Patent Description:
<CIT> discloses an atomizer that includes a housing, a conductive part at an end of the housing, a mouthpiece with an air outlet, a liquid chamber, and at least one heating element. The liquid chamber is in the housing and configured for storing tobacco liquid. The at least one heating element is electrically connected to the conductive part. The heating element includes a liquid carrier and a heating part integrally formed with the liquid carrier. The liquid carrier has a micro porous structure. The liquid carrier is in contact with the tobacco liquid. The liquid carrier is configured for absorbing the tobacco liquid, and the heating part is configured for heating the tobacco liquid to form aerosol.

<CIT> discloses an atomizing device for an electronic cigarette, which includes: an atomizing sleeve defining a liquid storage chamber for containing e-liquid; a heating element positioned in the atomizing sleeve and configured to heat the e-liquid to generate vapor; a liquid absorbing unit configured to absorb the e-liquid in the liquid storage chamber and transfer the e-liquid to the heating element; and a holder defining a hollow cavity. The holder fixes the liquid absorbing unit and the heating element, and the heating element is positioned in the hollow cavity. A temporary storage cavity is positioned under the holder. The holder defines at least one airflow through hole which is configured to communicate with the temporary storage cavity with the hollow cavity, the temporary storage cavity is configured to communicate with an air inlet, and the air inlet is in a higher position than a bottom of the temporary storage cavity.

<CIT> discloses a leakproof atomizer, which includes a cigarette holder assembly, an atomization assembly, a heating assembly, and a liquid storage assembly. The liquid storage assembly is provided with an annular wall for dividing an internal cavity thereof into a first and a second liquid storage chambers in communication with each other via liquid holes in the annular wall. When the liquid storage assembly is assembled with the heating assembly and the cigarette holder assembly is disassembled from the liquid storage assembly, a bottom portion of the atomization assembly is separated from the heating assembly and hermetically connected with the liquid holes. When both the cigarette holder assembly and the heating assembly are assembled with the liquid storage assembly, the cigarette holder assembly presses downwards the atomization assembly, the atomization assembly is separated from the liquid holes, and the bottom portion of the atomization assembly is press-fitted with the heating assembly.

<CIT> discloses a device for storing and vaporizing liquid media, which comprises an annular liquid media storage tank and a heater configured to vaporize liquid stored in the annular liquid media storage tank.

<CIT> discloses an electronic cigarette, which includes an atomizing device for vaporizing cigarette liquid, a battery which is electrically connected with and supply power to the atomizing device, and a first electrode assembly set between the battery and the atomizing device. The first electrode assembly includes an electrode seat, an electrode and a resilient mechanism. The electrode seat is electrically connected with the battery, the electrode resiliently connects electrode of the atomizing device, and the resilient mechanism is resiliently connected between the electrode seat and the electrode. <CIT> discloses an electronic cigarette comprising an atomizer, a mouthpiece located at one end of a reservoir and a base located at an opposite end of the reservoir. A refilling port is located in the base and allows to refill the reservoir with liquid.

Many devices have been proposed through the years as improvements upon, or alternatives to, smoking products that require combusting tobacco for use. Many of those devices purportedly have been designed to provide the sensations associated with cigarette, cigar, or pipe smoking, but without delivering considerable quantities of incomplete combustion and pyrolysis products that result from the burning of tobacco. To this end, there have been proposed numerous alternative smoking products, flavor generators, and medicinal inhalers that utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant degree. See, for example, the various alternative smoking articles, aerosol delivery devices and heat generating sources set forth in the background art described in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>. See also, for example, the various embodiments of products and heating configurations described in the background sections of <CIT>.

However, it may be desirable to provide aerosol delivery devices with alternate configurations. Such configurations may provide for refilling and reuse of the aerosol delivery device. Thus, advances with respect to aerosol delivery devices may be desirable.

The present disclosure relates to aerosol delivery devices configured to produce aerosol and which aerosol delivery devices, in some embodiments, may be referred to as electronic cigarettes. In one aspect, an aerosol delivery device is provided. The aerosol delivery device includes an outer body, a base, and a flow director extending from a first flow director end to a second flow director end through the outer body such that a reservoir may be defined between the flow director and the outer body. The reservoir defines an open space configured to receive an aerosol precursor composition. Additionally, the aerosol delivery device includes an atomizer extending through the flow director at a position between the first flow director end and the second flow director end. The atomizer includes a liquid transport element and a heating element configured to vaporize at least a portion of the aerosol precursor composition to produce an aerosol within the flow director.

In some embodiments the liquid transport element may include a capillary channel extending therethrough. The liquid transport element may include a porous monolith. The heating element may include a wire defining a plurality of coils extending around the liquid transport element. The aerosol delivery device may additionally include first and second connectors contacting the coils at first and second opposing ends of the heating element.

A longitudinal axis of the liquid transport element extends substantially perpendicularly to a longitudinal axis of the flow director. The outer body may be sealed to the base. The outer body may engage the base via threaded engagement. The aerosol delivery device may additionally include an O-ring compressed between the outer body and the base. The aerosol delivery device further includes a mouthpiece. The mouthpiece may be sealed to the outer body and the flow director. The base includes one or more fill ports configured to receive the aerosol precursor composition therethrough. The atomizer may be sealed to the flow director.

In an additional aspect, an aerosol delivery device operation method is provided. The method includes retaining an aerosol precursor composition in a reservoir defined between a flow director and an outer body. The flow director extends between a first flow director end and a second flow director end. Further, the method includes directing the aerosol precursor composition from the reservoir through a liquid transport element of an atomizer extending through the flow director at a position between the first flow director end and the second flow director end. The method additionally includes receiving an electrical current through a heating element of the atomizer. The method further includes vaporizing at least a portion of the aerosol precursor composition to produce an aerosol within the flow director.

The method further includes receiving the aerosol precursor composition through one or more fill ports defined in a base. Directing the aerosol precursor composition through the liquid transport element may include directing the aerosol precursor composition through a capillary channel. Directing the aerosol precursor composition through the liquid transport element may further include directing the aerosol precursor composition through a porous monolith to the heating element.

In some embodiments receiving the electrical current through the heating element may include receiving the electrical current through a wire defining a plurality of coils extending around the liquid transport element. Additionally, the method may include directing the aerosol out of the flow director through a mouthpiece. The method may further include retaining the aerosol precursor composition in the reservoir with a seal between the outer body and the base. The method may additionally include retaining the aerosol precursor composition in the reservoir with a seal between the mouthpiece and the outer body and a seal between the mouthpiece and the flow director.

The present disclosure thus includes, without limitation, the following:
An aerosol delivery device, comprising:.

This aerosol delivery device, wherein the liquid transport element comprises a capillary channel extending therethrough.

This aerosol delivery device, wherein the liquid transport element comprises a porous monolith.

This aerosol delivery device, wherein the heating element comprises a wire defining a plurality of coils extending around the liquid transport element.

This aerosol delivery device, further comprising first and second connectors contacting the coils at first and second opposing ends of the heating element.

This aerosol delivery device, wherein the outer body is sealed to the base.

This aerosol delivery device, wherein the outer body engages the base via threaded engagement.

This aerosol delivery device, further comprising an O-ring is compressed between the outer body and the base.

This aerosol delivery device, wherein the mouthpiece is sealed to the outer body and the flow director.

An aerosol delivery device operation method, comprising: retaining an aerosol precursor composition in a reservoir defined between a flow director and an outer body, the outer body having a base coupled to a first end of the outer body and a mouthpiece coupled to an opposing second end of the outer body, and the flow director extending between a first flow director end and a second flow director end;.

vaporizing at least a portion of the aerosol precursor composition to produce an aerosol within the flow director, wherein a longitudinal axis of the liquid transport element extends substantially perpendicularly to a longitudinal axis of the flow director, and wherein the flow director, the atomizer, and the reservoir are entirely retained within the outer body.

This aerosol delivery device operation method, wherein directing the aerosol precursor composition through the liquid transport element comprises directing the aerosol precursor composition through a capillary channel.

This aerosol delivery device operation method, wherein directing the aerosol precursor composition through the liquid transport element further comprises directing the aerosol precursor composition through a porous monolith to the heating element.

This aerosol delivery device operation method, wherein receiving the electrical current through the heating element comprises receiving the electrical current through a wire defining a plurality of coils extending around the liquid transport element.

This aerosol delivery device operation method, further comprising directing the aerosol out of the flow director through a mouthpiece.

This aerosol delivery device operation method, further comprising retaining the aerosol precursor composition in the reservoir with a seal between the outer body and the base.

This aerosol delivery device operation method, further comprising retaining the aerosol precursor composition in the reservoir with a seal between the mouthpiece and the outer body and a seal between the mouthpiece and the flow director.

These and other features, aspects, and advantages of the present disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure or recited in any one or more of the claims, regardless of whether such features or elements are expressly combined or otherwise recited in a specific embodiment description or claim herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its aspects and embodiments, should be viewed as intended to be combinable, unless the context of the disclosure clearly dictates otherwise.

The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms "a", "an", "the", include plural variations unless the context clearly dictates otherwise.

The present disclosure provides descriptions of aerosol delivery devices. The aerosol delivery devices may use electrical energy to heat a material (preferably without combusting the material to any significant degree) to form an inhalable substance; such articles most preferably being sufficiently compact to be considered "hand-held" devices. An aerosol delivery device may provide some or all of the sensations (e.g., inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical feel, use rituals, visual cues such as those provided by visible aerosol, and the like) of smoking a cigarette, cigar, or pipe, without any substantial degree of combustion of any component of that article or device. The aerosol delivery device may not produce smoke in the sense of the aerosol resulting from by-products of combustion or pyrolysis of tobacco, but rather, that the article or device most preferably yields vapors (including vapors within aerosols that can be considered to be visible aerosols that might be considered to be described as smoke-like) resulting from volatilization or vaporization of certain components of the article or device, although in other embodiments the aerosol may not be visible. In highly preferred embodiments, aerosol delivery devices may incorporate tobacco and/or components derived from tobacco. As such, the aerosol delivery device can be characterized as an electronic smoking article such as an electronic cigarette or "e-cigarette.

While the systems are generally described herein in terms of embodiments associated with aerosol delivery devices such as so-called "e-cigarettes," it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with a variety of articles. For example, the description provided herein may be employed in conjunction with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and related packaging for any of the products disclosed herein. Accordingly, it should be understood that the description of the mechanisms, components, features, and methods disclosed herein are discussed in terms of embodiments relating to aerosol delivery devices by way of example only, and may be embodied and used in various other products and methods.

Aerosol delivery devices of the present disclosure also can be characterized as being vapor-producing articles or medicament delivery articles. Thus, such articles or devices can be adapted so as to provide one or more substances (e.g., flavors and/or pharmaceutical active ingredients) in an inhalable form or state. For example, inhalable substances can be substantially in the form of a vapor (i.e., a substance that is in the gas phase at a temperature lower than its critical point). Alternatively, inhalable substances can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term "aerosol" as used herein is meant to include vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not visible, and whether or not of a form that might be considered to be smoke-like.

Aerosol delivery devices of the present disclosure generally include a number of components provided within an outer shell or body. The overall design of the outer shell or body can vary, and the format or configuration of the outer body that can define the overall size and shape of the aerosol delivery device can vary. Typically, an elongated body resembling the shape of a cigarette or cigar can be a formed from a single, unitary shell; or the elongated body can be formed of two or more separable pieces. For example, an aerosol delivery device can comprise an elongated shell or body that can be substantially tubular in shape and, as such, resemble the shape of a conventional cigarette or cigar. However, various other shapes and configurations may be employed in other embodiments (e.g., rectangular or fob-shaped).

In one embodiment, all of the components of the aerosol delivery device are contained within one outer body or shell. Alternatively, an aerosol delivery device can comprise two or more shells that are joined and are separable. For example, an aerosol delivery device can possess at one end a control body comprising a shell containing one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of that article), and at the other end and removably attached thereto a shell containing a disposable portion (e.g., a disposable flavor-containing cartridge). More specific formats, configurations and arrangements of components within the single shell type of unit or within a multi-piece separable shell type of unit will be evident in light of the further disclosure provided herein. Additionally, various aerosol delivery device designs and component arrangements can be appreciated upon consideration of the commercially available electronic aerosol delivery devices.

Aerosol delivery devices of the present disclosure most preferably comprise some combination of a power source (i.e., an electrical power source), at least one control component (e.g., means for actuating, controlling, regulating and/or ceasing power for heat generation, such as by controlling electrical current flow from the power source to other components of the aerosol delivery device), a heater or heat generation component (e.g., an electrical resistance heating element or component commonly referred to as part of an "atomizer"), and an aerosol precursor composition (e.g., commonly a liquid capable of yielding an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid" and "e-juice"), and a mouthend region or tip for allowing draw upon the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the article such that aerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of the present disclosure can vary. In specific embodiments, the aerosol precursor composition can be located near an end of the aerosol delivery device which may be configured to be positioned proximal to the mouth of a user so as to maximize aerosol delivery to the user. Other configurations, however, are not excluded. Generally, the heating element can be positioned sufficiently near the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorants, medicaments, or the like that may likewise be provided for delivery to a user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, a vapor is formed with subsequently condenses to an aerosol suitable for inhalation by a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof, wherein such terms are also interchangeably used herein except where otherwise specified.

As noted above, the aerosol delivery device may incorporate a battery and/or other electrical power source (e.g., a capacitor) to provide current flow sufficient to provide various functionalities to the aerosol delivery device, such as powering of a heater, powering of control systems, powering of indicators, and the like. The power source can take on various embodiments. Preferably, the power source is able to deliver sufficient power to rapidly heat the heating element to provide for aerosol formation and power the aerosol delivery device through use for a desired duration of time. The power source preferably is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Additionally, a preferred power source is of a sufficiently light weight to not detract from a desirable smoking experience.

More specific formats, configurations and arrangements of components within the aerosol delivery device of the present disclosure will be evident in light of the further disclosure provided hereinafter. Additionally, the selection of various aerosol delivery device components can be appreciated upon consideration of the commercially available electronic aerosol delivery devices. Further, the arrangement of the components within the aerosol delivery device can also be appreciated upon consideration of the commercially available electronic aerosol delivery devices. Examples of commercially available products, for which the components thereof, methods of operation thereof, materials included therein, and/or other attributes thereof may be included in the devices of the present disclosure as well as manufacturers, designers, and/or assignees of components and related technologies that may be employed in the aerosol delivery device of the present disclosure are described in <CIT>.

One example embodiment of an aerosol delivery device <NUM> is illustrated in <FIG>. In particular, <FIG> illustrates an aerosol delivery device <NUM> including a control body <NUM> and a cartridge <NUM>. The control body <NUM> and the cartridge <NUM> can be permanently or detachably aligned in a functioning relationship. Various mechanisms may connect the cartridge <NUM> to the control body <NUM> to result in a threaded engagement, a press-fit engagement, an interference fit, a magnetic engagement, or the like. The aerosol delivery device <NUM> may be substantially rod-like, substantially tubular shaped, or substantially cylindrically shaped in some embodiments when the cartridge <NUM> and the control body <NUM> are in an assembled configuration. However, as noted above, various other configurations such as rectangular or fob-shaped may be employed in other embodiments. Further, although the aerosol delivery devices are generally described herein as resembling the size and shape of a traditional smoking article, in other embodiments differing configurations and larger capacity reservoirs, which may be referred to as "tanks," may be employed.

In specific embodiments, one or both of the cartridge <NUM> and the control body <NUM> may be referred to as being disposable or as being reusable. For example, the control body <NUM> may have a replaceable battery or a rechargeable battery and/or capacitor and thus may be combined with any type of recharging technology, including connection to a typical alternating current electrical outlet, connection to a car charger (i.e., cigarette lighter receptacle), and connection to a computer, such as through a universal serial bus (USB) cable. Further, in some embodiments the cartridge <NUM> may comprise a single-use cartridge, as disclosed in <CIT> to Chang et al.

<FIG> illustrates an exploded view of the control body <NUM> of the aerosol delivery device <NUM> (see, <FIG>) according to an example embodiment of the present disclosure. As illustrated, the control body <NUM> may comprise a coupler <NUM>, an outer body <NUM>, a sealing member <NUM>, an adhesive member <NUM> (e.g., KAPTON® tape), a flow sensor <NUM> (e.g., a puff sensor or pressure switch), a control component <NUM>, a spacer <NUM>, an electrical power source <NUM> (e.g., a capacitor and/or a battery, which may be rechargeable), a circuit board with an indicator <NUM> (e.g., a light emitting diode (LED)), a connector circuit <NUM>, and an end cap <NUM>. Examples of electrical power sources are described in <CIT>.

With respect to the flow sensor <NUM>, representative current regulating components and other current controlling components including various microcontrollers, sensors, and switches for aerosol delivery devices are described in <CIT>, <CIT>, <CIT>, and <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>. Reference also is made to the control schemes described in <CIT>.

In one embodiment the indicator <NUM> may comprise one or more light emitting diodes. The indicator <NUM> can be in communication with the control component <NUM> through the connector circuit <NUM> and be illuminated, for example, during a user draw on a cartridge coupled to the coupler <NUM>, as detected by the flow sensor <NUM>. The end cap <NUM> may be adapted to make visible the illumination provided thereunder by the indicator <NUM>. Accordingly, the indicator <NUM> may be illuminated during use of the aerosol delivery device <NUM> to simulate the lit end of a smoking article. However, in other embodiments the indicator <NUM> can be provided in varying numbers and can take on different shapes and can even be an opening in the outer body (such as for release of sound when such indicators are present).

Still further components can be utilized in the aerosol delivery device of the present disclosure. For example, <CIT> discloses indicators for smoking articles; <CIT> discloses piezoelectric sensors that can be associated with the mouth-end of a device to detect user lip activity associated with taking a draw and then trigger heating of a heating device; <CIT> discloses a puff sensor for controlling energy flow into a heating load array in response to pressure drop through a mouthpiece; <CIT> discloses receptacles in a smoking device that include an identifier that detects a non-uniformity in infrared transmissivity of an inserted component and a controller that executes a detection routine as the component is inserted into the receptacle; <CIT> describes a defined executable power cycle with multiple differential phases; <CIT> discloses photonic-optronic components; <CIT> discloses means for altering draw resistance through a smoking device; <CIT> discloses specific battery configurations for use in smoking devices; <CIT> discloses various charging systems for use with smoking devices; <CIT> discloses computer interfacing means for smoking devices to facilitate charging and allow computer control of the device; <CIT> discloses identification systems for smoking devices; and <CIT>discloses a fluid flow sensing system indicative of a puff in an aerosol generating system. Further examples of components related to electronic aerosol delivery articles and disclosing materials or components that may be used in the present article include <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>; and <CIT>; <CIT>and <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. A variety of the materials disclosed by the foregoing documents may be incorporated into the present devices in various embodiments.

<FIG> illustrates the cartridge <NUM> of the aerosol delivery device <NUM> (see, <FIG>) in an exploded configuration. As illustrated, the cartridge <NUM> may comprise a base <NUM>, a control component terminal <NUM>, an electronic component <NUM>, a flow director <NUM>, an atomizer <NUM>, a reservoir <NUM> (e.g., a reservoir substrate), an outer body <NUM>, a mouthpiece <NUM>, a label <NUM>, and first and second heating terminals <NUM>, <NUM> according to an example embodiment of the present disclosure.

In some embodiments the first and second heating terminals <NUM>, <NUM> may be embedded in, or otherwise coupled to, the flow director <NUM>. For example, the first and second heating terminals <NUM>, <NUM> may be insert molded in the flow director <NUM>. Accordingly, the flow director <NUM> and the first and second heating terminals are collectively referred to herein as a flow director assembly <NUM>. Additional description with respect to the first and second heating terminals <NUM>, <NUM> and the flow director <NUM> is provided in <CIT>.

The atomizer <NUM> may comprise a liquid transport element <NUM> and a heating element <NUM>. The cartridge may additionally include a base shipping plug engaged with the base and/or a mouthpiece shipping plug engaged with the mouthpiece in order to protect the base and the mouthpiece and prevent entry of contaminants therein prior to use as disclosed, for example, in <CIT>.

The base <NUM> may be coupled to a first end of the outer body <NUM> and the mouthpiece <NUM> may be coupled to an opposing second end of the outer body to substantially or fully enclose other components of the cartridge <NUM> therein. For example, the control component terminal <NUM>, the electronic component <NUM>, the flow director <NUM>, the atomizer <NUM>, and the reservoir <NUM> may be substantially or entirely retained within the outer body <NUM>. The label <NUM> may at least partially surround the outer body <NUM>, and optionally the base <NUM>, and include information such as a product identifier thereon. The base <NUM> may be configured to engage the coupler <NUM> of the control body <NUM> (see, e.g., <FIG>). In some embodiments the base <NUM> may comprise anti-rotation features that substantially prevent relative rotation between the cartridge and the control body as disclosed in <CIT>.

The reservoir <NUM> may be configured to hold an aerosol precursor composition. Representative types of aerosol precursor components and formulations are also set forth and characterized in <CIT>, <CIT>, and <CIT>; and <CIT>;<CIT>; and <CIT>, as well as <CIT> Other aerosol precursors that may be employed include the aerosol precursors that have been incorporated in the VUSE® product by R. Reynolds Vapor Company, the BLU product by Lorillard Technologies, the MISTIC MENTHOL product by Mistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirable are the so-called "smoke juices" for electronic cigarettes that have been available from Johnson Creek Enterprises LLC. Embodiments of effervescent materials can be used with the aerosol precursor, and are described, by way of example, in <CIT> Further, the use of effervescent materials is described, for example, in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>; as well as <CIT> and <CIT> Additional description with respect to embodiments of aerosol precursor compositions, including description of tobacco or components derived from tobacco included therein, is provided in <CIT> and <CIT>.

The reservoir <NUM> may comprise a plurality of layers of nonwoven fibers formed into the shape of a tube encircling the interior of the outer body <NUM> of the cartridge <NUM>. Thus, liquid components, for example, can be sorptively retained by the reservoir <NUM>. The reservoir <NUM> is in fluid connection with the liquid transport element <NUM>. Thus, the liquid transport element <NUM> may be configured to transport liquid from the reservoir <NUM> to the heating element <NUM> via capillary action or other liquid transport mechanism.

As illustrated, the liquid transport element <NUM> may be in direct contact with the heating element <NUM>. As further illustrated in <FIG>, the heating element <NUM> may comprise a wire defining a plurality of coils wound about the liquid transport element <NUM>. In some embodiments the heating element <NUM> may be formed by winding the wire about the liquid transport element <NUM> as described in <CIT> Further, in some embodiments the wire may define a variable coil spacing, as described in <CIT> Various embodiments of materials configured to produce heat when electrical current is applied therethrough may be employed to form the heating element <NUM>. Example materials from which the wire coil may be formed include Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi<NUM>), molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)<NUM>), graphite and graphite-based materials; and ceramic (e.g., a positive or negative temperature coefficient ceramic).

However, various other embodiments of methods may be employed to form the heating element <NUM>, and various other embodiments of heating elements may be employed in the atomizer <NUM>. For example, a stamped heating element may be employed in the atomizer, as described in <CIT> Further to the above, additional representative heating elements and materials for use therein are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT> Further, chemical heating may be employed in other embodiments. Various additional examples of heaters and materials employed to form heaters are described in <CIT>.

A variety of heater components may be used in the present aerosol delivery device. In various embodiments, one or more microheaters or like solid state heaters may be used. Microheaters and atomizers incorporating microheaters suitable for use in the presently disclosed devices are described in <CIT>.

The first heating terminal <NUM> and the second heating terminal <NUM> (e.g., negative and positive heating terminals) are configured to engage opposing ends of the heating element <NUM> and to form an electrical connection with the control body <NUM> (see, e.g., <FIG>) when the cartridge <NUM> is connected thereto. Further, when the control body <NUM> is coupled to the cartridge <NUM>, the electronic component <NUM> may form an electrical connection with the control body through the control component terminal <NUM>. The control body <NUM> may thus employ the electronic component <NUM> (see, <FIG>) to determine whether the cartridge <NUM> is genuine and/or perform other functions. Further, various examples of electronic control components and functions performed thereby are described in <CIT>.

During use, a user may draw on the mouthpiece <NUM> of the cartridge <NUM> of the aerosol delivery device <NUM> (see, <FIG>). This may pull air through an opening in the control body <NUM> (see, e.g., <FIG>) or in the cartridge <NUM>. For example, in one embodiment an opening may be defined between the coupler <NUM> and the outer body <NUM> of the control body <NUM> (see, e.g., <FIG>), as described in <CIT> However, the flow of air may be received through other parts of the aerosol delivery device <NUM> in other embodiments. As noted above, in some embodiments the cartridge <NUM> may include the flow director <NUM>. The flow director <NUM> may be configured to direct the flow of air received from the control body <NUM> to the heating element <NUM> of the atomizer <NUM>.

A sensor in the aerosol delivery device <NUM> (e.g., the flow sensor <NUM> in the control body <NUM>; see, <FIG>) may sense the puff. When the puff is sensed, the control body <NUM> may direct current to the heating element <NUM> through a circuit including the first heating terminal <NUM> and the second heating terminal <NUM>. Accordingly, the heating element <NUM> may vaporize the aerosol precursor composition directed to an aerosolization zone from the reservoir <NUM> by the liquid transport element <NUM>. Thus, the mouthpiece <NUM> may allow passage of air and entrained vapor (i.e., the components of the aerosol precursor composition in an inhalable form) from the cartridge <NUM> to a consumer drawing thereon.

Various other details with respect to the components that may be included in the cartridge <NUM> are provided, for example, in <CIT> Additional components that may be included in the cartridge <NUM> and details relating thereto are provided, for example, in <CIT>.

Various components of an aerosol delivery device according to the present disclosure can be chosen from components described in the art and commercially available. Reference is made for example to the reservoir and heater system for controllable delivery of multiple aerosolizable materials in an electronic smoking article disclosed in <CIT>.

In another embodiment substantially the entirety of the cartridge may be formed from one or more carbon materials, which may provide advantages in terms of biodegradability and absence of wires. In this regard, the heating element may comprise carbon foam, the reservoir may comprise carbonized fabric, and graphite may be employed to form an electrical connection with the power source and control component. An example embodiment of a carbon-based cartridge is provided in <CIT>.

However, in some embodiments it may be desirable to provide aerosol delivery devices with alternative configurations. In this regard, <FIG> and <FIG> illustrate a cartridge <NUM> according to an additional example embodiment of the present disclosure. <FIG> illustrates the cartridge in an exploded configuration. <FIG> illustrates the cartridge <NUM> in an assembled configuration. Where not otherwise described and/or illustrated, the components of the cartridge <NUM> may be substantially similar to, or the same as, corresponding components described above in relation to <FIG>.

As illustrated, the cartridge <NUM> may include a base <NUM>, a flow director <NUM>, an atomizer <NUM>, an outer body <NUM>, and a mouthpiece <NUM>. A first end of the outer body <NUM> may engage the base <NUM>. An opposing second end of the outer body <NUM> may engage the mouthpiece <NUM>.

The flow director <NUM> may extend from a first end 408A at the base <NUM> through the outer body <NUM> to a second end 408B at the mouthpiece <NUM>. Thereby, as illustrated in <FIG>, a reservoir <NUM> may be defined between the flow director <NUM> and the outer body <NUM>. The reservoir <NUM> may define an open space configured to receive an aerosol precursor composition. In one or more embodiments, a fibrous substrate may be present in at least a portion of the reservoir <NUM> to hold aerosol precursor composition similar to the reservoir substrate <NUM> illustrated in <FIG>.

The atomizer <NUM> may be configured to vaporize the aerosol precursor composition received from the reservoir <NUM>. In this regard, as illustrated in <FIG>, the atomizer <NUM> may include a liquid transport element <NUM> and a heating element <NUM>. The heating element <NUM> may comprise a wire defining a plurality of coils extending around the liquid transport element <NUM>. Further, the atomizer <NUM> may include first and second connectors 428A, 428B contacting the coils at first and second opposing ends of the heating element <NUM>. The connectors 428A, 428B may be configured to engage first and second heating terminals <NUM>, <NUM> (see, <FIG>) in order to supply power thereto.

The atomizer <NUM> may extend through the flow director <NUM>. More particularly, a longitudinal axis of the liquid transport element <NUM> may extend substantially perpendicularly to a longitudinal axis of the flow director <NUM> such that the atomizer <NUM> extends across the flow director <NUM>. In this regard, as illustrated in <FIG>, the flow director <NUM> may include one or more apertures 429A, 429B extending therethrough, transverse to a longitudinal aperture <NUM> extending through the flow director. The atomizer <NUM> may extend at least partially through each of the apertures 429A, 429B such that the atomizer extends across the longitudinal aperture <NUM>.

The liquid transport element <NUM> may include a capillary channel <NUM> extending therethrough. The capillary channel <NUM> may be configured to receive aerosol precursor composition from the reservoir <NUM>. In this regard, as illustrated in <FIG>, the capillary channel <NUM> may be in fluid communication with the reservoir <NUM>. Accordingly, the aerosol precursor composition contained in the reservoir <NUM> may enter the liquid transport element <NUM> via the capillary channel <NUM>. Further, the liquid transport element <NUM> may comprise a porous monolith. For example, the liquid transport element <NUM> may comprise a porous ceramic material composed of silica and/or alumina as exemplary materials. In some examples, where the liquid transport element <NUM> comprises a mixture of silica and alumina then a heater may be utilized. In some instances, the heater may be in the form of a conductive mesh, rather than a heater coil, formed from a plurality of crossing, conductive filaments that wrap around the liquid transport element <NUM> in order to provide a more uniform heat distribution. Example embodiments of conductive meshes are described in <CIT>.

Alternatively, the porous liquid transport element may also be comprised of an electrically conducted ceramic (e.g., boron-doped silicon) that may act as a semiconductor for which resistance is controllable. As such, the liquid transport element may act as the heating element, thereby forgoing the necessity of a heating coil with a plurality of coils and desirably extending a lifetime of the atomizer. Accordingly, the aerosol precursor composition may be wicked from the capillary channel <NUM> generally radially outwardly such that the liquid transport element <NUM> is saturated and such that the aerosol precursor composition reaches the heating element <NUM>.

The cartridge <NUM> may be coupled to a control body such as the control body <NUM> of <FIG>. The control body <NUM> may verify that the cartridge <NUM> is genuine and/or perform other functions (e.g., preventing further heating of the heating element <NUM> after a predetermined number of cumulative seconds of heating have occurred, which may correspond to a substantially empty cartridge) by communicating with an electronic component <NUM> via an electronic component terminal <NUM>. Thereafter, when the flow sensor <NUM> (see, <FIG>) of the control body <NUM> detects a puff on the cartridge <NUM>, the control body <NUM> may direct current from the electrical power source <NUM> (see, <FIG>) to the cartridge. The electrical current may thereby be directed through the first and second heating terminals <NUM>, <NUM> to the first and second connectors 428A, 428B.

In some embodiments, as illustrated, the first and second heating terminals <NUM>, <NUM> may extend at least partially through the flow director <NUM>. For example, the first and second heating terminals <NUM>, <NUM> may be molded into the flow director <NUM> (e.g., in-molded in the flow director during the formation thereof) and extend along at least a portion of the length thereof. By way of further example, the first and second heating terminals <NUM>, <NUM> may extend along a portion of a length thereof and terminate at a location at which the atomizer <NUM> extends across the flow director <NUM>. Thereby, the first and second heating terminals <NUM>, <NUM> may contact the first and second connectors 428A, 428B, respectively, without blocking the apertures 429A, 429B in the flow director <NUM> through which the atomizer <NUM> extends. The other ends of the first and second heating terminals <NUM>, <NUM> and the outer end of the electronic component terminal <NUM> may extend through openings defined in the base <NUM> such that the ends are exposed and configured for engagement with corresponding electrical contacts of a control body.

Accordingly, the electrical current may be directed through the heating element <NUM>, in order to produce heat (e.g., via joule heating), or may be conducted directly through the liquid transport element. The heat may be transferred to the aerosol precursor composition directed through the liquid transport element <NUM> such that a vapor is produced inside of the flow director <NUM>. The vapor may join with air directed through the flow director <NUM> and travel to a user via the mouthpiece <NUM> (see, e.g., <FIG>). More particular, the vapor may be produced by the atomizer <NUM> within the longitudinal aperture <NUM> extending through the flow director <NUM>. Thereby, by configuring the atomizer <NUM> such that it extends through the flow director <NUM>, provision of a separate atomization cavity may not be necessary. In other words, by producing the vapor within the flow director <NUM>, it may not be necessary to include a separate atomization cavity upstream or downstream of the flow director. Accordingly, the capacity of the reservoir <NUM> for a given cartridge size may be relatively larger.

In some embodiments the longitudinal aperture <NUM> may define a substantially constant cross-section, perpendicular to the longitudinal length of the flow director <NUM>, at each location along the length of the flow director. Further, the base <NUM> may define a base opening <NUM> that may match a size and shape of the longitudinal aperture <NUM> extending through the flow director <NUM>. Additionally, the flow director <NUM> may extend through the mouthpiece <NUM> (see, e.g., <FIG>) or mate with an aperture in the mouthpiece having the same size and shape of the longitudinal aperture <NUM> extending the flow director. Accordingly, a smooth flow path may be defined through the cartridge <NUM> so as to allow flow therethrough with reduced pressure drop.

As noted above, the reservoir <NUM> may define an open space configured to receive an aerosol precursor composition. The reservoir <NUM> may be sealed such that aerosol precursor composition cannot escape therefrom other than through the atomizer <NUM> in the manner described herein. In this regard, the atomizer <NUM>, and more particularly, the first and second connectors 428A, 428B, may engage the apertures 429A, 429B defined through the flow director <NUM> and through which the atomizer extends. For example, the first and second connectors 428A, 428B may respectively engage one of the apertures 429A, 429B via press fit. Thereby, the atomizer <NUM> may be sealed with respect to the flow director <NUM>.

Further, the outer body <NUM> may be sealed to the mouthpiece <NUM> and a first end of the flow director <NUM> may be sealed to the mouthpiece. For example, the mouthpiece <NUM> may be ultrasonically welded to the outer body <NUM> and the flow director <NUM>. Additionally, the outer body <NUM> may be sealed to the base <NUM>. For example, in some embodiments the outer body <NUM> may be ultrasonically welded to the base <NUM>.

However, in other embodiments it may be desirable to provide alternative mechanisms for sealing the reservoir <NUM>. For example, it may be desirable to configure the cartridge <NUM> such that the atomizer <NUM> is removable. However, the atomizer <NUM> may be irremovably engaged with the flow director <NUM>. Further, the flow director <NUM> may be irremovably engaged with the base <NUM> (e.g., ultrasonically welded, adhesively attached, or otherwise substantially permanently connected thereto). As such, replacement of the atomizer <NUM> may involve replacement of an assembly including the atomizer, the flow director <NUM>, the first and second heating terminals <NUM>, <NUM>, the electronic component <NUM> (which may be received in a compartment defined between the base and the flow director), the electronic component terminal <NUM>, and the base <NUM>.

Accordingly, these components may be configured to be removable from a remainder of the cartridge <NUM>. For example, as illustrated in <FIG>, the base <NUM> may include a plurality of threads 402A configured to engage a plurality of threads 414A of the outer body <NUM> such that the outer body engages the base via threaded engagement. Although the threads 402A, 414A may form a seal, in some embodiments the cartridge <NUM> may further comprise a sealing member configured to seal the outer body <NUM> to the base <NUM>. For example, an O-ring <NUM>, which may comprise silicone or other resilient material, may extend around the base <NUM> and may be compressed between the outer body <NUM> and the base as the base is threaded into engagement with the outer body.

Further, the flow director <NUM> may releasably engage the mouthpiece <NUM>. For example, as illustrated in <FIG>, the flow director <NUM> may include a plurality of threads 408A configured to engage a plurality of threads 416A of the mouthpiece <NUM> such that the flow director engages the mouthpiece via threaded engagement. Although the threads 408A, 416A may form a seal, in some embodiments the cartridge <NUM> may further comprise a sealing member configured to seal the flow director <NUM> to the mouthpiece <NUM>. For example, an O-ring <NUM>, which may comprise silicone or other resilient material, may extend around the flow director <NUM> and may be compressed between the flow director and the mouthpiece as the flow director is threaded into engagement with the mouthpiece.

As may be understood, the flow director <NUM> may threadingly engage the mouthpiece <NUM> (see, <FIG>) simultaneously with the base <NUM> threadingly engaging the outer body <NUM> (see, <FIG>). Further, a pitch of the threads 408A of the flow director <NUM> and the threads 416A of the mouthpiece <NUM> may be equal to a pitch of the threads 402A of the base <NUM> and the threads 414A of the outer body <NUM> to allow simultaneous engagement of the flow director and the mouthpiece and the base and the outer body without one set of threads binding before the other, thereby allowing the threads to form a seal by themselves and/or compressing the O-rings <NUM>, <NUM> to form a seal.

Accordingly, by employing the threads 402A, 408A, 414A, 416A, the cartridge <NUM> may be configured such that an assembly including the atomizer <NUM> may be removed and replaced. In this regard, the assembly including the atomizer <NUM> may be replaced when the useful life of the atomizer is complete, or the assembly may be replaced with a differing assembly including a differing atomizer that may, for example, be configured to produce a greater or lesser amount of aerosol with each puff.

As noted above, in some embodiments an assembly including the atomizer <NUM> may be replaceable such that a new atomizer may be provided when the atomizer reaches the end of its useable life. In this regard, in some embodiments the cartridge <NUM> may be refillable such that the cartridge <NUM> may be repeatedly reused.

Thus, the cartridge <NUM> may include features configured to facilitate refilling. For example, as illustrated in <FIG>, the base <NUM> may define one or more fill ports <NUM>. Thus, the open space defined by the reservoir <NUM> within the outer housing <NUM> may receive aerosol precursor composition directed through the one or more fill ports <NUM>. Further, the one or more fill ports <NUM> may respectively comprise a one-way valve <NUM>. The one-way valves <NUM> may be configured to allow flow of the aerosol precursor composition through the fill ports <NUM> into the reservoir <NUM>, and prevent flow outwardly therefrom. For example, the one-way valves <NUM> may comprise diaphragm check valves, which may be formed from silicone or other resilient material and which may be biased to a closed configuration. Accordingly, a nozzle or extension of a refilling bottle may engage the filling port(s) <NUM> and/or the one way valve(s) <NUM> and direct aerosol precursor composition therethrough to refill the cartridge <NUM>. In some embodiments the outer body <NUM> may be transparent or translucent along at least a portion thereof, such that a user may view the quantity of aerosol precursor composition contained therein, which may be useful to determine the level of aerosol precursor composition in the reservoir <NUM> during use and refilling of the cartridge <NUM>.

Example embodiments of one-way valves that may be included in the cartridge <NUM> and associated refilling bottles and other aerosol precursor composition refilling components are described in <CIT> and <CIT>. Further, <CIT>, discloses an aerosol delivery device including a refillable reservoir and a container for refilling the reservoir.

In some embodiments the refilling bottle may threadingly engage the cartridge, snap into engagement therewith, or otherwise create a secure connection with the cartridge. The refilling bottle may then dispense the aerosol precursor composition into the cartridge by pumping or squeezing the refilling bottle, or by allowing pressurized fluid within the refilling bottle to expel the aerosol precursor composition into the cartridge. In some embodiments the filling port(s) may be configured to receive aerosol precursor composition from a refilling bottle that is also configured to refill a so-called "tank," which defines a relatively large reservoir for an aerosol delivery device. For example, the filling ports may be sized and configured to receive the nozzle of a tank refilling bottle, or the tank refilling bottle may be provided with a second nozzle configured to engage the filling port of the cartridge. Accordingly, the reservoir of the cartridge may be refilled with embodiments of refilling bottles that may be employed to refill multiple types of aerosol delivery devices.

Thus, the cartridge of the present disclosure may be refilled and reused. As may be understood, reuse of the cartridge may provide cost savings and reduce the amount of waste associated with use of the cartridge as compared to single-use disposable cartridges. As noted above, cartridges for aerosol delivery devices have traditionally employed fibrous wicks to transport aerosol precursor composition to a heating element. In view of the relatively short lifespan of suck wicks, cartridges have not generally been configured to be refillable. However, by employing a porous monolith as the liquid transport element, and/or by configuring the atomizer such that it is replaceable, and/or utilizing the liquid transport element itself as the heater, as described herein, the cartridge may be refilled and reused repeatedly.

In an additional embodiment an aerosol delivery device operation method is provided. As illustrated in <FIG>, the method may include retaining an aerosol precursor composition in a reservoir defined between a flow director and an outer body, the flow director extending between a first flow director end and a second flow director end at operation <NUM>. Further, the method may include directing the aerosol precursor composition from the reservoir through a liquid transport element of an atomizer extending through the flow director at a position between the first flow director end and the second flow director end at operation <NUM>. The method may additionally include receiving an electrical current through a heating element of the atomizer at operation <NUM>. The method may further include vaporizing at least a portion of the aerosol precursor composition to produce an aerosol within the flow director at operation <NUM>.

In some embodiments the method may further include receiving the aerosol precursor composition through one or more fill ports defined in a base. Directing the aerosol precursor composition through the liquid transport element at operation <NUM> may include directing the aerosol precursor composition through a capillary channel. Directing the aerosol precursor composition through the liquid transport element at operation <NUM> may further include directing the aerosol precursor composition through a porous monolith to the heating element.

In some embodiments receiving the electrical current through the heating element at operation <NUM> may include receiving the electrical current through a wire defining a plurality of coils extending around the liquid transport element. The method may further include directing the aerosol out of the flow director through a mouthpiece. Additionally, the method may include retaining the aerosol precursor composition in the reservoir with a seal between the outer body and the base. Further, the method may include retaining the aerosol precursor composition in the reservoir with a seal between the mouthpiece and the outer body and a seal between the mouthpiece and the flow director.

Claim 1:
An aerosol delivery device, comprising:
an outer body (<NUM>, <NUM>);
a base (<NUM>, <NUM>) coupled to a first end of the outer body (<NUM>, <NUM>);
a mouthpiece (<NUM>, <NUM>) coupled to an opposing second end of the outer body (<NUM>, <NUM>);
a flow director (<NUM>, <NUM>) extending from a first flow director end to a second flow director end through the outer body (<NUM>, <NUM>) such that a reservoir (<NUM>, <NUM>) is defined between the flow director (<NUM>, <NUM>) and the outer body (<NUM>, <NUM>), the reservoir (<NUM>, <NUM>) defining an open space configured to receive an aerosol precursor composition and the base (<NUM>, <NUM>) comprising one or more fill ports (<NUM>) configured to receive the aerosol precursor composition therethrough; and
an atomizer (<NUM>, <NUM>) extending through the flow director (<NUM>, <NUM>) at a position between the first flow director end and the second flow director end, the atomizer (<NUM>, <NUM>) including a liquid transport element (<NUM>, <NUM>) and a heating element (<NUM>, <NUM>) configured to vaporize at least a portion of the aerosol precursor composition to produce an aerosol within the flow director (<NUM>, <NUM>), wherein a longitudinal axis of the liquid transport element (<NUM>, <NUM>) extends substantially perpendicularly to a longitudinal axis of the flow director (<NUM>, <NUM>), and wherein the flow director (<NUM>, <NUM>), the atomizer (<NUM>, <NUM>), and the reservoir (<NUM>, <NUM>) are entirely retained within the outer body (<NUM>, <NUM>).