wall portion to the other side of the outlet wall portion. The outlet wall portion 70 is provided at the mouthpiece outlet 50 end of the channel 34 formed by the side wall portion 32. The outlet wall portion 70 may be inset slightly inward from the end of the channel 34 and may define a planar surface. As shown in FIG. 2B, the plurality of holes may be formed by providing a series or array of parallel rods. A second series or array of parallel rods may be provided adjacent and non-parallel to the first series of parallel rods to provide a grid array of holes. It will be appreciated that the first and second series of rods may be regularly spaced and that the holes defined by the rods may have a regular pattern (e.g., spacing) that depends on the periodicity of the first and second series of rods.

The angle between the two sets of rods defines the shape of the hole. For example, if the angle is 90°, the hole will be a square or rectangle, while if the angle is less than 90°, the hole will be a parallelogram. It will be appreciated that different configurations of rods may be used to form different shaped holes in the outlet wall portion, and that these embodiments are not limited to square, rectangular, or parallelogram shaped holes. In some examples, parallel curved rods may be provided. The parallel curved rods may provide holes with curved sides and further with corners where the rods meet.

In some examples, the outlet wall portion 70 may be configured to provide holes having a diameter of 0.2 mm to 1 mm, preferably 0.3 mm to 0.7 mm, and most preferably 0.4 mm. The outlet wall portion 70 according to these examples may allow steam to penetrate the flavoring material 36 while retaining the flavoring material (e.g., loose tobacco or tobacco granules) within the receptacle 8. It will be appreciated that the preferred diameter of the hole depends on the size and configuration of the flavoring material 36 to be held within the receptacle 38. For example, the size and configuration of the hole may depend on whether the flavoring material 36 is provided in a single piece or multiple pieces and may be based on the dimensions of the piece or pieces. In examples where the flavoring material 36 is provided in multiple pieces, the size of the hole may be smaller than 90% of the pieces, and preferably smaller than 95% of the pieces.

The side wall portion 32 may be further configured to define a retention mechanism 60 for retaining the channel inlet wall portion 40 (not shown) in the end of the channel 34 opposite the mouthpiece outlet end 50. By retention mechanism, we mean a mechanism for retaining the channel inlet wall portion 40 in the channel 34. In other words, the retention mechanism 60 blocks or otherwise prevents the channel inlet wall portion 40 from exiting the channel 34 after insertion. It will be appreciated that due to the presence of the channel outlet wall portion 70 and/or due to flavoring materials that may be present in the channel 34 during normal use, the channel inlet wall portion 40 is prevented from exiting the channel 34 through the end having the channel outlet wall portion 70.

2B and 2C, the retention mechanism 60 may comprise a plurality of tabs. The tabs are configured to fold upwardly and inwardly toward the center of the channel 34 upon application of pressure (and optionally heat). In use, the inlet wall portion 40 is inserted into the channel 34 formed by the side wall portion 32, and then the retention mechanism 60 is adjusted to narrow the diameter of the channel 34 upstream of the inlet wall portion, thereby preventing the inlet wall portion 40 from exiting the channel 34. It will be appreciated that the inlet wall portion 40 is configured to have a shape that is small enough to be inserted into the channel 34, but large enough to be retained by the retention mechanism 60 after it is engaged/activated/deformed. By way of example, the lower opening of the channel 34 may have an elliptical shape with a minor axis diameter of 1.00 cm and a major axis diameter of 2.00 cm. The tabs of the retention mechanism 60 may be folded inward as described to form an opening having an elliptical shape with a minor axis diameter of 0.80 cm and a major axis diameter of 1.80 cm. As such an example, the inlet wall portion 40 may have an elliptical shape with a minor axis diameter of 0.95 cm and a major axis diameter of 1.95 cm.

In other examples (not shown), the retention mechanism 60 may be established by conventional techniques, such as based on threads, clips, or latch mechanisms. Alternatively or additionally, the retention mechanism 60 may use adhesives or ultrasonic welding to adhere the inlet wall portion 40 to the housing. This may be an alternative or an addition to the tabs shown in FIGS. 2A, 2B, and 2C.

As noted above, the receptacle 8 may be formed with a single, integrally formed sidewall portion 32 that defines the mouthpiece, the sidewalls of the channel 34, and the outlet wall portion 70, and a separate inlet wall portion 40. This allows for a simplified manufacturing process, where only two components (the sidewall portion 32 and the inlet wall portion 40) need to be combined after the scented material 36 is provided in the channel 34, rather than combining a larger number of components in a complex manufacturing process.

3A and 3B show a receptacle 8 according to the exemplary vapor delivery system 1 of FIG. 1. FIG. 3A provides a perspective view, while FIG. 3B provides a cross-sectional view through the receptacle 8, the cross-sectional plane being perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of FIGS. 2A, 2B, and 2C, the side wall portion 32 of the receptacle 8 of FIGS. 3A and 3B is shaped to define a liquid collection area for collecting liquid. Aspects of FIGS. 3A and 3B that are substantially similar to those shown in FIGS. 2A, 2B, and 2C will not be described in detail.

The vapor held within the receptacle may condense as a liquid onto the scented material 36 or onto the sidewalls forming the channel 34. For example, when the user stops inhaling on the device, the vapor may stop moving towards the mouthpiece outlet 50 and cooling may begin. The condensed liquid adheres to the surface of the wall of the receptacle 8 by surface tension. The liquid may be drawn towards the user's mouth during inhalation. The liquid may collect in areas where the flow of the liquid is impeded, for example due to impermeable walls. As shown in Figures 3A and 3B, a liquid collection area or region for collecting liquid provided as a recess or valley 90 may be provided within the channel 34 near the mouthpiece outlet 50. For example, the recess 90 may be provided by the intersection of the sidewall portion 32 and the outlet wall portion 70.

The receptacle 8 (e.g., the outlet wall portion 70 of the receptacle 8) may define an indentation toward the center of the receptacle that is substantially aligned with the airflow direction in use. This airflow direction 8 may be parallel to the longitudinal axis of the receptacle 8. Indentation means that the central region of the receptacle 8 is closer to the center of the receptacle 8 than the peripheral regions of the receptacle 8. As shown in FIG. 3A, the peripheral region of the mouthpiece end of the receptacle 8 may form an oval shape, which may define the mouthpiece outlet 50. The multiple openings in the outlet wall portion 70 may be provided in a planar wall portion in the central region of the indentation perpendicular to the airflow direction. The indentation has an inner surface (i.e., an upstream surface facing into the receptacle) and an outer surface (i.e., a downstream side visible to a user in normal use).

As shown in FIG. 3B, the recess 90 may be provided as a valley (e.g., a U-shaped valley or a V-shaped valley) formed by the sidewall portion 32 and the channel outlet wall portion 70. The portion of the channel outlet wall portion 70 forming the valley may be an inner surface of an indentation forming a peripheral region that does not include any of the multiple openings. In some examples, the valley or recess 90 may be formed at an intersection of the channel outlet wall 90 and the sidewall 34. For example, a portion of the outlet wall portion 70 may meet the sidewall 34 at an angle of less than 90°. It will be appreciated that by having an angle of less than 90°, the outlet wall portion 70 and the sidewall 34 may be considered to define a V-shape. In other examples, the intersection between the outlet wall portion 70 and the sidewall 34 may be smoothed or rounded to obtain a shape that more closely resembles a U-shape. In a further example, the outlet wall portion 70 and the sidewall 34 may include parallel portions to obtain a U-shaped valley. It will be appreciated that the valleys or recesses 90 can be provided in many different configurations.

In some examples, the valley or recess 90 may be formed only at a portion of the intersection between the channel outlet wall portion 70 and the sidewall 34. For example, the second length of the periphery of the outlet wall portion 70 may have an intersection angle of more than 90° over the portion not forming the first length, and/or some of the openings may be adjacent to the intersection in the second length, thereby allowing liquid to flow substantially unimpeded toward the mouthpiece outlet 50. In these examples, the liquid collection area may be a valley having an elongated configuration, or may be a more bowl-shaped recess. The curvature of the wall surrounding the valley or recess 90 may promote the flow of liquid condensate toward the valley or recess 90. In some examples, the valley or recess 90 may be formed all around the intersection of the channel outlet wall portion 70 and the sidewall portion 32 (in other words, all around the circumference of the channel outlet wall portion 70).

The recess 90 is open on one side (e.g., the upstream side) to allow liquid to enter the recess. In some examples, the recess 90 may have a depth, typically parallel to the airflow direction, of 1 mm to 5 mm, preferably 2 mm to 4 mm, and most preferably 3 mm. The recess may have a liquid volume capacity of 0.2 ml to 1 ml, preferably 0.3 ml to 0.5 ml.

The channel 34 may be configured to provide one or more internal ridges or channels 80 for liquid guidance. The ridges or channels 80 aid or facilitate the movement of liquid within the receptacle 8 toward the recess 90 and/or away from the multiple openings. It will be appreciated that ridges and channels may be used interchangeably to describe the liquid guidance mechanism. For example, a liquid guidance channel may be considered to be formed by the facing edges of two liquid guidance ridges, and similarly, a liquid guidance ridge may be considered to be formed by the facing edges of two liquid guidance channels.

The ridges or channels 80 are typically parallel to the airflow direction during normal use, as shown in FIG. 3B. In other examples, not shown, the sidewall portion 32 may be configured to provide non-parallel ridges and channels 80. In some other examples, the channels 34 may be configured to provide curved ridges and channels. In most examples, the ridges or channels 80 terminate in or adjacent to the recesses 90. Curved channels may be advantageous when the recesses or valleys 90 are provided around only a portion of the channel outlet wall portion 70 so that liquid can be guided to the recesses or valleys 90. In some examples, the outer surface of the sidewall portion 32 adjacent the channel outlet wall portion 70 may have an exterior channel 82 (i.e., a channel on the outer surface of the receptacle). In some examples, the channel outlet wall portion 70 may also be provided with a channel 80 and/or an exterior channel 82. The liquid-guiding channel 80 in the channel outlet wall portion 70 may promote or assist the flow or movement of liquid toward the recesses and/or valleys 90.

4A and 4B show a receptacle 8 according to the exemplary vapor delivery system 1 of FIG. 1. FIG. 4A provides a perspective view, while FIG. 4B provides a cross-sectional view through the receptacle 8, the cross-sectional plane being perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of FIG. 3A and 3B, the channel outlet wall portion 70 of the receptacle 8 of FIG. 4A and 4B is formed in a non-planar region 72 of the receptacle 8, such that the multiple openings of the channel outlet wall portion 70 are provided on a non-planar surface. Aspects of FIG. 4A and 4B that are substantially similar to those shown in FIG. 3A and 3B will not be described in detail.

By configuring the housing 23 to define a non-planar region 72, an increased surface area is provided, as opposed to a planar region. For example, it will be appreciated that a circular surface has a surface area of π* ^radius2 , while a hemispherical surface has a surface area of 2*π* ^radius2 . By providing a three dimensional surface, the surface area of the channel outlet wall portion 70 is increased relative to a channel outlet wall having a two dimensional surface, depending on the extent of the surface in the third dimension.

The non-planar region 72 is bounded by the peripheral region of the mouthpiece outlet 50. The non-planar region 72 may have a continuously curved surface. The non-planar region may define a continuously curved surface within the boundaries of the peripheral region such that the non-planar region and the peripheral region form a bowl-shaped or concave shape. The curved surface of the non-planar region may not be constant and may be defined by a radius of curvature. In some examples, the non-planar region 72 may have a larger radius of curvature closer to the peripheral region and a smaller radius of curvature further from the peripheral region. Furthermore, in some examples, the non-planar region 72 may have different radii of curvature in the first and second planes. For example, as shown in FIG. 4, the mouthpiece outlet 50 may have an elliptical shape. The radius of curvature in the plane defined by the major axis of the ellipse and the airflow direction has a smaller radius of curvature than the radius of curvature in the plane defined by the minor axis of the ellipse and the airflow direction.

In some examples, the radius of curvature of the non-planar region has a range selected from the group consisting of 0.3 cm to 3.0 cm, 0.3 to 2.5 cm, 0.3 cm to 2.0 cm, 0.3 cm to 1.5 cm, and 0.3 cm to 1.0 cm, and the radius of curvature is in a first plane, the first plane being perpendicular to the airflow direction during normal use. In some examples, the first plane may be defined by an axis of the shape of the peripheral portion of the mouthpiece outlet 50 and an axis of the airflow direction. For example, the axis of the shape may be the major or minor axis of an ellipse defined by the peripheral portion.

In some examples, the second radius of curvature of the non-polar region has a range selected from the group consisting of 0.3 cm to 3.0 cm, 0.3 to 2.5 cm, 0.3 cm to 2.0 cm, 0.3 cm to 1.5 cm, and 0.3 cm to 1.0 cm, the second radius of curvature being relative to an axis perpendicular to both the airflow direction in normal use and the normal to the first plane (e.g., the airflow direction can be considered to define a first axis, the normal to the first plane can be considered to define a second axis, and a third axis can be considered to be perpendicular to the first and second axes, with the second radius of curvature being relative to the third axis). In some examples, it will be appreciated that the second radius of curvature of the continuously curved surface is substantially infinite relative to the second axis, in which case the non-planar surface is flat or effectively uncurved relative to an axis perpendicular to both the airflow direction in normal use and the first plane.

Figure 5 provides a cross-sectional view through a receptacle 8 according to the exemplary vapor delivery system 1 of Figure 1, with the plane of the cross-section perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of Figure 4B, the side wall portion 32 does not define an indentation, instead the non-planar surface 72 of the channel outlet wall portion 70 of the receptacle 8 of Figure 5 curves outward from the center of the receptacle 8. Aspects of Figure 5 that are substantially similar to those shown in Figure 4B will not be described in detail.

5 depicts a mouthpiece outlet of the receptacle 8 that is convex relative to the interior region of the receptacle 8. As in FIGS. 4A and 4B, configuring the sidewall portion 32 to define a non-planar region 72 provides an increased surface area as opposed to a planar region. In contrast to FIGS. 4A and 4B, the sidewall portion 32 defines the outer surface of the mouthpiece, including a central region furthest from the center of the receptacle 8 and a peripheral region surrounding the central region. The peripheral region may be generally adjacent to the end of the channel 34 and/or a recess 90 for collecting liquid.

The recess 90 may be provided as a valley (e.g., a U-shaped valley or a V-shaped valley) that surrounds the entire circumference of the channel 34 or a portion of the circumference of the channel 34. The recess may be created by the intersection of the channel outlet wall portion 70 and the sidewall portion 32. The channel outlet wall portion 70 may be provided at an angle relative to the sidewall portion 32 such that the channel outlet wall portion 70 and the sidewall portion 32 define a recess, and the recess 90 is open on one side to allow liquid to enter the recess. In some examples, the recess may be defined by additional wall features extending from either the outlet wall portion 70 or the sidewall portion 32. In some examples, the recess 90 may have a depth, typically parallel to the airflow direction, of 1 mm to 5 mm, preferably 2 mm to 4 mm, and most preferably 3 mm. The recess may have a liquid volume capacity between 0.2 ml and 1 ml, preferably between 0.3 ml and 0.5 ml.

5, the radius of curvature of the non-planar region has a range selected from the group consisting of 0.3 cm to 3.0 cm, 0.3 to 2.5 cm, 0.3 cm to 2.0 cm, 0.3 cm to 1.5 cm, and 0.3 cm to 1.0 cm, and the radius of curvature is in a first plane, the first plane being perpendicular to the airflow direction during normal use. In some examples, the first plane may be defined by an axis of the shape of the peripheral portion of the mouthpiece outlet 50 and an axis of the airflow direction. For example, the axis of the shape may be the major or minor axis of an ellipse defined by the peripheral portion.

In some examples according to FIG. 5, the second radius of curvature of the non-polar region has a range selected from the group consisting of 0.3 cm to 3.0 cm, 0.3 to 2.5 cm, 0.3 cm to 2.0 cm, 0.3 cm to 1.5 cm, and 0.3 cm to 1.0 cm, the second radius of curvature being relative to an axis perpendicular to both the airflow direction in normal use and the normal to the first plane. It will be appreciated that in some examples, the second radius of curvature of the continuously curved surface is substantially infinite relative to the second axis, in which case the non-planar surface is effectively uncurved relative to an axis perpendicular to both the airflow direction in normal use and the normal to the first plane.

Figure 6 provides a cross-sectional view through a receptacle 8 according to the exemplary vapor delivery system 1 of Figure 1, with the plane of the cross section perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of Figure 4B, the sidewall portion 32 does not define a recess 90 for collecting liquid. Aspects of Figure 6 that are substantially similar to those shown in Figure 4B will not be described in detail.

In FIG. 6, the non-planar region 72 having multiple holes may extend to the edge of the channel 34, in which case no recess is formed for collecting liquid. This provides a larger surface area for the multiple holes. Furthermore, this may promote a more uniform air flow throughout the channel 34 and avoid concentrating the air flow in a central region.

7 provides a cross-sectional view through the receptacle 8 of the exemplary vapor delivery system 1 of FIG. 1, with the plane of the cross-section perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of FIG. 4B, the receptacle 8 includes a side wall portion 32, a mouthpiece, and an inlet wall portion 40 (rather than an outlet wall portion 70) that are formed as an integrally formed single component. Aspects of FIG. 6 that are substantially similar to those shown in FIG. 4B will not be described in detail.

As with the above examples, the integrally formed components may be formed by integrally molding the mouthpiece, sidewall portion, and inlet wall portion 40 using a single mold. The components may be formed using injection molding or any other conventional process. For example, the components may be integrally formed by an additive manufacturing process, such as top-down or bottom-up 3D printing of a suitable material. In some examples, a casting process may be used.

As shown in Figure 7, the inlet wall portion 40 may include a non-planar region 72 having a plurality of holes. By configuring the housing 23 to define the non-planar region 72, an increased surface area is provided as opposed to a planar region. For example, it will be appreciated that a circular surface has a surface area of π* ^radius2 , while a hemispherical surface has a surface area of 2*π* ^radius2 . By providing a three-dimensional surface, the surface area of the channel inlet wall portion 40 is increased relative to a channel inlet wall having a two-dimensional surface, depending on the extent of the surface in the third dimension.

The non-planar region 72 is bounded by a peripheral region at the base of the insert portion 38. The non-planar region 72 may have a continuously curved surface. The non-planar region may define a continuously curved surface within the boundaries of the peripheral region such that the non-planar region and the peripheral region form a bowl or concave shape. The curved surface of the non-planar region may not be constant and may be defined by a radius of curvature. In some examples, the non-planar region 72 may have a larger radius of curvature closer to the peripheral region and a smaller radius of curvature further from the peripheral region. Furthermore, in some examples, the non-planar region 72 may have different radii of curvature in the first and second planes.

After filling the receptacle 8 with the fragrance material 36, the outlet wall portion 70 may be provided. The side wall portion 32 may be further configured to define a retention mechanism 60 (not shown) for retaining the channel outlet wall portion 70 in the end of the channel 34 opposite the end having the channel outlet wall portion 70. By retention mechanism, it is meant a mechanism for retaining the channel outlet wall portion 70 in the channel 34. In other words, the retention mechanism 60 blocks or prevents the channel outlet wall portion 70 from exiting the channel 34 after insertion. It will be appreciated that due to the presence of the channel inlet wall portion 40, the end having the channel inlet wall portion 40 prevents the channel outlet wall portion 70 from exiting the channel 34.

2B and 2C, the retention mechanism 60 may comprise a plurality of tabs. The tabs are configured to fold upward and face inward toward the center of the channel 34 upon application of pressure (and optionally heat). In use, the outlet wall portion 70 is inserted into the channel 34 formed by the side wall portions 32, and then the retention mechanism 60 is adjusted to narrow the diameter of the channel 34, thereby preventing the outlet wall portion 70 from exiting the channel 34. It will be appreciated that the outlet wall portion 70 is configured to have a shape that is small enough to be inserted into the channel 34, but large enough to be retained by the retention mechanism 60.

In other examples, not shown, the retention mechanism 60 may be established by conventional techniques, such as based on threads, clips, or latch mechanisms. Alternatively or additionally, the retention mechanism 60 may use adhesive or ultrasonic welding to bond the inlet wall portion 40 to the housing. This may be in place of the tabs shown in FIG. 7.

Figure 8 provides a cross-sectional view through a receptacle 8 according to the exemplary vapor delivery system 1 of Figure 1, with the plane of the cross-section perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of Figure 4B, the non-planar region 72 having multiple holes comprises a planar or flat central region 73 and a curved region 74. Aspects of Figure 8 that are substantially similar to those shown in Figure 4B will not be described in detail.

An example of a non-planar region 72 may include a planar region 73 and at least one other adjacent curved region 74 that borders the planar region 73. As shown in FIG. 8, the planar region 73 includes a central portion of the outlet wall portion 70, and at least one adjacent curved region 74 surrounds or borders at least a portion of the central portion. In some examples, the planar region 73 defines a circular or elliptical central portion of the non-planar region 72, and the adjacent non-planar region defines a non-planar surface that extends from an edge of the circular or elliptical surface. As an example, the adjacent curved region 74 may be an annulus that surrounds the circular central portion of the planar region 73.

In other examples, the planar portion 73 may have a surface having a polygonal shape with several edges (e.g., the surface may be a square). A curved surface 74 extends from an edge of the planar surface 73. A second adjacent curved surface 74 may extend from a different edge of the surface, such as an opposite edge of the surface (i.e., a parallel edge of a square). In some examples, adjacent curved surfaces or portions 74 may not be adjacent to each other. For example, adjacent curved surfaces 74 may be connected by a wall that does not include any of the holes of the non-planar region 72.

8 depicts the central region of the outlet wall portion 70 having a planar or flat surface, in other examples the central region may have a curved surface and one or more adjacent regions may have a flat surface. It will be appreciated that the outlet wall portion 70 may be configured to provide a variety of different curved and planar surfaces depending on particular requirements.

Figure 9 provides a cross-sectional view through a receptacle 8 according to the exemplary vapor delivery system 1 of Figure 1, with the plane of the cross-section perpendicular to the longitudinal axis of the device. In contrast to the receptacle 8 of Figure 4B, the non-planar region 72 having multiple holes comprises multiple planar regions 73, each of which defines a surface having a normal that is non-parallel to any other surface of the multiple planar regions 73. Aspects of Figure 9 that are substantially similar to those shown in Figure 4B will not be described in detail.

In some examples, the non-planar portion 72 may be formed from multiple planar portions, each defining a surface having a plane that is different from the plane defined by the surfaces of the remaining portions.

In other examples, the planar portion 73 may comprise a surface having a polygonal shape with several edges (e.g., the surface may be a square). An adjacent curved surface 74 extends from an edge of the surface. A second adjacent curved surface 74 may extend from a different edge of the surface, such as an opposite edge of the surface (i.e., a parallel edge of a square). In some examples, the adjacent curved surfaces 74 may not be adjacent to each other. For example, the adjacent curved surfaces 74 may be connected by a wall that does not include any of the holes of the non-planar region 72.

Figure 10 provides a top-down view of the example receptacle 8 of Figure 9. Aspects of Figure 10 that are substantially similar to those shown in Figure 9 will not be described in detail. Top-down means that the view is in a plane perpendicular to the airflow direction during normal use. In other words, this is a view that is in a plane perpendicular to the longitudinal axis of the receptacle 8.

In the example shown, the non-planar portion 72 includes a set of seven planar portions 73. The central planar portion defines a surface having a hexagonal shape. Extending from each of the six sides of the hexagonal central portion is one of the remaining six planar portions. Each of the planar portions 73 defines a surface that extends from the central planar portion to an edge of the mouthpiece outlet 50 defined by the sidewall portion 32. The plane of each of the planar portions surrounding the central portion is at an angle to the central portion such that the normal defined by any of the planar portions 73 is not parallel to the normal of any of the remaining planar portions 73.

In some examples, the holes in the non-planar region 72 may be regularly spaced throughout each of the planar portions 73. In other examples, one or more of the planar portions 73 may have a greater density of holes. For example, a planar portion 73 located in the center of the non-planar surface may have a greater or lesser density of holes compared to the planar portions around the outside of the non-planar region 72. In other examples, not shown, it will be appreciated that there may be other configurations of the planar portions 73 to provide the non-planar region 72. For example, there may be no central region, or the central region may have a different number of edges, e.g., 3-12 edges.

Figure 11 provides a top-down view of the example receptacle 8 of Figure 8. Aspects of Figure 11 that are substantially similar to those shown in Figure 8 will not be described in detail. Top-down means that the view is in a plane perpendicular to the airflow direction during normal use. In other words, this is a view that is in a plane perpendicular to the longitudinal axis of the receptacle 8.

As shown, the holes in the non-planar region 72 may be concentrically arranged around the center of the non-planar region 72. The center of the non-planar region 72 may be the center of a longitudinal axis through the device, with at least one fold of symmetry about the longitudinal axis. In some examples, the longitudinal axis may also be the center of the airflow during normal use. In some examples, the density of holes may be constant across the non-planar region. In other examples, the density of holes may increase or decrease with distance from the center.

Figure 12 provides a cross-sectional view of a portion of the mouthpiece outlet 50 and sidewall portion 32 of the exemplary vapor delivery system 1 of Figure 1. Certain aspects of Figure 12 are substantially similar to those shown in the preceding figures and will not be described in detail again.

12 illustrates the location of multiple holes in the non-planar region 72. As discussed above, the outlet wall portion 70 has multiple holes that allow air to pass from one side of the outlet wall to the other side of the outlet wall. The outlet wall portion 70 is disposed at the mouthpiece outlet 50 end of the channel 34 formed by the sidewall portion 32. The outlet wall portion 70 is inset slightly inboard of the end of the channel 34. The sidewall portion 32 and the outlet wall portion 70 may further define a recess 90 for retaining liquid.

As shown, the outlet wall portion 70 includes a non-planar region 72 having a plurality of holes or openings 77. Each of the openings is disposed parallel to the longitudinal axis of the receptacle 8, which is substantially parallel to the direction of airflow through the receptacle 8 during normal use.

Figure 13 provides a cross-sectional view of a portion of the mouthpiece outlet 50 and sidewall portion 32 of the exemplary vapor delivery system 1 of Figure 1. Certain aspects of Figure 13 are substantially similar to those shown in the preceding figures and will not be described in detail again.

13 illustrates the location of multiple holes in the non-planar region 72. As described above, the outlet wall portion 70 has multiple holes that allow air to pass from one side of the outlet wall to the other side of the outlet wall. The outlet wall portion 70 is disposed at the mouthpiece outlet 50 end of the channel 34 formed by the sidewall portion 32. The outlet wall portion 70 is inset slightly inboard of the end of the channel 34. The sidewall portion 32 and the outlet wall portion 70 may further define a recess 90 for retaining liquid.

As shown, the outlet wall portion 70 includes a non-planar region 72 having a plurality of holes or openings 77. Each of the openings 77 includes a hole through the outlet wall, the hole having a longitudinal axis parallel to the normal of the non-planar region as the location of the corresponding opening. This may aid in the flow of air from the peripheral region of the flavoring material 36.

Figure 14 provides a cross-sectional view through the receptacle 8 of the exemplary vapor delivery system 1 of Figure 1, with the plane of the cross-section perpendicular to the longitudinal axis of the receptacle 8. Aspects of Figure 14 that are substantially similar to those shown in the preceding figures will not be described in detail.

The sidewall portion 32 may include a ledge or lip 120 configured to prevent movement of the inlet wall portion 40 in a certain direction. For example, the inlet wall portion 40 may be inserted into the channel 34 from the mouthpiece outlet 50 end. The inlet wall portion 40 may move within the channel 34 between the mouthpiece outlet 50 and the lip 120, but the inlet wall portion 40 may not move beyond the lip 120. In this manner, the inlet wall portion 40 may be attached to the sidewall portion 32 using the lip 120.

The lip or ledge 120 may be formed by one or more protrusions extending inwardly from the sidewall portion 32 that defines the channel 34. The lip or ledge 120 is thus configured to prevent movement of the inlet wall portion 40 and retain the inlet wall within the channel, thereby maintaining the position of the inlet wall portion 40 within the receptacle 8. In some examples, the inlet wall portion 40 may be additionally connected to the sidewall portion 32 by ultrasonic welding, adhesive, or any other conventional technique to maintain the position of the inlet wall portion 40.

In other examples, the side wall portion 32 and the inlet wall portion 40 may be integrally formed, for example, by injection molding using a single mold or by 3D printing a single component. In these other examples, the receptacle 8 may or may not include a lip 110. Furthermore, while the inlet wall portion 40 in FIG. 14 is planar or flat, in other examples the inlet wall portion 40 may be non-planar and may be configured, for example, as described in FIG. 7 and related embodiments.

The receptacle 8 includes a sidewall portion 32, a mouthpiece element 110, an outlet wall portion 70, and an inlet wall portion 40. The mouthpiece element 110 is integrally formed with or otherwise connected to the outlet wall portion 70. For example, the mouthpiece element 110 may be integrally formed with the outlet wall portion 70 using a single mold, or the mouthpiece element 110 and the outlet wall portion 70 may be formed separately and connected by ultrasonic welding, adhesive, or any other conventional technique to form a single component. The receptacle 8 includes a sidewall portion 32 that defines a channel 34 within which a flavoring material 36 may be provided.

In the example of FIG. 14, the outlet wall portion 70 comprises a channel insert portion 130 that is inserted into the channel 34 of the receptacle 8 when the outlet wall portion 70 is attached to the sidewall portion 32 (e.g., by attaching the mouthpiece element 110 to the sidewall portion 32). The outlet wall portion 70 may be provided at the base of the channel insert portion 130 as shown. The channel insert portion 130 is configured to have a shape that approximately matches but is slightly smaller than the portion of the channel 34 into which it is inserted, such that the channel insert portion 130 fits closely to the sidewall of the channel 34 when the channel insert portion 130 is inserted into the channel (i.e., an interference fit such that the channel insert portion 130 fits closely to the sidewall of the channel 34). By way of example, the channel insert portion 130 and the channel 34 may be cylindrical, and the diameter of the channel insert portion 130 may be only slightly smaller than the diameter of the channel 34. The outlet wall portion 70 may be provided as a circular portion that plugs the cylinder formed by the channel insert portion 130. It will be appreciated that the configuration of the channel 34 and the channel insert 130 may be provided in a variety of corresponding shapes that still allow for a close fit between the channel 34 and the channel insert 130. Furthermore, while the outlet wall portion 70 in FIG. 14 is planar or flat, in other examples the outlet wall portion 70 may be non-planar and may be configured, for example, as described in FIGS. 4A, 4B, 5, 6, and 8-13 and related embodiments.

In some examples, the sidewall portion 32 and the mouthpiece element 110 may be removably coupled together. Once the scented material 36 in the receptacle 8 is used up, or simply when the user desires to replace with a different scented material, the mouthpiece element 110 can be separated from the sidewall portion 32, and the scented material 36 in the channel 34 can be replaced. The sidewall portion 32 and the mouthpiece element 110 may be coupled together such that a structural connection between the two parts is established. In the example of FIG. 14, retention of the mouthpiece element 110 relative to the sidewall portion 32 is facilitated by a latching element or clip 150 and a corresponding latch member 160 for receiving a portion of the latching element 150.

The mouthpiece element 110 may comprise a pair of latching elements 150. Two latching elements 150 are disposed on each side of the mouthpiece element 110 in an opposing manner. The latching elements 150 comprise a foot portion 152 and a leg portion 151. In this example, the leg 151 is a substantially elongated element, and the foot 152 is an element that protrudes from the end of the leg 151 at substantially 90 degrees to the longitudinal axis of the leg 151. The flexibility of the leg 151 allows the foot 152 to move relative to the rest of the mouthpiece element 110 (e.g., the channel insert portion 130) when an external force is applied to the leg 151. The movement of the leg 151 (and thus the foot) can be thought of as a hinged movement that increases or decreases the angle of the leg 151 relative to the rest of the mouthpiece element 110 from a neutral position. When the force is removed, the elasticity of the leg 151 causes the angle to return to its original size, maintaining the normal shape of the latching element.

The latching element 150 is secured to the sidewall portion 32 with the legs 151 and feet 152 extending beyond the top surface of the housing. In other words, a portion of the sidewall portion 32 and at least the legs 151 overlap in the longitudinal direction of the receptacle 8. The latching element 150 may be secured by engaging the foot portion 152 within the latch member 160. The foot portion 152 is generally in the plane of the latch member 160. The latch member 160 is shaped to receive the foot portion 152, e.g., a hole or recess formed by a protruding portion of the latch member 160 extending from a side edge of the sidewall portion 32, into which the foot portion 152 is inserted. For example, the sidewall portion 32 may be molded or otherwise include a molded portion formed from a rigid plastic that engages around and receives the foot portion, thereby holding it in place.

In other examples, not shown, the mouthpiece element 120 may be mechanically or chemically coupled to the sidewall portion 32 by conventional techniques, such as by using threads, latching mechanisms, or bayonet fastening openings to appropriately establish electrical connections and air paths between the two portions. In some examples, the foot portion 152 may be locked by screws or rivets that pass through the latching elements 150 and are attached into the sidewall portion 32, or by being glued or welded to the housing. It will be appreciated that in these examples, the sidewall portion 32 and the mouthpiece element 110 may not be intended to be removably coupled together.

FIGS. 15A-15C provide a series of cross-sectional views of the example receptacle 8 of FIG. 14 depicting the loading of the receptacle with flavoring material and the attachment of the mouthpiece element 110 to the sidewall portion 32. Aspects of FIGS. 15A-15C that are substantially similar to those shown in FIG. 14 will not be described in detail.

The receptacle 8 is configured to hold the scented material 36 between the inlet wall portion 40 and the outlet wall portion 70 in the channel 34. As shown in FIG. 15A, the receptacle 8 is intended to be substantially filled with a quantity of scented material 36 after the inlet wall portion 40 is provided in the channel 34. The inlet wall portion 40 may be held in the channel 34, for example, due to the orientation of the receptacle 8 and the lip 120 (i.e., by gravity) or by any other means (e.g., adhesive or welding). The scented material 36 may then be fed into the receptacle 8 through the open outlet end of the channel 34. The filling of the receptacle 8 with the scented material 36 may be aided by a funnel 170, chute, or similar element for directing the scented material.

The mouthpiece element 110 can then be attached to the sidewall portion 32 by the latching element 150 and corresponding latch member 160, as shown in FIG. 15B. Once the mouthpiece element 110 is attached to the sidewall portion 32, the channel insert portion 130 is inserted into the channel 34.

15C, attachment of the mouthpiece element 110 to the sidewall portion 32 causes the channel insert portion 130 to compress the flavor material 36 within the channel 34. The channel insert portion 130 may compress the flavor material 36 by effectively reducing or eliminating the empty space within the volume bounded by the sidewalls, the inlet wall portion 40, and the outlet wall portion 70 of the channel 34. The receptacle may be configured to compress the flavor material in a range selected from the group consisting of 5% to 40%, 10% to 35%, 15% to 30%, and 20% to 30% of the uncompressed volume of the flavor material.

Still further, the volume defined by the inlet wall portion 40, the side wall portion 32, and the opening at the outlet end of the channel defined by the side wall may have a volume within a range selected from the group consisting of ² cm to ¹⁰ cm, ³ cm to 9 ^cm , ⁴ cm to ⁸ cm, and 5 ^cm to 8 ^cm . The volume defined by the inlet wall portion 40, the side wall portion 32, and the outer wall portion 70 (when the mouthpiece element 110 is attached to the side wall portion 32) may have a volume within a range selected from the group consisting of ¹ cm to ⁸ cm, ² cm to 7 ^cm , 2.5 ^cm to ⁶ cm, and ³ cm to 5 ^cm . Furthermore, the volume defined by the inlet wall portion 40, the side wall portion 32, and the opening at the outlet end of the channel defined by the side wall may be filled by the uncompressed volume of the fragrance material within a range selected from the group consisting of 50% to 95%, 60% to 85%, 65% to 80%, and 70% to 80%.

16 provides a cross-sectional view through the receptacle 8 of the exemplary vapor delivery system 1 of FIG. 1, with the plane of the cross-section perpendicular to the longitudinal axis of the receptacle 8. In contrast to the receptacle of FIG. 14, the receptacle of FIG. 16 includes a mounting 180 comprising an inlet wall portion 40 and a latching element 150 configured to be connected to the side wall portion 32. Aspects of FIG. 16 that are substantially similar to those shown in the preceding figures will not be described in detail.

The receptacle 8 comprises a sidewall portion 32, an outlet wall portion 70, and an inlet wall portion 40. The sidewall portion 32 is configured to define a mouthpiece outlet 50, a channel 34 in which a flavoring material 36 can be provided, and optionally an outlet wall. The outlet wall portion 70 can be separately attached to the sidewall portion 32 (e.g., using ultrasonic welding or adhesive) or can be positioned using a lip feature as shown in detail in FIG. 14. The ledge or lip 120 used in the receptacle of FIG. 16 can be configured to prevent movement of the outlet wall portion 70 (but not the inlet wall) in a certain direction. The outlet wall portion 70 can move within the channel 34 between the inlet end of the channel 34 and the lip 120, but the outlet wall portion 70 cannot move beyond the lip 120. Alternatively, the sidewall portion 32 and the outlet wall portion 70 (and any other components of the housing) can be integrally formed, for example by injection molding using a single mold or other methods described above. The side wall portion 32 may also define an insert portion 38 of the receptacle 8 that is inserted into a receptacle 54 at an open end of the air passage 52 opposite the end of the cartridge 4 that couples to the control unit 2. The insert portion may be integrally formed with the side wall portion 32 and the outlet wall portion 70. Furthermore, although the outlet wall portion 70 in FIG. 14 is planar or flat, in other examples the outlet wall portion 70 may be non-planar and may be configured, for example, as described in FIGS. 4A, 4B, 5, 6, and 8-13 and related embodiments.

In the example of FIG. 16, the inlet wall portion 40 is provided as part of the mounting body 180, which also includes a channel insert portion 130 that is inserted into the channel 34 of the receptacle 8 when the inlet wall portion 40 is mounted to the housing. The inlet wall portion 40 is provided at the base of the channel insert portion 130. The channel insert portion 130 is configured to have a shape that approximately matches but is slightly smaller than the portion of the channel 34 into which it is inserted, so that the channel insert portion 130 fits closely to the side wall of the channel 34 when the channel insert portion 130 is inserted into the channel. By way of example, the channel insert portion 130 and the channel 34 may be cylindrical, and the diameter of the channel insert portion 130 may be only slightly smaller than the diameter of the channel 34. The inlet wall portion 40 may be provided as a circular portion that plugs the cylinder formed by the channel insert portion 130. It will be appreciated that the configuration of the channel 34, channel insert 130 may be provided in a variety of shapes that still allow for a close fit between the channel 34 and the channel insert 130.

In some examples, the sidewall portion 32 and the attachment 180 may be removably coupled together. When the scented material 36 in the receptacle 8 is used up, or simply when the user desires to replace with a different scented material, the attachment 180 can be separated from the sidewall portion 32 and the scented material 36 in the channel 34 can be replaced. The sidewall portion 32 and the attachment 180 may be coupled together such that a structural connection between the two portions is established. In the example of FIG. 14, retention of the attachment 180 to the sidewall portion 32 is facilitated by a latching element or clip 150 and a corresponding latch member 160 for receiving a portion of the latching element 150.

The mounting body 180 may include a pair of latching elements 150. Two latching elements 150 are disposed on each side of the mouthpiece element 110 in an opposing manner. The latching elements 150 include a foot portion 152 and a leg portion 151. In this example, the leg 151 is a substantially elongated element, and the foot 152 is an element that protrudes from the end of the leg 151 at substantially 90 degrees to the longitudinal axis of the leg 151. The flexibility of the leg 151 allows the foot 152 to move relative to the rest of the mounting body 180 (e.g., the channel insert portion 130) when an external force is applied to the leg 151. The movement of the leg 151 (and thus the foot) can be thought of as a hinged movement that increases or decreases the angle of the leg 151 relative to the rest of the mounting body 180 from its normal position. When the force is removed, the elasticity of the leg 151 causes the angle to return to its original size, maintaining the normal shape of the latching element.

The latching element 150 is secured to the sidewall portion 32 with the legs 151 and feet 152 extending beyond the top surface of the housing. In other words, a portion of the sidewall portion 32 and at least the legs 151 overlap in the longitudinal direction of the receptacle 8. The latching element 150 may be secured by engaging the foot portion 152 within the latch member 160. The foot portion 152 is generally in the plane of the latch member 160. The latch member 160 is shaped to receive the foot portion 152, e.g., a hole or recess formed by a protruding portion of the latch member 160 extending from a side edge of the sidewall portion 32, into which the foot portion 152 is inserted. For example, the sidewall portion 32 may be molded or otherwise include a molded portion formed from a rigid plastic that engages around and receives the foot portion, thereby holding it in place.

In other examples, not shown, the mouthpiece element 120 may be mechanically or chemically coupled to the sidewall portion 32 by conventional techniques, such as by using threads, latching mechanisms, or bayonet fastening openings to appropriately establish electrical connections and air paths between the two portions. In some examples, the foot portion 152 may be locked by screws or rivets that penetrate the latching elements 150 and are attached into the sidewall portion 32, or by being glued or welded to the housing. In these examples, it will be appreciated that the sidewall portion 32 and the mounting 180 may not be intended to be removably coupled together.

During the filling process, the receptacle 8 is intended to be substantially filled with a quantity of the fragrance material 36 after the outlet wall portion 70 is provided in the channel 34. The outlet wall portion 70 may be held in the channel 34, for example, due to the orientation of the receptacle 8 and the lip 120 (i.e., by gravity) or by any other means (e.g., adhesive or welding). The fragrance material 36 may then be fed into the receptacle 8 through the open inlet end of the channel 34. The filling of the fragrance material 36 into the receptacle 8 may be aided by a funnel, chute, or similar element to direct the fragrance material. The attachment 180 may be attached to the sidewall portion 32 by a latching element 150 and a corresponding latch member 160. Once the attachment 180 is attached to the sidewall portion 32, the channel insert portion 130 is inserted into the channel 34. Attachment of the attachment 180 to the sidewall portion 32 causes the channel insert portion 130 to compress the fragrance material 36 within the channel 34. The channel insert portion 130 may compress the fragrance material 36 by effectively reducing or eliminating the empty space within the volume bounded by the sidewalls, the inlet wall portion 40, and the outlet wall portion 70 of the channel 34. As detailed above, the receptacle may be configured to compress the fragrance material in a range selected from the group consisting of 5% to 40%, 10% to 35%, 15% to 30%, and 20% to 30% of the uncompressed volume of the fragrance material.

Still further, the volume defined by the inlet wall portion 40, the side wall portion 32, and the opening at the outlet end of the channel defined by the side wall may have a volume within a range selected from the group consisting of ² cm to ¹⁰ cm, ³ cm to 9 ^cm , ⁴ cm to ⁸ cm, and 5 ^cm to 8 ^cm . The volume defined by the inlet wall portion 40, the side wall portion 32, and the outer wall portion 70 (when the mouthpiece element 110 is attached to the side wall portion 32) may have a volume within a range selected from the group consisting of ¹ cm to ⁸ cm, ² cm to 7 ^cm , 2.5 ^cm to ⁶ cm, and ³ cm to 5 ^cm . Furthermore, the volume defined by the inlet wall portion 40, the side wall portion 32, and the opening at the outlet end of the channel defined by the side wall may be filled by the uncompressed volume of the fragrance material within a range selected from the group consisting of 50% to 95%, 60% to 85%, 65% to 80%, and 70% to 80%.

17 is a schematic representation of a method of manufacturing a receptacle for flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium according to certain embodiments of the present disclosure. The receptacle comprises a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the method comprising a first step S1 of providing a side wall portion to which one of the inlet wall portion and the outlet wall portion is attached, a second step S2 of placing the flavoring material in the cavity, and a third step S3 of attaching the other of the inlet wall portion and the outlet wall portion to the side wall portion such that the flavoring material is compressed between the inlet wall portion and the outlet wall portion.

Thus, an aerosol delivery system is described that includes an air passageway extending from a vapor-generating region where vapor is generated for inhalation by a user to a flavoring region of a receptacle for receiving a flavoring medium for flavoring the vapor, the receptacle including a wall for holding the flavoring material, the wall including a plurality of openings for airflow and a non-planar region, the plurality of openings being disposed within the non-planar region.

Still further described is an aerosol delivery system comprising an air passageway extending from a vapor-generating region where vapor is generated for inhalation by a user to a flavoring region of a receptacle for receiving a flavoring medium for flavoring the vapor, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall portion and the outlet wall portion being attached to the side wall portion to compress the flavoring material in the cavity between the inlet wall portion and the outlet wall portion.

Furthermore, an aerosol delivery system is described that includes an air passageway extending from a vapor-generating region where vapor is generated for inhalation by a user to a flavoring region of a receptacle for receiving a flavoring medium for flavoring the vapor generated by the aerosol delivery system, the receptacle including a mouthpiece portion, a sidewall, and an outlet wall of the mouthpiece portion having a plurality of openings for airflow, the mouthpiece portion, the sidewall, and the outlet wall being integrally formed.

Furthermore, an aerosol delivery system is described that includes an air passageway extending from a vapor-generating region where vapor is generated for inhalation by a user to a flavoring region of a receptacle for receiving a flavoring medium for flavoring the vapor, the receptacle including a housing having a sidewall and a lip extending inwardly from the sidewall for supporting one of the inlet or outlet walls of the receptacle.

1 has focused to some extent on devices having an aerosolizable liquid material for generating an inhalable medium, but as already pointed out, the same principles can be employed in devices based on other aerosolizable materials, for example solid materials, including plant-derived materials such as tobacco-derived materials, or other forms of aerosolizable materials, such as gel, paste, or foam-based aerosolizable materials. In this case, the aerosolizable material can be in the form of a solid, liquid, or gel, which may or may not contain nicotine and/or flavorings. In some embodiments, the aerosolizable material can include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dry gel. An amorphous solid is a solid material that can hold some fluid, e.g., liquid, within it. In some embodiments, the aerosolizable material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% of the amorphous solid, up to about 90 wt%, 95 wt%, or 100 wt% of the amorphous solid.

The aerosolizable material (sometimes referred to as an aerosol-generating material or an aerosol precursor material) may, in some embodiments, include a vapor generating agent or an aerosol generating agent, or a humectant. Exemplary such agents are glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Formulations that include one or more aerosol generating agent(s) are referred to herein as active agents.

Still further, as already noted, it will be appreciated that the techniques described above can be implemented in aerosol delivery systems, e.g., electronic smoking articles, having an overall structure different from that depicted in FIG. 1. For example, the same principles can be employed in aerosol delivery systems that do not include a two-part modular construction but instead include a single-part device, e.g., a disposable (i.e., non-rechargeable and non-refillable) device. Still further, in some implementations of the modular device, the configuration of components may differ. For example, in some implementations, the control unit may also include a vaporizer having a replaceable cartridge that provides a source of aerosolizable material used to generate the aerosol.

Furthermore, in some instances, the receptacle (flavor insert/pod) that is positioned in the airflow path through the device may be upstream of the vaporizer as opposed to downstream of the vaporizer.

As used herein, the terms "flavor" and "flavoring agent" and related terms refer to materials that can be used to produce a desired taste or odor in products for adult consumers, to the extent permitted by local regulations. The materials may be imitation, synthetic or natural, or mixtures thereof. The materials may be in any suitable form, such as an oil, liquid, or powder.

In order to address various problems and advance the art, the present disclosure provides, by way of example, various embodiments in which the claimed invention(s) may be implemented. The advantages and features of the present disclosure are merely for a representative sample of embodiments and are not exhaustive and/or exclusive. They are presented merely to aid in the understanding of and to teach the claimed invention(s). It should be understood that the advantages, embodiments, examples, features, features, structures, and/or other aspects of the present disclosure should not be considered as limiting the present disclosure as defined by the claims or the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claims. It will be appreciated that the various embodiments suitably comprise, consist of, or essentially consist of various combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein, and thus the features of the dependent claims may be combined with the features of the independent claims in other combinations than those explicitly set forth in the claims. This disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims (15)

1. An apparatus for producing an inhalable medium, comprising: a receptacle containing a flavoring material for imparting flavor to an inhalable medium produced by the apparatus, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall portion, the outlet wall portion and the side wall portion being configured such that attachment of the inlet wall portion and the outlet wall portion to the side wall portion compresses the flavoring material in the cavity between the inlet wall portion and the outlet wall portion compared to a state before the inlet wall portion and the outlet wall portion are attached to the side wall portion . The device of claim 1, wherein a selected one of the inlet wall portion and the outlet wall portion includes an insert portion that extends into the cavity and compresses the flavoring material in the cavity when the selected one of the inlet wall portion and the outlet wall portion is attached to the side wall portion. The device of claim 2, wherein the plurality of openings in the selected one of the inlet wall portion and the outlet wall portion are provided in the insert portion. The apparatus of claim 2 or 3, wherein the selected one of the inlet wall portion and the outlet wall portion is the inlet wall portion. The apparatus of claim 2 or 3, wherein the selected one of the inlet wall portion and the outlet wall portion is the outlet wall portion. The device of any one of claims 1 to 5, wherein the inlet wall portion and/or the outlet wall portion are attached to the side wall portion by an engagement mechanism selected from the group consisting of a latch, a bayonet, a press fit, an adhesive connection, a welded connection, and a threaded connection. The device of any one of claims 1 to 6, wherein the side wall portion includes a lip extending inwardly into the cavity, and one of the inlet wall portion or the outlet wall portion is held in place by the lip. The device according to any one of claims 1 to 7, wherein the inlet wall portion and/or the outlet wall portion are removably attached to the side wall portion. the outlet wall portion comprises a plurality of openings for airflow and a non-planar region, the plurality of openings in the outlet wall portion being within the non-planar region; and/or
the inlet wall portion includes a plurality of openings for airflow and a non-planar region, the plurality of openings in the inlet wall portion being within the non-planar region;
An apparatus according to any one of claims 1 to 8. The device according to any one of claims 1 to 9, further comprising a mouthpiece portion having the outlet wall portion, the mouthpiece portion, the sidewall portion, and the outlet wall portion being integrally formed. The device of any one of claims 1 to 10, further comprising an aerosolizable material, a heater configured to selectively aerosolize the aerosolizable material to produce the inhalable medium, and an airflow channel for directing the inhalable medium toward an inlet of the receptacle. 1. A receptacle containing a flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity, the inlet wall portion, the outlet wall portion and the side wall portion being configured such that attachment of the inlet wall portion and the outlet wall portion to the side wall portion compresses the flavoring material in the cavity between the inlet wall portion and the outlet wall portion compared to a state before the inlet wall portion and the outlet wall portion are attached to the side wall portion. 1. A means for producing an inhalable medium, comprising: a receptacle means containing a flavoring material means for imparting flavor to the inhalable medium produced by said means for producing an inhalable medium, said receptacle means comprising side wall means, outlet wall means and inlet wall means, said side wall means defining a cavity for said flavoring material means , said inlet wall means and said outlet wall means each comprising a plurality of openings for permitting airflow through said cavity, said inlet wall means, said outlet wall means and said side wall means being configured such that attachment of said inlet wall means and said outlet wall means to said side wall means compresses said flavoring material means in said cavity between said inlet wall means and said outlet wall means compared to a state before said inlet wall means and said outlet wall means are attached to said side wall means. 1. A method for imparting a flavoring to an inhalable medium produced by an apparatus for producing an inhalable medium, comprising the steps of: providing a receptacle containing a flavoring material, the receptacle having a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each having a plurality of openings for allowing airflow through the cavity, the inlet wall portion, the outlet wall portion and the side wall portion being configured such that attachment of the inlet wall portion and the outlet wall portion to the side wall portion compresses the flavoring material in the cavity between the inlet wall portion and the outlet wall portion compared to a state before the inlet wall portion and the outlet wall portion are attached to the side wall portion; and further comprising the step of passing the inhalable medium through the receptacle to impart the flavoring to the inhalable medium. 1. A method of manufacturing a receptacle containing a flavoring material for imparting flavor to an inhalable medium produced by an apparatus for producing an inhalable medium, the receptacle comprising a side wall portion, an outlet wall portion and an inlet wall portion, the side wall portion defining a cavity for the flavoring material, the inlet wall portion and the outlet wall portion each comprising a plurality of openings for allowing airflow through the cavity;
providing a sidewall portion having one of the inlet wall portion and the outlet wall portion attached thereto;
placing the fragrance material within the cavity;
and a step of attaching the other of the inlet wall portion and the outlet wall portion to the side wall portion, wherein attaching the other of the inlet wall portion and the outlet wall portion to the side wall portion compresses the fragrance material between the inlet wall portion and the outlet wall portion compared to before the other of the inlet wall portion and the outlet wall portion was attached to the side wall portion .

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