Smoking substitute apparatus

Abstract

A smoking substitute apparatus comprises: an air inlet; an outlet; an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user, the aerosol generator comprising a heating element; an air flow path between the air inlet and the outlet for conveying the aerosol to the user. An upstream portion of the air flow path is disposed between the air inlet and the aerosol generator. The upstream portion is defined at least in part by an inner wall of the apparatus, the inner wall being formed from plastics material by moulding. Electrical connectors are provided for electrically connecting the heating element to a power source. The electrical connectors are at least partially moulded into, and extend along, the inner wall of the upstream portion of the air flow path, thereby increasing the available cross sectional area for air flow and reducing the flow velocity in the upstream portion.

1 . A smoking substitute apparatus comprising:
 an air inlet;   an outlet;   an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user, the aerosol generator comprising a heating element;   an air flow path between the air inlet and the outlet for conveying the aerosol to the user;   an upstream portion of the air flow path being disposed between the air inlet and the aerosol generator, the upstream portion being defined at least in part by an inner wall of the apparatus, the inner wall being formed from plastics material by moulding;   one or more electrical connectors for electrically connecting the heating element to a power source;   wherein the one or more electrical connectors are at least partially moulded into, and extend along, the inner wall of the upstream portion of the air flow path.   
     
     
         2 . A smoking substitute apparatus according to  claim 1  wherein the electrical conductor has a length direction substantially parallel to the air flow direction along the air flow path in the upstream portion and, along the length of the electrical connector, some parts of the length are moulded, or partially moulded, into the inner wall of the upstream portion of the air flow path. 
     
     
         3 . A smoking substitute apparatus according to  claim 2  wherein other parts of the electrical connector, corresponding to one of more parts between the parts of the length that are moulded into the inner wall, abut the inner wall. 
     
     
         4 . A smoking substitute apparatus according to  claim 1  wherein the electrical conductor has a length direction substantially parallel to the air flow direction along the air flow path in the upstream portion and a width direction corresponding to a circumferential direction of the upstream portion of the air flow path, perpendicular to the length direction, and a depth direction corresponding to a radial direction of the upstream portion of the air flow path, perpendicular to both the length direction and the circumferential direction, wherein the width of the electrical connector varies along its length. 
     
     
         5 . A smoking substitute apparatus according to  claim 4  wherein the electrical connector has wide portions at which the electrical connectors is moulded or partially moulded to the inner wall of the upstream portion, the inner wall being moulded into an aperture formed in the wide portion. 
     
     
         6 . A smoking substitute apparatus according to any one of  claims 1  to  5  wherein an aspect ratio of the electrical connector, defined as width/depth, is not less than 4. 
     
     
         7 . A smoking substitute apparatus according to any one of  claims 1  to  6  wherein the electrical connector is partially moulded into the inner wall along the length of the electrical connector in the upstream portion of the air flow path such that a proportion of the depth of the electrical connector is moulded into the inner wall, this proportion being at least 30%. 
     
     
         8 . A smoking substitute apparatus according to any one of  claims 1  to  6  wherein the electrical connector is fully moulded into the inner wall of the upstream portion of the air flow path. 
     
     
         9 . A smoking substitute system comprising a smoking substitute apparatus according to any one of  claims 1  to  8  and a main body, the main body comprising a power source, the smoking substitute apparatus and the main body being engageable together to form the smoking substitute system. 
     
     
         10 . A method of operating a smoking substitute apparatus according to any one of  claims 1  to  8  in which air is drawn through the apparatus at an air flow rate in the range 1.3-2.0 L/min and the aerosol generator operated to produce an aerosol with Dv50 in the range 2-5 μm.