Patent Description:
Many smoking 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 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>, and <CIT> See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heat generating sources referenced by brand name and commercial source in <CIT>.

<CIT> discloses a dose unit comprising at least one isolated bioactive agent applied on a carrier material in thermal contact with an electrically heating element configured to vaporize a predetermined amount of the agent for pulmonary delivery.

It would be desirable to provide a vapor-forming unit of an aerosol delivery device, the vapor-forming unit being configured for improved vapor formation and/or improved integration with a power unit. It would also be desirable to provide aerosol delivery devices that are prepared utilizing such vapor-forming units.

The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. The aerosol delivery devices can particularly integrate ceramic wicks to form vapor-forming units that can be combined with power units to form the aerosol delivery devices.

In one or more embodiments, the present disclosure can relate to an atomizer that is particularly useful in an aerosol delivery device. The atomizer particularly can include at least a fluid transport element and a heater. The fluid transport element can be formed of a rigid material and particularly can be a porous monolith, such as a porous ceramic or porous glass. The combined heater and fluid transport element can exhibit improved vapor formation in light of certain configurations of the individual materials.

The present disclosure relates to an atomizer comprising: a fluid transport element in the form of a rigid, porous monolith, the fluid transport element having a first end and a second end; and a conductive mesh heater circumferentially contacting at least a portion of an outer surface of the fluid transport element, the conductive mesh heater comprising a network of intercrossing, conductive filaments that defines a first end with a first clasp and a second end with a second clasp, the first clasp and the second clasp being configured to secure the conductive mesh heater to the fluid transport element. In further embodiments, such atomizer may be defined in relation to one or more of the following statements, which may be combined in any number and order.

The conductive mesh can have a regular pattern of conductive filaments forming parallelograms (or other geometric shapes) surrounding insulating spaces.

The insulating spaces can be open or can be at least partially filled.

The insulating spaces can have an average individual area of about <NUM> to about <NUM>.

The fluid transport element can have an overall longitudinal length, and the conductive mesh can be present on about <NUM>% to about <NUM>% of the overall longitudinal length of the fluid transport element.

The conductive mesh can be present on about <NUM>% to about <NUM>% of the overall longitudinal length of the fluid transport element.

In one or more embodiments, the present disclosure specifically can relate to an aerosol delivery device comprising an atomizer as otherwise described herein. In particular, such aerosol delivery device can comprise a reservoir including an aerosol precursor composition, and the second end of the fluid transport element from the atomizer can extend into the reservoir so as to be in contact with the aerosol precursor composition. The fluid transport element can wick or otherwise transport aerosol precursor composition from the reservoir to the heater that is in thermal connection with the fluid transport element (the heater having any configuration as otherwise described herein). The heater is positioned exterior to the reservoir so as to vaporize at least a portion of the aerosol precursor composition that is transported from the reservoir via the fluid transport element. The formed vapor can combine with air that is drawn into the aerosol delivery device to form an aerosol that flows to a mouthend of the aerosol delivery device and exits the aerosol delivery device. The aerosol delivery device including the atomizer can be a single, unitary structure housing all elements as described herein useful for forming an aerosol (e.g., power, control, and vaporization elements). The aerosol delivery device can be a cartridge or tank that does not include any power element (e.g., does not include a battery) and/or does not include a control element (e.g., does not include a printed circuit board with a sensor or other electronic controller thereon).

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The disclosure includes combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context 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. As used in the specification, and in the appended claims, the singular forms "a", "an", "the", include plural referents unless the context clearly dictates otherwise.

As described hereinafter, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat a material (preferably without combusting the material to any significant degree and/or without significant chemical alteration of the material) to form an inhalable substance; and components of such systems have the form of articles that most preferably are sufficiently compact to be considered hand-held devices. That is, use of components of preferred aerosol delivery systems does not result in the production of smoke - i.e., from byproducts of combustion or pyrolysis of tobacco, but rather, use of those preferred systems results in the production of vapors resulting from volatilization or vaporization of certain components incorporated therein. In preferred embodiments, components of aerosol delivery systems may be characterized as electronic cigarettes, and those electronic cigarettes most preferably incorporate tobacco and/or components derived from tobacco, and hence deliver tobacco derived components in aerosol form.

Aerosol generating pieces of certain preferred aerosol delivery systems may provide many 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 that is employed by lighting and burning tobacco (and hence inhaling tobacco smoke), without any substantial degree of combustion of any component thereof. For example, the user of an aerosol generating piece of the present disclosure can hold and use that piece much like a smoker employs a traditional type of smoking article, draw on one end of that piece for inhalation of aerosol produced by that piece, take or draw puffs at selected intervals of time, and the like.

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 body or shell, which may be referred to as a housing. The overall design of the outer body or shell 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 housing, or the elongated housing can be formed of two or more separable bodies. 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. In one embodiment, all of the components of the aerosol delivery device are contained within one housing. Alternatively, an aerosol delivery device can comprise two or more housings that are joined and are separable. For example, an aerosol delivery device can possess at one end a control body (or power unit) comprising a housing containing one or more components (e.g., a battery and various electronics for controlling the operation of that article), and at the other end and removably attached thereto an outer body or shell containing aerosol forming components (e.g., one or more aerosol precursor components, such as flavors and aerosol formers, one or more heaters, and/or one or more wicks).

Aerosol delivery devices of the present disclosure can be formed of an outer housing or shell that is not substantially tubular in shape but may be formed to substantially greater dimensions. The housing or shell can be configured to include a mouthpiece and/or may be configured to receive a separate shell (e.g., a cartridge or tank) that can include consumable elements, such as a liquid aerosol former, and can include a vaporizer or atomizer.

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 ceasing power for heat generation, such as by controlling electrical current flow the power source to other components of the article - e.g., a microcontroller or microprocessor), a heater or heat generation member (e.g., an electrical resistance heating element or other component, which alone or in combination with one or more further elements may be commonly referred to as an "atomizer"), 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 mouthpiece or mouth region for allowing draw upon the aerosol delivery device for aerosol inhalation (e.g., a defined airflow path through the article such that aerosol generated can be withdrawn therefrom upon draw).

More specific formats, configurations and arrangements of components within the aerosol delivery systems of the present disclosure will be evident in light of the further disclosure provided hereinafter. Additionally, the selection and arrangement of various aerosol delivery system components can be appreciated upon consideration of the commercially available electronic aerosol delivery devices, such as those representative products referenced in the background art section of the present disclosure.

One example embodiment of an aerosol delivery device <NUM> illustrating components that may be utilized in an aerosol delivery device according to the present disclosure is provided in <FIG>. As seen in the cut-away view illustrated therein, the aerosol delivery device <NUM> can comprise a power unit <NUM> and a cartridge <NUM> that can be permanently or detachably aligned in a functioning relationship. Engagement of the power unit <NUM> and the cartridge <NUM> can be press fit (as illustrated), threaded, interference fit, magnetic, or the like. In particular, connection components, such as further described herein may be used. For example, the power unit may include a coupler that is adapted to engage a connector on the cartridge.

In specific embodiments, one or both of the power unit <NUM> and the cartridge <NUM> may be referred to as being disposable or as being reusable. For example, the power unit may have a replaceable battery or a rechargeable battery and thus may be combined with any type of recharging technology, including connection to a typical 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. For example, an adaptor including a USB connector at one end and a power unit connector at an opposing end is disclosed in <CIT> Further, in some embodiments the cartridge may comprise a single-use cartridge, as disclosed in <CIT>.

As illustrated in <FIG>, a power unit <NUM> can be formed of a power unit shell <NUM> that can include a control component <NUM> (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller, or the like), a flow sensor <NUM>, a battery <NUM>, and an LED <NUM>, and such components can be variably aligned. Further indicators (e.g., a haptic feedback component, an audio feedback component, or the like) can be included in addition to or as an alternative to the LED. Additional representative types of components that yield visual cues or indicators, such as light emitting diode (LED) components, and the configurations and uses thereof, are described in <CIT>; <CIT>and <CIT>; <CIT>et al. ; and <CIT>. It is understood that not all of the illustrated elements are required. For example, an LED may be absent or may be replaced with a different indicator, such as a vibrating indicator. Likewise, a flow sensor may be replaced with a manual actuator, such as a push button.

A cartridge <NUM> can be formed of a cartridge shell <NUM> enclosing the reservoir <NUM> that is in fluid communication with a liquid transport element <NUM> adapted to wick or otherwise transport an aerosol precursor composition stored in the reservoir housing to a heater <NUM>. A liquid transport element can be formed of one or more materials configured for transport of a liquid, such as by capillary action. A liquid transport element can be formed of, for example, fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabrics, glass fibers), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. The liquid transport element thus can be any material that contains an open pore network (i.e., a plurality of pores that are interconnected so that fluid may flow from one pore to another in a plurality of direction through the element). As further discussed herein, some embodiments of the present disclosure can particularly relate to the use of non-fibrous transport elements. As such, fibrous transport elements can be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be utilized. Various embodiments of materials configured to produce heat when electrical current is applied therethrough may be employed to form the resistive 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>), titanium, platinum, silver, palladium, alloys of silver and palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), conductive inks, boron doped silica, and ceramics (e.g., positive or negative temperature coefficient ceramics).

An opening <NUM> may be present in the cartridge shell <NUM> (e.g., at the mouthend) to allow for egress of formed aerosol from the cartridge <NUM>. Such components are representative of the components that may be present in a cartridge and are not intended to limit the scope of cartridge components that are encompassed by the present disclosure.

The cartridge <NUM> also may include one or more electronic components <NUM>, which may include an integrated circuit, a memory component, a sensor, or the like. The electronic component <NUM> may be adapted to communicate with the control component <NUM> and/or with an external device by wired or wireless means. The electronic component <NUM> may be positioned anywhere within the cartridge <NUM> or its base <NUM>.

Although the control component <NUM> and the flow sensor <NUM> are illustrated separately, it is understood that the control component and the flow sensor may be combined as an electronic circuit board with the air flow sensor attached directly thereto. Further, the electronic circuit board may be positioned horizontally relative the illustration of <FIG> in that the electronic circuit board can be lengthwise parallel to the central axis of the power unit. In some embodiments, the air flow sensor may comprise its own circuit board or other base element to which it can be attached. In some embodiments, a flexible circuit board may be utilized. A flexible circuit board may be configured into a variety of shapes, include substantially tubular shapes. Configurations of a printed circuit board and a pressure sensor, for example, are described in <CIT>.

The power unit <NUM> and the cartridge <NUM> may include components adapted to facilitate a fluid engagement therebetween. As illustrated in <FIG>, the power unit <NUM> can include a coupler <NUM> having a cavity <NUM> therein. The cartridge <NUM> can include a base <NUM> adapted to engage the coupler <NUM> and can include a projection <NUM> adapted to fit within the cavity <NUM>. Such engagement can facilitate a stable connection between the power unit <NUM> and the cartridge <NUM> as well as establish an electrical connection between the battery <NUM> and control component <NUM> in the power unit and the heater <NUM> in the cartridge. Further, the power unit shell <NUM> can include an air intake <NUM>, which may be a notch in the shell where it connects to the coupler <NUM> that allows for passage of ambient air around the coupler and into the shell where it then passes through the cavity <NUM> of the coupler and into the cartridge through the projection <NUM>.

A coupler and a base useful according to the present disclosure are described in <CIT> For example, a coupler as seen in <FIG> may define an outer periphery <NUM> configured to mate with an inner periphery <NUM> of the base <NUM>. In one embodiment the inner periphery of the base may define a radius that is substantially equal to, or slightly greater than, a radius of the outer periphery of the coupler. Further, the coupler <NUM> may define one or more protrusions <NUM> at the outer periphery <NUM> configured to engage one or more recesses <NUM> defined at the inner periphery of the base. However, various other embodiments of structures, shapes, and components may be employed to couple the base to the coupler. In some embodiments the connection between the base <NUM> of the cartridge <NUM> and the coupler <NUM> of the power unit <NUM> may be substantially permanent, whereas in other embodiments the connection therebetween may be releasable such that, for example, the power unit may be reused with one or more additional cartridges that may be disposable and/or refillable.

The aerosol delivery device <NUM> may be substantially rod-like or substantially tubular shaped or substantially cylindrically shaped in some embodiments. In other embodiments, further shapes and dimensions are encompassed - e.g., a rectangular or triangular cross-section, multifaceted shapes, or the like. In particular, the power unit <NUM> may be non-rod-like and may rather be substantially rectangular, round, or have some further shape. Likewise, the power unit <NUM> may be substantially larger than a power unit that would be expected to be substantially the size of a conventional cigarette.

The reservoir <NUM> illustrated in <FIG> can be a container (e.g., formed of walls substantially impermeable to the aerosol precursor composition) or can be a fibrous reservoir. Container walls can be flexible and can be collapsible. Container walls alternatively can be substantially rigid. A container preferably is substantially sealed to prevent passage of aerosol precursor composition therefrom except via any specific opening provided expressly for passage of the aerosol precursor composition, such as through a transport element as otherwise described herein. In exemplary embodiments, the reservoir <NUM> can comprise one or more layers of nonwoven fibers substantially formed into the shape of a tube encircling the interior of the cartridge shell <NUM>. An aerosol precursor composition can be retained in the reservoir <NUM>. Liquid components, for example, can be sorptively retained by the reservoir <NUM> (i.e., when the reservoir <NUM> includes a fibrous material). The reservoir <NUM> can be in fluid connection with a liquid transport element <NUM>. The liquid transport element <NUM> can transport the aerosol precursor composition stored in the reservoir <NUM> via capillary action to the heating element <NUM> that is in the form of a metal wire coil in this embodiment. As such, the heating element <NUM> is in a heating arrangement with the liquid transport element <NUM>.

In use, when a user draws on the article <NUM>, airflow is detected by the sensor <NUM>, the heating element <NUM> is activated, and the components for the aerosol precursor composition are vaporized by the heating element <NUM>. Drawing upon the mouthend of the article <NUM> causes ambient air to enter the air intake <NUM> and pass through the cavity <NUM> in the coupler <NUM> and the central opening in the projection <NUM> of the base <NUM>. In the cartridge <NUM>, the drawn air combines with the formed vapor to form an aerosol. The aerosol is whisked, aspirated, or otherwise drawn away from the heating element <NUM> and out the mouth opening <NUM> in the mouthend of the article <NUM>. Alternatively, in the absence of an airflow sensor, the heating element <NUM> may be activated manually, such as by a push button.

An input element may be included with the aerosol delivery device (and may replace or supplement an airflow or pressure sensor). The input may be included to allow a user to control functions of the device and/or for output of information to a user. Any component or combination of components may be utilized as an input for controlling the function of the device. For example, one or more pushbuttons may be used as described in <CIT> Likewise, a touchscreen may be used as described in <CIT> As a further example, components adapted for gesture recognition based on specified movements of the aerosol delivery device may be used as an input.

In some embodiments, an input may comprise a computer or computing device, such as a smartphone or tablet. In particular, the aerosol delivery device may be wired to the computer or other device, such as via use of a USB cord or similar protocol. The aerosol delivery device also may communicate with a computer or other device acting as an input via wireless communication. See, for example, the systems and methods for controlling a device via a read request as described in <CIT> In such embodiments, an APP or other computer program may be used in connection with a computer or other computing device to input control instructions to the aerosol delivery device, such control instructions including, for example, the ability to form an aerosol of specific composition by choosing the nicotine content and/or content of further flavors to be included.

The aerosol delivery device can incorporate a sensor or detector for control of supply of electric power to the heat generation element when aerosol generation is desired (e.g., upon draw during use). As such, for example, there is provided a manner or method for turning off the power supply to the heat generation element when the aerosol delivery device is not be drawn upon during use, and for turning on the power supply to actuate or trigger the generation of heat by the heat generation element during draw. Additional representative types of sensing or detection mechanisms, structure and configuration thereof, components thereof, and general methods of operation thereof, are described in <CIT>; <CIT>; and <CIT>.

The aerosol delivery device most preferably incorporates a control mechanism for controlling the amount of electric power to the heat generation element during draw. Representative types of electronic components, structure and configuration thereof, features thereof, and general methods of operation thereof, are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>; <CIT>, <CIT>, and <CIT>; and <CIT>.

Representative types of substrates, reservoirs or other components for supporting the aerosol precursor are described in <CIT>; <CIT>et al. and<CIT>et al. ; and <CIT>et al. Additionally, various wicking materials, and the configuration and operation of those wicking materials within certain types of electronic cigarettes, are set forth in <CIT> to Sears et al.

For aerosol delivery systems that are characterized as electronic cigarettes, the aerosol precursor composition most preferably incorporates tobacco or components derived from tobacco. In one regard, the tobacco may be provided as parts or pieces of tobacco, such as finely ground, milled or powdered tobacco lamina. Tobacco beads, pellets, or other solid forms may be included, such as described in <CIT> In another regard, the tobacco may be provided in the form of an extract, such as a spray dried extract that incorporates many of the water soluble components of tobacco. Alternatively, tobacco extracts may have the form of relatively high nicotine content extracts, which extracts also incorporate minor amounts of other extracted components derived from tobacco. In another regard, components derived from tobacco may be provided in a relatively pure form, such as certain flavoring agents that are derived from tobacco. In one regard, a component that is derived from tobacco, and that may be employed in a highly purified or essentially pure form, is nicotine (e.g., pharmaceutical grade nicotine).

The aerosol precursor composition, also referred to as a vapor precursor composition, may comprise a variety of components including, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, and/or flavorants. Representative types of aerosol precursor components and formulations also are set forth and characterized in <CIT> and <CIT>et al. ; <CIT> et al. ; <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 BEU™ 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.

The amount of aerosol precursor that is incorporated within the aerosol delivery system is such that the aerosol generating piece provides acceptable sensory and desirable performance characteristics. For example, it is highly preferred that sufficient amounts of aerosol forming material (e.g., glycerin and/or propylene glycol), be employed in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. The amount of aerosol precursor within the aerosol generating system may be dependent upon factors such as the number of puffs desired per aerosol generating piece. In one or more embodiments, about <NUM> or more, about <NUM> or more, about <NUM> or more, or about <NUM> or more of the aerosol precursor composition may be included.

Yet other features, controls or components that can be incorporated into aerosol delivery systems of the present disclosure are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>et al. ; <CIT>et al. ; <CIT>et al. ;<CIT>, <CIT>, <CIT>. , and <CIT>.

The foregoing description of use of the article can be applied to the various embodiments described herein through minor modifications, which can be apparent to the person of skill in the art in light of the further disclosure provided herein. The above description of use, however, is not intended to limit the use of the article but is provided to comply with all necessary requirements of disclosure of the present disclosure. Any of the elements shown in the article illustrated in <FIG> or as otherwise described above may be included in an aerosol delivery device according to the present disclosure.

In one or more embodiments, the present disclosure particularly can relate to aerosol delivery devices that are configured to provide increased vapor production. Such increase can arise from a variety of factors. In some embodiments, a liquid transport element (i.e., a wick or wicking element) can be formed partially or completely from a porous monolith, such as a porous ceramic, a porous glass, or the like. Exemplary monolithic materials suitable for use according to embodiments of the present disclosure are described, for example, in <CIT>, and <CIT>. The porous monolith can form a substantially solid wick. In particular, the transport element can be substantially a single, monolithic material rather than a bundle of individual fibers as known in the art.

The use of a rigid, porous monolith as a fluid transport element is beneficial for improving uniformity of heating and reducing possible charring of the fluid transport element when non-uniform heating occurs. It can also be desirable to eliminate the presence of any fibrous materials in an aerosol delivery device. Despite such benefits, porous monoliths also present certain challenges for successful implementation as a fluid transport element. Such challenges are in part due to the different material properties of porous monoliths (e.g., porous ceramics) compared to fibrous wicks. For example, alumina has both a higher thermal conductivity and a higher heat capacity than silica. These thermal properties cause heat to be drawn away from the aerosol precursor composition at the interface of the wick and the heater, and this can require a higher initial energy output to achieve comparable fluid vaporization. The present disclosure realizes means for overcoming such difficulties.

In some embodiments utilizing a porous monolith, energy requirements for vaporization when using a porous monolith can be minimized, and vaporization response time can be improved by increasing heat flux density (measured in Watts per square meter - W/m<NUM>) over the surface of the porous monolith fluid transport element. The present disclosure particularly describes embodiments suitable to provide such increase in heat flux density.

In one or more embodiments, the present disclosure than can relate to an atomizer configuration wherein a porous monolithic fluid transport element has a specifically shaped portion that is combined with a heater having a substantially matching shape. For example, a fluid transport element <NUM> is shown in <FIG> and is in the form of a substantially rigid, porous monolith. As seen in <FIG> (not part of the claimed invention), the fluid transport element has a substantially round cross section, but other cross sectional geometries are also encompassed. The fluid transport element <NUM> has a main body 236a, a first end that is tapered 236b, and a second end 236c. While the fluid transport element <NUM> is illustrated as being substantially straight, other configurations are also encompassed, such having one or more bends or being curved. The main body 236a of the fluid transport element <NUM> has a diameter d that is substantially constant along the longitudinal length of the main body 236a. The second end 236c can have a diameter that is substantially the same as the diameter d of the main body 236a; however, the diameter of the second end 236c can be lesser or greater than the diameter d of the main body 236a. As illustrated, the tapered end 236b of the transport element <NUM> forms approximately <NUM>% of the total length L of the transport element. In various embodiments, the tapered end 236b forms about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, or about <NUM>% to about <NUM>% of the total length L of the transport element <NUM>. The tapered end 236b of the transport element <NUM> is configured so as to start with a diameter that is approximately the same as the diameter d of the main body 236a and then gradually decrease to a point 236d. Although the point 236d is illustrated as a sharp point, such configuration is not required. Preferably, the point 236d has a diameter that is about <NUM>% or less, about <NUM>% or less, about <NUM>% or less, or about <NUM>% or less of the diameter d of the main body 236a, with an exemplary lower range of about <NUM>% or about <NUM>% of the diameter d of the main body. In some embodiments, the point 236d can be substantially rounded or flattened.

A heater <NUM> is shown in <FIG> (not part of the claimed invention), and the heater is formed of a heating wire 235a that is shaped to substantially match the tapered end 236b of the transport element <NUM>. As illustrated, the heater <NUM> is substantially basket shaped. In order to substantially match the tapered end 236b of the transport element <NUM>, the heater <NUM> can have dimensions that are substantially similar to dimensions of the transport element <NUM>. In an exemplary embodiment, the heater <NUM> has an upper end 234a with a diameter A that is substantially the same as the diameter d of the main body 236a of the transport element <NUM>. Substantially the same indicates that the diameter A of the upper end 234a of the heater <NUM> is ±<NUM>% of the diameter d of the main body 236a of the transport element <NUM>. The heater <NUM> also has a height C that is substantially the same as the length of the tapered end 236b of the transport element <NUM>. Substantially the same indicates that the height C of the heater <NUM> is ±<NUM>% of the length of the tapered end 236b of the transport element <NUM>. In some embodiments, the height C of the heater <NUM> is no greater than the length of the tapered end 236b of the transport element <NUM>. For example, the height C of the heater <NUM> can be about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, or about <NUM>% to about <NUM>% of the length of the tapered end 236b of the transport element <NUM>. The heater <NUM> also can have a lower end 234b with a diameter D that is less than the diameter A of the upper end 234a of the heater. The diameter D of the lower end 234b of the heater <NUM> preferably is about <NUM>% or less, about <NUM>% or less, about <NUM>% or less, or about <NUM>% or less of the diameter A of the upper end 234a of the heater. For example, diameter D can be about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, or about <NUM>% to about <NUM>% of diameter A. The diameter of the heater <NUM> can gradually decrease from diameter A at the upper end 234a of the heater to diameter D at the lower end 234b of the heater. The heater <NUM> has an open interior area that is configured to receive the tapered end 236b of the transport element <NUM>.

The heater <NUM> can further include electrical leads (235b, 235c) to provide positive and negative electrical connections for the heater. The electrical leads (235b, 235c) can be integrally formed with the heating wire 235a or can be separate elements that can be attached (e.g., by welding or using a connector) to the heating wire. The heater <NUM> can have an overall width B that can include the overall width of the coil formed by the heating wire 235a and the length of the electrical leads (235b, 235c).

The combination of the transport element <NUM> and the heater <NUM> is shown in <FIG> (not part of the claimed invention). As seen therein, an atomizer <NUM> is formed of a transport element <NUM> in the form of a rigid, porous monolith and a heater <NUM> wrapped around a tapered end of the transport element. The heater <NUM> comprises nine coils of the heater wire 235a. As seen, the heater <NUM> is in a substantially conical configuration and includes an interior area that receives and substantially matches the tapered end of the fluid transport element. In this configuration, energy from the heater <NUM> is focused into the smaller surface area of the tapered end of the wick. By comparison, as illustrated in <FIG> (not part of the claimed invention), a heater <NUM>' formed of nine coils of heater wire 235a' wrapped around a constant diameter portion of a fluid transport element <NUM>' covers a significantly larger surface area of the fluid transport element and thus causes the energy to be less focused. In such comparative atomizer, heat flux density is significantly less than when the heater wire is coiled over a smaller surface area, as shown in <FIG> (not part of the claimed invention).

In one or more embodiments, increased heat flux density and, thus, improved heating and vapor formation, may be achieved using an alternate heater configuration. For example, as illustrated in <FIG>, a mesh or screen heater <NUM> may be used and can be effective to increase heater surface area coverage over a porous monolithic fluid transport element <NUM>. The heater is configured for contacting at least a portion of an outer surface of a fluid transport element, the heater being in the form of a conductive mesh. As used herein, the terms mesh and screen are meant to be interchangeable and to specifically refer to a network of intercrossing, conductive filaments 335a. As such, the conductive mesh is considered to be network of conductive filaments and/or an interlaced structure. The conductive filaments 335a can be formed of any suitable, electrically conductive material, such as otherwise listed herein for formation of a heater. In one or more embodiments, the conductive filaments 335a can be at least partially interwoven with non-conductive filaments <NUM> or similar mater, which can be effective to improve direction of the flow of electrical current between the clasps 338a and 338b.

The conductive mesh heater <NUM> circumferentially surrounds at least a portion of an outer surface of the fluid transport element <NUM>. In some embodiments, the conductive mesh heater <NUM> may only partially surround at least a portion of an outer surface of the fluid transport element <NUM>. The conductive mesh heater <NUM> includes a first end 334a and a second end 334b whereat coverage of the conductive mesh heater over the outer surface of the fluid transport element <NUM> terminates. The first end 334a and second end 334b of the conductive mesh heater <NUM> includes respective first and second clasps 338a and 338b that secure the conductive mesh heater to the fluid transport element and/or can function as electrical connections between the conductive mesh heater and a power source.

As seen in <FIG>, the conductive mesh heater <NUM> can comprise a plurality of crossing, conductive filaments 335a. The conductive mesh heater <NUM> can define a regular patter of conductive filaments 335a forming parallelograms <NUM> or other shapes consistent with a mesh configuration. The conductive filaments 335a particularly can surround insulating spaces <NUM>. The insulating spaces <NUM> may be open (e.g., insulated by air) or may be at least partially filled with an insulator. The insulating spaces <NUM> can be configured to have a defined area so that the heating ability of the conductive mesh heater <NUM> is maximized for a minimized amount of power delivery to the conductive mesh heater. In some embodiments, the insulating spaces can have an average individual area of about <NUM><NUM> to about <NUM><NUM>. In further embodiments, the insulating spaces can have an average individual area of about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM> to about <NUM><NUM>. In some embodiments, the insulating spaces can have an average individual area in an upper range, such as about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM> to about <NUM><NUM>. In some embodiments, the insulating spaces can have an average individual area in a lower range, such as about <NUM><NUM> to about <NUM><NUM>, about <NUM><NUM> to about <NUM><NUM>, or about <NUM><NUM> to about <NUM><NUM>.

Returning to <FIG>, the conductive mesh heater <NUM>, as illustrated, covers approximately <NUM>% of the overall longitudinal length of the fluid transport element <NUM>. In further embodiments, the conductive mesh heater <NUM> can be present on about <NUM>% to about <NUM>%, about <NUM>% to about <NUM>%, or about <NUM>% to about <NUM>% of the overall longitudinal length of the fluid transport element <NUM>. The conductive mesh heater <NUM> may be positioned substantially proximate one end of the fluid transport element <NUM>, or the conductive mesh heater may be positioned substantially centrally along the longitudinal length of the fluid transport element.

In further embodiments, an atomizer (<NUM>) such as illustrated in <FIG> may be included in an aerosol delivery device (<NUM>) such as illustrated in <FIG>. As such, any of the relevant elements from the aerosol delivery device <NUM> of <FIG> may be included in such aerosol delivery device including an atomizer (<NUM>) as described herein. As an exemplary embodiment, an aerosol delivery device <NUM> is illustrated in <FIG>. The aerosol delivery device <NUM> includes a tank (or cartridge) <NUM> defined by an outer body or shell <NUM>. The tank <NUM> includes a reservoir <NUM> that is at least partially filled with an aerosol precursor composition <NUM>. The reservoir <NUM> is particularly configured as a closed body with a single aperture <NUM> configured to sealingly engage the porous monolithic fluid transport element <NUM>. As such, the fluid transport element <NUM> extends or projects into the reservoir <NUM> so as to be in fluid communication or other contact with the aerosol precursor composition <NUM> and transport the aerosol precursor composition to the heater <NUM>. When the heater <NUM> is activated, the aerosol precursor composition is vaporized to at least partially fill a vaporization zone <NUM> within the tank <NUM>. Air drawn through air intake <NUM> whisks the formed vapor (e.g., in the form of an aerosol wherein the formed vapor is mixed with the air) from the vaporization zone <NUM> to the mouthpiece <NUM>. As illustrated, the reservoir <NUM> is substantially centrally located in the tank <NUM>, and the aerosol passes around the reservoir; however, other configurations of the elements are also encompassed. The tank <NUM> includes a connector <NUM> for connecting the tank to a control body or power unit (e.g., element <NUM> in <FIG>). The connector <NUM> may have a similar structure as the base <NUM> illustrated in <FIG> or may have any further structure suitable for connecting the tank <NUM> to a control body/power unit. Although not illustrated, it is understood that electrical connections are included to provide an electrical connection between the heater <NUM> and a battery (e.g., element <NUM> in <FIG>) or other power delivery device. An atomizer <NUM> illustrated in <FIG> is used in the alternative to the combined heater <NUM> and fluid transport element <NUM> illustrated in <FIG>.

A heater described herein generally may be positioned about an exterior portion of the fluid transport element. In one or more embodiments, however, a heater may be positioned at least partially internal to the fluid transport element. For example, a ceramic fluid transport element may be formed in the presence of a heater so that the ceramic fluid transport element and the heater are monolithic. In such embodiments, at least a sufficient amount of the heater suitable for forming an electrical contact will be positioned external to the fluid transport element. In some embodiments, a fluid transport element may be at least partially hollow - i.e., including an open space in which a heater may be positioned. In this manner, heating may proceed from the inside to the outside so that maximal vapor production is formed outwardly from the fluid transport element. If desired, a heater as described herein may be positioned at least partially internal to the fluid transport element. In some embodiments, a heater as described herein may be positioned on an outside surface of the fluid transport element, and a second heater may be positioned at least partially internal to the fluid transport element as noted above.

The use of at least two, separate heaters can be beneficial to improve vapor production. Specifically, a first heater can be used to pre-heat the liquid for vaporization within the liquid transport element, and a second heater can be used to actually vaporize the liquid. The pre-heating can reduce the total power and/or the absolute temperature and/or the duration of heating required to provide a desired volume of vapor. An internal heater, for example, may be a pre-heater, and an external heater may be a vaporizing heater. Alternatively, at least two separate heaters may be positioned on an external surface of the liquid transport element. One of the heaters may function as a pre-heater, and the other of the heaters may function as a vaporizing heater. For example, as illustrated in <FIG>, a pre-heater (not illustrated) may be positioned between heater <NUM> (which may function as a vaporizing heater) and the reservoir <NUM>. The pre-heater may pre-heat liquid aerosol precursor composition <NUM> flowing from the reservoir <NUM> to the vaporizing heater <NUM> so that the vaporizing heater may achieve vaporization more easily, as described above, and/or the pre-heater may reduce a viscosity of the liquid aerosol precursor composition to improve flow of the liquid from the reservoir to the vaporizing heater. A similar combination of heaters may be applied to the liquid transport element <NUM> in <FIG>. In <FIG>, the second heater positioned between heater <NUM> and the reservoir <NUM> may be a mesh heater as described herein, may be a simple wire coil, or may be any other type of heater useful for providing pre-heating to the liquid in the liquid transport element. In <FIG>, the second heater on the liquid transport element <NUM> may be a further mesh heater, may be a simple wire coil, or may be any other type of heater useful for providing pre-heating to the liquid in the liquid transport element. For example, a heater coil <NUM>' as illustrated in <FIG> may be added as a second heater in combination with a wire mesh heater (see <FIG>) as described herein.

Claim 1:
An atomizer (<NUM>) comprising:
a fluid transport element (<NUM>) in the form of a rigid, porous monolith, the fluid transport element (<NUM>) having a first end and a second end;
a conductive mesh heater (<NUM>) circumferentially contacting at least a portion of an outer surface of the fluid transport element (<NUM>), the conductive mesh heater (<NUM>) comprising a network of intercrossing, conductive filaments 335a that defines a first end (334a) with a first clasp (338a) and a second end (334b) with a second clasp (338b), the first clasp (338a) and the second clasp (338b) being configured to secure the conductive mesh heater (<NUM>) to the fluid transport element (<NUM>).