Patent Description:
<CIT> discloses a surface having an artificial surface structure of eminences and depressions, with a distance between the eminences being less than <NUM> and at least the eminences on top consist of a hydrophobic material or have a hydrophobic layer on the outside.

<CIT> discloses a super-hydrophobic and self-cleaning article.

<CIT> discloses a method of forming a hierarchical microstructure using partial curing.

The article "<NPL> describes biological surfaces providing multifunctional interfaces to the environment.

The article "<NPL>a describes an overview of the diversity of plant surface structures.

<CIT> discloses an aerosol generating system for heating a liquid aerosol-forming substrate, comprising an aerosol-forming chamber, and leakage prevention means configured to prevent or reduce leakage or liquid aerosol condensate from the aerosol generating system.

<CIT> discloses an article comprising a surface portion having a plurality of primary features, wherein the primary features have a median height dimension in the range from about <NUM> micron to about <NUM> microns, a median aspect ratio in the range from about <NUM> to about <NUM>, and a median spacing dimension in the range from about <NUM> to about <NUM> feature width units, and wherein the surface portion comprising the features has a wettability of the surface sufficient to generate, with a reference fluid, a static contact angle of greater than about <NUM> degrees, and a total transmission of at least about <NUM>% in the visible range of electromagnetic radiation.

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>, <CIT>, <CIT>, <CIT>, and <CIT> See also, for example, the various embodiments of products and heating configurations described in the background sections of <CIT> and <CIT>.

Usage of aerosol delivery devices involves inhaling aerosol produced by the aerosol delivery device. A user typically places the aerosol delivery device against his or her lips to draw on the aerosol delivery device and receive the aerosol. However, such usage may expose the aerosol delivery device to saliva and/or other biological matter. Accordingly, it may be desirable to provide the aerosol delivery device with features configured to resist microbial growth.

The present disclosure relates to assembly of cartridges for 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 production assembly is provided. The aerosol production assembly includes an aerosol precursor composition, an atomizer, and a body. The body includes a surface of which at least a portion includes a micro-pattern imparting at least one of hydrophobic and anti-microbial properties.

The body includes a mouthpiece defining an outlet. The micro-pattern is a biomimicry micro-pattern. The surface may define a sharkskin micro-pattern or a lotus leaf micro-pattern. The surface may not include a chemical coating. The surface may be positioned at an inner surface of the body. The surface may be positioned at an outer surface of the body.

In some embodiments the body may be formed in a mold configured to define the micro-pattern at the surface. The mold may be etched. The aerosol production assembly may be included in a cartridge or a tank for an aerosol delivery device.

In an additional aspect, a method of forming an aerosol production assembly is provided. The method includes providing an aerosol precursor composition. Further, the method includes positioning an atomizer in fluid communication with the aerosol precursor composition. The method additionally includes assembling the atomizer with a body comprising a surface of which at least a portion includes a micro-pattern imparting at least one of hydrophobic and anti-microbial properties.

In some embodiments assembling the atomizer with the body may include positioning the body in fluid communication with the atomizer. Further, the method may include forming the body including the micro-pattern. Forming the body may not include coating the surface with a chemical.

In some embodiments, forming the body may include forming the micro-pattern at at least one of an inner surface and an outer surface of the body. Forming the body may include forming the micro-pattern in a mold. The method may additionally include etching the mold.

In an additional aspect, a method of improving cleanliness of an aerosol delivery device is provided. The method may include providing the aerosol delivery device with a surface of which at least a portion includes a micro-pattern imparting at least one of hydrophobic and anti-microbial properties. The micro-pattern may be a biomimicry micro-pattern. The surface may define a sharkskin micro-pattern or a lotus leaf micro-pattern.

The present disclosure thus includes, without limitation, the following:
An aerosol production assembly comprising: an outer body; an aerosol precursor composition within the outer body; an atomizer configured to vaporize the aerosol precursor composition to produce an aerosol; and a mouthpiece defining an outlet and provided at an end of the outer body so that the aerosol passes through the outlet for delivery to a user; wherein at least a portion of a surface of the mouthpiece is configured with a biomimicry micro-pattern that is an engineered surface topography including ordered three-dimensional features at the micro-meter scale and that mimic a surface topography of a surface of a natural organism so as to impart anti-microbial properties to at least a portion of the surface of the mouthpiece.

This assembly, wherein the surface defines a sharkskin micro-pattern or a lotus leaf micro-pattern.

This assembly, wherein the surface does not include a chemical coating.

This assembly, wherein the body is formed in a mold configured to define the micro-pattern at the surface.

This assembly, wherein the mold is etched.

This assembly, wherein the aerosol production assembly is included in a cartridge or a tank for an aerosol delivery device.

A method of forming an aerosol production assembly, the method comprising: providing an aerosol precursor composition; positioning an atomizer in fluid communication with the aerosol precursor composition; and assembling the atomizer with a body comprising a mouthpiece with a surface of which at least a portion includes a biomimicry micro-pattern that is an engineered surface topography including ordered three-dimensional features at the micro-meter scale and that mimic a surface topography of a surface of a natural organism so as to impart anti-microbial properties to at least a portion of the surface of the mouthpiece.

This method, wherein assembling the atomizer with the body comprises positioning the body in fluid communication with the atomizer.

A method of improving cleanliness of an aerosol delivery device, the method comprising: providing the aerosol delivery device with a mouthpiece having a surface of which at least a portion includes a biomimicry micro-pattern that is an engineered surface topography including ordered three-dimensional features at the micro-meter scale and that mimic a surface topography of a surface of a natural organism so as to impart anti-microbial properties to the surface of the mouthpiece.

This method, wherein the surface defines a sharkskin micro-pattern or a lotus leaf micro-pattern.

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 present disclosure is generally directed to 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.) and heat-not-burn cigarettes. 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 mechanisms 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 smoking articles.

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, an aerosol is formed, released, or generated in a physical form 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 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.

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, various other configurations such as rectangular or fob-shaped may be employed in other embodiments.

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>.

<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 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 drawing 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> and <CIT>; and <CIT>; <CIT> and <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

<FIG> illustrates the cartridge <NUM> in an exploded configuration. As illustrated, the cartridge <NUM> may comprise a base <NUM>, a control component terminal <NUM>, an electronic control component <NUM>, a flow director <NUM>, an atomizer <NUM>, a reservoir such as a container and/or a reservoir substrate <NUM>, an outer body <NUM>, a mouthpiece <NUM>, a label <NUM>, and first and second heating terminals 320a, 320b according to an example embodiment of the present disclosure.

In some embodiments the first and second heating terminals 320a, 320b may be embedded in, or otherwise coupled to, the flow director <NUM>. For example, the first and second heating terminals 320a, 320b may be insert molded in the flow director <NUM>. Accordingly, the flow director <NUM> and the first and second heating terminals may be collectively referred to as a flow director assembly <NUM>. Additional description with respect to the first and second heating terminals 320a, 320b 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 control component <NUM>, the flow director <NUM>, the atomizer <NUM>, and the reservoir substrate <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 substrate <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>et al. ; 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>; and <CIT>; as well as <CIT>. and <CIT>; and <CIT>.

The reservoir substrate <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 substrate <NUM>. The reservoir substrate <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 substrate <NUM> to the heating element <NUM> via capillary action or other liquid transport mechanisms.

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>), titanium, platinum, silver, palladium, 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 320a and the second heating terminal 320b (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 control 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 control 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>.

Various other details with respect to the components that may be included in the cartridge <NUM>, are provided, for example, in <CIT> In this regard, <FIG> thereof illustrates an enlarged exploded view of a base and a control component terminal; <FIG> thereof illustrates an enlarged perspective view of the base and the control component terminal in an assembled configuration; <FIG> thereof illustrates an enlarged perspective view of the base, the control component terminal, an electronic control component, and heating terminals in an assembled configuration; <FIG> thereof illustrates an enlarged perspective view of the base, the atomizer, and the control component in an assembled configuration; <FIG> thereof illustrates an opposing perspective view of the assembly of <FIG> thereof; FIG. <NUM> thereof illustrates an enlarged perspective view of the base, the atomizer, the flow director, and the reservoir substrate in an assembled configuration; FIG. <NUM> thereof illustrates a perspective view of the base and an outer body in an assembled configuration; FIG. <NUM> thereof illustrates a perspective view of a cartridge in an assembled configuration; FIG. <NUM> thereof illustrates a first partial perspective view of the cartridge of FIG. <NUM> thereof and a coupler for a control body; FIG. <NUM> thereof illustrates an opposing second partial perspective view of the cartridge of FIG. <NUM> thereof and the coupler of FIG. <NUM> thereof; FIG. <NUM> thereof illustrates a perspective view of a cartridge including a base with an anti-rotation mechanism; FIG. <NUM> thereof illustrates a perspective view of a control body including a coupler with an anti-rotation mechanism; FIG. <NUM> thereof illustrates alignment of the cartridge of FIG. <NUM> with the control body of FIG. <NUM>; FIG. <NUM> thereof illustrates an aerosol delivery device comprising the cartridge of FIG. <NUM> thereof and the control body of FIG. <NUM> thereof with a modified view through the aerosol delivery device illustrating the engagement of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body; FIG. <NUM> thereof illustrates a perspective view of a base with an anti-rotation mechanism; FIG. <NUM> thereof illustrates a perspective view of a coupler with an anti-rotation mechanism; and FIG. <NUM> thereof illustrates a sectional view through the base of FIG. <NUM> thereof and the coupler of FIG. <NUM> thereof in an engaged configuration. Various other details with respect to the components that may be included in the cartridge <NUM>, 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 substrate 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>.

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>) 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 320a and the second heating terminal 320b. Accordingly, the heating element <NUM> may vaporize the aerosol precursor composition directed to an aerosolization zone from the reservoir substrate <NUM> by the liquid transport element <NUM>. In this regard, components of the aerosol delivery device <NUM> (see, <FIG>) including at least a reservoir (e.g., the reservoir substrate <NUM>) configured to contain an aerosol precursor composition and an atomizer (e.g., the atomizer <NUM>) may be referred to as an aerosol production assembly. 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> through an outlet <NUM> to a consumer drawing thereon.

Accordingly, when a user draws on the aerosol delivery device <NUM> (see, <FIG>), his or her lips may contact a portion thereof, such as the mouthpiece <NUM>. Further, when the user draws on the aerosol delivery device <NUM>, aerosol may be produced inside the aerosol delivery device and directed to the user. However, operation in this manner may result in certain problems.

In this regard, due to repeated contact with a user's lips, the mouthpiece <NUM> and/or other portions of the aerosol delivery device <NUM> (see, <FIG>) may be exposed to a user's breath and saliva and any pathogens therein. By way of further example, in the event that the user exhales into the aerosol delivery device <NUM>, the portions of the aerosol delivery device along the airflow path therethrough may be exposed to such pathogens. Accordingly, microbial growth may occur at the mouthpiece <NUM> and/or other portions of the aerosol delivery device <NUM>.

Further, some of the aerosol produced in the aerosol delivery device <NUM> (see, <FIG>) may condense on the internal surfaces thereof. Fluid droplets may thus form inside the aerosol delivery device <NUM>. In some instances the fluid droplets may exit the aerosol delivery device <NUM> though the mouthpiece <NUM> or other aperture leading to the surrounding environment. Thereby, such fluid droplets may undesirably contact surrounding structures, such as a user's pocket when received therein. Further, the liquid droplets are wasted, rather than delivered to the user as an aerosol. This may reduce the efficiency of delivery of aerosol to the user and/or the condensed aerosol may be received by the user in liquid form, which may affect the taste or other sensory characteristics associated with using the aerosol delivery device.

Accordingly, embodiments of the present disclosure may include features configured to address the above-noted problems. In this regard, <FIG> illustrates a partial sectional view through the cartridge <NUM>. As illustrated, in one embodiment air <NUM> may flow through the flow director <NUM> past the atomizer <NUM>. At least a portion of the air <NUM> may combine with vapor produced at the atomizer <NUM> to form aerosol <NUM>, which exits through the mouthpiece <NUM>.

Thus, the portions of the aerosol delivery device <NUM> (see, <FIG>) most likely to be subjected to microbial growth and/or condensation formation from the aerosol include those surfaces surrounding and downstream of the atomizer <NUM> in terms of a flow path through the aerosol delivery device <NUM>. For example, aerosol may condense at one or more inner surfaces 316A of the mouthpiece <NUM> and/or one or more inner surfaces 314A of the outer body <NUM>. The inner surfaces 316A of the mouthpiece <NUM> and the inner surfaces 314A of the outer body <NUM> may also be subjected to microbial growth due to exposure to the user's breath and saliva and any pathogens therein. Microbial growth may additionally occur at the surfaces contacted by the user. In particular, an outer surface 316B of the mouthpiece <NUM> may be subjected to repeated contact with a user's lips and hence the outer surface may be subject to microbial growth.

Accordingly, in some embodiments the aerosol delivery device <NUM> (see, <FIG>) may include features at the inner and outer surfaces 316A, 316B of the mouthpiece and the inner surfaces 314A of the outer body <NUM> configured to resist microbial growth. For example, in some embodiments these surfaces 316A, 316B, 314A may include a coating configured to address the above-noted problems. For example, the surfaces 316A, 316B, 314A may include an antimicrobial coating. Antimicrobial coatings are either configured to kill microorganisms or prohibit their growth. Thereby, usage of an antimicrobial coating may address issues with respect to microbial growth in or on the aerosol delivery device. Further, as noted above, condensing of the aerosol may present issues. Accordingly, the selected coating may be hydrophobic. Hydrophobic surfaces may resist the formation of fluid droplets thereon, such that issues with respect to condensing of the aerosol may be mitigated. However, usage of an antimicrobial and/or hydrophobic coating may expose the user to the chemicals in such coatings. In this regard, some coatings having antimicrobial and/or hydrophobic properties may be toxic. Further, coatings may wear off during usage such that the efficacy thereof may diminish.

For these reasons usage of a coating to address the issues with respect to microbial growth and/or aerosol condensation may be less than optimal. Thus, embodiments of the present disclosure are directed to aerosol delivery devices and components thereof configured to resist microbial growth and/or resist condensing of aerosol without the use of a coating applied to the surfaces thereof.

Thus, embodiments of the present disclosure are directed to an aerosol production assembly including a surface with engineered hydrophobic and/or anti-microbial properties. In other words, the surface can include three-dimensional structures imparting hydrophobic and/or anti-microbial characteristics to the surface. For the reasons noted above, the surface may expressly exclude a chemical coating, particularly chemical anti-microbial coatings.

Rather, the surface of the aerosol production assembly may comprise a micro-pattern. In this regard, a micro-pattern can refer to an engineered surface topography including ordered three-dimensional features at the micro-meter scale. Such a surface may be distinguished from inherent surface features of objects at least on the basis of the three-dimensional pattern being specifically, intentionally formed to define the ordered pattern at the micro-meter scale. As described below, in some embodiments the micro-pattern may comprise a biomimicry micro-pattern configured to mimic the surface topography of certain surfaces of natural organisms that provide anti-microbial and/or hydrophobic properties, which further distinguishes the present micro-patterns from inherent surface topographies of objects.

The micro-pattern can exhibit a variety of geometries (e.g., pillars, channels, platelets, cones, divots, etc.) and can be specifically engineered with a defined roughness, which can provide specific biological responses and/or can control bioadhesion. The micro-pattern can be substantially constant (e.g., exhibiting a single, repeating feature of substantially unchanging dimensions) and/or can exhibit a substantially repeating pattern (e.g., a plurality of features differing in one or more of size, shape, and spacing, that define an ordered, repeating pattern). The micro-pattern may be defined at least in part in relation to the size and/or spacing of the geometric elements forming the micro-pattern. For example, the geometric elements can have an average height of about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM>. The geometric elements can have an average spacing of about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM>. Usage of a surface having a micro-pattern so as to be hydrophobic may resist buildup of biological matter thereon and may resist the formation of condensation thereon, thereby addressing the above-noted issues with respect to microbial growth and condensation.

As noted above, a surface may be provided with a micro-pattern to impart at least one of hydrophobic and anti-microbial properties thereto. The surface including the micro-pattern may be positioned at an inner surface of the aerosol production assembly. For example, the surface including a micro-pattern may be provided at the inner surface(s) 316A of the mouthpiece <NUM> and/or at the inner surface(s) 314A of the outer body <NUM>. Additionally or alternatively, the surface including a micro-pattern may be positioned at an outer surface of the aerosol production assembly. For example, the surface including a micro-pattern may be provided at the outer surface 316B of the mouthpiece <NUM>. Accordingly, the surface including a micro-pattern may be positioned at the surfaces noted above at which microbial growth and/or condensing of the aerosol may occur. As may be understood, the surface including a micro-pattern may be provided at any surface of the aerosol delivery device <NUM> (see, <FIG>).

Various embodiments of surfaces including a micro-pattern may be employed. In one or more embodiments, however, it can be desirable for the micro-pattern to substantially mimic a micro-pattern found in nature. In other words, the micro-pattern may be substantially an engineered replicant of a natural, microscale topographical pattern or a biomimicry micro-pattern. As an example, sharkskin is known to be highly resistant to the attachment of living organisms such as barnacles and algae thereto. Further, sharkskin may be hydrophobic. Such attachment resistance and water resistance may be provided at least in part by a topographical pattern on the skin defining a rough surface.

An microscopic image of sharkskin <NUM> is illustrated in <FIG>. As illustrated, the sharkskin comprises a matrix of hard, tooth-like structures <NUM> called dermal denticles or placoid scales. The tooth-like structures <NUM> may define a pattern of diamond or parallelogram shapes <NUM> at the locations where the tooth-like structures are exposed. Each tooth-like structure <NUM> may include a plurality of raised parallel ribs <NUM> separated by recesses <NUM>.

One embodiment of a surface including a micro-pattern <NUM> is illustrated in <FIG>. The surface including a micro-pattern <NUM> may be employed at any of the surfaces of the aerosol delivery device <NUM> such as the surfaces particularly noted above that may be subject to microbial growth or condensation formation. As illustrated, the micro-pattern <NUM> is a biomimicry micro-pattern that is substantially a sharkskin micro-pattern. In this regard, the surface including a micro-pattern <NUM> may include a pattern of diamond or parallelogram shapes <NUM>. The parallelograms <NUM> may define a width from about twenty micrometers to about thirty micrometers. Each parallelogram <NUM> may include a plurality of raised parallel ribs <NUM> separated by recesses <NUM>. The ribs <NUM> may extend from about two micrometers to about four from micrometers outwardly from the recesses <NUM>. Accordingly, the surface including a micro-pattern <NUM> defining the sharkskin micro-pattern may embody properties resembling those of natural sharkskin. Thus, for example, the surface including a micro-pattern <NUM> defining the sharkskin micro-pattern may provide anti-microbial and/or hydrophobic properties. Example embodiments of products including a sharkskin micro-pattern are available from Sharklet Technologies, Inc. of Aurora, Colorado. Surface topographies suitable for use as a micro-pattern according to embodiments of the present disclosure are described in <CIT>.

Various other embodiments of surfaces including a micro-pattern may be employed. In this regard, the lotus leaf defines superhydrophobic properties, which may resist the buildup of water and matter thereon. The superhydrophobic properties are provided in part by an epicuticular wax. However, the superhydrophobic properties may be additionally provided by the structure of the surface thereof. In this regard, <FIG> is a scanning electron microscope (SEM) image of a lotus leaf <NUM> at scales of five micrometers and fifty micrometers. As illustrated, the lotus leaf <NUM> may include a plurality of papillae <NUM>. The papillae <NUM> may define a height from about ten to about twenty micrometers and a width from about ten to about fifteen micrometers.

<FIG> is a scanning electron microscope image of an additional embodiment of a surface including a micro-pattern <NUM> at scales of five micrometers and fifty micrometers. As illustrated, the micro-pattern <NUM> is a biomimicry micro-pattern that is substantially a lotus leaf micro-pattern. In this regard, the surface including a micro-pattern may include a plurality of protrusions <NUM> that mimic the size and shape of the papillae <NUM> of the lotus leaf <NUM> (see, <FIG>). For example, the protrusions <NUM> may define a height from about ten to about twenty micrometers and a width from about ten to about fifteen micrometers. Additional description with respect to surfaces including a lotus leaf micro-pattern is provided in <NPL>et al.

Accordingly, the surface including a micro-pattern <NUM> defining the lotus leaf micro-pattern may embody properties resembling those of a natural lotus leaf. Thus, for example, the surface including a micro-pattern <NUM> defining the lotus leaf micro-pattern may provide anti-microbial and/or hydrophobic properties.

Note that although the surface including a micro-pattern is generally described herein as being employed in embodiments of aerosol delivery devices including cartridges, it should be understood that the surface including a micro-pattern may be included in any embodiment of an aerosol delivery device. For example, <FIG> illustrates a sectional view through a tank <NUM> for an aerosol delivery device. The tank <NUM> may include a base <NUM>, a control component terminal <NUM>, an electronic control component <NUM>, a flow director <NUM> which may be defined by an outer body <NUM> or a separate component, an atomizer <NUM>, and a mouthpiece <NUM> according to an example embodiment of the present disclosure. The atomizer <NUM> may comprise a first heating terminal 916a and a second heating terminal 916b, a liquid transport element <NUM> and a heating element <NUM>. The tank <NUM> may additionally include a base shipping plug, a label, and a mouthpiece shipping plug, as described above.

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 at least partially enclose the remaining components of the tank <NUM> therein. In some embodiments the base <NUM> may comprise anti-rotation features that substantially prevent relative rotation between the tank and associated device including a power source as disclosed in <CIT>.

The tank <NUM> may further comprise a sealing member <NUM> and an initial liquid transport element <NUM>. In this regard, the outer body <NUM> and/or an additional component may be configured to hold an aerosol precursor composition <NUM> in a reservoir <NUM>. In some embodiments the reservoir <NUM> may be configured to be refillable, whereas in other embodiments the tank <NUM> may be configured for a single use. The sealing member <NUM> may be positioned at an end of the chamber <NUM> and include one or more apertures <NUM> that allow the aerosol precursor composition <NUM> to contact the initial liquid transport element <NUM>. Further, the liquid transport element <NUM> of the atomizer <NUM> may be in contact with the initial liquid transport element <NUM>. Both the initial liquid transport element <NUM> and the liquid transport element <NUM> of the atomizer <NUM> may comprise wicking and/or porous materials that allow movement of the aerosol precursor composition <NUM> therethrough (e.g., via capillary action), such that the aerosol precursor composition may be drawn to the heating element <NUM> and heated and vaporized when current is applied to the heating element via the heating terminals 916a, 916b by a control body.

Accordingly, the tank <NUM> may include an aerosol production assembly. Aerosol may be produced at the atomizer <NUM> and directed through the flow director <NUM>, the outer body <NUM>, and the mouthpiece <NUM> to the user. Thus, by way of example an inner surface 908A of the flow director <NUM>, an inner surface 912A of the outer body <NUM>, and/or an inner surface 914A of the mouthpiece <NUM> may comprise a surface of which at least a portion includes a micro-pattern, and the micro-pattern may have anti-microbial and/or hydrophobic properties. Further, an outer surface 914B of the mouthpiece <NUM> may comprise a surface of which at least a portion includes a micro-pattern, and the micro-pattern may have anti-microbial and/or hydrophobic properties. Accordingly embodiments of the present disclosure include aerosol production assemblies included in a cartridge or a tank for an aerosol delivery device, or any other embodiment of an aerosol delivery device or portion thereof.

Various embodiments of methods may be employed to form the surfaces including a micro-pattern of the present disclosure. In one example method, one or more components of the aerosol delivery device <NUM> (see, <FIG>) may be formed in a mold configured to define the surface including a micro-pattern. The mold may be etched (e.g., chemical, electrochemical, or laser etched) to define a surface configured to form the surface including a micro-pattern. However, various other embodiments of methods for forming the surface including a micro-pattern may be employed. For example, the surface including a micro-pattern may be produced by one or more methods such as self-assembly of a monolayer, photolithography, plasma polymerization, ultraviolet illumination, electrospinning, irradiation, template methods, chemical deposition, and blasting (e.g., with sodium bicarbonate) followed by anodizing the blasted surface. Various examples of such methods for producing surfaces including a micro-pattern are described in <NPL>et al.

Thus, various methods may be used for forming a micro-pattern as described herein. For example, patterning may be via an additive technique or a reductive technique. In an additive technique, a material may be deposited on the surface to form the pattern. The patterning material may be identical in composition to the thin film or may be of a different composition. In a reductive technique, a portion of the surface may be removed to form a series of grooves defining the micro-pattern. Non-limiting examples of patterning techniques that are encompassed by the present disclosure include nanoimprinting, photolithography, electron beam, ion beam, x-ray, self-assembly, lift-off, and similar patterning methods.

<FIG> illustrates a method for assembling an aerosol production assembly. As illustrated, the method may include providing an aerosol precursor composition at operation <NUM>. The method may additionally include positioning an atomizer in fluid communication with the aerosol precursor composition. Further, the method may include assembling the atomizer with a body comprising a surface of which at least a portion includes a micro-pattern imparting at least one of hydrophobic and anti-microbial properties.

Assembling the atomizer with the body at operation <NUM> may include positioning the body in fluid communication with the atomizer. The method may further include forming the body including the micro-pattern. Forming the body may not include coating the surface with a chemical. Forming the body may include forming the micro-pattern at at least one of an inner surface and an outer surface of the body. Additionally, forming the body may include forming the micro-pattern in a mold. The method may further include etching the mold.

<FIG> illustrates a method of improving cleanliness of an aerosol delivery device. As illustrated, the method may include providing the aerosol delivery device with a surface of which at least a portion includes a micro-pattern imparting at least one of hydrophobic and anti-microbial properties at operation <NUM>. In some embodiments the micro-pattern may be a biomimicry micro-pattern. The surface may define a sharkskin micro-pattern or a lotus leaf micro-pattern.

Claim 1:
An aerosol production assembly comprising:
an outer body (<NUM>, <NUM>);
an aerosol precursor composition within the outer body (<NUM>, <NUM>);
an atomizer (<NUM>) configured to vaporize the aerosol precursor composition to produce an aerosol; and
a mouthpiece (<NUM>) defining an outlet (<NUM>) and provided at an end of the outer body (<NUM>, <NUM>) so that the aerosol passes through the outlet (<NUM>) for delivery to a user;
characterized in that
at least a portion of a surface (316A, 316B, 914A, 914B) of the mouthpiece (<NUM>, <NUM>) is configured with a biomimicry micro-pattern (<NUM>, <NUM>) that is an engineered surface topography including ordered three-dimensional features at the micro-meter scale and that mimic a surface topography of a surface of a natural organism so as to impart anti-microbial properties to at least a portion of the surface (316A, 316B, 914A, 914B) of the mouthpiece (<NUM>, <NUM>).