Atomizer and aerosol delivery device

Abstract

A nebulizer and an aerosol delivery device are described wherein the nebulizer has a fluid delivery element formed from a rigid monomer having a first side and a second side opposite the first side. The atomizer also has a heater. The heater provides a substantially flat heating surface. The heating surface is positioned to face the first side of the rigid cell.

Description

[0001] This divisional patent application is a divisional application of a patent application for an "atomizer and aerosol delivery device" with international application number PCT / IB2019 / 054038, international filing date of May 15, 2019, and entering the Chinese national phase with application number 201980048066.9. Technical Field

[0002] The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices (e.g., smoking articles commonly referred to as electronic cigarettes) that can generate an aerosol using heat generated by electricity through conduction or induction. The smoking article can be configured to heat an aerosol precursor, which can include materials made from or derived from tobacco or otherwise include tobacco, and the precursor is capable of forming an inhalable substance for human intake. Background Art

[0003] In recent years, many smoking devices have been proposed as improvements or alternatives to smoking products that require burning tobacco. Many of the above-mentioned devices are alleged to have been designed to provide a sensation associated with smoking cigarettes, cigars, or pipes, but without delivering a large amount of incomplete combustion products and pyrolysis products resulting from the burning of tobacco. To this end, many cigarette products, aroma generators, and drug inhalers have been proposed that use electrical energy to evaporate or heat volatile materials or attempt to provide the sensation of smoking a cigarette, cigar, or pipe without significantly burning the tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0255702 to Griffith Jr. et al., and U.S. Patent Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference. For example, see also the various types of smoking articles, aerosol delivery devices, and electric heat sources with reference to trademark names and commercial sources in U.S. Patent Application Serial No. 14 / 170,838 filed on February 3, 2014 by Bless et al., the entire text of which is incorporated herein by reference.

[0004] It is desirable to provide a vapor formation unit for an aerosol delivery device that is configured to improve the formation of vapor. It is also desirable to provide an aerosol delivery device that is prepared to use such vapor. Summary of the Invention

[0005] The present disclosure relates to aerosol delivery devices and elements of such devices. The aerosol delivery device can specifically be integrated with a core to form a vapor formation unit, which can be combined with a power unit to form an aerosol delivery device.

[0006] In one or more embodiments, the present disclosure may relate to an atomizer that is particularly useful in an aerosol delivery device. The atomizer may specifically include at least a fluid delivery element and a heater. The fluid delivery element may be formed of a rigid material, such as a porous or non-porous monomer. Given certain configurations of the individual components and materials, the combined heater and fluid delivery element may exhibit improved vapor formation.

[0007] In some embodiments, an exemplary atomizer may include a fluid delivery element and a heater, the fluid delivery element including a rigid monomer having a first side and a second side opposite the first side, wherein the heater includes a substantially flat heating surface, and wherein the heating surface is positioned to face the first side of the rigid monomer.

[0008] In some embodiments, the rigid monomer is formed of a porous material capable of wicking an aerosol precursor composition core into the vicinity of the heating surface by capillary action.

[0009] In some embodiments, the rigid monomer is formed of a substantially non-porous material, and wherein the rigid monomer includes at least one hole extending from the first side to the second side to provide a conduit for the aerosol precursor for evaporation.

[0010] In certain embodiments, the fluid delivery element further includes an absorbent pad along the first side of the rigid monomer.

[0011] In an exemplary embodiment, the rigid monomer further includes at least one channel adjacent its periphery to provide a conduit for the liquid aerosol precursor to travel from the second side of the rigid monomer to the first side.

[0012] In some embodiments, the rigid monomer has a recess formed in the first side, and the heating surface is positioned to face the base surface of the recess. According to some embodiments, the rigid monomer includes at least one hole extending from the base surface to the second side. The at least one hole may include a centrally located hole. The at least one hole may include a plurality of holes, and the centrally located hole may have a larger diameter than the remaining holes of the plurality of holes. In some cases, the base surface includes a boss, and the centrally located hole passes through the boss. In some embodiments, the depth of the recess of the rigid monomer is greater than about 30% of the thickness of the disk. In the case where an absorbent pad and a recess are provided, the pad may reside in the recess. In some embodiments, the absorbent pad may include a centrally located hole.

[0013] In some embodiments, the heater includes at least one heating element selected from the group consisting of heating wire, conductive grid, and conductive traces printed on a substrate or on a surface of the heater covered with a heat-conductive material.

[0014] In some embodiments, the atomizer further includes a thermal insulator separate from the heater, where the thermal insulator can be a mica disk or other material having a low thermal conductivity.

[0015] In certain aspects of the present disclosure, an atomizer as described herein may be included for use in an aerosol delivery device.

[0016] In some embodiments, the aerosol delivery device defines an air flow path from an air inlet opening to a mouthpiece, and the air flow path passes along a second side of the rigid monomer.

[0017] In some embodiments, the rigid monomer includes at least one hole extending from a first side to a second side, wherein the aerosol delivery device is configured such that the evaporated aerosol precursor is drawn through the at least one hole by gravity or by a pressure differential created by suction of air moving along the air flow path, and the air flow path is along the second side of the rigid monomer.

[0018] In some embodiments, the aerosol delivery device includes a reservoir (e.g., a tank) that contains an aerosol precursor composition. The reservoir can be tubular or another shape such as rectangular, and the aerosol delivery device can form an air flow path from an air inlet opening to a mouthpiece that passes through the reservoir.

[0019] In some embodiments, the rigid monomer further includes circumferential grooves formed in its second side, and these grooves are configured to help seal the rigid monomer to the reservoir.

[0020] The fluid delivery element can wick or otherwise convey the aerosol precursor composition from the reservoir to a heater that is thermally connected to the fluid delivery element. The heater is positioned outside the reservoir to evaporate at least a portion of the aerosol precursor composition conveyed from the reservoir via the fluid delivery element. The formed vapor can combine with air drawn into the aerosol delivery device to form an aerosol, and the aerosol flows to the mouth end of the aerosol delivery device and exits the aerosol delivery device. The aerosol delivery device including the atomizer can be a single integral structure that houses all the elements (e.g., power elements, control elements, and evaporation elements) that can be used to form an aerosol as described herein. The aerosol delivery device can be a cartridge or a tank attached to a separate control body, where the control body can include a power element (e.g., a battery) and / or a control element.

[0021] The present invention includes, without limitation, the following embodiments:

[0022] Example 1: An atomizer, comprising: a fluid delivery element including a rigid monomer having a first side and a second side opposite the first side; and a heater, wherein the heater includes a substantially flat heating surface, and wherein the heating surface is positioned to face the first side of the rigid monomer.

[0023] Example 2: The atomizer according to any one of the preceding examples, wherein the rigid monomer is formed of a porous material capable of wicking an aerosol precursor composition core into the vicinity of the heating surface by capillary action.

[0024] Example 3: The atomizer according to any one of the preceding examples, wherein the rigid monomer is formed of a substantially non-porous material, and wherein the rigid monomer includes at least one hole extending from the first side to the second side to provide a conduit for the evaporated aerosol precursor.

[0025] Example 4: The atomizer according to any one of the preceding examples, wherein the fluid transfer element further includes an absorbent pad along the first side of the rigid monomer.

[0026] Example 5: The atomizer according to any one of the preceding examples, wherein the rigid monomer further includes at least one channel adjacent its periphery to provide a conduit for the liquid aerosol precursor to travel from the second side of the rigid monomer to the first side.

[0027] Example 6: The atomizer according to any one of the preceding examples, wherein the rigid monomer has a recess formed in the first side, and the heating surface is positioned to face the base surface of the recess.

[0028] Example 7: The atomizer according to any one of the preceding examples, wherein the rigid monomer includes at least one hole extending from the base surface to the second side.

[0029] Example 8: The atomizer according to any one of the preceding examples, wherein the at least one hole includes a centrally located hole.

[0030] Example 9: The atomizer according to any one of the preceding examples, wherein the at least one hole includes a plurality of holes, and the centrally located hole has a larger diameter than the remaining holes of the plurality of holes.

[0031] Example 10: The atomizer according to any one of the preceding examples, wherein the base surface includes a boss, and the centrally located hole passes through the boss.

[0032] Example 11: The atomizer according to any one of the preceding examples, wherein the depth of the recess is greater than about 30% of the thickness of the rigid monomer.

[0033] Example 12: The atomizer as described in any of the foregoing examples further includes an absorbent pad positioned in the recess between the heating surface and the base surface.

[0034] Example 13: The atomizer as described in any of the foregoing examples, wherein the heater includes at least one heating element selected from the group consisting of heating wires, conductive meshes, and conductive traces printed on the surface of a substrate.

[0035] Example 14: The atomizer as described in any of the foregoing examples further includes an insulator separate from the heater.

[0036] Example 15: The atomizer as described in any of the foregoing examples, wherein the insulator includes mica.

[0037] Example 16: An aerosol delivery device including the atomizer as described in any of the foregoing examples.

[0038] Example 17: The aerosol delivery device as described in any of the foregoing examples, wherein the aerosol delivery device defines an air flow path from an air inlet opening to a mouthpiece, and the air flow path passes along a second side of the rigid monomer.

[0039] Example 18: The aerosol delivery device as described in any of the foregoing examples, wherein the rigid monomer includes at least one hole extending from a first side to a second side, and the aerosol delivery device is configured such that the evaporated aerosol precursor is drawn through the at least one hole by a pressure difference generated by suction of air moving along the air flow path, and the air flow path is along the second side of the rigid monomer.

[0040] Example 19: The aerosol delivery device as described in any of the foregoing examples includes a reservoir including an aerosol precursor composition, wherein the aerosol delivery device generates an air flow path from an air inlet opening to a mouthpiece, and the air flow path passes through the reservoir.

[0041] Example 20: The aerosol delivery device as described in any of the foregoing examples, wherein the rigid monomer further includes circumferential grooves formed in its second side, and the grooves are configured to help seal the rigid monomer to the reservoir.

[0042] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description and the accompanying drawings briefly described herein. The present disclosure includes combinations of any two, three, four, or more of the above-described embodiments of the present disclosure, as well as combinations of any two, three, four, or more features or elements, whether or not such features or elements are explicitly combined in the specific embodiments described herein. Unless otherwise specifically provided in the context, the present disclosure is intended to be read as a whole, such that any separable feature or element of the present invention should be considered capable of combination in any one of its various aspects and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The present disclosure has been generally described above and will now be described with reference to the accompanying drawings, which are not necessarily drawn to scale, in which:

[0044] Figure 1 is a partial cross-sectional view of an aerosol delivery device according to various embodiments of the present disclosure, the aerosol delivery device including a cartridge and a power unit, the power unit including various elements that can be employed in the aerosol delivery device;

[0045] Figure 2 is an illustration of a fluid delivery element according to an embodiment of the present disclosure;

[0046] Figure 3 is an illustration of a heater and an insulator according to an embodiment of the present disclosure;

[0047] Figure 4 is an exploded view of an atomizer according to an embodiment of the present disclosure;

[0048] Figure 5 is an end perspective view of a reservoir acting as a storage tank according to an embodiment of the present disclosure;

[0049] Figure 6 is according to an embodiment of the present disclosure including Figure 5 of the reservoir and Figure 4 is a schematic partial cross-sectional view of an aerosol delivery device including an atomizer, the aerosol delivery device including a reservoir and an atomizer according to an embodiment of the present disclosure;

[0050] Figure 7 is an exploded perspective view of a heater as seen from a first side according to another embodiment of the present disclosure;

[0051] Figure 8 is from Figure 7 is an exploded perspective view of the heater as seen from a second side.

[0052] Figure 9 is including Figure 5 of the reservoir and Figure 7 and 8Schematic partial cross-sectional view of an aerosol delivery device of an atomizer. Detailed Description

[0053] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments of the disclosure. Describing these exemplary embodiments makes the present disclosure thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. In fact, the present disclosure may be embodied in many 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. Unless clearly stated otherwise in the text, the singular forms "a", "an", and "the" as used in this specification and the appended claims include plural referents.

[0054] As described below, embodiments of the present disclosure relate to aerosol delivery systems. An aerosol delivery system according to the present disclosure uses electrical energy to heat a material (e.g., without burning the material to any significant extent and / or without significant chemical alteration of the material) to form an inhalable substance; and the components of such a system are in the form of an article that can be sufficiently compact to be considered a handheld device. That is, the use of the components of the aerosol delivery system does not result in the generation of smoke - i.e., smoke that is a by-product of the combustion or pyrolysis of tobacco - while the use of those systems results in the generation of vapor, which is caused by the volatilization or evaporation of certain components therein. In some embodiments, the components of the aerosol delivery system may be characterized as electronic cigarettes, and those electronic cigarettes may contain tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0055] The aerosol generating member of certain aerosol delivery systems can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the habits of inhaling and exhaling, the types of flavors or scents, the sensory effects, the physical sensations, the usage habits, the visual cues provided by the visible aerosol, etc.) without burning any of the ingredients therein to a significant extent, and these cigarettes, cigars, or pipes are used by lighting and burning tobacco (and thus inhaling tobacco smoke). For example, a user of an aerosol generating member of the present disclosure can hold and use the article in the same manner as a smoker uses a traditional type of smoking article, inhale at one end of the article to inhale the aerosol generated by the article, and take puffs or inhalations at selected time intervals, etc.

[0056] The aerosol delivery device of the present disclosure may also be characterized as a vapor generating article or a medicament delivery article. Thus, such an article or device can be modified to provide one or more substances (e.g., flavors and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in the form of vapor (i.e., a substance in the gas phase at a temperature below the critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For purposes of simplicity, the term "aerosol" as used herein is intended to include forms or types of vapor, gas, or aerosol suitable for human inhalation, whether visible or not, and whether or not considered to be in a smoky form.

[0057] The aerosol delivery device of the present disclosure generally includes a plurality of components disposed within an outer body or housing that may be referred to as a shell. The overall design of the outer body or housing may vary, and the form or configuration of the outer body that can define the overall size and shape of the aerosol delivery device may vary. Typically, an elongated body similar in shape to a cigarette or cigar may be formed from a single integral housing, or the elongated housing may be formed from two or more separable bodies. For example, the aerosol delivery device may include an elongated housing or body that may be generally tubular in shape and thus similar in shape to a conventional cigarette or cigar. In another embodiment, the outer housing may have a rectangular, triangular, elliptical, or other cross-sectional shape. In one embodiment, all components of the aerosol delivery device are housed within a single housing. Alternatively, the aerosol delivery device may include two or more housings that are connected and separable. For example, the aerosol delivery device may have a control body (or power unit) at one end that includes a housing that houses one or more components (e.g., a battery and various electronic components for controlling the operation of the device), and an outer body or housing at the other end of the aerosol delivery device may be removably attached thereto, and the outer body or housing houses 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).

[0058] The aerosol delivery device of the present disclosure may be formed by an outer housing or shell that is not substantially tubular in shape but may be formed to be of a substantially larger size. The housing or shell may be configured to include a mouthpiece member and / or may be configured to receive a separate housing (e.g., a cartridge or reservoir) that may include a consumable element such as a liquid aerosol former and may include an evaporator or atomizer.

[0059] The aerosol delivery device of the present invention generally includes certain combinations of the following components: a power source (i.e., a power supply); at least one control component (e.g., a device such as a microcontroller or microprocessor that controls the current flowing from the power source to other components of the article for actuation, control, regulation, and stopping of the power for heating); a heater or heating component (e.g., a resistive heating element or material configured to generate heat through an induced eddy current, which element or material alone or in combination with one or more additional elements is generally referred to as an "atomizer"); an aerosol precursor composition (e.g., a liquid such as ingredients commonly referred to as "e-juice", "e-liquid", and "e-juice" that is generally capable of generating an aerosol when sufficient heat is applied); and a mouthpiece or mouth end region that allows inhalation of the aerosol on the aerosol delivery device (e.g., through a defined air flow path through the article such that the generated aerosol can be withdrawn from the air flow path during inhalation).

[0060] Based on the further disclosure provided below, more specific forms, configurations, and arrangements of the components within the aerosol delivery system of the present disclosure will be apparent. Additionally, considering commercially available electronic aerosol delivery devices, it can be understood the selection and arrangement of different aerosol delivery device components, such as those representative products cited in the background art section of the present disclosure.

[0061] Figure 1 An exemplary embodiment of an aerosol delivery device 100 according to the present disclosure is provided in the figure, which shows the components that can be employed in an aerosol delivery device. As seen in the sectional view shown therein, the aerosol delivery device 100 can include a power unit 102 and a cartridge 104, and the power unit 102 and the cartridge 104 can be permanently or removably aligned in a functional relationship. The mating of the power unit 102 and the cartridge 104 can be a press fit (as shown), a threaded fit, an interference fit, magnetic, or similar means. Specifically, connection components such as those further described herein can be used. For example, the power unit can include a coupling adapted to mate with a connector on the cartridge. As another example, in some exemplary embodiments, the housing of the power unit 102 can define a cavity configured to receive at least a portion of the cartridge 104. In such embodiments where at least a portion of the cartridge 104 is received into the cavity of the power unit 102, the cartridge 104 can be held in the cavity of the power unit 102 by an interference fit (e.g., by using a pawl and / or other features to form an interference fit between the outer surface of the cartridge 104 and the inner surface of the cavity wall), a magnetic fit, or other suitable techniques.

[0062] In a specific embodiment, one or both of the power unit 102 and the cartridge 104 may be disposable or reusable. For example, the power unit may have a replaceable battery or a rechargeable battery and may thus be combined with any type of charging technology, including: connection to a wall charger, connection to a vehicle charger (e.g., cigarette lighter socket), and connection to any one of a computer using a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a photovoltaic cell (sometimes referred to as a solar cell) or a solar panel of a solar cell, or a wireless charger such as a charger using inductive wireless charging (e.g., including wireless charging according to the Qi wireless charging standard of the Wireless Power Consortium (WPC)), or a charger based on radio frequency (RF). An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the cartridge may include a disposable cartridge, such as the cartridge disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference.

[0063] As Figure 1 shown, the power unit 102 may be formed by a power unit housing 101, which may include control components 106 (e.g., a printed circuit board (PCB), integrated circuits, memory components, a microcontroller, etc., and a resistance temperature detector for temperature control), a flow sensor 108, a battery 110, and an LED 112, and such components can be variably aligned. In addition to or in place of the LED, additional indicators (e.g., a tactile feedback component, an audio feedback component, etc.) may be included. Representative additional types of components or indicators that produce visual cues, such as light-emitting diode (LED) components, and their construction and use are described in U.S. Patent No. 5,154,192 to Sprinkel et al.; U.S. Patent No. 8,499,766 to Newton and U.S. Patent No. 8,539,959 to Scatterday; U.S. Patent Publication No. 2015 / 0020825 to Galloway et al.; and U.S. Patent Publication No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference. It should be understood that not all of the elements shown are required. For example, the LED may not be present, or may be replaced by other indicators such as a vibration indicator. Similarly, the flow sensor may also be replaced by a manual actuator such as a button.

[0064] The cartridge 104 may be formed by a cartridge housing 103 that encloses a reservoir 144, the cartridge housing 103 being in fluid communication with a fluid delivery element 136 that is adapted to wick or otherwise deliver an aerosol precursor composition stored in the reservoir housing to the heater 134. The fluid delivery element may be composed of one or more materials configured to deliver a liquid, for example, by capillary action. The liquid delivery element may be formed from materials such as fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics (aluminum oxide, silica, zirconia, SiC, SiN, AlN, etc.), porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, porous polymers, etc. Thus, the fluid delivery element may be any material that includes a network of open pores (i.e., multiple interconnected pores such that a fluid can flow through the element from one pore in multiple directions to another pore). The pores may be nanopores, micropores, macropores, or a combination thereof. As further discussed herein, some embodiments of the present disclosure may specifically relate to the use of non-fibrous delivery elements. Thus, in some embodiments, fibrous delivery elements may be explicitly excluded. Alternatively, a combination of fibrous and non-fibrous delivery elements may be employed. In some embodiments, the fluid delivery element may be a substantially solid, non-porous material, such as a polymer or a dense ceramic or metal, configured to direct a liquid through holes or slots without relying on wicking by capillary action. Such a solid body may be used in combination with a porous absorbent pad. The absorbent pad may be formed from silica-based fibers, organic cotton, rayon fibers, cellulose acetate, regenerated cellulose fabric, highly porous ceramics, or metal meshes, etc.

[0065] Various embodiments of materials configured to generate heat when an electric current is passed through them may be used to form the heater 134. Exemplary materials that may form a coil include Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tin oxide, tungsten, molybdenum disilicide (MoSi 2 )), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al) 2 ), 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 temperature coefficient ceramics or negative temperature coefficient ceramics). The heater 134 may be a resistive heating element or a heating element configured to generate heat by induction. The heater 134 may be coated with a thermally conductive ceramic, such as aluminum nitride, silicon carbide, beryllium oxide, aluminum oxide, silicon nitride, or a composite thereof.

[0066] An opening 128 may be present in the cartridge housing 103 (e.g., at the mouth end) to allow the formed aerosol to exit the cartridge 104. Such components represent components that may be present in the cartridge and are not intended to limit the scope of cartridge components covered by the present disclosure.

[0067] The cartridge 104 may also include one or more electronic components 150, which may include integrated circuits, storage components, sensors, etc. The electronic components 150 may be adapted to communicate with the control component 106 and / or with an external device in a wired or wireless manner. The electronic components 150 may be located anywhere within the cartridge 104 or its base 140.

[0068] Although the control component 106 and the flow sensor 108 are shown separately, it should be understood that the control component and the flow sensor may be combined into an electronic circuit board to which the air flow sensor is directly attached. The control assembly 106 may be considered to include a resistance temperature detector, or the resistance temperature detector may be combined with the electronic component 150. Further, the electronic circuit board may be positioned horizontally with respect to Figure 1 the illustrated orientation because the electronic circuit board may be parallel to the central axis of the power unit in the longitudinal direction. In some embodiments, the air flow sensor may include its own circuit board or other base element to which it may be attached. In some embodiments, a flexible circuit board may be employed. The flexible circuit board may be configured in various shapes, including a substantially tubular shape. For example, the construction of a printed circuit board and a pressure sensor is described in U.S. Patent Publication No. 2015 / 0245658 to Worm et al., the disclosure of which is incorporated herein by reference.

[0069] The power unit 102 and the cartridge 104 may include components adapted to facilitate fluid engagement therebetween. As Figure 1 shown, the power unit 102 may include a coupler 124 having a cavity 125 therein. The cartridge 104 may include a base 140 adapted to mate with the coupler 124 and may include a protrusion 141 adapted to fit within the cavity 125. Such mating may contribute to a stable connection between the power unit 102 and the cartridge 104 and to establish an electrical connection between the battery 110 and the control component 106 in the power unit and the heater 134 in the cartridge. Further, the power unit housing 101 may include an air inlet 118, which may be a notch in the housing where it connects to the coupler 124, allowing ambient air around the coupler to pass through and enter the housing, and then the air passes through the cavity 125 of the coupler and enters the cartridge through the protrusion 141. The air inlet 118 is not limited to being above or adjacent to the power unit housing 101, but may be formed through the exterior of the cartridge or some other part of the aerosol delivery device, such as a detachable mouthpiece.

[0070] Useful couplings and bases in accordance with the present disclosure are described in U.S. Patent Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference. For example, as Figure 1 shown, the coupling may be defined with an outer peripheral edge 126 configured to mate with an inner peripheral edge 142 of the base 140. In one embodiment, the inner peripheral edge of the base may be defined with a radius that is substantially equal to or slightly greater than the radius of the outer peripheral edge of the coupling. Further, the coupling 124 may be defined with one or more protrusions 129 at the outer peripheral edge 126, the protrusions 129 being configured to mate with one or more recesses 178 defined at the inner peripheral edge of the base. However, various other configurations, shapes, and components may be employed to couple the base to the coupling. In some examples, the connection between the base 140 of the cartridge 104 and the coupling 124 of the power unit 102 may be substantially permanent, while 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, which may be disposable and / or refillable.

[0071] In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped or substantially tubular or substantially cylindrical. In other embodiments, other shapes and sizes are contemplated, e.g., rectangular, oval, hexagonal, or triangular cross-sections, polyhedral shapes, etc. Specifically, the power unit 102 may be non-rod-shaped and may be generally rectangular, circular, or have some other shape. Similarly, the power unit 102 may be substantially larger than a power unit that would be of a size that is substantially conventional for a cigarette.

[0072] Figure 1The illustrated reservoir 144 can be a container (e.g., formed by walls that are substantially impermeable to the aerosol precursor composition) or can be a fibrous reservoir. The walls of the container can be flexible and can be collapsible. Alternatively, the walls of the container can be substantially rigid. The container can be substantially sealed to prevent the aerosol precursor composition from passing therethrough, except via any specific openings that are expressly provided for the passage of the aerosol precursor composition, such as through a delivery element as otherwise described herein. In an exemplary embodiment, the reservoir 144 can include one or more layers of nonwoven fibers that are substantially formed in the shape of a tube surrounding the interior of the cartridge housing 103. The fibers can be composed of polycarbonate, silicone, polyester, polyethylene, polypropylene, or ceramic. The aerosol precursor composition can be retained within the reservoir 144. For example, the liquid component can be absorbently retained by the reservoir 144 (i.e., when the reservoir 144 includes fibrous material). The reservoir 144 can be in fluid communication with a fluid delivery element 136. The fluid delivery element 136 can transport the aerosol precursor composition stored in the reservoir 144 to the heating element 134, which in this embodiment is in the form of a metal coil, via capillary action. Thus, the heating element 134 is in a heating arrangement with the fluid delivery element 136.

[0073] In use, when a user inhales on the article 100, the sensor 108 detects the airflow, the heating element 134 is activated, and the components of the aerosol precursor composition are vaporized by the heating element 134. Inhaling on the mouth end of the article 100 causes ambient air to enter the intake port 118 and pass through the cavity 125 in the coupling 124 and the central opening in the protrusion 141 of the base 140. In the cartridge 104, the inhaled air combines with the vapor formed to form an aerosol. The aerosol is agitated, inhaled, or otherwise drawn away from the heating element 134 and withdrawn through the mouth opening 128 in the mouth end of the article 100. Alternatively, in the absence of an airflow sensor, the heating element 134 can be manually activated, such as by a button.

[0074] The input component may be included in an aerosol delivery device (and may replace or supplement an airflow sensor or a pressure sensor). An input section may be included to allow a user to control the functions of the device and / or output information to the user. Any component or combination of components may be employed as an input end for controlling the functions of the device. For example, as described in U.S. Patent Publication No. 2015 / 0245658 to Worm et al., one or more buttons may be used, which is incorporated herein by reference. Similarly, as described in U.S. Patent Application Serial No. 14 / 643,626 filed on March 10, 2015 by Sears et al., a touch screen may be used, which is incorporated herein by reference. As a further example, a component adapted to perform gesture recognition based on a specified motion of the aerosol delivery device may be used as the input section. See U.S. Patent Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference. As yet another example, a capacitive sensor may be implemented on the aerosol delivery device to enable a user to provide input, for example, by touching the surface of the device on which the capacitive sensor is implemented.

[0075] In some embodiments, the input section may include a computer or computing device such as a smartphone or a tablet. Specifically, the aerosol delivery device may be connected to the computer or other device, such as by using a USB cable or a similar protocol cable. The aerosol delivery device may also communicate with the computer or other device used as an input via wireless communication. For example, see the system and method for controlling a device via a read request as described in U.S. Patent Publication No. 2016 / 0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference. In such embodiments, an application or other computer program may be used in combination with the 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 a specific composition by selecting the nicotine content and / or the content of additional flavorings included.

[0076] The various components of the aerosol delivery device according to the present disclosure may be selected from the components described in the prior art and commercially available components. Examples of batteries that may be used according to the present disclosure are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference.

[0077] An aerosol delivery device may incorporate a sensor or detector for controlling the power supplied to a heating element when aerosol generation is required (e.g., during puffing while in use). Thus, for example, a method or way is provided for turning off the power to the heating element when not inhaling on the aerosol delivery device during use and for turning on the power during inhalation to activate or trigger the heat generated by the heating element. Additional representative types of sensing or detecting mechanisms, their structures and configurations, their components, and their general methods of operation are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr.; U.S. Patent No. 5,372,148 to McCafferty et al.; and PCT WO2010 / 003480 to Flick, the disclosures of which are incorporated herein by reference.

[0078] An aerosol delivery device may include a control mechanism for controlling the amount of electrical power to a heating element during inhalation. Representative electronic components, their structures and configurations, their features, and their general methods of operation are described in U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patent No. 4,947,874 to Brooks et al.; U.S. Patent No. 5,372,148 to McCafferty et al.; U.S. Patent No. 6,040,560 to Fleischhauer et al.; U.S. Patent No. 7,040,314 to Nguyen et al.; U.S. Patent No. 8,205,622 to Pan; U.S. Patent Publication No. 2009 / 0230117 to Fernando et al.; U.S. Patent Publication No. 2014 / 0060554 to Collet et al.; U.S. Patent Publication No. 2014 / 0270727 to Ampolini et al.; and U.S. Patent Publication No. 2015 / 0257445 to Henry et al., the disclosures of which are incorporated herein by reference.

[0079] Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton; U.S. Patent Publication No. 2014 / 0261487 to Chapman et al.; U.S. Patent Publication No. 2014 / 0059780 to Davis et al.; and U.S. Patent Publication No. 2015 / 0216232 to Bless et al., the disclosures of which are incorporated herein by reference. Additionally, various wicking materials and the construction and operation of those wicking materials within a particular type of electronic cigarette are set forth in U.S. Patent No. 8,910,640 to Sears et al., the disclosure of which is incorporated herein by reference.

[0080] For an aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition may comprise tobacco or tobacco-derived components. In one aspect, the tobacco may be provided as parts or pieces of tobacco, such as finely ground, shredded, or powdered tobacco flakes. Tobacco beads, pellets, or other solid forms, such as those described in U.S. Patent Publication No. 2015 / 0335070 to Sears et al., the disclosure of which is incorporated herein by reference, may be included. In another aspect, the tobacco may be provided in the form of an extract, such as a spray-dried extract that contains many of the water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of an extract having a relatively high nicotine content that also contains minor amounts of components from other extracts of tobacco. In another aspect, tobacco-derived components may be provided in a relatively pure form, such as certain flavorants derived from tobacco. In one aspect, a component derived from tobacco and that may be used in a highly purified or substantially pure form is nicotine (e.g., pharmaceutical-grade nicotine). In other embodiments, non-tobacco materials may form the aerosol precursor composition alone.

[0081] The aerosol precursor composition, also referred to as a vapor precursor composition or "e-liquid", may comprise a variety of components, including, for example, polyols (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or edible flavorants. The components and compositions of representative types of aerosol precursors are also described and characterized in U.S. Patent No. 7,217,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Publication No. 2013 / 0213417 to Chong et al., U.S. Patent Publication No. 2014 / 0060554 to Collett et al., U.S. Patent Publication No. 2015 / 0030823 to Lipowicz et al., and U.S. Patent Publication No. 2015 / 0020830 to Koller, as well as WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein in their entireties by reference. Other aerosol precursors that may be employed include those already included in products of Products; the BLU™ product of Lorillard Technologies; the MISTIC MENTHOL product of Mistic Ecigs; the MARK TEN product of Nu Mark LLC; the JUUL product of Juul Labs, Inc.; and the VYPE product of CNCreative Limited. It is also desirable to have the so-called "e-juice" for electronic cigarettes that has been available from Johnson Creek Limited. Additional exemplary aerosol precursor compositions are sold under the following trade names: BLACK NOTE, COSMIC FOG, MILKMAN E-LIQUID, FIVE PAWNS, VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOODLIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THE JUICE MAN. The amount of aerosol precursor incorporated within the aerosol delivery system enables the aerosol generating member to provide acceptable sensory and desired performance characteristics. For example, it is desirable to use sufficient amounts of aerosol forming materials such as glycerin and / or propylene glycol to ensure the production of a visible mainstream aerosol that in many respects resembles the appearance of tobacco smoke. The amount of aerosol precursor within the aerosol generating system can depend on factors such as the desired number of puffs per aerosol generating member. In one or more embodiments, an aerosol precursor composition of about 0.5 milliliters or more, about 1 milliliter or more, about 2 milliliters or more, about 5 milliliters or more, or about 10 milliliters or more can be included.

[0082] Other features, controllers or components that can be incorporated into the aerosol delivery systems of the present disclosure are described in U.S. Patent No. 5,967,148 to Harris et al.; No. 5,934,289 to Watkins et al.; U.S. Patent No. 5,954,979 to Counts et al.; U.S. Patent No. 6,040,560 to Fleischhauer et al.; U.S. Patent No. 8,365,742 to Hon; U.S. Patent No. 8,402,976 to Fernando et al.; U.S. Patent Publication No. 2010 / 0163063 to Fernando et al.; U.S. Patent Publication No. 2013 / 0192623 to Tucker et al.; U.S. Patent Publication No. 2013 / 0298905 to Leven et al.; U.S. Patent Publication No. 2013 / 0180553 to Kim et al.; U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al.; U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al. and U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al., the disclosures of which are incorporated herein by reference.

[0083] Based on the further disclosure provided herein, it will be apparent to those skilled in the art that the above-described usage descriptions of the articles can be applied to the various embodiments described herein with some modifications. However, the above descriptions of usage are not intended to limit the use of the articles, but rather to provide all the necessary requirements for the disclosure in accordance with the present disclosure. Figure 1 Any element shown in the articles or any element otherwise described above can be included in the aerosol delivery device according to the present disclosure.

[0084] In one or more embodiments, the present disclosure can specifically relate to an aerosol delivery device configured to provide an increased delivery of the generated vapor. This increase can be caused by a variety of factors. In some embodiments, the fluid delivery element can be formed in part or entirely from a porous monomer such as porous ceramic, porous glass, porous polymer, etc. For example, exemplary monomer materials suitable for embodiments according to the present disclosure are described in U.S. Patent Application Serial No. 14 / 988,109 filed on January 5, 2016 and U.S. Patent No. 2014 / 0123989 to LaMothe, the disclosures of which are incorporated herein by reference. In some embodiments, the porous monomer can form a substantially rigid wicking portion. Specifically, the delivery element can be substantially a single monomer material, rather than a bundle of individual fibers as is known in the art.

[0085] Using a rigid porous monomer as a fluid delivery element can be beneficial for improving heating uniformity and reducing potential carbonization of the fluid delivery element when non-uniform heating occurs. It may also be desirable to eliminate the presence of fibrous materials in the aerosol delivery device. Despite these benefits, porous monomers also pose some challenges for successful implementation as fluid delivery elements. These challenges are due in part to the different material properties of porous monomers (e.g., porous ceramics) compared to fibrous cores. For example, alumina has a higher thermal conductivity and higher heat capacity than silica. These thermal properties cause heat to be drawn away from the aerosol precursor composition at the interface between the wicking section and the heater, and this may require a higher initial energy output to achieve comparable fluid evaporation. The present disclosure provides ways to overcome such difficulties.

[0086] In some embodiments employing a porous monomer, when using the porous monomer, the energy required for evaporation can be reduced, and the evaporation response time can be improved by increasing the heat flux density (measured in watts per square meter - W / m 2 2) on the surface of the porous monomer fluid delivery element. The present disclosure specifically describes embodiments suitable for providing such an increase in heat flux density.

[0087] In some embodiments, the present disclosure provides an atomizer configuration in which the fluid delivery element provides a flat heat-receiving surface to receive heat from the flat heating surface of the heater. Figure 2 A first embodiment of the present disclosure is shown, where the fluid delivery element 236 is in the form of a substantially rigid porous monomer. The fluid delivery element 236 has a body 240 in the shape of a disc, which has a first side 244 and a second side 248. The perimeter of the body 240 can have other shapes in addition to being circular, to correspond to the overall cross-section of the aerosol delivery device that utilizes the fluid delivery element 236. In the illustrated embodiment, the first side 244 and the second side 248 generally correspond to the opposite faces of the disc. The first side 244 and the second side 248 can be substantially parallel surfaces. The circular disc can have an outer diameter D M , which is between about 6 mm and about 14 mm, although the dimensions of the body 240 can vary depending on the dimensions of the components of the relevant aerosol delivery device. For example, in the case where the aerosol delivery device resembles a cigarette, as Figure 1 shown, the outer diameter D M can be selected such that the body fits within the housing 103 ( Figure 1 ) when the disc is arranged perpendicular to the longitudinal axis of the aerosol delivery device. The outer diameter D M can be constant as shown, or can vary, for example to form a stepped portion or a tapered outer surface, to facilitate the assembly of the aerosol delivery device, including but not limited to facilitating operable fluid contact between a reservoir containing the aerosol precursor composition and the radially outer portion of the body 240.

[0088] In Figure 2 the embodiment, the first side 244 may be a heat-receiving side intended to be adjacent to and optionally in contact with the heater. The second side 248 may be a smoke-releasing side through which, when a user inhales at the mouth end of the aerosol delivery device, a user-generated air stream carries vapor out of the fluid delivery element 236. In other embodiments not shown, heat may be applied to the second side 248, the aerosol may be carried out from the first side 244, or both heating and carrying out may be mainly with respect to a single side of the body 240. In some embodiments, specifically in embodiments where the air flow will pass adjacent to each side of the body, heating and agitation at each side of the body 240 are contemplated.

[0089] In Figure 2 the illustrated embodiment, the first side 244 may include a recess 252 formed within or otherwise disposed within the body 240. The recess 252 may have a shape that matches the shape of the periphery of the body 240. In the illustrated circular case, the diameter D R of the recess 252 may be between about 5 mm and about 12 mm, and generally greater than half of the diameter D M of the body 240. The diameter D R may be selected partly based on the radius of the conduit passing through the reservoir at a location adjacent to the fluid delivery element 236.

[0090] The portion of the body 240 between the outer periphery and the recess 252 may be referred to as the absorption region 254, which may be placed in contact with the reservoir either in whole or in part, as Figure 6 shown.

[0091] The recess 252 may have a depth Z, where Z is between about 1 mm and about 4 mm, and possibly between about 1.75 mm and about 2 mm, which may be about one-third to about three-quarters of the thickness T M of the body 240. Similarly, the absolute and relative depths of the recess 252 may vary. In one embodiment, the depth Z may be large enough such that the heater and the insulator (e.g., heat insulator) may be substantially completely received within the recess 252. In another embodiment, the recess 252 receives the heater and the insulator may be placed on the top surface 255 of the body 240.

[0092] The recess 252 defines a base surface 256, which may be referred to as a heat receiving surface. In some embodiments, the recess may be omitted, and the top surface 255 may be the heat receiving surface. The body 240 has a vapor formation region 260 defined between the base surface 256 of the recess 252 and the second side 248. The vapor formation region 260 may have a thickness T of from about 0.5 mm to about 2.5 mm V . In one embodiment, T V is about 1 mm. The area of the base surface 256 determined by the diameter D R of the recess 252 and the thickness T of the vapor formation region 260 may be selected V to optimize the heat flux density and the ratio of the surface area from which the aerosol precursor can be released to the volume of the vapor formation region in which the aerosol precursor can be formed.

[0093] As Figure 2 shown, one or more holes 270 may be provided in the vapor formation region 260, which extend from the base surface 256 to the second side 248 of the body 240. The diameter D A of the holes may be in the range of from about 0.1 mm to about 0.9 mm and may be about 0.35 mm, although other sizes may also be considered. The holes 270 are provided in the porous body 240 to increase the exposed surface area from which the aerosol precursor can be released as vapor. In addition to selecting the size of each hole 270, the number and arrangement of the holes may be varied to optimize the effective release of the aerosol. The efficiency of aerosol release may be determined based on factors such as the power required to heat the fluid delivery element 236 and the volume of the aerosol precursor to be vaporized. The sizes of the holes 270 may all be substantially equal, or their sizes may vary. For example, smaller holes may be located near the center of the vapor formation region 260, while larger holes may be located near the periphery of the vapor formation region, and vice versa. The holes 270 may be arranged randomly or in various ordered arrays, such as a square grid, concentric circles, or with the holes aligned along the radial lines of the circular base surface 256.

[0094] The spacing of the holes 270 may also vary. The holes 270 with close spacing may be separated by a thickness of 0.5*D A or less, while the holes with wider spacing may be about D Aare spaced apart by a distance or even further. Relative to the total area of the base surface 256, the cumulative surface area of the ends of the holes 270 can also vary from an opening area of approximately 90% to an opening area of approximately 10% or less, ignoring the porosity of the body 240 itself. For example, in some embodiments, there may be no holes 270 at all, in which case the percentage of the opening area will be defined as zero. The use of the holes 270 can facilitate heat transfer from the heater by convection and conduction to provide more uniform heating of the fluid delivery element 236, or alternatively help avoid overheating of the heater or the fluid delivery element. In cases where the holes 270 are used to increase the surface area, alternative surface defects such as dimples, cavities, grooves, ribs, protrusions, projections, etc. can be provided at the vapor formation region 260 of the second side 248 to similarly increase the surface area exposed to the second side 248 of the body 240.

[0095] The heater 234 is shown in Figure 3 and is configured to present a substantially flat heating surface 280 that is configured to face and be adjacent to the heat receiving surface of the fluid transfer element 236 (e.g., the base surface 256, or the absorbent pad if present). In one embodiment, the heating wire 282 is arranged substantially along a plane to provide a substantially flat heating element. In one embodiment, the heating element can be sandwiched between high thermal conductivity materials such as ceramics (aluminum oxide, zirconium oxide, beryllium oxide, etc.). In one embodiment, the heating wire 282 is formed as a conductive trace printed or otherwise deposited on the surface of a flat disk 283 made of ceramic or other heat-resistant material. The periphery of the heater 234 can be configured to be similar in shape and diameter to the base surface 256 ( Figure 2 ), such that the heater 234 can be located substantially closely within the recess 252 or even in contact with the base surface to transfer heat from the heating surface 280 of the heater 234 to the vapor formation region 260 of the fluid delivery element 236. In some embodiments, the radius R of the heater 234 is no larger than half of the diameter D of the recess 252 R . In one embodiment, the heater 234 can be a stamping heater according to USP 9,491,974, which is incorporated herein by reference.

[0096] There is no specific limitation on the internal layout of the heating wire 282 within the planar arrangement with respect to the trajectory of the heating wire, the number of its coils, or the resulting spacing between adjacent portions of the heating wire. Similarly, the heating wire 282 can be on or inserted from the heating surface 282.

[0097] The heater 234 may also include electrical leads 284 to provide positive and negative electrical connections to the heater. The electrical leads 284 may be integrally formed with the heating wire 282 or may be separate elements that are attachable (e.g., by welding or using a connector) to the heating wire. There is no specific limitation on the position of the leads 284. The leads 284 may be arranged adjacent to each other or separated from each other.

[0098] In Figure 4 FIG. shows an exploded view of the fluid delivery element 236 and the heater 234. Electrical insulators 288 and thermal insulators 288 may also be provided, such as in the form of sheets of mica or similar insulating materials. From Figure 4 it will be appreciated that the insulator 288 may be disposed on the first side 244 of the body 240 and may be configured to substantially enclose the heater 234 within the recess 252. The electrical leads 284 may be understood to pass through or around the insulator 288 to make an electrical connection to a power source. The size and dimensions of the insulator 288 may be designed to mate with the heater 234 within the recess 252, or the insulator 288 may have a larger diameter and be positioned along the top surface 255 of the body 240.

[0099] The combination of the delivery element 226, the heater 234, and the optional insulator 288 provides an atomizer 290. As can be seen from Figure 4 it is understood that the heater 234 may be configured to be within the recess 252 of the fluid delivery element 236. In this configuration, the energy from the heater 234 is concentrated into a smaller surface area of the vapor formation region 260 of the body 240.

[0100] In one or more alternative embodiments, the heating wire 282 of the heater 234 can be provided in the form of a mesh or screen heater, which can effectively increase the heater surface area coverage on the porous monolithic fluid delivery element 236. Similarly, the heater 234 may be configured to contact at least a portion of the first side 244 of the fluid delivery element, such as the base surface 256, and the heater is in the form of a conductive mesh. As used herein, the terms mesh and screen are meant to be interchangeable and specifically refer to a network of intersecting conductive filaments. Thus, a conductive mesh can be considered a network and / or an interleaved structure of conductive filaments. The conductive filaments can be formed from any suitable conductive material, such as the conductive materials listed elsewhere herein for forming heaters. In one or more embodiments, the conductive filaments may be at least partially intertwined with non-conductive filaments or similar materials.

[0101] If the heater 234 is formed of a conductive mesh, the heater 234 can define a regular pattern of conductive filaments that forms a parallelogram or other shape consistent with the mesh configuration. The conductive filaments can specifically surround an insulating space. The insulating space can be open (e.g., insulated by air) or can be at least partially filled with an insulator. The insulating space can be configured to have a defined area such that the heating capacity of the conductive mesh heater 334 is increased to reduce the amount of power delivered to the heater. In some embodiments, the insulating space can have an average individual area of from about 0.01 square microns to about 2 square millimeters. In additional embodiments, the insulating space can have an average individual area of from about 0.05 square microns to about 1.5 square millimeters, from about 0.1 square microns to about 1 square millimeter, from about 0.25 square microns to about 0.5 square millimeters, or from about 0.5 square microns to about 0.1 square millimeter. In some embodiments, the insulating space can have an average individual area within a larger range, such as from about 0.005 square millimeters to about 2 square millimeters, from about 0.01 square millimeters to about 1.5 square millimeters, or from about 0.02 square millimeters to about 1 square millimeter. In some embodiments, the insulating space can have an average individual area within a lower range, such as from about 0.01 square microns to about 10 square microns, from about 0.02 square microns to about 5 square microns, or from about 0.05 square microns to about 1 square micron.

[0102] The heating wire 282 or alternatively the conductive mesh is not limited to generating heat by the resistance of an electric current directly applied thereto. The heating wire 282 or the conductive mesh can similarly be configured to generate heat by induced current and eddy current in the presence of an alternating magnetic field without being directly electrically connected to a power source. For induction heating, other types of materials can be used as the heating element, such as ferritic steel, ferromagnetic ceramics, aluminum, etc.

[0103] In additional embodiments, such as Figure 4 the atomizer 290 shown can be included in an aerosol delivery device 300 ( Figure 6 ), which can include a reservoir 304. Figure 5 An end perspective view of a reservoir 304 adapted to be combined with the atomizer 290 is shown. The reservoir 304 can include an outer body or housing 303 that defines a structure configured to store a liquid aerosol precursor 345 ( Figure 6) a reservoir 344. The reservoir 304 may include at least one air inlet opening 308. In the illustrated embodiment, the air inlet openings 308 are circumferentially spaced and extend radially from the periphery of the reservoir 304. The air inlet openings 308 lead to a chamber 310 that is along or below the top of the support 318 or embedded in the support 318. In both cases, the ends of the reservoir 304 are designed to avoid mixing between the air path and the liquid in the reservoir 344. The inner cavity 314 may extend from the chamber 310 through the reservoir 304 to the mouthpiece 327( Figure 6 ) to allow the drawn air to leave the aerosol delivery device 300. One or more holes 316 allow access to the reservoir 344. The holes 316 may be formed in the support 318 that surrounds the cavity 310. The support 318 may include one or more annular rings 320 that project axially therefrom. The annular rings 320 may be configured to mate with mating grooves( Figure 8 516) to assist in sealing the liquid delivery element to the reservoir 304.

[0104] As Figure 6 shown, the atomizer 290 may be mounted on the support 318. The aerosol precursor 345 may leave the reservoir through one or more holes 316( Figure 5 ) and be absorbed by the porous fluid delivery element 236. Alternatively, as described below, the fluid delivery element may be coupled with an absorbent pad between the heater and the fluid delivery element for absorbing the aerosol precursor. When the heater 234 is activated, the aerosol precursor composition is vaporized and introduced into the chamber 310 through the holes 270 or wicked from the second side 248 of the porous fluid delivery element 236.

[0105] In the illustrated embodiment, the air inhaled through the air inlet openings 308 carries the formed vapor (e.g., in the form of an aerosol, where the formed vapor is mixed with air) from the chamber 310 through the inner cavity 314 to the mouthpiece 327. In Figure 6The air flow path P, shown by a dotted line in the middle, from the air inlet opening 308 to the mouthpiece 327 passes along the second side 248 of the fluid delivery element 236. In the illustrated embodiment, the air flow path P does not pass through or around the fluid delivery element 236 and does not pass through the hole 270. Instead, the air flowing out of the air inlet opening 308 is sucked through the outlet of the hole 270 and out of the mouthpiece 327 to create a pressure difference in the chamber 310, which draws the generated aerosol out of the hole 270 and into the chamber 310, where the aerosol is entrained by the air flow. The pressure difference can also assist in further wicking the aerosol precursor 345 from the reservoir 344 into the fluid delivery element 236. As shown, the reservoir 344 can be substantially tubular, and the aerosol passes through the reservoir along the air flow path P. The outer shape of the reservoir 344 can match the shape of the housing 303, and the shape of the housing 303 is not limited to a cylindrical tube but can include other outer shapes having a center or other internal cavity passing therethrough. Other configurations of the elements can also be considered. The reservoir 304 can include a connector 340 for connecting the reservoir to a control body or a power unit (e.g., Figure 1 element 102 in Figure 1 ). The connector 340 can have a structure similar to the base 140 shown in Figure 1 , or can have any additional structure suitable for connecting the reservoir 304 to the control body / power unit. Although not shown, it should be understood that electrical connections are included to provide an electrical connection between the heater 234 and a battery (e.g., Figure 1 element 110 in Figure 1 ) or other power delivery device. Any relevant elements from Figure 1 the aerosol delivery device 100 can also be included in the aerosol delivery device 300.

[0106] Using at least two separate heaters can be beneficial for improving vapor generation. Specifically, a first heater can be used to preheat the liquid for evaporation within the fluid delivery element, and a second heater can be used for actual evaporation of the liquid. Preheating can reduce the total power and / or the absolute temperature and / or the heating time required to provide a desired volume of vapor. For example, an external heater can be the preheater, and an internal heater can be the evaporation heater. Additionally or alternatively, at least two separate heaters can be positioned on the outer surface of the fluid delivery element. One of the heaters can act as the preheater, and the other heater can act as the evaporation heater. For example, as Figure 6As shown, a pre-heater (not shown) may be positioned between the heater 234 (which may act as an evaporation heater) and the reservoir 344. As described above, the pre-heater may pre-heat the liquid aerosol precursor composition flowing from the reservoir 344 to the evaporation heater 234 such that the evaporation heater can more easily effect evaporation, and / or the pre-heater can reduce the viscosity of the liquid aerosol precursor composition to improve the flow of the liquid from the reservoir to the evaporation heater. In Figure 6 , a second heater positioned between the heater 234 and the reservoir 344 may be a mesh heater as described herein, may be a simple coil, or may be any other type of heater for providing pre-heating to a liquid in a fluid delivery element.

[0107] Turning to Figure 7 and 8 , an exploded view of an atomizer 490 according to a second embodiment is shown. The atomizer 490 may include an insulator 488 that may be substantially similar to the insulator 288 of the first embodiment. The atomizer 490 may include a heater 434 that may be substantially similar to the heater 234 of the first embodiment. The atomizer 490 may include a high-absorbency pad 504 that may include a fibrous material adapted to absorb and wick a liquid aerosol precursor composition. Suitable materials for the pad 504 include silica, ceramic, or cotton. The pad 504 may include an optional central opening 508.

[0108] Further, the atomizer 490 includes a fluid delivery element 436 according to the second embodiment, wherein the fluid delivery element is a non-porous monomer formed of ceramic, metal, or polymer. The fluid delivery element 436 may be configured to deliver fluid without relying on its porosity. The fluid delivery element 436 has a body 440 that has a first side 444 and a second side 448. The thickness between the first side 444 and the second side 448 may be substantially less than the other dimensions of the body 440 such that the body may be considered to be substantially flat. In the illustrated embodiment, the body 440 has a circular shape and may thus be described as a disk. Other peripheral shapes may also be considered, such as rectangular, hexagonal, triangular, other regular and irregular polygons, oval, and other shapes.

[0109] In Figure 7 the illustrated embodiment, the first side 444 includes a recess 452 formed within or otherwise disposed within the body 440. If present, the recess 452 may be defined by a base surface 456. In other embodiments, the recess may not be present.

[0110] One or more channels 458 may be provided near the periphery of the body 440, and these channels extend between the second side 448 and the first side 444. The channels 458 are configured to provide a passage for the aerosol precursor composition 345 (Figure 6 and 9 ) a pipe flowing from the reservoir 344( Figure 6 and 9 ) to the first top side 444 of the fluid delivery element 436, for example flowing into the recess 452 from its periphery. When the body 440 cooperates with the storage tank 404( Figure 9 ), the channel 458 can be understood to be arranged corresponding to the hole 316( Figure 5 ). The number of holes 316 and the number of channels 458 can be selected according to the required flow rate of the liquid aerosol precursor composition. The edge of the channel 458 on the first side 444 can be tangent to the perimeter of the base surface 456, or can protrude into the base surface.

[0111] Then, the aerosol precursor composition 345 can travel into the space between the base surface 456 and the heater 434, for example wicked by the absorbent pad 504, or if the absorbent pad is omitted, freely flow into the space so that the aerosol precursor composition can be in direct contact with the heater. When the heater 434 is energized, the collected aerosol precursor composition is aerosolized and can leave through the hole 470 of the fluid delivery element 436 into the chamber 410( Figure 9 ) to be entrained in the air flow along the air flow path P( Figure 9 ).

[0112] In one embodiment, the hole 470 can be substantially similar to the hole 270 described above. In the presence of the porous pad 504, the size range of the hole 470 can be increased, such as between about 0.1 mm and about 1 mm.

[0113] In some embodiments, the hole 470 includes a central hole 472. The central hole 472 can be larger than the remaining holes of the hole 470. The size of the central hole can be between about 0.5 mm and about 4 mm. In Figure 7 the illustrated embodiment, the central hole 472 passes through the raised boss 474 extending from the base surface 456 of the body 440. The boss 474 can serve to inhibit the leakage of the liquid aerosol precursor composition from the pad 504 into the central hole 472. In the illustrated embodiment, the boss 474 includes at least one recess 476 formed on its exterior. The recess 476 can cause the aerosol to be released from the absorbent pad 504 towards the central hole 472. In other embodiments, the raised boss 474 may not be present. The raised boss 474 is understood to pass through the central opening 508 of the absorbent pad 504. If the boss 474 is omitted, the central opening 508 can be similarly omitted or retained without any boss.

[0114] In one embodiment, the base surface 456 is further formed with a support 512 formed around the periphery of the base surface. The support 512 can support the heater 434 and maintain a desired gap between the heater and the base surface 456. The aforementioned gap accommodates the aerosol precursor composition. The size of the gap can range from about 0.1*Z to about 0.75*Z, where Z( Figure 2 ) is the depth of the recess 452. The height of the gap can also correspond to the height reached by the channel 458 above the base surface 456.

[0115] In one embodiment, the second side 448( Figure 8 ) of the body 440 is provided with a groove 516. The groove 516 can facilitate the contact and assembly between the body 440 and the reservoir 404( Figure 9 ) to help form a mechanical seal to prevent leakage of the liquid aerosol precursor into the chamber 410. For example, the assembly can include the mating of the aforementioned groove 516 with the annular ring 320( Figure 5 ).

[0116] In one or more instances, the values described herein can be characterized by the word “about”. It should be understood that a value of “about” the stated amount means that the amount can be precisely the value indicated or can differ from the indicated value by at most 5%, at most 2%, or at most 1%.

[0117] Many modifications and other embodiments of the present disclosure will come to the mind of those skilled in the art to which the present disclosure pertains, having the benefit of the teachings presented in the foregoing description and the associated drawings. Accordingly, it is to be understood that the present disclosure is not limited to the specific embodiments disclosed and that various modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a general and descriptive sense and not for purposes of limitation.

Claims

1. An atomizer, comprising: a single-piece ceramic element having a first side and a second side opposite the first side; a heater, wherein the heater includes a substantially flat heating surface, and wherein the heating surface is positioned to face the first side of the rigid single-piece; and an insulator, wherein the insulator is separated from the heater.

2. The atomizer according to claim 1, wherein, the heater includes a heating element sandwiched between heat-conducting materials.

3. The atomizer according to claim 1, wherein, the single-piece ceramic element is a fluid transfer element.

4. The atomizer according to any one of claims 1 to 3, wherein, the single-piece ceramic element further includes an absorbent pad along the first side of the single-piece ceramic element.

5. The atomizer according to any one of claims 1 to 4, wherein, the single-piece ceramic element further includes at least one channel adjacent to its periphery to provide a conduit for a liquid aerosol precursor to travel from the second side of the single-piece ceramic element to the first side.

6. The atomizer according to any one of claims 1 to 5, wherein, the single-piece ceramic element has a recess formed in the first side, and wherein the heating surface is positioned to face the base surface of the recess.

7. The atomizer according to claim 6, wherein, the single-piece ceramic element includes at least one hole extending from the base surface to the second side.

8. The atomizer according to claim 7, wherein, the at least one hole includes a centrally positioned hole.

9. The atomizer according to any one of claims 6 - 8, wherein, the heater is completely received within the recess.

10. The atomizer according to any one of claims 6 to 9, wherein, the insulator substantially encloses the heater within the recess.

11. The atomizer according to any one of claims 6 to 10, wherein, the insulator is completely received within the recess.

12. The atomizer according to claim 10, wherein, the first side includes the base surface and a top surface, and the insulator is positioned along the top surface.

13. The atomizer according to claim 9, wherein, it further includes an electrical wire passing through or around the insulator.

14. The atomizer according to any one of claims 1 to 13, wherein, the atomizer is rectangular.

15. An aerosol delivery device comprising the atomizer according to any one of claims 1 to 14.

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