Consumable Cartridge and Cartridge Support for an Aerosol Generation Device

FIELD OF THE INVENTION

[0001]The present invention relates to a consumable cartridge support and consumable cartridge for an aerosol generation device. The disclosure is particularly applicable to a portable aerosol generation device.

BACKGROUND

[0002]Known aerosol generation devices, such as electronic cigarettes and vapes, normally involve a consumable, e.g. a cartridge or a pod, having a mouthpiece being inserted into the device. However, due to movement or positional variance of the pod inside the device and/or the manufacturing tolerances of the two components, it has been found that the airflow path through the device and the pod to can be inconsistent, which in turn can cause variable draw resistances as the device is used. Consequently, the distribution of airflow velocity is inconsistent and unreliable between devices and pods, which is mainly due to the lack of control over the airflow path.

[0003]An object of the invention is to improve the airflow and control through aerosol generation devices.

SUMMARY OF THE INVENTION

[0004]According to an aspect of the invention, there is provided a consumable cartridge support for receiving a consumable cartridge in an aerosol generation device, comprising: a tube-shaped wall configured to receive a consumable cartridge through an opening at a first end of the tube-shaped wall and to direct airflow from outside of the consumable cartridge support along at least a length of the tube-shaped wall, said tube-shaped wall extending at least partially along the received consumable cartridge; a rigid base arranged at a second end of the tube-shaped wall, the rigid base comprising: an aperture configured to align with a corresponding air inlet of the received consumable cartridge; and one or more channels configured to further direct the airflow to the aperture of the rigid base; and a seal arranged at least around an edge of the aperture so as to provide a sealed airflow connection between the one or more channels and the corresponding air inlet of the received consumable cartridge.

[0005]In this way, a seal is provided between the consumable cartridge support of the present disclosure and a received consumable cartridge/pod which ensures that airflow must follow a designed path in the device in delivering a generated aerosol to a user. When outside air is drawn into the support, it flows along the tube-shaped wall (the term “tube-shaped wall” may be used interchangeably with “sleeve”) toward the rigid base. The one or more channels introduce the single or multiple airflow control channels to the aerosol generation device, through which the outside air must pass through to enter the received pod. Known devices allow a received pod to rock or otherwise move in the device which cause an inconsistent draw resistance and distribution of airflow velocity between the device and pod. For instance, the movement of a pod in known devices may cause an airflow path to be squashed or otherwise restricted, and/or allow air to flow or leak into the pod away from the intended airflow path.

[0006]Advantageously, it has been found that the sealed airflow connection of the present disclosure allows the improved control over the airflow path from outside the device, through the device to the pod, and from the pod to a user. The control of the airflow path upstream of the received consumable cartridge eliminates the influence of the cartridge position in the device and any effects due to manufacturing tolerances of both the pod and the device. This provides a more stable airflow distribution or consistent change in the overall dynamic pressure and controlled performance of the aerosol generation device.

[0007]In order to have a reliable and consistent change in the dynamic pressure through the one or more channels, it is advantageous to have the one or more channels (which controls the pressure) formed with a rigid material (i.e. in the rigid base). With higher dynamic pressure change in the one or more channels of the rigid base, the local velocity of the airflow can be increased to reach high velocity regions (above 20 m/s or 70 km/h) and high velocity gradients.

[0008]Such high velocities and velocity gradients passing through a flexible structure, such as a silicone sealing lip or a control channel formed using a flexible material, could potentially deform the flexible structure, which in turn would affect the pressure distribution. This may also cause unreliable or inconsistent resistance to draw that may vary from user to user (since each user applies a different vacuum at the outlet of the pod as they take a puff).

[0009]Therefore, to avoid such deformations, the base is rigid and prevents any undesirable deformation of the one or more channels and/or seal. It should be understood that the change in dynamic pressure in the present invention primarily occurs in the one or more channels/rigid base so that the seal would not be significantly affected by any high velocities or velocity gradients. Additionally, a rigid base provides firm control over the cross-sectional area of the one or more channels, which eliminates possible misalignments in its production and generally makes it easier to manufacture the component with higher tolerances.

[0014]Preferably, the consumable cartridge support is configured to, in use, control an airflow path for air to flow from outside of the consumable cartridge support into the received consumable cartridge by flowing along the tube-shaped wall to the one or more channels of the rigid base, and from the one or more channels through the aperture of the rigid base into the received consumable cartridge. In this way, the consumable cartridge support better controls the airflow path through an aerosol generation device into a received consumable cartridge.

[0015]Preferably, the sealed airflow connection between the consumable cartridge support and the received consumable cartridge is formed when the corresponding air inlet is pressed against the seal. In this way, any potential air gaps between the seal and the consumable cartridge can be effectively eliminated.

[0016]Preferably, the seal comprises a sealing lip arranged to extend toward the first end of the tube-shaped wall. In this way, the sealing lip increases an interfacing surface of the seal to form the sealed airflow connection with air inlet of the consumable cartridge. The sealing lip may be deformed when the consumable cartridge is pressed against it.

[0017]Preferably, the tube-shaped wall further comprises one or more holes, and wherein the tube-shaped wall is shaped to, in use, allow the airflow to travel inside the aerosol generation device, preferably wherein the airflow includes a first portion between the consumable cartridge and the tube-shaped wall, and more preferably wherein the one or more holes allow the first portion of the airflow to join with a second portion of the airflow before reaching the one or more channels.

[0018]Preferably the second portion of the airflow is configured to pass through a space formed between the consumable cartridge support and a side wall of the aerosol generation device, preferably wherein the space is at least partially between the tube-shaped wall and the side wall of the aerosol generation device. In this way, additional airflow outside of the consumable cartridge support can be effectively used in the delivery of air and generated aerosol to the user. The second portion of the airflow may include the airflow outside of/away from the tube-shaped wall (i.e. not between the tube-shaped wall and the cartridge). In other words, the second portion of the airflow may also include air that is directed toward the one or more channels without flowing alongside the tube-shaped wall before entering the one or more channels (for example, where the second portion of airflow is from an additional air inlet hole in an aerosol generation device which is configured to deliver airflow directly to the one or more channels, without passing alongside the tube-shaped wall). Importantly, the cross-sectional area of the one or more channels is smaller than the cross-sectional area in the device for the airflow before entering the one or more channels so that the dynamic pressure change is controlled by the one or more channels.

[0019]In this way, the outside air is drawn into the one or more channels from both within and outside of the consumable cartridge tube-shaped wall (also described herein as the airflow along the inner surface of the tube-shaped wall (between the wall and the cartridge) and along the outer surface of the tube-shaped wall). In other words, airflow along the tube-shaped wall is not limited to the air travelling within the tube-shaped wall between the received cartridge and the tube-shaped wall (the primary upstream airflow in the present disclosure). When the support is provided in an aerosol generation device, a bypass airflow may travel along the outer surface of the tube-shaped wall, and the one or more holes in the wall allow this bypass airflow to be combined with the primary upstream airflow within the tube-shaped wall. This increases the capacity of the upstream airflow before it enters the one or more channels in the base. It should be understood that the one or more channels comprises the smallest cross-section area compared to the rest of the airflow through the device to ensure that the dynamic pressure change occurs within the one or more channels.

[0020]Preferably, the one or more channels are arranged through the rigid base to provide a closed channel flow. In this way, the shape and cross-sectional area of the one or more channels can be controlled to provide a more consistent airflow through the base, and into the received cartridge through the aperture. Closed channels in the rigid base also ensures that dust or other matter does not fall into the channels when the support is empty/does not have a cartridge within, which may block or impede airflow. It has been found that the aperture in the base (around which the seal is provided) is not the restrictive or limiting section which defines the most significant pressure change in the device. Instead it has been found that the one or more channels control the most significant pressure change in the device, and can therefore be designed to achieve a desired overall pressure change through the device. A desirable pressure change is −0.5 to −1 kPa.

[0021]Preferably, the aperture and one or more channels is formed in the rigid base using a material that is more rigid than the seal, and wherein the seal comprises an elastomer material. In this way, the seal provides an optimal sealed connection between the aperture of the base and the corresponding air inlet of the received consumable cartridge. The rigidity of the base ensures that the consumable cartridge can be firmly pressed against the base when it is inserted into the aerosol generation device, and the elastomer material provides the flexibility to seal the connection from any undesirable gaps that may cause leakage in the airflow.

[0022]Preferably, the seal is overmoulded onto the rigid base. In this way, the seal is effectively and easily provided on the base to form a single integrated piece. Both the base and the seal may be manufactured using a polymer material, and a two-component injection moulding process may be used, where the base is first injection moulded using a rigid material, for example a rigid/hard thermoplastic such as high-density polyethylene or polycarbonate, and where the seal is overmoulded in a second injection moulding step using an elastomer material, such as silicone, a thermoplastic elastomer or thermoplastic polyurethane. A two-component injection moulding process simplifies the overall manufacturing of the support and device. Further chemical bonding may be applied between the rigid base and the seal prior to the overmoulding to enhance the attachment of the seal to the rigid base.

[0023]Preferably, a cross-sectional area of the one or more channels is between 0.5 mm² to 3.0 mm² . It has been found that a cross-sectional area between 0.5 to 3.0 mm² provides an overall pressure change between −0.5 to −1 kPa. This has been found to be a desirable draw resistance for aerosol generation devices.

[0024]Preferably, the consumable cartridge support further comprises a fastening mechanism for the received consumable cartridge, preferably wherein the fastening mechanism comprises at least one of: a magnet or a push-fit arrangement. In this way, a consumable cartridge received in the support can be effectively secured against the rigid base according to an arrangement that ensures that the connection between the one or more channels and the air inlet of the cartridge is sealed. As will be appreciated, a received cartridge must be sufficiently pressed against the seal and rigid base for the seal to eliminate any air gaps between the base and the cartridge. A magnet or a push-fit arrangement (such as a ridge or protrusion along a circumference in the inner surface of the tube-shaped wall) may be used to hold a received cartridge in an optimal position for the sealed connection.

[0025]According to another aspect of the invention, there is provided an aerosol generation device configured to generate an aerosol for inhalation by a user, the aerosol generation device comprising the consumable cartridge support according to the first aspect. In this way, the aerosol generation device can provide an improved user experience by eliminating any inconsistency of draw resistance and ensure a more reliable aerosol delivery to the user.

[0026]Preferably, the tube-shaped wall of the consumable cartridge support in the aerosol generation device further comprises one or more holes, wherein the tube-shaped wall is shaped to, in use, allow the airflow to travel inside the aerosol generation device, preferably wherein the airflow includes a first portion between the consumable cartridge and the tube-shaped wall, and more preferably wherein the one or more holes allow the first portion of the airflow to join with a second portion of the airflow before reaching the one or more channels. Preferably, the second portion of the airflow is configured to pass through a space formed between the consumable cartridge support and a side wall of the aerosol generation device, preferably wherein the space is at least partially between the tube-shaped wall and the side wall of the aerosol generation device.

[0027]Preferably, the aerosol generation device further comprises a cavity, wherein the consumable cartridge support is arranged in the cavity. In this way, the consumable cartridge support can be easily inserted into the cavity and be used across various different types of aerosol generation devices. To improve the manufacturability of the device, in particular the assembly of the consumable cartridge support into the cavity, the cavity and support may be configured to allow air to pass into the cavity around the outer surface of the tube-shaped wall / support (in addition to airflow within the tube-shaped wall), thereby providing the bypass airflow described above. It has been found that the distance between an outer edge of the cartridge (or tube-shaped wall) and an inner surface of the cavity cannot be perfectly controlled due to manufacturing tolerances, and the present disclosure thus advantageously directs both the primary airflow within the tube-shaped wall and the bypass airflow around the tube-shaped wall to the one or more channels in the support base. Preferably, the aerosol generation device further comprises one or more air inlet holes arranged to, in use, direct air from outside of the aerosol generation device to the first end of the tube-shaped wall.

[0028]Preferably, the aerosol generation device further comprises a puff sensor, preferably wherein the puff sensor is arranged in the aerosol generation device to detect a user puff before the airflow reaches the one or more channels of the consumable cartridge support. In this way, a puff sensor, such as a pressure sensor, may be used to trigger or activate a heater in the aerosol generation device so as to optimise the aerosol generation and delivery of the device to the user. As will be appreciated, there may be a ramp-up or pre-heating time for the heater to reach an optimum or desired operating temperature, and a puff sensor arranged upstream of the one or more channels accordingly allows more time for the heater to this temperature before the airflow reaches the consumable cartridge. In other words, positioning of the puff sensor further upstream in the airflow path of a device means that the device activates earlier and has increased control over the operation of the device (for example, heater times).

[0029]According to another aspect of the invention, there is provided an aerosol generation system comprising the aerosol generation device according to the second aspect, further comprising a consumable cartridge for the aerosol generation device, the consumable cartridge comprising: a rigid casing having an outlet and an air inlet, the outlet configured to deliver aerosol formed from an aerosol forming substance to a user upon inhalation by the user, the air inlet configured to receive air from outside the consumable cartridge into the consumable cartridge upon inhalation by the user; the aerosol forming substance arranged in the rigid casing; and a seal arranged around an edge of the air inlet so as to provide a sealed airflow connection between the air inlet and the aerosol generation device when the consumable cartridge is received in the aerosol generation device.

[0030]In this way, a sealed airflow connection is also provided on a consumable cartridge, which further enhances the sealed airflow connection. This advantageously minimises any undesired pressure changes due to movement or rocking of the consumable cartridge of this aspect received in the device, thereby ensuring that the draw resistance and distribution of airflow velocity through the device is consistent and well-controlled.

[0031]Preferably, the seal of the consumable cartridge comprises an elastomer material. Preferably, the rigid casing of the consumable cartridge comprises a more rigid material than the elastomer material of the seal. In this way, the sealed airflow connection can be more effectively ensured when the consumable cartridge is inserted into the device.

BRIEF DESCRIPTION OF DRAWINGS

[0032]Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:

[0033]FIGS. 1A, 1B and 1C are schematic views of an aerosol generation device and consumable cartridge according to the art;

[0034]FIGS. 2A and 2B are schematic views of the consumable cartridge support according to the present invention;

[0035]FIG. 2C is a further schematic view of the consumable cartridge support of FIGS. 2A and 2B with a consumable cartridge;

[0036]FIG. 3 is a schematic view of the seat base of the consumable cartridge support according the present invention; and

[0037]FIGS. 4A, 4B and 4C are schematic views of the consumable cartridge support an aerosol generation device according to the present invention.

DETAILED DESCRIPTION

[0038]As described herein, a vapour is generally understood to refer to a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms ‘aerosol’ and ‘vapour’ may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.

[0039]FIG. 1A shows a schematic view of a known aerosol generation device with a consumable pod 102 inserted in the device 100. The device 100 typically includes a battery and control circuitry which connects with battery terminals in the pod 102 when it is received into a cup 104 of the device 100. The pod 102 typically includes an aerosol forming substance, such as an e-liquid, a wick and a heating element, which on receipt of electrical energy from the device battery generates heat to aerosolise the aerosol forming substance in the wick.

[0040]When a user inhales, or takes a puff, from the mouthpiece 106 of the pod 102, air outside of the device 100 enters the device 100 through air inlets 108 arranged at a pod end 110 of the device 100, where an outer ridge 112 of the pod 102 meets an upper lip of the device 100 at the pod end 110 when the pod 102 is received in the device cup 104.

[0041]FIGS. 1B and 1C show different cross-sectional schematic views of the pod 102 in the device 100 toward the pod end 110. FIG. 1B shows the outer surface of the pod 102 in a cross-sectioned view of the pod end 110 of the device 100. FIG. 1C shows the cross-sectional view through the middle of the pod 102 along the line A-A in FIG. 1A.

[0042]As can be seen with reference to FIG. 1B, upon user inhalation, outside air (that is, air from outside the device 100 and the pod 102) enters the device cup 104 through the device air inlets 108 and travels toward the base 114 of the cup 104. A pod air inlet 116 is positioned in the centre of the bottom surface (facing the device 100) through which the air in the cup 104 enters the pod 102. Typical airflow paths are shown in FIG. 1B using dashed lines 118. As shown in FIG. 1C, air that enters the pod 102 through the pod inlet 116 travels up a central airflow tube 118 of the pod 102 and combines with generated aerosol in the pod 102 (along arrowed lines 120). The combined air and generated aerosol mixture exits the pod 102 through the pod outlet 122 for the user to inhale.

[0043]FIGS. 1B and 1C show the device cup 104 having a side wall 124 that meets a side wall 126 of the device 100 toward the device air inlets 108 at the pod end 110 of the device 100. The cup side wall 124 has a tapered section 128 which tapers inwardly away from the device air inlets 108 and extends to a straight section 130 of the cup side wall 124, which is shaped to correspond with a side wall of the pod 102 to prevent or limit any rocking of the pod 102 when it is received in the cup 104. The tapered section 128 of the cup side wall 124 is to ensure that outside air that enters the device 100 through the air inlets 108 flows into the device cup 104 (for subsequent entry into the pod air inlet 116), as opposed to round the outside of the cup 104 between the outer surface of the cup side wall 124 and the inner surface of the device side wall 126.

[0044]FIGS. 2A and 2B show different cross-sectional views of a consumable cartridge support 200 according to the present invention. The support 200 includes a cup 202 having an opening 204 at a first end, a base wall 206 at a second end of the cup 202, and a tube-shaped wall 208 extending between the opening 204 and the base wall 206. The support 200 further includes a seat base 210 arranged at the second end of the cup 202, adjacent to the base wall 206 of the cup 202, and the seat base 210 includes a push-fit fastening mechanism 212 configured to hold the cup 202 in position.

[0045]A first aperture 214 is provided in the base wall 206 of the cup 202, and a second aperture 216 is provided in the seat base 210. When assembled, the first and second apertures 214, 216 are aligned to form an airflow path from the seat base 210 into the cup 202. The support 200 further includes a seal 218 arranged around the second aperture 216 so that the airflow path between the seat base 210 and the cup 202 is sealed. In this particular example, the first aperture 214 in the base wall 206 of the cup 202 does not deform the sealing lip of the seal 218 (see corresponding description to FIG. 3 for further details). Instead the first aperture 214 is shaped to prevent the seal 218 from moving out of position when the cup 202 is held in place by the push-fit fastening mechanism 212. However, other techniques of keeping the seal 218 in place (such as chemical bonding or seal designs) will be apparent to the skilled person.

[0046]The base wall 206 of the cup 202 and the seat base 210 each include further corresponding apertures 220 for connections between a device and a received pod, such as battery terminal and electrical control connections.

[0047]The seat base 210 includes at least one air control channel 222 which extends between a seat base air inlet 224 and the second aperture 216. The seat base air inlet 224 is configured to draw in outside air into the air control channels 222, which is further directed by the air control channels 222 through the second and first apertures 216, 214 (past the seal 218) into the cup 202. More details of the seat base 210 and the airflow control relating to the control channel 222, inlet 224 and aperture 216 will be described later in reference to FIG. 3.

[0048]FIG. 2B shows the consumable cartridge support 200 provided in a cavity 226 of an aerosol generation device 228. The top, or first end, of the cup 202 is positioned toward the opening of the cavity 226 and the tube-shaped wall 208 has a tapered section 230 and a straight section 232. The tapered section 230 is configured to press against the wall 234 of the cavity 226 and the straight section 232 is configured to correspond with the shape of a consumable cartridge to be received in the cup 202. The tapered section 230 is shaped to direct outside air into the device 228/cup 202 to flow into the cup 202 (and between the inner surface of the tube-shaped wall 208 and the outer surface of the wall of a received consumable cartridge). This is described herein as the primary airflow. However, in real life scenarios, the interface between the tapered section 230 and the cavity wall 234 is not expected to be air-tight, for example due to normal manufacturing tolerances, and a bypass airflow may flow along the outer surface of the tube-shaped wall 208 when a user takes a puff from the aerosol generation device 228.

[0049]Therefore, in order to draw both the primary airflow and the bypass airflow into the air control channel 224 in the seat base 210, one or more holes 236 are provided in the tube-shaped wall 208 so that primary airflow in the cup 202 passes out through the one or more holes 236 to combine with the bypass airflow before the combined airflow enters the seat base air inlet 224. As can be seen more clearly in FIG. 2A, the seat base 210 has an outer rim 238 which has a greater perimeter than the perimeter of the cup 202 or tube-shaped wall 208. The seat base air inlet 224 is provided in the outer rim 238, i.e. beyond the perimeter of the cup 202/tube-shaped wall 208, for the combined airflow to enter into the inlet 224. Different designs and locations of the air inlet 224 in the seat base 210 will be apparent to the skilled person.

[0050]FIG. 2C shows the consumable cartridge support 200 with a consumable cartridge or pod 250 received in the cup 202 of the support 200. The pod 250 comprises an outer lip 252 which sits on the top edge of the cavity 226 at the opening to limit the depth of insertion of the pod 252. The pod 250 further comprises a mouthpiece 254 with an outlet 256 through which generated aerosol can be inhaled by a user.

[0051]Air from outside the pod 250 and the device 228 enters the pod 250 through an air inlet 258 of the pod 250. The air inlet 258 is pressed against the seal 218 of the support 200 to form a sealed connection between the support 200 and the pod 250. The air inlet 258 is connected to the outlet 256 with an airflow tube 260 of the pod 250. An aerosol forming substance (not shown), such as an e-liquid, is provided in the pod 250, which when heated forms an aerosol that mixes with the outside air from the pod air inlet 258 and is delivered to the user on inhalation. The pod 250 may include a further seal (not shown) at pod air inlet 258 to provide additional sealing to the connection between the support 200 and the pod 250. Alternatively, in another example, a consumable cartridge support may not include a seal and the sealing mechanism is provided by the seal on the pod.

[0052]In the specific examples depicted in FIGS. 2, 3 and 4, the tube-shaped wall 208 is the side wall of the cup 202 that sits on the seat base 210. However, it should be understood that the cup 202, and the support 200 may be designed to have the tube-shaped wall 208 extend directly from the seat base 210, i.e. formed as a single integrated piece, as one example. As another example, a seal may be provided where the end of the tube-shaped wall 208 meets the seat base 210, i.e. such that the tube-shaped wall is in the form of a sleeve (and not a cup).

[0053]FIG. 3 shows a further schematic view of a seat base 210 and an exploded view of the seal 218 portion according to the present invention. The push-fit fastening mechanism 212 comprises of two arms 300 which are configured to extend along a length of the tube-shaped wall 208 of the cup 202, and each arm 300 has a projection 302 configured to fit into a corresponding notch in the tube-shaped wall 208.

[0054]In the exploded view of the seal 218 portion in the seat base 210, dotted lines represent the air control channels 222 in the seat base 210, which are closed channels between the air inlet 224 and the seat base aperture 216 (the second aperture described in reference to FIG. 2). The cross-sectional area(s) of the one or more air control channels 222 are designed according to pressure change requirements. For example the combined cross-sectional area of all the air control channels is between 0.5 to 3 mm^{2 .}

[0055]The seal 218 is configured to extend around the edge of the seat base aperture 216, and has a sealing lip 304 which extends upwards. The sealing lip 304 is shaped so as to deform when a consumable cartridge is received in the cup 202 and the edge of the air inlet of the received consumable cartridge is pressed and sealed against the sealing lip 304, thereby providing a sealed airflow connection from the seat base air inlet 224 and the air inlet of the consumable cartridge.

[0056]FIG. 4A shows schematic outer view of a consumable cartridge 400 received in an aerosol generation device 402 according to the present invention. The consumable cartridge 400 has a mouthpiece 404 with an outlet 406 through which a user can inhale generated aerosol. The cartridge 400 has an outer lip 408 which limits the depth of insertion of the cartridge 400 into a cavity of the device 402 when it meets an upper edge of the cavity opening. A portion of the cartridge 400 having a reduced cross-sectional area to the outer lip 408 is received into the cavity of the device 402. Device air inlets 410 are provided at the cartridge outer lip 408 and cavity upper edge interface to allow air outside of the device 402 to be drawn into the cavity when a user takes a puff from the mouthpiece 404.

[0057]FIG. 4B shows a schematic view of the portion of the consumable cartridge 400 received in the consumable cartridge support 200 of the present invention. A gap 412 is provided between the top edge of the cup 202 and the outer lip 408 of the cartridge. This is to ensure that the cup 202 do not impede or block the airflow through the device air inlets 410.

[0058]As shown using two styles of dotted lines 414, 416, when a user takes a puff, a primary airflow of outside air is drawn through the device air inlets 410 into the cup 202 between the inner surface of the tube-shaped wall 208 and the outer surface of the received cartridge 400. A secondary bypass airflow of outside air is drawn into the device cavity around the outer surface of the tube-shaped wall 208, where the secondary airflow passes through any gaps between the upper edge 418 of the cup 202 and the wall of the device (not shown) surround the device cavity. In one embodiment, air inlet holes are provided at the upper edge 418 of the cup 202 to allow airflow entrance in the space formed between the outer surface of the tube-shaped wall 208 and the corresponding wall of the device.

[0059]The primary airflow flows out from the inside of the cup 202 through one or more holes 236 in the tube-shaped wall 208 to the outer surface of the tube-shaped wall 208 (i.e. between the tube-shaped wall 208 and the device wall). Both the primary airflow and the secondary bypass airflow are drawn toward the seat base air inlet 224, where the two airflows will combine before it reaches the seat base air inlet 224 or after it passes through the air inlet 224 inside the air control channel 222 of the seat base 210.

[0060]FIG. 4C shows a cross-sectional schematic view of the cartridge 400 to illustrate the airflow path (shown using dotted lines) from device air inlet 410 to the cartridge outlet 406.

[0061]The primary airflow and bypass airflow flow into the seat base air inlet 224 through the air control channel 222 and out the apertures 214, 216 of the seat base 210 and the cup 202 into the cartridge 400. The connection between the apertures of the seat base 210 and the cup 202 and an air inlet 420 of the cartridge 400 is sealed by the seal 218, as described in reference to FIG. 3. The airflow entering the air inlet 420 of the cartridge 400 continues up through the cartridge 400 along an airflow tube 418 toward the outlet 406, where generated aerosol is combined in the airflow along the airflow tube 422.