Abstract:
An electronic smoking article, a method of manufacturing an electronic smoking article, and a method of achieving a smoking experience without combusting tobacco are disclosed. The electronic smoking article includes an authenticated first section, which includes an aerosol generation unit having at least one heater; an authenticated second section, which includes a power supply operable to apply voltage to the at least one heater for heating a liquid in at least a portion of the aerosol generation unit to form an aerosol; and a conductive ink circuit embedded within the first and second sections, and wherein the power supply and the aerosol generation unit are electrically connected upon joining the first and second sections, and wherein each of the first and second sections has a portion of the conductive ink circuit.

Description:
RELATED APPLICATION(S) 
       [0001]    The present application claims priority under 35 U.S.C. 119 to U.S. Provisional Patent Application No. 61/799,368, filed on Mar. 15, 2013, the entire content of which is hereby incorporated by reference. 
     
    
     WORKING ENVIRONMENT 
       [0002]    Electronic smoking articles, such as electronic cigarettes and aerosol generators can include a capillary tube and/or capillary wick designed to deliver liquid material from a liquid reservoir to a heater. Such articles can be activated by a consumer drawing on a mouth piece to deliver an aerosol to the user. 
         [0003]    Electronic smoking articles and cigarettes can consist of two pieces, for example, a first unit or piece, which includes a power supply and control unit, and a second unit or piece, which includes a flavor delivery unit. Alternatively, the smoking article can be a three-piece unit, which includes the power supply and control unit, an aerosol generator or aerosol generation unit, and a flavor delivery unit. Each of these parts is optimized to yield consistent performance. Using parts that are not optimized or made from inferior materials can deliver inferior quality output, damage other parts of the device, and damage the reputation of the manufacturer of the smoking article. Accordingly, it would be desirable to control the use of units manufacture and supplied by others and limit the use to genuine parts. 
       SUMMARY 
       [0004]    In accordance with an exemplary embodiment, an electronic smoking article is disclosed, the electronic smoking article comprising: an authenticated first section, which includes an aerosol generation unit having at least one heater; an authenticated second section, which includes a power supply operable to apply voltage to the at least one heater for heating a liquid in at least a portion of the aerosol generation unit to form an aerosol; and a conductive ink circuit embedded within the first and second sections, and wherein the power supply and the aerosol generation unit are electrically connected upon joining the first and second sections, and wherein each of the first and second sections has a portion of the conductive ink circuit. 
         [0005]    In accordance with an exemplary embodiment, a method of manufacturing an electronic smoking article is disclosed, the method comprising: embedding a first portion of a conduction ink circuit in an authenticated first section of a smoking article, the first section including an aerosol generation unit having at least one heater; and embedding a second portion of a conduction ink circuit in an authenticated second section, the second section including a power supply operable to apply voltage to the at least one heater for heating a liquid in at least a portion of the aerosol generation unit to form an aerosol. 
         [0006]    In accordance with an exemplary embodiment, a method of achieving a smoking experience without combusting tobacco is disclosed, the method comprising: joining an authenticated first section of a smoking article to an authenticated second section of the smoking article, the first section having a first portion of a conduction ink circuit and the second section having a second portion of a conduction ink circuit; and electrically connecting a power supply and an aerosol generation unit of the electronic smoking article upon the formation of a completed conductive ink circuit between the first and second portions of the smoking article, wherein the first section includes the aerosol generation unit having at least one heater and the second section includes a power supply operable to apply voltage to the at least one heater for heating a liquid in at least a portion of the aerosol generation unit to form an aerosol. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The disclosure is explained below with reference to the exemplary embodiments shown in the drawings. In the drawings: 
           [0008]      FIG. 1  is a cross-sectional view of an electronic smoking article in accordance with an exemplary embodiment having a conductive ink circuit; 
           [0009]      FIG. 2  is a side view of an electronic smoking article in accordance with an exemplary embodiment having a first portion and a second portion, which forms a conductive ink circuit upon assembly thereof; 
           [0010]      FIG. 3  is a side view of an electronic smoking article in accordance with an exemplary embodiment having a first section, which includes an aerosol generation portion and a liquid supply portion, and a second portion, which forms a conductive ink circuit upon assembly thereof; and 
           [0011]      FIG. 4  is an end view of the first portion and the second portion of an electronic smoking article in with an exemplary embodiment having a portion of a conductive ink circuit therein. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    In accordance with an exemplary embodiment, conductive ink based circuits, which are embedded as part of an electronic smoking article are disclosed. The conductive ink based circuits permit the operation of the electronic smoking article only when used with genuine or approved parts. In accordance with an exemplary embodiment, a conductive ink circuit can be embedded across a two-piece design or among a three-piece design such that the circuit, that activates the power supply and the aerosol generation unit, can be activated only when genuine parts are connected together. In accordance with an exemplary embodiment, a conductive ink based circuit can be placed between the flavor unit (or cartridge) and aerosol generation unit or power supply unit, to activate the article when a genuine or approved flavor unit or cartridge is connected to the electronic smoking article. 
         [0013]    In accordance with an exemplary embodiment, the conductive ink based circuit can be used to initiate pre-heating of the heater of the electronic smoking article when the user picks up the smoking article for smoking. The preheating of the heater can help to reduce the latency and improve quantity of aerosol delivered during the initial puffs. In addition, control measures can be incorporated to cut off the power supply to the heater, if a puff is not detected, using a puff detector, within a set time period after the initial handling of the smoking article. 
         [0014]      FIG. 1  shows an electronic smoking article  100  in accordance with an exemplary embodiment. As shown in  FIG. 1 , the electronic smoking article  100  includes a housing  110  having a mouth end  112  and an upstream end  114 . In the upstream end  114 , there is provided an electric power supply in the form of power supply  120  and electric circuitry in the form of circuitry  122 . In the mouth end  112 , the smoking article  100  includes a cartridge  140 , a heater  144 , and a capillary wick (or capillary tube)  146 . The cartridge  140 , the heater  144 , and the capillary wick (or capillary tube)  146  can form the aerosol generation unit  148 . In operation, the cartridge  140  delivers a liquid material  152  from a liquid supply reservoir (or fluid reservoir)  150  to the capillary wick  146 , which is surrounded by the heater  144 . In accordance with an exemplary embodiment, one end of the capillary wick  146  extends to the cartridge  140  and the other end of the capillary wick  146  is surrounded by the heater  144 . The heater  144  is connected to the electric circuitry  122  via connections (not shown). The housing  110  also includes an air inlet  160 , an outlet  162  at the mouth end  112 , and an aerosol forming chamber  170 . 
         [0015]    In use, the liquid material  152  is supplied from the fluid reservoir  150  to the capillary wick  146 , which as shown in  FIG. 1  is surrounded by the heater  144 . When a user draws on the electronic smoking article  100  at the air outlet  162 , ambient air can be drawn through air inlet  160 . In accordance with an exemplary embodiment, the electronic smoking article  100  can include a puff detection system (not shown), which is part of the circuitry  122  on the upstream end  114  of the smoking article  100 . The puff detection system can sense the puff and can activate the heater  144  and supply the liquid material to the capillary wick  146 . 
         [0016]    The power supply  120  supplies pulses of energy to the heater  144  to heat the end of the capillary wick  146  surrounded by the heater  144 . The liquid material  152  in the outlet end  147  of the capillary wick  146  is vaporized by the heater  144  to create a supersaturated vapor. At the same time, the liquid material  152  being vaporized is replaced by addition liquid material  152  moving along the capillary wick  146 . 
         [0017]    In accordance with an exemplary embodiment, the supersaturated vapor created is mixed with and carried in the air flow from the air inlet  160 . In the aerosol forming chamber  170 , the vapor condenses to form an inhalable aerosol, which is carried towards the outlet  162  and into the mouth of the user. The circuitry  122  and the puff detection system (not shown) are preferably programmable. In accordance with an exemplary embodiment, the circuitry  122  and puff detection system can be used to manage the operation of the electronic smoking article  100 . 
         [0018]    In use, once the capillary wick  146  is heated, the liquid material contained within a heated portion of the capillary wick  146  is volatilized and ejected out of the outlet  147  where it expands and mixes with air and forms an aerosol in a mixing chamber  170 . The electronic smoking article  100  also includes at least one air inlet  160  operable to deliver air to the mixing chamber  170 . Preferably, the air inlets  160  to the mixing chamber  170  can be arranged downstream of the capillary wick  146  so as to minimize drawing air along the capillary and thereby avoid cooling of the capillary wick  146  during heating cycles. 
         [0019]    In use, the volatilized material expands out of the wick  146  and into the mixing chamber  170  where the volatized material can mix with air to form an aerosol which is then drawn through the outlet  162 . In an exemplary embodiment, the at least one air inlet  160  includes one or two air inlets  160 . Alternatively, the air inlets  160  can be three, four, or five or more. In accordance with an exemplary embodiment, the size and number of air inlets  160  can also aid in establishing the resistance to draw of the electronic smoking article  100 . 
         [0020]    The power supply  120  can be a Lithium-ion battery or one of its variants, for example a Lithium-ion polymer battery. Alternatively, the power supply  120  may be a Nickel-metal hydride battery, a Nickel cadmium battery, a Lithium-manganese battery, a Lithium-cobalt battery or a fuel cell. In accordance with an exemplary embodiment, the electronic smoking article  100  is usable by a smoker until the energy in the power supply is depleted. Alternatively, the power supply  120  may be rechargeable and can include circuitry (not shown) allowing the battery to be chargeable by an external charging device. For example, the circuitry, when charged, can provide power for a pre-determined number of puffs, after which the circuitry must be re-connected to an external charging device. The electronic smoking article  100  can also include control circuitry  122 , which can be on a printed circuit board having a processor. 
         [0021]    In accordance with an exemplary embodiment, the liquid material  152  includes a tobacco-containing material including volatile tobacco flavor compounds which are released from the liquid upon heating. The liquid material  152  may also be a tobacco flavor containing material or a nicotine-containing material. Alternatively, or in addition, the liquid material  152  may include a non-tobacco material. For example, the liquid material  152  may include water, solvents, ethanol, plant extracts and natural or artificial flavors. Preferably, the liquid material further includes an aerosol former. Examples of suitable aerosol formers are glycerine and propylene glycol. 
         [0022]    In accordance with an exemplary embodiment, the aerosol generation unit includes the liquid supply reservoir  150  and a capillary wick  146  for holding liquid received from the liquid reservoir. In accordance with an exemplary embodiment, rather than a capillary wick  146 , the aerosol generation unit  148  can include a capillary tube (not shown) having an inlet and an outlet, the inlet being in communication with the outlet of the liquid supply reservoir, and the at least one heater  144  is operable to heat the capillary tube to a temperature sufficient to at least initially volatilize the liquid material contained within the capillary tube. 
         [0023]    The control circuitry  122  can also include a heater activation light (not shown) at an upstream end of the smoking article  100 , which is operable to glow when the heater  144  is activated. The control circuitry  122  can also include a timer operable to limit the time for which power is supplied to the heater  144 . The time-period of the electric current supply to the heater  144  may be pre-set depending on the amount of liquid material  152  desired to be vaporized. For example, the control circuitry  122  can be programmable for this purpose. 
         [0024]    In accordance with an exemplary embodiment, when activated, the heater  144  heats a portion of the wick  146  for less than about 10 seconds, more preferably less than about 7 seconds. Thus, the power cycle (or maximum puff length) can range in period from about 1 second to about 10 seconds. 
         [0025]      FIG. 2  is a side view of an electronic smoking article  100  in accordance with an exemplary embodiment having a first section  210  and a second section  220 , which forms a conductive ink circuit upon assembly thereof. As shown, the electronic smoking article  100  includes a first section  210 , which includes an aerosol generation unit  211  and a second section  220 , which includes a power supply portion  221 , which can be coupled together at a threaded joint (not shown) or by other convenience such as a snug-fit, snap-fit, detent, clamp and/or clasp. 
         [0026]    In accordance with an exemplary embodiment, the aerosol generation unit  211  can include the at least one heater  144 , a liquid reservoir  150  having a liquid material  152  therein, and a capillary wick (or capillary tube)  146 . The power supply section  221  includes a power supply  120  and circuitry  122 , which is operable to apply voltage to the at least one heater  144  for heating the liquid material  152  in at least a portion of the aerosol generation unit  148  to form an aerosol. 
         [0027]    In accordance with an exemplary embodiment, a portion  212 ,  222  of the conductive ink circuit is embedded within the first and second sections  210 ,  220 , respectively, and the power supply and the aerosol generation unit  148  can be activated upon formation of a circuit formed by connecting or coupling the first and second sections  210 ,  220  to one another. The portions  212 ,  222  of the conductive ink circuit can be embedded within the outer housing  216 ,  226  as shown in  FIG. 2 . Alternatively, the portions  212 ,  222  can form part of the electrical circuit within the smoking article  100 . For example, in accordance with an exemplary embodiment, the conductive ink circuit can be formed by the connection of the first and second sections  210 ,  220  to form the electrical circuit, which provides power from the power supply  120  to the at least one heater  144  within the aerosol generation unit. Alternatively, the conductive ink circuit formed by the connection of the first and second portions  212 ,  222  can form a circuit in communication with the circuitry  122  of the smoking article  100 , and upon establishing the conductive ink circuit, the circuitry  122  enables the power supply  122  to provide power to the at least one heater  144 . 
         [0028]    In accordance with an exemplary embodiment, the conductive circuit can be formed by bringing into contact, an end portion  214 ,  224  of each of the first and second sections  210 ,  220  to complete the conductive ink circuit. 
         [0029]    In accordance with an exemplary embodiment, upon forming the circuit, a pre-heating process of the at least one heater  144  of the smoking article  100  can be initiated. In addition, the pre-heating of the smoking article  100  can also be configured based on detection of a user picking up the smoking article  100 . For example, a smoking article  100  having a conductive ink circuit on an outer portion thereof upon detection of being handled by a user, the smoking article  100  can begin a pre-heating process, which can reduce the latency and improve quantity of the aerosol delivered during the initial puffs. 
         [0030]    In accordance with an exemplary embodiment, the first section  210  and the second section  220  each comprise an outer cylindrical housing  216 ,  226  extending in a longitudinal direction, and wherein each of the outer cylindrical housings has a portion  212 ,  222  of the conductive ink circuit embedded therein. 
         [0031]      FIG. 3  is a side view of an electronic smoking article  100  in accordance with an exemplary embodiment having a two-piece first section  210 , which includes an aerosol generation portion  240  and a liquid supply portion  230 , and a second portion  220 , which forms a conductive ink circuit upon assembly thereof. In accordance with an exemplary embodiment, the first section  210  includes an aerosol generation portion  240  and a liquid supply portion  230 , and wherein the conductive ink circuit  242 ,  232  is embedded within an outer cylindrical housing  241 ,  231  of the aerosol generation portion  240  and the liquid supply portion  230 . The at least one heater  144  housed within the aerosol generation portion  240  is activated only when the conductive ink circuit is formed by connecting the aerosol generation portion  240 , the liquid supply portion  230  and the second portion  220 , and wherein the aerosol generation portion  240 , the liquid supply portion  230  and the second section  210  each has a portion  242 ,  232 ,  222 .  224 ,  234 ,  236 , and  244  of the conductive ink circuit and upon assembly thereof forms the circuit. 
         [0032]    In accordance with an exemplary embodiment, for example, the conductive ink circuit can be embedded in parts manufactured by an authorized manufacturer of the first and second sections  210 ,  220  for a two-piece electronic smoking article  100 , or an authorized manufacturer of the aerosol generation portion  240 , the liquid supply portion  230 , and the second portion, for a three-piece electronic smoking article  100 . For example, if a user attempts to place a non-authorized part within the smoking article  100 , the smoking article  100  will not function. For example, in the absence of the conductive ink circuit, the power supply  120  will not provide power to the heater  144 . 
         [0033]      FIG. 4  is an end view of the first portion  210  and the second portion  220  of an electronic smoking article in with an exemplary embodiment, wherein each of the first and second portions  210 ,  220  includes a portion of a complete conductive ink circuit therein. As shown in  FIG. 4 , the conductive ink circuits  212 ,  222  can be embedded within the end portions  213 ,  223 , and upon connecting the first and second portions  210 ,  220  of the smoking article  100 , the conductive ink portions  212 ,  222  complete the circuit. In accordance with an exemplary embodiment, the conductive ink circuits  212 ,  222  can be elongated line, pattern or completely covered area forming a contact and/or contact pads. 
         [0034]    The electronic smoking article  100  is preferably about the same size as a conventional cigarette. In some embodiments, the electronic smoking article  100  can be about 80 mm to about 88 mm long and about 7 mm to about 8 mm in diameter. The outer cylindrical housing  110  of the electronic smoking article  100  may be formed of any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK), ceramic, and polyethylene. 
         [0035]    In an exemplary embodiment, the heater  144  includes a coil of wire at least partially surrounding the capillary wick  146 . In an exemplary embodiment, the heater  144  is a metal wire and/or a metal alloy wire. The heater  144  can be a coil, which can extend fully or partially along the length of the capillary wick  146 . 
         [0036]    The electronic smoking article  100  can include a puff indicator (not shown) for indicating when the heater  144  is activated. In the embodiment in which the electric circuitry includes a sensor to detect air flow indicative of a user taking a puff, the indicator, such as an LED, may be activated when the sensor senses air flow indicative of the user taking a puff. In the embodiment in which the electric circuitry includes a manually operable switch, the indicator may be activated by the switch. In addition, control measures can be incorporated to cut off the power supply to the heater if a puff is not detected by a puff detector, within a set time period after the initial handling of the smoking article. 
         [0037]    When the word “about” is used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value. Moreover, when reference is made to percentages in this specification, it is intended that those percentages are based on weight, for example, weight percentages. 
         [0038]    Moreover, when the words “generally” and “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. When used with geometric terms, the words “generally” and “substantially” are intended to encompass not only features, which meet the strict definitions, but also features, which fairly approximate the strict definitions. 
         [0039]    It will now be apparent that a new, improved, and nonobvious electronic smoking article has been described in this specification with sufficient particularity as to be understood by one of ordinary skill in the art. Moreover, it will be apparent to those skilled in the art that numerous modifications, variations, substitutions, and equivalents exist for features of the electronic smoking article, which do not materially depart from the spirit, and scope of the invention. Accordingly, it is expressly intended that all such modifications, variations, substitutions, and equivalents, which fall within the spirit and scope of the invention as defined by the appended claims, shall be embraced by the appended claims.