Aerosol delivery device

Abstract

The present disclosure relates to an aerosol delivery device comprising a housing divided into a first half and a second half along a longitudinal axis thereof. One or more batteries may be seated within the case along with battery leads that provide electrical connections to battery terminals. A base unit may be included and the base unit may have electrical contacts for mating with battery terminals and the battery leads. The base unit may include one or both of a printed circuit board and a pressure sensor. An aerosol-forming apparatus includes a housing attachable to a sleeve, the housing containing a reservoir for an aerosol-forming composition, a heater, a liquid transfer element configured to transfer the aerosol-forming composition between the reservoir and the heater, and a heater terminal. Such configurations may provide for simplified assembly of the device.

Description

[0001] This application is a divisional application of the invention patent application with application number 201680041314.3 (PCT / US2016 / 030990), application date May 5, 2016, and invention name “Aerosol delivery device and method for forming the same”. Technical Field

[0002] The present disclosure relates to aerosol delivery devices such as smoking articles and more particularly to aerosol delivery devices that can utilize electrically generated heat for generating an aerosol (e.g., smoking articles commonly referred to as electronic cigarettes). The smoking article can be configured to heat an aerosol precursor that can incorporate a material that can be made or derived from tobacco or otherwise incorporate tobacco, the precursor being capable of forming an inhalable substance that is consumed by a human. Background Art

[0003] Many smoking devices have been proposed in these years, as the improvement or replacement of the smoking product that needs to burn tobacco for use.Many devices in those devices are allegedly designed to provide the sensation associated with cigarette, cigar or pipe, and can not deliver a considerable amount of incomplete combustion and pyrolysis products caused by the burning of tobacco.For this purpose, numerous smoking products, taste generators and medicinal inhalers have been proposed, which utilize electric energy to evaporate or heat volatile materials or attempt to provide the sensation of cigarette, cigar or pipe to a great extent when tobacco is not burned.See, for example, various alternative smoking articles, aerosol delivery devices and heat generation sources described in the background technology in the U.S. Patent No. 7,726,320 of Robinson et al., the U.S. Patent No. 2013 / 0255702 of Griffith Jr. et al. and the U.S. Patent No. 2014 / 0096781 of Sears et al., which are incorporated herein by reference in their entirety. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically driven heat generating sources referenced by trade name and commercial source in U.S. patent application Ser. No. 14 / 170,838 to Bless et al., filed on Feb. 3, 2014, which is incorporated herein by reference in its entirety.

[0004] It would be desirable to provide a reservoir of an aerosol precursor composition for an aerosol delivery device that provides for improved formation of the aerosol delivery device. It would also be desirable to provide an aerosol delivery device prepared using such a reservoir. Summary of the invention

[0005] The present disclosure relates to aerosol delivery devices, methods of forming such devices and elements of such devices. In some embodiments, the present disclosure relates to a power unit for an aerosol delivery device, the power unit being configured to provide ease of manufacture thereof and / or ease of recycling of part or all of the elements used to form the power unit. The power unit may additionally provide lower capital expenditures, and thus enable the formation of a lower cost aerosol delivery device suitable for total disposal after its use. Thus, an aerosol delivery device incorporating such a power unit may be referred to as a low-cost disposable device. The aerosol delivery device may be configured so that disposal may be performed by recycling of its various elements. For example, the connection of the power unit to the sleeve may be configured for easy disassembly. The shell of the power unit may likewise be configured for easy disassembly for removal of the elements contained therein. Various advantages of the power unit and an aerosol delivery device incorporating such a power unit are additionally disclosed in the description of the various embodiments provided herein.

[0006] In some embodiments, the present disclosure specifically provides a power unit for an aerosol delivery device. The power unit may include an elongated shell having a proximal end and an opposite distal end, the elongated shell being divided into two separate halves along its longitudinal axis. The power unit according to the present disclosure may be further described with respect to one or more of the following characteristics, which may be combined in any number without limitation.

[0007] The two halves of the elongated housing may be detachably joined together.

[0008] The two halves of the elongated shell may be permanently joined together.

[0009] The two halves of the elongated shell may be welded together.

[0010] The power unit may include at least one elongated battery housed within the elongated housing, the at least one elongated battery extending from a distal end of the elongated housing toward a proximal end of the elongated housing.

[0011] The power unit may include a battery lead including a protrusion configured for electrical connection with a terminal of at least one battery and including an arm extending from the protrusion along a length of the at least one battery.

[0012] The power unit may include a base unit attached at the proximal end of the elongated housing.

[0013] The base unit is attachable to at least one battery.

[0014] The base unit may include one or both of a printed circuit board (PCB) and a pressure sensor.

[0015] The base unit may include a first contact configured for electrical connection with a terminal of the at least one battery, and may include a second contact configured for electrical connection with an opposing terminal of the at least one battery.

[0016] The battery lead protrusion may be configured for electrical connection with a negative terminal of at least one battery, and the battery lead arm may be configured for electrical connection with one of the first contact and the second contact of the base unit.

[0017] The electrical connections in the power unit may not be fused.

[0018] In some embodiments, the present disclosure may specifically provide a base unit configured to interconnect a power unit and a sleeve to form an aerosol delivery device. The base unit may be configured to facilitate assembly of an aerosol delivery device by providing "mix-in" connectivity between the power unit and the sleeve regarding the electrical connections required therein. Specifically, the present disclosure may provide a base unit for an aerosol delivery device, and the base unit may include a first section configured to engage with the power unit and a second section configured to engage with the sleeve, the base unit including a cavity extending at least partially therethrough. The base unit according to the present disclosure may be further described with respect to one or more of the following characteristics, which may be combined in any number without limitation.

[0019] The first section of the base unit may have a first diameter, and the second section of the base unit may have a second diameter that is smaller than the first diameter.

[0020] The first section of the base unit may be defined by a wall and a skirt extending longitudinally from the wall.

[0021] The skirt of the first section of the base unit may include at least one aperture, which may be characterized as an air inlet.

[0022] The wall of the first section of the base unit may include a plurality of apertures which may be characterized as heater terminal openings in that terminals extending from the heater in the sleeve may pass therethrough.

[0023] The second section of the base unit may be defined by longitudinal walls extending from the walls of the first section of the base unit.

[0024] The cavity of the base unit may extend from a free end of the second section of the base unit completely therethrough and at least partially into the first section of the base unit a sufficient distance to provide an air passage from the air inlet on the skirt of the first section through at least a portion of the first section of the base unit and through the second section of the base unit.

[0025] The second section of the base unit may be sized and shaped to engage the flow tube in the sleeve.

[0026] The base unit may have a PCB housed therein.

[0027] The base unit may have one or more contacts configured for electrical connection to one or more of a battery terminal, a battery lead, and a heater terminal.

[0028] One or more of the contacts may be disposed on the PCB.

[0029] One or more of the contacts may be located on the skirt of the first section of the base unit.

[0030] The base unit may include one or more clips configured for attaching the base unit to the battery in the power unit.

[0031] The first section of the base unit may include a support plate disposed therein.

[0032] The support plate may be positioned between the air inlet and the distal end of the first section of the base unit.

[0033] The PCB may be attached to the support plate.

[0034] The backing sheet may provide a liquid impermeable barrier.

[0035] Further with respect to the foregoing, the present disclosure may also provide an aerosol delivery device comprising one or both of a power unit and a base unit as described above and throughout the present disclosure. In some embodiments, the aerosol delivery device may include: a first elongated shell configured to contain an aerosol-forming composition and having a mouth end and an opposing engagement end; and a second elongated shell having a proximal end configured to connect to the engagement end of the first elongated shell and having an opposing distal end, the second elongated shell being divided into two separate halves along its longitudinal axis. An aerosol delivery device according to the present disclosure may be further described with respect to one or more of the following characteristics, which may be combined in any number without limitation.

[0036] The two halves of the second elongated shell may be detachably joined together.

[0037] The two halves of the second elongated shell may be permanently joined together.

[0038] The two halves of the second elongated shell may be welded together.

[0039] The second elongated housing may contain at least one elongated battery disposed therein, the at least one elongated battery extending from a distal end of the second elongated housing toward a proximal end of the second elongated housing.

[0040] The aerosol delivery device may include a base unit configured for connection with the first elongated shell and the second elongated shell. The base unit may be defined detachably or in combination according to any embodiment described herein.

[0041] The base unit may include one or both of a printed circuit board (PCB) and a pressure sensor.

[0042] The base unit may include a first contact configured for electrical connection with a terminal of the at least one battery, and may include a second contact configured for electrical connection with an opposing terminal of the at least one battery.

[0043] The aerosol delivery device may include a battery lead comprising a protrusion configured for electrical connection with opposing terminals of at least one battery and comprising an arm extending from the protrusion along a length of the at least one battery for electrical connection with a second contact of the base unit.

[0044] The electrical connections in the aerosol delivery device may not be fused.

[0045] An elongated flow tube may be included that is at least partially disposed within the first elongated housing, the elongated flow tube including a central air flow passage therethrough.

[0046] The elongated flow tube may be configured for one or both of physical and electrical connection with the base unit.

[0047] The elongated flow tube may include a plurality of heater terminals configured for electrical connection with the base unit.

[0048] The aerosol delivery device may include a heater disposed within the first elongated housing.

[0049] The aerosol delivery device may comprise a reservoir housed within the first housing and configured for storing an aerosol-forming composition.

[0050] The aerosol delivery device may comprise a liquid transport element configured to transfer the aerosol-forming composition from the reservoir to the heater.

[0051] The aerosol delivery device may include a mouthpiece attached to the mouth end of the first elongated shell.

[0052] In some embodiments, an aerosol delivery device may include: a first elongated shell having a mouth end and an opposite engagement end, the first elongated shell accommodating: a reservoir for an aerosol-forming composition: a heater; a liquid transfer element configured to transfer the aerosol-forming composition between the reservoir and the heater; and a heater terminal. The aerosol delivery device may further include a second elongated shell having a proximal end configured to be connected to the engagement end of the first elongated shell and having an opposite distal end, the second elongated shell being divided into two separate halves along its longitudinal axis; at least one battery being housed in the second elongated shell; a base unit including: one or both of a printed circuit board (PCB) and a pressure sensor; a first contact configured to be electrically connected to a terminal of at least one battery; and a second contact configured to be electrically connected to an opposite terminal of at least one battery. The base unit may specifically be electrically connected to the heater terminal. The aerosol delivery device according to the present disclosure may be further described with respect to one or more of the following characteristics, which may be combined in any number without limitation.

[0053] The aerosol delivery device may include a battery lead comprising a protrusion configured for electrical connection with opposing terminals of at least one battery and comprising an arm extending from the protrusion along a length of the at least one battery for electrical connection with a second contact of the base unit.

[0054] The aerosol delivery device may include an elongated flow tube at least partially disposed within the first elongated housing, the elongated flow tube including a central airflow channel therethrough.

[0055] The heater terminal can pass through the flow tube. Specifically, the heater terminal can pass through the flange portion of the flow tube.

[0056] The flow tube may be attached to the base unit.

[0057] The engagement end of the first elongated shell may be connected to at least a portion of the base unit.

[0058] The proximal end of the second elongated shell may be connected to at least a portion of the base unit.

[0059] In some embodiments, the present disclosure may further provide a method for forming an aerosol delivery device. As described herein, the method may be characterized by the ability to easily combine many elements of an aerosol delivery device and simply disassemble the device for recycling one or more components thereof. In some embodiments, the method for forming an aerosol delivery device may include: providing a first longitudinal half shell configured to be attached to a second longitudinal half shell to form an elongated clamshell, the elongated clamshell being divided into a first half and a second half along its longitudinal axis; placing battery leads and at least one battery into the first longitudinal half shell such that a protrusion of the battery lead is electrically connected to a first terminal of the at least one battery and such that an arm of the battery lead extends from the protrusion along the length of the at least one battery; providing a base unit, the base unit including one or both of a printed circuit board (PCB) and a pressure sensor, and further including a base unit configured to communicate with at least one The invention relates to a method of forming an aerosol delivery device according to the present disclosure, wherein the first contact of the base unit is electrically connected to the second terminal of the at least one battery and the second contact of the base unit is electrically connected to the arm of the battery lead; providing a sleeve including a shell, the shell containing: a reservoir for an aerosol-forming composition; a heater; a liquid transfer element configured to transfer the aerosol-forming composition between the reservoir and the heater; and a heater terminal; combining the sleeve, the base unit and the first longitudinal half shell so that the heater terminal is electrically connected to the base unit, the first contact of the base unit is electrically connected to the second terminal of the at least one battery, and the second contact of the base unit is electrically connected to the arm of the battery lead; and mating the second longitudinal half shell to the first longitudinal half shell. The method of forming an aerosol delivery device according to the present disclosure may be further described with respect to one or more of the following characteristics, which may be combined in any number without limitation.

[0060] The method may include first adding a base unit to the first longitudinal half-shell, and subsequently attaching the sleeve to the base unit.

[0061] The method may include first attaching the sleeve to the base unit, and subsequently adding the base unit to the first longitudinal half-shell.

[0062] The method may include one or more of crimping, welding (eg, laser welding or ultrasonic welding), and gluing the clamshell to one or both of the base unit and the sleeve shell.

[0063] The method may include adding a label to the aerosol delivery device. For example, a suitably sized sheet of paper or similar material commonly used to form wrappers or labels may be placed around the aerosol delivery device. The label may completely or partially surround the aerosol delivery device along a circumference. The label may completely or partially cover the junction (or connection point) between the base unit and the sleeve, and may extend substantially from the distal end of the base unit to the mouthpiece on the sleeve. The label may be adhered to one or both of the base unit and the sleeve. The presence of the label and its attachment to the base unit and the sleeve can be used to secure the sleeve to the base unit. The presence of the label may replace or supplement one or more additional methods described herein for attaching the base unit and the sleeve.

[0064] The present invention includes (but is not limited to) the following embodiments.

[0065] Embodiment 1: An aerosol delivery device comprises: a first slender shell configured to contain an aerosol-forming composition and having a mouth end and a relative joining end; and a second slender shell having a proximal end configured to be connected to the joining end of the first slender shell and having a relative distal end, the second slender shell being divided into two separate halves along its longitudinal axis.

[0066] Embodiment 2: The aerosol delivery device of any subsequent or preceding embodiment, wherein the two halves of the second elongated housing are detachably joined together.

[0067] Embodiment 3: The aerosol delivery device of any subsequent or preceding embodiment, wherein the two halves of the second elongated housing are permanently joined together.

[0068] Embodiment 4: The aerosol delivery device of any subsequent or preceding embodiment, wherein the two halves of the second elongated housing are welded together.

[0069] Embodiment 5: The aerosol delivery device of any subsequent or preceding embodiment, wherein the second elongated housing comprises at least one elongated battery disposed therein, the at least one elongated battery extending from a distal end of the second elongated housing toward a proximal end of the second elongated housing.

[0070] Embodiment 6: The aerosol delivery device of any subsequent or preceding embodiment, wherein the aerosol delivery device comprises a base unit configured for connection with the first elongated shell and the second elongated shell.

[0071] Embodiment 7: The aerosol delivery device of any subsequent or preceding embodiment, wherein the base unit comprises one or both of a printed circuit board (PCB) and a pressure sensor.

[0072] Embodiment 8: An aerosol delivery device according to any subsequent or preceding embodiment, wherein the base unit includes a first contact configured for electrical connection with a terminal of at least one battery and includes a second contact configured for electrical connection with an opposite terminal of at least one battery.

[0073] Embodiment 9: An aerosol delivery device according to any subsequent or preceding embodiment, wherein the aerosol delivery device includes a battery lead, wherein the battery lead includes a protrusion configured for electrical connection to the relative terminals of at least one battery and includes an arm extending from the protrusion along the length of at least one battery for electrical connection to a second contact of the base unit.

[0074] Embodiment 10: The aerosol delivery device of any subsequent or preceding embodiment, wherein the electrical connection is not fused.

[0075] Embodiment 11: The aerosol delivery device of any subsequent or preceding embodiment, wherein the aerosol delivery device comprises an elongated flow tube at least partially disposed within the first elongated housing, the elongated flow tube comprising a central airflow channel therethrough.

[0076] Embodiment 12: The aerosol delivery device of any subsequent or preceding embodiment, wherein the elongated flow tube is configured for one or both of physical and electrical connection with the base unit.

[0077] Embodiment 13: The aerosol delivery device of any subsequent or preceding embodiment, wherein the elongated flow tube comprises a plurality of heater terminals configured for electrical connection with the base unit.

[0078] Embodiment 14: The aerosol delivery device of any subsequent or preceding embodiment, wherein the aerosol delivery device comprises a heater disposed within the first elongated housing.

[0079] Embodiment 15: The aerosol delivery device of any subsequent or preceding embodiment, wherein the aerosol delivery device comprises a reservoir disposed within the first housing and configured for storing an aerosol-forming composition.

[0080] Embodiment 16: The aerosol delivery device of any subsequent or preceding embodiment, wherein the aerosol delivery device comprises a liquid transport element configured to transfer the aerosol-forming composition from the reservoir to the heater.

[0081] Embodiment 17: The aerosol delivery device of any subsequent or preceding embodiment, wherein the aerosol delivery device comprises a mouthpiece attached to the mouth end of the first elongated shell.

[0082] Embodiment 18: An aerosol delivery device, comprising: a first elongated shell having a mouth end and a relative engagement end, the first elongated shell accommodating: a reservoir for an aerosol-forming composition; a heater; a liquid transfer element configured to transfer the aerosol-forming composition between the reservoir and the heater; and a heater terminal; a second elongated shell having a proximal end configured to be connected to the engagement end of the first elongated shell and having a relative distal end, the second elongated shell being divided into two separate halves along its longitudinal axis; at least one battery housed in the second elongated shell; a base unit, the base unit comprising one or both of a printed circuit board (PCB) and a pressure sensor, and further comprising a first contact configured to be electrically connected to a terminal of at least one battery and a second contact configured to be electrically connected to an opposite terminal of at least one battery, the base unit being electrically connected to the heater terminal.

[0083] Embodiment 19: An aerosol delivery device according to any subsequent or preceding embodiment, wherein the aerosol delivery device includes a battery lead, wherein the battery lead includes a protrusion configured for electrical connection to relative terminals of at least one battery and includes an arm extending from the protrusion along the length of at least one battery for electrical connection to a second contact of the base unit.

[0084] Embodiment 20: The aerosol delivery device of any subsequent or preceding embodiment, further comprising an elongated flow tube at least partially disposed within the first elongated housing, the elongated flow tube comprising a central airflow channel therethrough.

[0085] Embodiment 21: An aerosol delivery device according to any subsequent or preceding embodiment, wherein the heater terminal passes through the flow tube.

[0086] Embodiment 22: An aerosol delivery device according to any subsequent or preceding embodiment, wherein the flow tube is attached to the base unit.

[0087] Embodiment 23: The aerosol delivery device of any subsequent or preceding embodiment, wherein the engagement end of the first elongated housing is connected to at least a portion of the base unit.

[0088] Embodiment 24: The aerosol delivery device of any subsequent or preceding embodiment, wherein the proximal end of the second elongated housing is connected to at least a portion of the base unit.

[0089] Embodiment 25: A method for forming an aerosol delivery device, comprising: providing a first longitudinal half shell configured to be attached to a second longitudinal half shell to form an elongated clamshell, the elongated clamshell being divided into a first half and a second half along its longitudinal axis; placing a battery lead and at least one battery into the first longitudinal half shell such that a protrusion of the battery lead is electrically connected to a first terminal of the at least one battery and such that an arm of the battery lead extends from the protrusion along the length of the at least one battery; providing a base unit, the base unit comprising one or both of a printed circuit board (PCB) and a pressure sensor, and further comprising a base unit configured to communicate with at least one A first contact electrically connected to a second terminal of at least one battery and a second contact configured to be electrically connected to an arm of a battery lead; providing a sleeve comprising a shell, the shell accommodating: a reservoir for an aerosol-forming composition; a heater; a liquid transfer element configured to transfer the aerosol-forming composition between the reservoir and the heater; and a heater terminal; combining the sleeve, the base unit and the first longitudinal half shell so that the heater terminal is electrically connected to the base unit, the first contact of the base unit is electrically connected to the second terminal of at least one battery, and the second contact of the base unit is electrically connected to the arm of the battery lead; and mating the second longitudinal half shell to the first longitudinal half shell.

[0090] Embodiment 26: The method of any subsequent or preceding embodiment, comprising first adding a base unit to the first longitudinal half-shell, and subsequently attaching the sleeve to the base unit.

[0091] Embodiment 27: The method of any subsequent or preceding embodiment, comprising first attaching the sleeve to the base unit, and subsequently adding the base unit to the first longitudinal half-shell.

[0092] Embodiment 28: The method of any subsequent or preceding embodiment, comprising one or more of crimping, welding, and gluing the clamshell to one or both of the base unit and the sleeve shell.

[0093] Embodiment 29: A power unit for an aerosol delivery device comprises an elongated housing having a proximal end and an opposite distal end, the elongated housing being divided into two separate halves along a longitudinal axis thereof.

[0094] Embodiment 30: The power unit of any subsequent or preceding embodiment, wherein the two halves of the elongated housing are detachably joined together. .

[0095] Embodiment 31 The power unit of any subsequent or preceding embodiment, wherein the two halves of the elongated housing are permanently joined together.

[0096] Embodiment 32: The power unit of any subsequent or preceding embodiment, wherein the two halves of the elongated housing are welded together.

[0097] Embodiment 33: The power unit of any subsequent or preceding embodiment, comprising at least one elongated battery housed within the elongated housing, the at least one elongated battery extending from a distal end of the elongated housing toward a proximal end of the elongated housing.

[0098] Embodiment 34: The power unit of any subsequent or preceding embodiment, comprising a battery lead comprising a protrusion configured for electrical connection to a terminal of at least one battery and comprising an arm extending from the protrusion along a length of the at least one battery.

[0099] Embodiment 35: The power unit of any subsequent or preceding embodiment, comprising a base unit attached at the proximal end of the elongated housing.

[0100] Embodiment 36: The power unit of any subsequent or preceding embodiment, wherein the base unit includes one or both of a printed circuit board (PCB) and a pressure sensor.

[0101] Embodiment 37: The power unit of any subsequent or preceding embodiment, wherein the base unit comprises a first contact configured for electrical connection with a terminal of at least one battery, and comprises a second contact configured for electrical connection with an opposing terminal of at least one battery.

[0102] Embodiment 38: A power unit according to any subsequent or preceding embodiment, wherein the battery lead protrusion is configured for electrical connection to a negative terminal of at least one battery, and the battery lead arm is configured for electrical connection to one of the first contact and the second contact of the base unit.

[0103] Embodiment 39: The power unit of any subsequent or preceding embodiment, wherein the electrical connection is not fused.

[0104] These and other features, aspects and advantages of the present disclosure will be understood by reading the following detailed description together with the accompanying drawings briefly described below. The present invention includes any combination of two, three, four or more of the above-noted embodiments and any combination of two, three, four or more features or elements set forth in the present disclosure, regardless of whether such features or elements are explicitly combined in the specific embodiments described herein. The present disclosure is intended to be read as a whole so that any separable features or elements of the present invention disclosed in any of its various aspects and embodiments should be considered to be combinable, unless the context clearly specifies otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

[0105] Having thus generally described the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0106] Figure 1 is a partial cross-sectional view of an aerosol delivery device comprising a cartridge and a control body including a plurality of elements that may be utilized in an aerosol delivery device according to various embodiments of the present disclosure.

[0107] Figure 2 is a cross section of a power unit according to an exemplary embodiment of the present disclosure illustrating the relationship of the battery and battery leads resulting in two halves of a clam shell, wherein the combination requires halves of the shell;

[0108] Figure 3 is a cross-section of a power unit according to an exemplary embodiment of the present disclosure illustrating the relationship of the battery and battery leads resulting in two halves of a clamshell, wherein the clamshell is in an open configuration;

[0109] Figure 4 is an exploded view of a power unit according to an exemplary embodiment of the present disclosure, wherein the power unit includes an associated base unit according to an exemplary embodiment of the present disclosure;

[0110] Figure 5a is a plan view of a distal end portion of a base unit according to an exemplary embodiment of the present disclosure;

[0111] Figure 5b is a plan view of a proximal end of a base unit according to an exemplary embodiment of the present disclosure;

[0112] Figure 6 is an exploded view of a sleeve suitable for combination with a power unit and / or a base unit according to an exemplary embodiment of the present disclosure;

[0113] Figure 7a is an exploded view of a portion of a flow tube, a base unit, and an insulator cover according to an exemplary embodiment of the present disclosure, illustrating the functional relationship therebetween;

[0114] Figure 7b is a cross-section of a portion of a flow tube, a base unit, and an insulator cover according to an exemplary embodiment of the present disclosure, illustrating their substantially permanent engagement;

[0115] Figure 8a is an exploded view of a portion of a flow tube, a base unit, and an intermediate housing according to an exemplary embodiment of the present disclosure, illustrating the functional relationship therebetween; and

[0116] Figure 8b is a cross-section of a portion of a flow tube, a base unit, and an intermediate housing illustrating their removable engagement according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0117] The present disclosure will now be more fully described below with reference to exemplary embodiments of the present disclosure. These exemplary embodiments are described so that the present disclosure will be thorough and complete, and these embodiments will fully convey the scope of the present disclosure to those skilled in the art. In fact, the present disclosure can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein; in fact, these embodiments are provided so that the present disclosure will satisfy applicable statutory requirements. Unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" as used in this specification and the appended claims include multiple referents.

[0118] As described below, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat materials (preferably without burning the materials to any significant degree and / or without significant chemical changes in the materials) to form inhalable substances; and the components of such systems have the form of articles that are most preferably compact enough to be considered as handheld devices. That is, the use of the components of the preferred aerosol delivery systems does not result in the production of smoke - that is, from byproduct combustion or tobacco pyrolysis, but in fact, the use of those preferred systems results in the production of vapors caused by the volatilization or gasification of certain components incorporated therein. In preferred embodiments, the components of the aerosol delivery system can be characterized as electronic cigarettes, and those electronic cigarettes most preferably incorporate tobacco and / or components derived from tobacco, and thus deliver tobacco-derived components in aerosol form.

[0119] The aerosol generating conditions of certain preferred aerosol delivery systems can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, taste or flavor type, sensory effects, physical sensations, usage habits, visual cues (such as those provided by visible aerosols), etc.) without requiring any significant degree of combustion of any of its components. For example, a user of the aerosol-generating member of the present disclosure can hold and use the member similar to a smoker using a conventional type of smoking article, drawing on one end of the member for inhaling the aerosol generated by the member, taking or puffing puffs at selected time intervals, etc.

[0120] Aerosol delivery devices of the present disclosure may also be characterized as steam-generating articles or drug delivery articles. Therefore, such articles or devices may be adapted to provide one or more substances (e.g., flavoring agents and / or pharmaceutically active ingredients) in an inhalable form or state. For example, inhalable substances may be substantially in the form of steam (i.e., substances in a gas phase at a temperature below its critical point). Alternatively, inhalable substances may be in the form of aerosols (i.e., suspensions of fine solid particles or droplets in a gas). For simplicity, the term "aerosol" as used herein means including steam, gas, and aerosol forms or types suitable for human inhalation, whether visible or not and whether or not it may be considered to be a smoke-like form.

[0121] The aerosol delivery system of the present disclosure generally includes several components provided within an outer body or shell (which may be referred to as an outer shell). The overall design of the outer body or shell may vary, and the format or configuration of the outer body that may define the overall size and shape of the aerosol delivery device may vary. Typically, an elongated body having a shape similar to that of a cigarette or cigar may be formed by a single integral outer shell; or the elongated outer shell may be composed of two or more separable bodies. For example, an aerosol delivery device may include an elongated shell or body that may be substantially tubular in shape and thus resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are contained within one outer shell. Alternatively, the aerosol delivery device may include two or more joined and separable outer shells. For example, an aerosol delivery device may have a control body at one end including a housing containing one or more base segments and / or control components (e.g., a battery and various electronic devices for controlling the operation of the article), and an outer body or shell at the other end and removably attached thereto containing aerosol-forming components (e.g., a heater and a reservoir for storing an aerosol precursor composition).

[0122] The aerosol delivery system of the present disclosure most preferably comprises some combination of a power source (i.e., a source of electrical power), at least one control component (e.g., a device for activating, controlling, regulating, and stopping the power used to generate heat, such as by controlling the current flowing from the power source to other components of the article - such as a microcontroller or microprocessor), a heater or heat-generating member (e.g., a resistive heating element or other component, which alone or in combination with one or more additional elements that may generally be referred to as an "atomizer"), an aerosol precursor composition (e.g., typically a liquid capable of generating an aerosol when sufficient heat is applied, such as ingredients commonly referred to as "cigarette juice," "e-liquid," and "e-juice"), and a mouth end region or tip for allowing suction on an aerosol delivery device for aerosol inhalation (e.g., a defined airflow path through the article so that the generated aerosol can be drawn out of it when suction is applied).

[0123] In view of the further disclosure provided below, more specific formats, configurations, and arrangements of components within the aerosol delivery system of the present disclosure will be understood. In addition, the selection and arrangement of various aerosol delivery system components can be understood after considering commercially available electronic aerosol delivery devices such as those representative products mentioned in the background section of the present disclosure.

[0124] In various embodiments, the aerosol delivery device may include a reservoir configured to retain an aerosol precursor composition (which may also be referred to as an aerosol-forming composition). The reservoir may be formed of a porous material (e.g., a fibrous material) and may therefore be referred to as a porous substrate (e.g., a fibrous substrate).

[0125] The fiber substrate used as a reservoir in an aerosol delivery device can be a woven or nonwoven material formed of a plurality of fibers or filaments and can be formed of one or both of natural fibers and synthetic fibers. For example, the fiber substrate can include a continuous glass fiber material or polyethylene terephthalate. In certain embodiments, cellulose acetate materials can be used. In other exemplary embodiments, carbon materials can be used. The reservoir can be substantially in the form of a container and can include a fiber material included therein.

[0126] exist Figure 1 An example embodiment of an aerosol delivery device 100 according to the present disclosure is provided in the . As seen in the cross-sectional view illustrated therein, the aerosol delivery device 100 may include a control body 102 and a sleeve 104 that may be permanently or removably aligned in a functional relationship. The engagement of the control body 102 and the sleeve 104 may be a snap fit (as illustrated), a thread, an interference fit, a magnetic fit, etc. Specifically, a connection assembly as further described herein may be used. For example, the control body may include a coupling adapted to engage a connector on a sleeve.

[0127] In a specific embodiment, one or both of the control body 102 and the sleeve 104 may be referred to as disposable or reusable. For example, the control body may have a replaceable battery or a rechargeable battery, and thus may be combined with any type of recharging technology, including connection to a typical socket, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer, such as through a universal serial bus (USB) cable. For example, an adapter including a USB connector at one end and a control body connector at an opposite end is disclosed in U.S. Patent Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety. In addition, in some embodiments, the sleeve may include a single-use sleeve, such as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0128] As in Figure 1 As described in , the control body 102 may be formed by a control body housing 101 that may include a control component 106 (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller, etc.), a flow sensor 108, a battery 110, and an LED 112, and such components may be variably aligned. In addition to or as an alternative to the LED, additional indicators (e.g., tactile feedback components, audio feedback components, etc.) may be included. Additional representative types of components that produce visual cues or indicators (such as light emitting diode (LED) components) and their configurations and uses are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al.; 8,499,766 to Newton and 8,539,959 to Scatterday; and U.S. Patent Application Serial No. 14 / 173,266 to Sears et al., filed on February 5, 2014; the patents are incorporated herein by reference.

[0129] The sleeve 104 can be comprised of a sleeve shell 103 surrounding a reservoir 144, the reservoir 144 being in fluid communication with a liquid transport element 136 adapted to wick or otherwise transport an aerosol precursor composition stored in the reservoir housing to the heater 134. Various embodiments of materials configured to generate heat when an electric current is applied therethrough can be used to form the resistive heating element 134. Example materials from which the coil can be formed include Kanthal (FeCrAl), Nichrome, Molybdenum Disilicide (MoSi2), Molybdenum Silicide (MoSi), Molybdenum Disilicide doped with aluminum (Mo(Si,Al)2), graphite and graphite-based materials (e.g., carbon-based foams and yarns), and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0130] An opening 128 may be present in the cartridge housing 103 (eg, at the mouth end) to allow the formed aerosol to be released from the cartridge 104. Such components are representative of components that may be present in a cartridge and are not intended to limit the scope of cartridge components encompassed by the present disclosure.

[0131] The sleeve 104 may also include one or more electronic components 150, which may include integrated circuits, memory components, sensors, etc. The electronic components 150 may be adapted to communicate with the control component 106 and / or external devices by wired or wireless means. The electronic components 150 may be placed anywhere within the sleeve 104 or its base 140.

[0132] Although the control assembly 106 and the flow sensor 108 are described separately, it should be understood that the control assembly and the flow sensor can be combined into an electronic circuit board with the airflow sensor directly attached thereto. Figure 1 In some embodiments, the airflow sensor may include its own circuit board or other base element that can be attached thereto. In some embodiments, a flexible circuit board may be utilized. The flexible circuit board may be configured in a variety of shapes, including a substantially tubular shape.

[0133] The control body 102 and the sleeve 104 may include components adapted to facilitate fluid engagement therebetween. Figure 1 As described in , the control body 102 may include a coupler 124 having a cavity 125 therein. The sleeve 104 may include a base 140 adapted to engage the coupler 124 and may include a protrusion 141 adapted to fit within the cavity 125. Such engagement may facilitate a stable connection between the control body 102 and the sleeve 104, and an electrical connection between the battery 110 and the control assembly 106 in the control body and the heater 134 in the sleeve. In addition, the control body housing 101 may include an air inlet 118, which may be a recess in the housing where it is connected to the coupler 124, the recess allowing ambient air around the coupler to pass through and into the housing where it then passes through the cavity 125 of the coupler, and into the sleeve through the protrusion 141.

[0134] Couplings and bases suitable for use according to 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 in its entirety. Figure 1 The coupling member seen can define an outer periphery 126 configured to match the inner periphery 142 of the base 140. In one embodiment, the inner periphery of the base can define a radius substantially equal to or slightly greater than the outer periphery radius of the coupling member. In addition, the coupling member 124 can define one or more protrusions 129 at the outer periphery 126, and the protrusions 129 are configured to engage with one or more grooves 178 defined at the inner periphery of the base. Such protrusions and grooves can interact with each other to act as an anti-rotation mechanism, so that the control body 102 and the sleeve 104 remain aligned. However, various other embodiments of structure, shape and assembly can be adopted to couple the base to the coupling member. In some embodiments, the connection between the base 140 of the sleeve 104 and the coupling member 124 of the control body 102 can be substantially permanent, and in other embodiments, the connection therebetween can be releasable, so that, for example, the control body can be reused with one or more additional sleeves that can be disposable and / or refillable.

[0135] In some embodiments, the aerosol delivery device 100 can be substantially rod-shaped or substantially tubular or substantially cylindrical. In other embodiments, additional shapes and sizes are contemplated - for example, rectangular or triangular cross-sections, multi-faceted shapes, etc.

[0136] exist Figure 1 The reservoir 144 illustrated in the figure may be a container or may be a fiber reservoir as currently described. For example, in this embodiment, the reservoir 144 may include one or more layers of non-woven fibers that are substantially formed into a tubular shape surrounding the interior of the sleeve shell 103. The aerosol precursor composition may be retained in the reservoir 144. The liquid component may be retained by the reservoir 144, for example, by adsorption. The reservoir 144 may be fluidly connected to the liquid transport element 136. The liquid transport element 136 may transport the aerosol precursor composition stored in the reservoir 144 to the heating element 134 (which is in the form of a metal coil in this embodiment) via capillary action. Thus, the heating element 134 is in a heating arrangement with the liquid transport element 136.

[0137] In use, when the user draws on the article 100, the airflow is detected by the sensor 108, the heating element 134 is activated, and the components for the aerosol precursor composition are vaporized by the heating element 134. Drawing on the mouth end of the article 100 causes ambient air to enter the air inlet 118 and pass through the central opening in the cavity 125 in the coupling 124 and the protrusion 141 of the base 140. In the sleeve 104, the drawn air combines with the formed vapor to form an aerosol. The aerosol is stirred, drawn or otherwise drawn away from the heating element 134 and exits the mouth opening 128 in the mouth end of the article 100.

[0138] An input element may be included in an aerosol delivery device. An input may be included to allow a user to control the functionality of the device and / or for outputting information to the user. Any component or combination of components may be utilized as an input for controlling the functionality of the device. For example, one or more buttons may be used as described in U.S. patent application serial number 14 / 193,961 filed by Worm et al. on February 28, 2014, which is incorporated herein by reference. Similarly, a touch screen may be used as described in U.S. patent application serial number 14 / 643,626 filed by Sears et al. on March 10, 2015, which is incorporated herein by reference. As another example, a component adapted for designated movement gesture recognition based on an aerosol delivery device may be used as an input. See U.S. patent application serial number 14 / 565,137 filed by Henry et al. on December 9, 2014, which is incorporated herein by reference.

[0139] In some embodiments, the input may include a computer or computing device, such as a smart phone or tablet computer. Specifically, the aerosol delivery device may be wired to a computer or other device, such as via the use of a USB cable or similar protocol. The aerosol delivery device may also communicate with a computer or other device acting as an input via wireless communication. See, for example, a system and method for controlling a device via a read request, as described in U.S. Patent Application Serial No. 14 / 327,776 filed by Ampol ini et al. on July 10, 2014, the disclosure of which is incorporated herein by reference. In such embodiments, an APP or other computer program may be used to connect to a computer or other computing device to input a control instruction to an aerosol delivery device, such control instructions including, for example, the ability to form an aerosol of a specific composition by selecting a nicotine content and / or the content of an additional flavoring agent included.

[0140] The various components of an aerosol delivery device according to the present disclosure may be selected from those described in the art and commercially available.Examples of batteries that may be used according to the present invention are described in U.S. Patent Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference.

[0141] The aerosol delivery device may incorporate a sensor or detector for controlling the supply of electrical power to the heat-generating element when aerosol generation is desired (e.g., when puffing during use). Thus, for example, a means or method is provided for shutting off the supply of electrical power to the heat-generating element when the aerosol delivery device is not puffing during use, and for switching on power during puffing to actuate or trigger heat generation by the heat-generating 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. Pat. No. 5,261,424 to Sprinkel, Jr.; U.S. Pat. No. 5,372,148 to McCafferty et al.; and PCT WO 2010 / 003480 to Flick; which are incorporated herein by reference.

[0142] The aerosol delivery device preferably incorporates a control mechanism for controlling the amount of electrical power to the heat generating element during puffing. Representative types of electronic components, their structure and configuration, their features, and their general methods of operation are described in the following patents: U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan; U.S. Pat. No. 2009 / 0230117 to Fernando et al., U.S. Pat. No. 2014 / 0060554 to Collet et al., and Ampol U.S. Patent Publication No. 2014 / 0270727 to ini et al.; and U.S. Patent Application Serial No. 14 / 209,191 filed on March 13, 2014 to Henry et al.; the patents are incorporated herein by reference.

[0143] Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in the following patents: U.S. Patent No. 8,528,569 to Newton; U.S. Patent Publication No. 2014 / 0261487 to Chapman et al. and U.S. Patent Publication No. 2014 / 0059780 to Davis et al.; and U.S. Patent Application Serial No. 14 / 170,838 filed on February 3, 2014 by Bless et al.; the patents are incorporated herein by reference. In addition, various wicking materials within certain types of electronic cigarettes and the configuration and operation of those wicking materials are described in U.S. Patent No. 8,910,640 to Sears et al.; which is incorporated herein by reference.

[0144] For the aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition is most preferably incorporated into tobacco or a component derived from tobacco. On the one hand, tobacco can be provided as a part or fragment of tobacco, such as finely ground, milled or powdered tobacco thin layer. On the other hand, tobacco can be provided in the form of an extract, such as a spray-dried extract of many water-soluble components of tobacco incorporated therein. Alternatively, the tobacco extract can have the form of a relatively high nicotine content extract, which also incorporates a small amount of other extracted components derived from tobacco. On the other hand, the component derived from tobacco can be provided in a relatively pure form, such as some flavorings derived from tobacco. On the one hand, the component derived from tobacco and that can be used in a highly purified or substantially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[0145] Aerosol precursor compositions (also referred to as vapor precursor compositions) may include a variety of components including, as examples, polyols (e.g., glycerol, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorings. Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Patent No. 7,217,320 to Robinson et al. and 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 / 0020823 to Lipowicz et al.; and U.S. Patent Publication No. 2015 / 0020830 to Koller and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those incorporated into RJ Reynolds Vapor Company. products, Lorillard Technologies' BLU TM Aerosol precursors in the products of ANTIQUE®, MISTIC MENTHOL products of Mistic Ecigs, and VYPE products of CNCreative, Inc. So-called "tobacco juices" for electronic cigarettes available from Johnson Creek Enterprises LLC are also desirable.

[0146] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating member provides an acceptable feel and desired performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material (e.g., glycerol and / or propylene glycol) is employed to provide the generation of a visible mainstream aerosol that is similar in appearance to tobacco smoke in many respects. The amount of aerosol precursor in the aerosol generating system may depend on factors such as the number of puffs required per aerosol generating member. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system and, in particular, the aerosol generating member is less than about 2 g, generally less than about 1.5 g, typically less than about 1 g and often less than about 0.5 g.

[0147] Still other features, controls, or components that may be incorporated into the aerosol delivery systems of the present disclosure are described in the following patents: U.S. Pat. No. 5,967,148 to Harris et al.; U.S. Pat. No. 5,934,289 to Watkins et al.; U.S. Pat. No. 5,954,979 to Counts et al.; U.S. Pat. No. 6,040,560 to Fleischhauer et al.; U.S. Pat. No. 8,365,742 to Hon; U.S. Pat. No. 8,402,976 to Fernando et al.; U.S. Pat. No. 4,636,976 to Fernando et al. No. 2010 / 0163063; 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 Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Publication No. 2014 / 0261495 to Novak et al. and U.S. Patent Publication No. 2014 / 0261408 to DePiano et al.; the patents are incorporated herein by reference.

[0148] The foregoing descriptions of uses of the articles of manufacture may be applied to the various embodiments described herein with minor modifications, which may be apparent to those skilled in the art based on the other disclosures provided herein. However, the above descriptions of uses are not intended to limit the uses of the articles of manufacture, but are provided to meet all necessary requirements of the disclosures of the present disclosure. Figure 1 Any of the elements shown in the articles illustrated in or otherwise described above may be included in an aerosol delivery device according to the present disclosure.

[0149] In some embodiments, the present disclosure may be directed to a power unit suitable for use in an aerosol delivery device. The power unit may include an elongated housing, and the housing may be substantially tubular so as to define a cavity within the housing. The housing may have a proximal end and an opposite distal end.

[0150] The elongated shell may be characterized specifically with respect to its separable nature. More specifically, the shell may be divided into two separate halves along its longitudinal axis. In other words, the shell may be a cross-section that passes substantially through an axis extending from the proximal end to the distal end. Although the separable portions of the shells throughout the present disclosure may be referred to as "halves," it should be understood that such references are not intended to limit the relative sizes of the separable portions. In some embodiments, the separable halves (or separable portions) of the shell may be substantially equidistant about the distance around the outer (or inner) surface of the shell. For example, Figure 2An embodiment is described in which the halves are substantially equal in size so that each separable half (or separable portion) of the shell can form approximately 50% of the circumference of the shell. As seen therein, the shell 201 is separated substantially through the middle of its cross-section to form a first half (portion) 2201a and a second half (portion) 2201b, each of which is approximately 50% of the circumference of the shell when the halves are combined. Also seen in the cross-section are the battery 210 and the battery leads 233, as further described below. While it may be applicable to two halves that are substantially equal in size, other embodiments are contemplated in which the shell 201 is separated through it at a point other than the middle of the cross-section. The relative sizes may be such that either half (portion) of the shell may be a larger portion.

[0151] In some embodiments, the configuration in which the shell is divided into separable parts may be referred to as a clamshell structure. Thus, the two separate halves of the shell may be hinged together substantially along at least a portion of the length of the shell. Figure 3 , for example, shell 301 may be formed of a first half 301a hingedly attached to a second half 301b via a connecting member 315. Connecting member 315 may be formed of the same material as shell 301 and may be a thinned or scored portion of the shell. In other embodiments, the two separate halves of the shell may be completely detached from each other, but are configured to be attached to each other to form a complete power unit. In some embodiments, the seam formed by connecting the two halves may be sealed, such as by using a seal or by processing the shell (e.g., welding at the seam). Also seen in cross section are battery 310 and battery leads 333, as further described below.

[0152] In some embodiments, two halves of an elongated housing for forming a power unit may be detachably joined together. Thus, the halves may be configured for repeated attachment and detachment without any anticipated damage to the housing. For example, the two halves may include elements adapted to form a snap fit between the halves.

[0153] In other embodiments, the two halves of the elongated shell may be substantially permanently joined together. By this is meant that the two halves of the shell (integrally combined to form a complete shell) may not be physically separated by a non-destructive action. For example, the two halves of the shell may be welded together, glued together, etc.

[0154] The structure of the shell (i.e., provided in separate halves) may facilitate easy assembly of the complete power unit. In conventional aerosol-forming articles utilizing a substantially tubular shell, the shell is preformed in its complete state, and the internal components (e.g., battery, electronics, electrical connections, etc.) are inserted into the complete shell from either end of the shell. Thus, the internal components must be substantially fully connected prior to insertion. In other words, wires and the like used to form electrical connections between the battery and PCB, sensor and / or connector elements must be soldered to corresponding elements prior to inserting the elements into the shell.

[0155] The power unit according to the present disclosure can therefore solve the problem of easy manufacturing of the power unit, including easy automation of the manufacture of the power unit. As will be further described below, a half (or portion) of the shell can be provided, and the various internal components of the power unit can be laid into the partial shell. In some embodiments, this can eliminate the need for welding of components, as described in other ways herein. Once the desired components are laid into the partial shell, the rest of the shell can be attached to form a complete shell, in which the power unit components are installed.

[0156] In a similar manner, the present construction may also facilitate easy recycling of the various elements of the power unit. In conventional power units for aerosol-forming devices, the entire unit must be discarded as a single piece after use of the device. While it is desirable to recycle the various elements of the power unit individually, the nature of the construction of conventional devices (e.g., all elements are welded together and inserted from the end into a non-separable housing) may prevent such recycling or significantly increase the difficulty of recycling.

[0157] However, the power unit used in accordance with the present disclosure can be easily deconstructed by simply separating the two halves of the shell. Although such separation may require cutting at least a portion of the shell to free the two halves from each other, once one of the halves is removed, the individual elements within the shell can be easily removed for recycling, particularly in embodiments as described herein, where the elements can be combined without the need for fusing (e.g., welding).

[0158] Shells according to the present disclosure can be formed from a variety of materials. In some embodiments, plastic materials such as high-density polyethylene terephthalate (HDPE), polypropylene, polycarbonate, etc. can be used. In other embodiments, metal materials such as aluminum or steel can be used. In specific embodiments, the shell can be substantially a plastic clamshell.

[0159] Many of the elements included in the power unit as described herein may be present in previously known power units. However, as will be seen below, in view of the ease of manufacturing the device of the present invention, the various elements may be provided in different forms.

[0160] In some embodiments, the power unit may include at least one elongated battery housed within the elongated shell. The at least one battery may extend from the distal end of the second elongated shell toward the proximal end of the elongated shell. In other words, the at least one battery may be housed closer to the distal end of the shell than the proximal end of the shell (specifically adjacent to the distal end). In certain embodiments, a single battery may be used or two batteries may be used. The total number of batteries utilized may depend on the rated capacity of the batteries used (e.g., the rated voltage of the batteries).

[0161] This type of configuration Figure 4 4, wherein the power unit 401 is formed by a first shell half 4201a and a second shell half 4201b, which when combined to form the complete shell 4201 surround a battery 410 and a battery lead 433. The battery 410 includes a positive terminal 410a and a negative terminal 410b. In an embodiment where, for example, two batteries can be utilized, the batteries can be aligned in electrical series such that the negative terminal of the first battery is substantially adjacent to the distal end 4301b of the power unit shell 4201, and the positive terminal of the second battery is substantially adjacent to the proximal end 4301a of the power unit shell 4201.

[0162] The power unit 401 further includes a battery lead 433 configured to form electrical connections to various components of the aerosol delivery device of the battery 410. As illustrated, the battery lead 433 includes a protrusion 433b configured to be electrically connected to a terminal of the battery 410. In the illustrated embodiment, the protrusion 433b is configured to be electrically connected to the negative terminal 410b. The protrusion is illustrated as being substantially circular; however, other configurations are also contemplated. A biasing member 445 may be included to bias the protrusion 433b toward the terminal 410b of the battery 410. In the illustrated embodiment, the biasing member 445 is a spring; however, other embodiments are also contemplated. The biasing member 445 may be specifically configured to contact the end cap 411 of the power unit 401. The end cap 411 may be attached to one or both of the first shell half 4201a and the second shell half 4201b, such as by crimping, welding, gluing, etc., and the end cap may be made of any material, including metal and plastic. If desired, end cap 411 may be transparent or translucent and may, for example, allow external visibility of a light source that may be included in power unit 401. See, for example, Figure 1 112 in the clamshell. In such embodiments, the biasing member 445 can be attached to, for example, one or both of the first shell half 4201a and the second shell half 4201b. In some embodiments, the end cap 411 can be substantially captured between the clamshell halves 4201a and 4201b.

[0163] The battery lead 433 further includes an arm 433a extending from the protrusion 433b along the length of the battery 410. The arm 433a can be configured to provide an electrical connection to one or more additional elements of the power unit 401 or additional components of the aerosol delivery device. The battery lead 433 can be formed of any conductive material, particularly a metal such as copper. Advantageously, the battery lead 433 can be configured to form an electrical connection to the battery and one or more additional elements of the aerosol delivery device without the need for welding or other means for fusing the electrical connection.

[0164] In some embodiments, the power unit 401 may further include a base unit 424 attached at the proximal end 4301a of the shell 4201. As will be apparent from the additional disclosure provided herein, the base unit 424 may be an element of the complete power unit 401, may be an element of the complete sleeve (see Figure 1 104), or may be a separate element of an aerosol delivery device (see Figure 1 100 ), which can, for example, interconnect a power unit to the sleeve.

[0165] The base unit 424 may include a first base segment 424a having a first diameter and a second base segment 424b having a second diameter less than the first diameter. The first diameter may be substantially similar to the diameter of the shell 4201 of the power unit 401. Specifically, the first diameter of the first base segment 424a may be substantially equivalent to the inner diameter of the shell 4201, so that the shell can be attached to the first base segment. The first base segment 424a may include a first heater terminal opening 427a and a second heater terminal opening 427b provided for heater terminal access to pass through the base unit 424 for connecting to control and / or power components, as further discussed below. As illustrated, the first and second heater terminal openings are disposed in the wall 4424a defining the first segment of the base unit. The first base segment 424a may further include an air inlet 418 through which air can be drawn during use of the complete aerosol delivery device. As illustrated, the air inlet 418 is disposed in a skirt 4424a' extending longitudinally from the wall so as to further define the first segment 424a of the base unit 424. The wall 4424a and skirt 4424a' of the first section 424a of the base unit 424 may intersect at substantially right angles (although other angular arrangements are also contemplated). The base unit 424 may include a cavity 425 extending at least partially therethrough. For example, the cavity 425 may extend from the air inlet 418 through at least the open end of the second base segment 424b. As further described herein, the second base segment 424b may be connected to a portion of the sleeve such that air drawn through the air inlet 418 passes through the inlet, through the cavity 425, through the second base segment 424b, and into the sleeve for combination with the formed vapor. The second base segment 424b may be formed by a longitudinal wall 4424b extending from the wall 4424a of the first base segment 424a, and may be substantially parallel to the skirt 4424a' of the first base segment. The skirt may include an anti-rotation element (see Figure 1 ).

[0166] As previously mentioned, the aerosol delivery device may include one or both of the control assembly and the pressure sensor. In some embodiments, the base unit may include one or both of the control assembly and the pressure sensor. For example, the PCB may be mounted to (or otherwise combined with) the base unit. In some embodiments, the PCB may be at least partially within the base unit.

[0167] One embodiment of the base unit 524 is Figure 5a5524a of the base unit. The PCB 5106 is disposed at the distal end 5524a of the base unit 524 and may include circuitry necessary to provide control functions for the aerosol delivery device incorporated therein. The PCB 5106 may be specifically within the skirt 5424a' of the first base segment 524a. The PCB 5106 may include a sensor 5108. As illustrated, the sensor 5108 is disposed on the opposite side of the PCB 5106 so as to be close to the air inlet 418. In some embodiments, a support plate 537 may be present and may substantially or completely separate the PCB 5106 from the cavity 525 in the base unit 524. The support plate 537 may form a liquid-impermeable or airtight relationship with the base unit 524 so that liquid from the sleeve may not pass through it into the power unit, and / or so that air does not pass through or from the power unit before being drawn into the sleeve. The sensor 5108 may pass through the support plate 537 so as to be at least partially disposed within the cavity 525 of the base unit 524.

[0168] PCB 5106 may include a plurality of electrical contacts. Because PCB 5106 may be combined with base unit 524 in some embodiments, the base unit may be characterized as including a plurality of electrical contacts. Figure 5a In the example of , the PCB 5106 includes a first battery contact 5106c that can be configured to be electrically connected to the positive terminal 410a of the battery 410. The first battery contact 5106c can extend from the PCB 5106 a sufficient distance to bridge any open space between the base unit 524 and the battery 410. The PCB 5106 further includes a first heater contact 5106a and a second heater contact 5106b that are configured to be electrically connected to the first and second heater terminals, respectively, which can pass through the first heater terminal opening 527a and the second heater terminal opening 527b in the base unit 524.

[0169] The base unit 524 may additionally include a second battery contact 531 that may be mounted on the base unit so as to make contact with a corresponding contact on the PCB 5106. Alternatively, the second battery contact 531 may be mounted on the PCB 5106, which itself is attached to the base unit 524. Figure 5aAs illustrated in , the second battery contact 531 is connected to the first base section 524a of the base unit 524, and the PCB 5106 is electrically connected thereto. The second battery contact 531 may be configured to be electrically connected to the negative terminal 410b of the battery 410. The electrical connection between the second battery contact 531 and the negative terminal 410b of the battery 410 may be via the battery lead 433. The second battery contact 531 may be sized to ensure contact with the battery lead 433 through a variety of positions. In some embodiments, the second battery contact 531 may be shaped to receive a portion of the battery lead 433. For example, the second battery contact 531 may be substantially tubular, and the battery lead 433 may slide into the tubular portion of the second battery contact to maintain electrical connection. Alternatively, a clip may be used to interconnect the second battery contact 531 and the battery lead 433. Such a configuration may allow the electrical connection between the second battery contact 531 and the battery lead 433 to be unfused-that is, solder is not required to form or secure the connection.

[0170] The proximal end 5524b of the base unit 524 is Figure 5b As seen therein, cavity 525 extends through second base segment 524b such that support plate 537 is visible. Likewise, first heater contact 5106a and second heater contact 5106b are visible through first heater terminal opening 527a and second heater terminal opening 527b, respectively, in wall 5424a of first base segment 524a.

[0171] The power unit, alone or in combination with a base unit, may be utilized in forming an aerosol delivery device. Specifically, the power unit may be combined with a sleeve that includes an atomizer and is configured to receive and store an aerosol-forming composition. Even more specifically, the sleeve may be configured to attach to the proximal end of the base unit so that the power unit, base unit, and sleeve together form an aerosol delivery device. Sleeves that may be configured for use in combination with a power unit and / or base unit as described herein are described in U.S. Patent Application Serial No. 14 / 286,552 filed by Brinkley et al. on May 23, 2014, the disclosure of which is incorporated herein by reference.

[0172] An example embodiment of a sleeve 604 configured for use in combination with a power unit is shown in FIG. Figure 663. As shown therein, the sleeve 604 includes an elongated shell 603 having a reservoir 644 therein. The reservoir 644 may be, for example, a fiber mat (e.g., cellulose acetate), but other types of reservoirs (e.g., containers) are also contemplated. The liquid transport element 636 may be combined with the heater 634 to form an atomizer. In an exemplary embodiment, the liquid transport element 636 may specifically extend at least partially through the reservoir 644. The heater 634 may be placed near the midpoint of the liquid transport element 636. For example, the heater 634 may be a resistive heating wire wrapped around the liquid transport element 636. The heater-wound portion of the liquid transport element 636 may extend away from one end of the reservoir 644, specifically an end of the reservoir near the proximal end 603a of the sleeve shell 603. The mouthpiece 647 may be combined with the sleeve shell 603 at its proximal end 603a. The proximal end 603a of the sleeve shell 603 may be characterized as a mouth end, and the distal end 603b of the sleeve shell may be characterized as a coupling end of the shell. The coupling end of the sleeve shell and the proximal end 4301a may be configured for connection together.

[0173] The base unit 524 may be configured to be connected to the power unit housing 4201. The base unit 524 may be configured to be connected to the sleeve housing 603. The base unit 524 may be configured to be connected to both the power unit housing 4201 and the sleeve housing 603.

[0174] The sleeve 604 may further include an elongated flow tube 648 that may be configured to direct airflow through the sleeve. Specifically, the flow tube 648 may include a central airflow channel 648a extending therethrough. The flow tube 648 may further be configured to be physically connected to the base unit 524, electrically connected to the base unit, or both physically and electrically connected to the base unit.

[0175] In some embodiments, the proximal end 5524b of the second base segment 524b can be configured to engage the flow tube 648, such as by being at least partially inserted into the central airflow channel 648a. With such a physical connection, when suction is applied to the mouthpiece 647 of the sleeve 604, air can enter the air inlet 418 of the base unit 424, pass through the cavity 425, enter the central airflow channel 648a of the flow tube 648, traverse the heater 634 combined with the liquid transport element 636, and exit through the mouthpiece.

[0176] The flow tube 648 includes a first heater terminal 649a and a second heater terminal 649b, and such terminals may be specifically configured to establish an electrical connection between the cartridge and the base unit 524. For example, the ends of the heater terminals extending from the end of the flow tube 648 near the distal end 603b of the cartridge housing 603 may be configured to be inserted into the first heater terminal 527a and the second heater terminal 527b for electrical connection with the first heater contact 5106a and the second heater contact 5106b of the PCB 5106. Thus, the heater terminals may be configured to be electrically connected to the base unit 524. The heater terminals (527a, 527b) may be characterized as extending through the flow tube 648. In the illustrated embodiment, the heater terminals (527a, 527b) are integrated with the flow tube 648 and extend through the flange 675 of the flow tube.

[0177] The formation of the aerosol delivery device may include attaching a base unit to one of the power unit shell and the sleeve shell and subsequently attaching the other of the power unit shell and the sleeve shell to it. In some embodiments, the base unit may be attached to the flow tube of the sleeve, and this combination may be combined with the power unit before connecting the first and second halves of the power unit shell. In this way, the second battery contact on the base unit can be placed in electrical connection with the battery lead. The two halves of the power unit shell can then be interconnected. This type of connection can provide a substantially tight fit with the sleeve shell, so that no additional retaining means are required. A label can be placed around the aerosol delivery device, and the presence of the label can additionally maintain the interconnection of the power unit shell and the sleeve shell. In some embodiments, gluing, welding, crimping, etc. can be used to interconnect the power unit shell and the sleeve shell.

[0178] In some embodiments, a method for forming an aerosol delivery device may include providing a first shell half of a power cell shell. As discussed above, the first shell half may be configured to be attached to a second shell half to form an elongated clamshell of the power cell shell. Thus, the power cell clamshell may be characterized as being divided into a first half and a second half along its longitudinal axis. The assembly method may further include placing a battery lead and a battery (or multiple batteries) into the first shell half. This placement may cause a protrusion of the battery lead to be electrically connected to a first terminal of the battery, and an arm of the battery lead to extend from the protrusion along the length of the battery. Specifically, the battery lead protrusion may be configured to be electrically connected to the negative terminal of the battery, and the arm of the battery lead may be configured to be electrically connected to the positive terminal of the battery (including using one or more interconnecting elements, such as battery contacts on a base unit). The assembly method may further include providing a base unit that may include various elements as discussed above. For example, the base unit may include a PCB, a pressure sensor, a first battery contact configured for electrical connection with a positive terminal of a battery, and a second battery contact configured for electrical connection with an arm of a battery lead. The first battery contact may be part of the PCB, and the second battery contact may be attached to the base unit, to the PCB, or to both the base unit and the PCB. The assembly method may further include providing a sleeve as described herein. For example, the sleeve may include a shell containing: a reservoir for an aerosol-forming composition; a heater; a liquid transfer element configured for transferring the aerosol-forming composition between the reservoir and the heater; and a heater terminal. The assembly method may further include combining the sleeve, the base unit, and the first shell half such that the heater terminal is electrically connected to the base unit, the first battery contact of the base unit is electrically connected to the second terminal of the battery (in this example, the positive terminal), and the second battery contact of the base unit is electrically connected to the arm of the battery lead (which ultimately provides an electrical connection to the negative terminal of the battery. The assembly method may further include mating the second shell half to the first shell half. The connection of the power unit shell, the sleeve shell, and the base unit may include one or more of crimping, laser welding, and gluing the clamshell to one or both of the base unit and the sleeve shell.

[0179] In addition to the foregoing, the present disclosure encompasses alternative configurations whereby an electrical connection between the heater and the power unit may be provided. Such configurations may include, for example, modifications to one or both of the convection tube and the base unit, as otherwise described herein. Configurations may specifically involve removable attachment of the sleeve and the control body. Thus, the control body may be reusable (i.e., including a rechargeable battery and a charging element). Configurations may also specifically involve non-removable attachment of a fixed sleeve and the control body.

[0180] In such Figure 7a and 7bIn the embodiment illustrated in FIG. 1 , the heater terminals 749a and 749b may be configured for lateral sliding arrangement with the base unit 724 to provide a substantially permanent engagement therebetween with the power unit housing assembly. The base unit 724 may include a PCB 7106 having a sensor 7108, a first battery contact 7106c, and a second battery contact 731. The base unit 724 may be configured to engage the flow tube 748 of the cartridge unit (see FIG. 1 ). Figure 6 ), the flow tube may include a first heater terminal 749a and a second heater terminal 749b that are substantially L-shaped (i.e., include an extension substantially parallel to the longitudinal axis of the flow tube and a protrusion substantially perpendicular to the longitudinal axis of the flow tube), but other similar structures are also contemplated. In assembly, the first and second heater terminals (749a and 749b) slide around the periphery of the base unit 724 so that the protrusions on the heater terminals are placed under the base unit and the extensions of the heater terminals are along the sides of the base unit. In this way, the base unit is substantially supported by the flow tube 748 and the heater terminals (749a and 749b), and the flow tube cannot be released from the base unit via longitudinal movement. Once the combined flow tube 748 and base unit 724 are placed in the power unit housing (see Figure 4 4201 in the sensor 7108), a sliding relationship is no longer possible, and a substantially permanent attachment is provided. As configured, the first heater terminal 749a is electrically connected to the first heater contact 7106a of the PCB 7106, and the second heater terminal 749b is electrically connected to the second heater contact 7106b of the PCB. The construction may further include an insulator cover 781 that substantially covers the sensor 7108 to prevent electrical shorting. The insulator cover 781 may include an aperture 788 that provides for fluid entry to the sensor.

[0181] In such as Figure 8a and 8b In the embodiment illustrated in , the heater terminals 849a and 849b can be configured to longitudinally engage with the heater contacts 8106a and 8106b of the base unit 824 to provide a substantially removable engagement therebetween. Specifically, the base unit 824 can include a PCB 8106 having a sensor 8108, a first battery contact 8106c, and a second battery contact 831. The base unit 824 can be configured to engage the flow tube 848 of the cartridge unit (see Figure 6), the flow tube may include a first heater terminal 849a and a second heater terminal 849b extending therefrom. In assembly, the first and second heater terminals (849a and 849b) make a "wipe" connection with the first and second heater contacts (8106a and 8106b) extending upward from the base unit 824. The first and second heater terminals 849a and 849b) and or the first and second heater contacts (8106a and 8106b) can be bent (i.e., exhibit spring characteristics) so that the heater terminals and heater contacts are biased together when the wipe connection is made. As described, the heater terminals and heater contacts include shaped segments to better promote contact therebetween in making an electrical connection. In this way, the base unit 824 and the flow tube 848 can present a substantially longitudinal press fit, whereby the engagement of the heater terminals and heater contacts participates in the structural connection therebetween. To enclose the space between the flow tube 848 and the base unit 824, where the heater terminals and the heater contacts make a wipe connection, an intermediate housing 880 may be included, and it may be formed by an outer wall 881 and an inner plate 882 (as in Figure 8a 848). In the case of such a configuration, the annular gap 883 provides space for the wipe connection to occur, and the intermediate housing can function to substantially prevent electrical shorting. The intermediate housing 880 can be permanently or removably connected to one of the base unit 824 and the flow tube 848 to prevent loss of sheets when the flow tube and the base unit are not connected. In a specific embodiment in which the power unit including the base unit 824 is a common component and the sleeve including the flow tube 848 is a disposable component, the intermediate housing 880 can be specifically permanently engaged with the base unit. In other embodiments, the intermediate housing 880 can be permanently or removably engaged with the power unit shell or the sleeve shell.

[0182] Although the foregoing disclosure may describe embodiments of an aerosol delivery device (or its power unit) with respect to using a clamshell structure, it should be understood that additional components of the device (i.e., other than the longitudinally separable tube) may be utilized with the single-piece shell. Thus, in some embodiments, the present disclosure is directed to a "blended" configuration in which the tube may be provided as a power unit shell (i.e., in place of the tube in the clamshell structure). Figure 4 4201a and the second shell half 4201b in the power unit housing). Specifically, a single-piece housing (including end caps) may be provided, and the biasing member 445, the battery leads 433, and the battery 410 may be dropped into the housing in sequence. Thereafter, the base unit 424 may be added. If desired, the base unit may be connected to the sleeve (e.g., to the flow tube, as described above with respect to Figure 8a and Figure 8b Any of the above embodiments may be utilized in this manner with a one-piece tube.

[0183] Many modifications and other embodiments of the present disclosure will occur to those skilled in the art to which the present disclosure relates, thanks to the teachings presented in the foregoing description and the related drawings. Therefore, it should be understood that the present disclosure should not be limited to the specific embodiments disclosed herein, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, the terms are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. An aerosol delivery device comprising: Battery; Nebulizer; as well as A base unit, the base unit comprising: a first base segment including a wall and a skirt extending longitudinally from the wall; a second base segment including a longitudinal wall extending from the wall of the first base segment; and A cavity extends from the first base segment through the second base segment and is configured to pass air through the cavity to the atomizer.

2. The aerosol delivery device according to claim 1, characterized in that The first base segment has a first diameter and the second base segment has a second diameter that is smaller than the first diameter.

3. The aerosol delivery device according to claim 1, characterized in that The longitudinal wall of the second base segment is substantially parallel to the skirt of the first base segment.

4. The aerosol delivery device according to claim 1, characterized in that The wall of the first base unit includes at least one opening therethrough for an electrical component.

5. The aerosol delivery device according to claim 1, characterized in that Also included is an electrical component positioned at least partially within the cavity in the first base segment.

6. The aerosol delivery device according to claim 5, characterized in that The electrical component is a printed circuit board.

7. The aerosol delivery device according to claim 1, characterized in that One or both of a controller and a sensor are also included.

8. The aerosol delivery device of claim 1, wherein: The base unit defines a liquid-impermeable barrier.

9. The aerosol delivery device according to claim 1, characterized in that Also included is a reservoir for holding an aerosol precursor composition.

10. The aerosol delivery device of claim 9, wherein: The reservoir comprises one or both of porous and fibrous materials.

11. The aerosol delivery device of claim 1, wherein: Also included is at least one LED.

12. The aerosol delivery device of claim 1, wherein: The atomizer also includes a resistive heater.

13. The aerosol delivery device of claim 12, wherein: The resistive heater includes a metal wire.

14. The aerosol delivery device of claim 1, wherein: The atomizer includes a liquid transport element.

15. The aerosol delivery device of claim 1, wherein: Also included is a flow tube engaged with the second base segment.

16. The aerosol delivery device of claim 15, wherein: The flow tube is configured to cause air to flow through the first base segment, the second base segment, and the flow tube before exiting the aerosol delivery device.

17. The aerosol delivery device of claim 15, wherein: The flow tube and the second base section are arranged to pass air through the heater of the atomizer before exiting the aerosol delivery device.

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