Charging control for aerosol delivery device

Abstract

To provide an aerosol delivery device allowing a user to vape while being coupled to an external power source for charging.SOLUTION: The aerosol delivery device comprises one or more rechargeable batteries 601, charging circuitry 603 including an electrical connector 602 configured to interconnect the one or more rechargeable batteries 601 with a power supply 604, and a sensor 605 configured to detect a user's action of using the aerosol delivery device and output a signal. The aerosol delivery device also comprises a microprocessor 606 coupled to the charging circuitry 603 and the sensor 605. The microprocessor 606 is configured to control, in response to receiving the signal from the sensor 605, the aerosol delivery device to allow a user to vape or puff while the aerosol delivery device is connected to a charger 604.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. patent application Ser. No. 16 / 537,784, filed Aug. 12, 2019, entitled "Charging Control for an Aerosol Delivery Device," and U.S. Provisional Patent Application Ser. No. 62 / 769,296, filed Nov. 19, 2018, entitled "Management System for Control Functions in a Vaporization System," both of which are incorporated herein by reference.

[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 the generation of aerosols (e.g., smoking articles commonly referred to as e-cigarettes). The smoking articles can be configured to heat an aerosol precursor that can be made or derived from tobacco or can incorporate a material that can incorporate tobacco, and the precursor can form an inhalable substance for human consumption. [Background technology]

[0003] Representative products that resemble many of the attributes of a traditional type of cigarette, cigar or pipe include ACCORD(R) by Philip Morris Incorporated, ALPHA(TM), JOYE 510(TM), and M4(TM) by InnoVapor LLC, CIRRUS(TM) and FLING(TM) by White Cloud Cigarettes, BLU(TM) by Fontem Ventures BV, COHITA(TM), COLIBRI(TM), ELITE CLASSIC(TM), MAGNUM(TM), PHANTOM(TM), and SENSE(TM) by EPUFFER(R) International Inc., DUOPRO(TM), STORM(TM), and VAPORKING(R) by Electronic Cigarettes, Inc., EGAR(TM) by Egar Australia, eGo-C(TM) and eGo-T(TM) by Joyetech, ELUSION(TM) by Elusion UK Ltd, and Eonsmoke. EONSMOKE(R) by FIN Branding Group, LLC, FIN(TM) by FIN Branding Group, LLC, SMOKE(R) by Green Smoke Inc.USA, GREENARETTE(TM) by Greenarette LLC, HALLIGAN(TM), HENDU(TM), JET(TM), MAXXQ(TM), PINK(TM), and PITBULL(TM) by SMOKE STIK(R), HEATBAR(TM) by Philip Morris International,Inc., HYDRO IMPERIAL(TM) and LXE(TM) by Crown7, LOGIC(TM) and THE CUBAN(TM) by LOGIC Technology, LUCI(R) by Luciano Smokes Inc., METRO(R) by Nicotek,LLC, NJOY(R) and ONEJOY(TM) by Sottera,Inc., NO.7(TM) by SS Choice LLC, PREMIUM ELECTRONIC by PremiumEstore LLC CIGARETTE(TM), Ruyan America, Inc.RAPP E-MYSTICK(TM) by Smoking Everywhere, LLC, RED DRAGON(TM) by Red Dragon Products, LLC, RUYAN(R) by Ruyan Group(Holdings) Ltd., SF(R) by Smoker Friendly International, LLC, GREEN SMART SMOKER(R) by The Smart Smoking Electronic Cigarette Company Ltd., SMOKE ASSIST(R) by Coastline Products LLC, SMOKING EVERYWHERE(R) by Smoking Everywhere,Inc., V2CIGS(TM) by VMR Products LLC, VAPOR NINE(TM) by VaporNine LLC, VAPOR4LIFE(R) by Vapor 4 Life,Inc., VEPPO(TM) by E-CigaretteDirect,LLC, VUSE(R) by RJReynolds Vapor Company, Mistic Menthol products by Mistic Ecigs, and Vype products by CN Creative Ltd., Philip Morris and GLO™ by British American Tobacco. Still other motorized aerosol delivery devices, specifically devices characterized as so-called e-cigarettes, are marketed under the trade names COOLER VISIONS™, DIRECT E-CIG™, DRAGONFLY™, EMIST™, EVERSMOKE™, GAMUCCI®, HYBRID FLAME™, KNIGHT STICKS™, ROYAL BLUES™, SMOKETIP®, and SOUTH BEACH SMOKE™. Summary of the Invention [Problem to be solved by the invention]

[0004] It would be desirable to allow a user to smoke while the aerosol delivery device is connected to a charger. Also, in some cases, an aerosol delivery device may stop allowing puffs due to a low battery condition. Therefore, it would be desirable to allow a puff to occur as soon as an aerosol delivery device (with a dead battery) is connected to a charger, even if the battery level has not yet returned. [Means for solving the problem]

[0005] The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. The present disclosure may particularly relate to an aerosol delivery system configured to allow a user to smoke while the aerosol delivery device is coupled to an external power source for charging. The present disclosure includes, but is not limited to, the following example embodiments:

[0006] Some exemplary embodiments are an aerosol delivery device comprising: a charging circuit including a rechargeable battery or multiple batteries, an electrical connector configured to interconnect the rechargeable battery(ies) with a power source, a sensor configured to detect an action of using the aerosol delivery device by a user and output a signal, and a microprocessor operatively coupled to the charging circuit and the sensor, the microprocessor configured to, in response to receiving a signal from the sensor, determine a condition indicative of an occurrence of a passage of current from the power source to the rechargeable battery(ies) through the electrical connector, interrupt the passage of current from the power source to the rechargeable battery(ies) through the electrical connector, activate the aerosol delivery device, and thus, deliver power from the rechargeable battery(ies) to further elements of the aerosol delivery device to provide an output in response to an action of using the aerosol delivery device by a user while the electrical connector is connected to the power source, An aerosol delivery device is provided.

[0007] In some exemplary embodiments of the aerosol delivery device of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiments, the microprocessor being configured to interrupt the passage of electrical current includes being configured to interrupt the passage of electrical current using a switch circuit between the electrical connector and the rechargeable battery(ies).

[0008] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, the switch circuit includes a pair of metal oxide semiconductor field effect transistor (MOSFET) switches respectively coupled to the positive and negative electrical connections of the electrical connector, and the microprocessor is configured to interrupt the passage of current includes configured to disconnect both the positive and negative electrical connections from the rechargeable battery(ies) using the switch circuit.

[0009] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, the switch circuit includes a pair of opto-isolator relays respectively coupled to the positive and negative electrical connections of the electrical connector, and the microprocessor is configured to interrupt the passage of electrical current includes being configured to disconnect both the positive and negative electrical connections from the rechargeable battery(ies) using the switch circuit.

[0010] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, a switch circuit is connected to one or both of the positive and negative electrical connections of the electrical connector, and the microprocessor is configured to interrupt the passage of electrical current includes being configured to disconnect only one of the positive and negative electrical connections from the rechargeable battery(ies) using the switch circuit.

[0011] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, the switch circuit includes a MOSFET switch integrated with the charging circuit and another switch external to the charging circuit, and the microprocessor is configured to interrupt the passage of current includes configured to disconnect the electrical connector from the rechargeable battery(ies) using the switch circuit.

[0012] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, in response to detecting completion of the action by the sensor, the microprocessor is further configured to determine that the electrical connector is connected to the power source, reconnect the electrical connector to the rechargeable battery, and reconnect the power source to the rechargeable battery(s) to charge the rechargeable battery(s).

[0013] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, the action includes a puffing action by the user.

[0014] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, further elements include a heating element configured to heat and vaporize components of an aerosol precursor composition contained within the housing of the aerosol delivery device, such that an output in response to an action using the aerosol delivery device is the formation of an aerosol.

[0015] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, the aerosol precursor composition included is liquid, solid, or semi-solid.

[0016] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, the microprocessor is further configured to compare the voltage of the battery(s) with a voltage threshold of the battery(s) to determine whether the voltage of the battery(s) is higher than the voltage threshold, and the microprocessor configuring to activate the aerosol delivery device includes configuring to activate the aerosol delivery device based on the comparison.

[0017] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, the microprocessor being configured to perform the comparison includes being configured to change a voltage threshold of the battery(ies) from a first value to a second value that is lower than the first value, and determine that the voltage of the battery(ies) is lower than the first value and higher than the second value.

[0018] Some exemplary embodiments provide an aerosol delivery device comprising: a rechargeable battery; a charging circuit including an electrical connector configured to interconnect the rechargeable battery with a power source; a sensor configured to detect an action of using the aerosol delivery device by a user and output a signal; and a microprocessor coupled to the charging circuit and the sensor, wherein the microprocessor determines whether the electrical connector is connected to the power source in response to receiving a signal from the sensor, performs a comparison between the battery voltage and a voltage threshold to determine whether the battery voltage is higher than the voltage threshold, and based on the comparison, determines whether to enable activation of the aerosol delivery device, and thus configured to deliver power to further elements of the aerosol delivery device to provide an output in response to an action of using the aerosol delivery device by a user while the electrical connector is connected to the power source.

[0019] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, the microprocessor being configured to compare includes being configured to change a voltage threshold of the battery(ies) from a first value to a second value lower than the first value and determine that the voltage of the battery(ies) is lower than the first value and higher than the second value, and the microprocessor being configured to determine whether to allow activation of the aerosol delivery device includes being configured to allow activation of the aerosol delivery device to perform the action.

[0020] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or any combination of any of the preceding exemplary embodiments, the first value is 3.5 volts and the second value is 3.3 volts or 3.4 volts.

[0021] In some exemplary embodiments of the aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, the microprocessor being configured to compare includes being configured to determine that the voltage of the battery(ies) is lower than a second value, and the microprocessor being configured to determine whether to allow activation of the aerosol delivery device includes being configured to disable activation of the aerosol delivery device to perform the action.

[0022] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, the action includes a puffing action by the user.

[0023] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, the further element comprises a heating element configured to heat and vaporize components of the aerosol precursor composition contained within the housing of the aerosol delivery device.

[0024] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, the aerosol precursor composition is liquid, solid, or semi-solid.

[0025] In some exemplary embodiments of the aerosol delivery device of any of the preceding exemplary embodiments, or of any combination of any of the preceding exemplary embodiments, in response to receiving a signal from the sensor, the microprocessor is further configured to determine a condition indicative of the occurrence of passage of current from the power source to the rechargeable battery(ies) through the electrical connector, and to interrupt the passage of current from the power source to the rechargeable battery(ies) through the electrical connector.

[0026] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features described in the present disclosure, regardless of whether such features or elements are explicitly combined or recited in a particular example embodiment described herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the present disclosure should be considered combinable, in any of its aspects and example embodiments, unless the context of the disclosure clearly dictates otherwise.

[0027] It should therefore be understood that this brief summary is provided solely for the purpose of summarizing some example embodiments to provide a basic understanding of some aspects of the present disclosure. It should therefore be understood that the above example embodiments are merely examples, and should not be construed in any way to narrow the scope or spirit of the present disclosure. Other example embodiments, aspects, and advantages will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of some described example embodiments.

[0028] Having described the present disclosure in general terms above, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 illustrates a control device for use in the aerosol delivery device or vaporization system of the present disclosure, according to an exemplary embodiment of the present disclosure. [Diagram 2] FIG. 2 is a partial cross-sectional view of the control device shown in FIG. [Diagram 3] FIG. 1 illustrates a cartridge for use in the aerosol delivery device or vaporization system of the present disclosure, according to an exemplary embodiment of the present disclosure. [Figure 4] FIG. 4 is a partial cross-sectional view of the cartridge shown in FIG. 3. [Figure 5A] FIG. 1 illustrates an external connector and two chargers for use with the aerosol delivery device or vaporization system of the present disclosure, according to an exemplary embodiment of the present disclosure. [Figure 5B] FIG. 1 illustrates an external connector and two chargers for use with the aerosol delivery device or vaporization system of the present disclosure, according to an exemplary embodiment of the present disclosure. [Figure 5C] FIG. 1 illustrates an external connector and two chargers for use with the aerosol delivery device or vaporization system of the present disclosure, according to an exemplary embodiment of the present disclosure. [Figure 6]FIG. 2 illustrates components of the control device shown in FIG. 1 in accordance with an exemplary embodiment of the present disclosure. [Figure 7A] FIG. 2 illustrates a switch circuit of the control device shown in FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 7B] FIG. 2 illustrates a switch circuit of the control device shown in FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 7C] FIG. 2 illustrates a switch circuit of the control device shown in FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 8] FIG. 4 shows a flow chart illustrating a method of charging control according to an exemplary embodiment of the present disclosure. [Figure 9] FIG. 4 shows a flow chart illustrating a method of charging control according to another exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] The present disclosure will now be described more fully with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0031] As described below, embodiments of the present disclosure relate to aerosol delivery systems or vaporization systems, the terms being used interchangeably herein. Aerosol delivery systems according to the present disclosure can use electrical energy to heat materials (preferably without burning the materials to any significant extent and / or without significantly chemically altering the materials) to form inhalable substances; such system components most preferably have the form of articles compact enough to be considered handheld devices. That is, the use of preferred aerosol delivery system components does not result in smoke generation, i.e., from by-products of tobacco combustion or pyrolysis, but rather the use of these preferred systems results in the production of vapor resulting from the volatilization or vaporization of certain components incorporated therein. In preferred example embodiments, the aerosol delivery system components can be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0032] The aerosol-generating components of certain preferred aerosol delivery systems can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the act of inhaling and exhaling, the type of taste or flavor, the sensory effects, the physical sensations, the act of use, visual cues such as those provided by a visible aerosol, etc.) used by a smoker to light and burn tobacco (and thus inhale tobacco smoke) without burning any of the components to any substantial extent. For example, a user of an aerosol-generating component of the present disclosure can hold and use the component as a smoker would use a traditional type of smoking article, drawing on one end of the component for inhalation of the aerosol generated by the component and puffing at selected time intervals.

[0033] The aerosol delivery device of the present disclosure can also be characterized as a vapor-generating article or a drug delivery article. Thus, such an article or device can be adapted to provide one or more substances (e.g., flavors and / or pharmaceutical active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in the form of a vapor (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is meant to include vapors, gases and aerosols in any form or type suitable for human inhalation, whether or not visible and whether or not in a form considered smoky.

[0034] The aerosol delivery device of the present disclosure most preferably includes some combination of a power source (i.e., an electrical power source), at least one control component (e.g., a means for activating, controlling, regulating, and terminating electrical power for heat generation, such as by controlling the flow of electrical current from the power source to other components of the article, e.g., a microcontroller or microprocessor), a heater or heat generating member (e.g., an electrical resistance heating element or other component that may be commonly referred to as an "atomizer" alone or in combination with one or more additional elements), an aerosol precursor composition (e.g., a liquid that can generally create an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece or mouth area that allows for drawing on the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the article such that the generated aerosol is drawn upon inhalation).

[0035] More specific forms, configurations and arrangements of components within the aerosol delivery systems of the present disclosure will become apparent in light of the further disclosure provided below. In addition, the selection and arrangement of the various aerosol delivery system components can be understood by considering commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure.

[0036] In one or more embodiments, the present disclosure relates to a vaporization system that includes at least an element for providing electrical power, an element for controlling the output of the electrical power and additional functional capabilities, and an element for forming vapor using the electrical power. In one or more embodiments, the vaporization system can be formed from a control device and a cartridge.

[0037] An exemplary embodiment of a control device 100 for use in the aerosol delivery device or vaporization system of the present disclosure is shown in Figure 1. The control device 100 comprises a device outer housing 102 defining a device outer wall 104, a device distal end 106, and a device proximal end 108. The device proximal end 108 includes an opening 110 providing access to a device chamber 112 defined by a device inner frame 114.

[0038] The nature of the control devices of the various embodiments may be further appreciated in relation to Figure 2, which illustrates a partial cross-section of the control device 100. As seen therein, the control device 100 further includes a device battery 116 disposed within the outer housing 102, and also includes a device external connection element 118. For example, the control device 100 can have replaceable or rechargeable batteries, solid-state batteries, thin-film solid-state batteries, rechargeable supercapacitors, etc., and can therefore be combined with any type of recharging technology, including connection to a wall charger, connection to an automobile's power source (e.g., via a cigarette lighter receptacle, USB port, etc.), and connection to a computer through a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), etc., connection to a USB (e.g., USB 2.0, 3.0, 3.1, USB Type-C) connector (which may be implemented, e.g., in an automobile, a wall outlet, an electronic device, etc.), connection to a photovoltaic cell (sometimes referred to as a solar cell) or solar panel, wireless chargers such as chargers using inductive wireless charging (including, e.g., wireless charging according to the Qi wireless charging standard from the Wireless Power Consortium (WPC)), or connection to an array of external batteries such as a radio frequency (RF) based charger, a power bank for charging via a USB connector or wireless charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated by reference in its entirety.

[0039] The device external connection element 118 of some embodiments is disposed at the distal end 106 of the device outer housing 102, although it will be understood that alternative locations of the device external connection element 118 are contemplated within the scope of the present disclosure. The device electrical connector 120 is disposed within the device chamber 112 and, as shown, is within the side wall 114a of the device inner frame 114, which frame 114 defines the boundary of the device chamber 112. However, it will be understood that the device electrical connector 120 may be disposed within the bottom wall 114b of the device inner frame 114. Furthermore, the device electrical connector 120 may be present at any location on the side wall 114a or the bottom wall 114b of the device inner frame 114. For example, the device electrical connector 120 may be disposed at a point on the side wall 114a between the proximal end 108 of the device outer housing 102 and the bottom wall 114b of the device inner frame 114. Additionally, the device electrical connector 120 may be disposed between a midpoint of the sidewall 114a and the proximal end 108 of the device outer housing 102 (i.e., in the top half of the sidewall). Alternatively, the device electrical connector 120 may be disposed between a midpoint of the sidewall 114a and the bottom wall 114b of the device inner frame 114 (i.e., in the bottom half of the sidewall).

[0040] The various components of the aerosol delivery device according to the present disclosure can be selected from those described in the art and commercially available. An example of a battery that can be used according to the present disclosure is described in U.S. Patent Publication No. 2010 / 0028766 by Peckerar et al., the disclosure of which is incorporated herein by reference.

[0041] As is evident from FIG. 2, the device chamber 112 is separate from the device outer housing 102. In other words, the chamber is not simply an interior space defined by the outer housing. Rather, the inner frame defining the chamber exists separately and distinct from the outer housing. The opening of the chamber may coincide with an opening at the proximal end of the outer housing. Thus, the inner frame may be a completely different element that is attached to the outer housing. Alternatively, the inner frame and the outer housing may be formed continuously. In either case, however, the sidewalls forming the inner frame exist within the outer housing and are separate from the outer housing. However, it is understood that, if desired, the device chamber 112 may be explicitly defined by the outer housing 102. In such an embodiment, the bottom wall 114b may extend between the walls forming the outer housing 102 to define the bottom wall of the chamber defined by the bottom wall and the walls of the outer housing.

[0042] The device outer housing 102 may be formed of any suitable material, such as metal, plastic, ceramic, glass, etc. Preferably, the device inner frame 114 is formed of the same material used to form the device outer housing 102. However, different materials may be used.

[0043] The systems of the present disclosure can include a single control device. Such a single control device can be interchangeably connectable with multiple cartridges to form multiple different vaporization systems. For example, the control device can be interchangeably connectable with a first cartridge to form a first functioning vaporization system having a first set of properties, and the control device can be interchangeably connectable with a second cartridge to form a second functioning vaporization system having a second, different set of properties. Such vaporization systems can include two different cartridges, three different cartridges, or even a larger number of different cartridges, all interchangeable with the first control device.

[0044] The systems of the present disclosure may include multiple control devices (e.g., a first control device and a second control device, and optionally a third control device or even multiple control devices). The multiple control devices are interchangeably connectable with at least one cartridge to form a plurality of different vaporization systems. For example, the first control device may be interchangeably connectable with a first cartridge to form a first functional vaporization system having a first set of properties, and the second control device may be interchangeably connectable with the first cartridge to form a second functional vaporization system having a second different set of properties.

[0045] An exemplary embodiment of a cartridge 300 for use in the aerosol delivery device or vaporization system of the present disclosure is shown in FIG. 3. The cartridge 300 includes a tank 301 defined by an outer tank wall 303 including a proximal end 305 and a closed distal end 307. The tank 301 can thus be characterized in that the tank wall 303 is a continuous sidewall around the tank and the distal end 307 defines a bottom wall. The tank is configured to contain a liquid composition for vaporization, i.e., an e-liquid or aerosol precursor composition, which can be configured as otherwise described herein. The cartridge 300 can further include a mouthpiece 309 defined by an outer mouthpiece wall 311 including a proximal end 313 with an exit portal 315 and a distal end 317 in engagement with the proximal end 305 of the tank 301.

[0046] The cartridge 300 is further illustrated in FIG. 4. As seen therein, the cartridge 300 further includes a heater 319 and a liquid transport element 321 extending between the heater and the liquid 323 contained within the tank 301. The heater 319 and the liquid transport element 321 may be configured as separate elements that are fluidly connected or may be configured as a combined element. Furthermore, the heater 319 and the liquid transport element 321 may be formed in any configuration, as otherwise described herein. In various implementations, the heating element may be provided in various forms, such as in the form of a foil, foam, mesh, hollow ball, half ball, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating elements often include a metallic material and are configured to generate heat as a result of electrical resistance associated with the passage of an electric current. Such resistive heating elements may be disposed in close proximity to and / or in direct contact with the liquid transport element 321. The heating assembly or heating member may be located within the control device 100 and / or the cartridge 300. In various embodiments, the liquid transport element may include components embedded in or otherwise part of the liquid transport element that can function or facilitate the function of the heating assembly (i.e., thermally conductive components). Some examples of various heating members and elements are described in U.S. Pat. No. 9,078,473 to Worm et al., the disclosure of which is incorporated herein by reference in its entirety. The cartridge 300 also includes one or more electrical contacts 325 configured to electrically connect the heater 319 with the battery 116 in the control device 100.

[0047] The liquid transport element 321 may be formed from one or more materials configured for transport of liquids, such as by capillary action. The liquid transport element may be formed, for example, from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose cloth, glass fiber), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillaries, and the like. Thus, the liquid transport element 321 may be any material that includes an open pore network (i.e., multiple pores interconnected such that fluid can flow from one pore to another in multiple directions through the element). As discussed further herein, some embodiments of the present disclosure may specifically relate to the use of non-fibrous transport elements. Thus, fibrous transport elements may be explicitly excluded. Alternatively, a combination of fibrous and non-fibrous transport elements may be utilized. Exemplary types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton; U.S. Patent Publication No. 2014 / 0261487 to Chapman et al.; U.S. Patent Publication No. 2014 / 0059780 to Davis et al.; and U.S. Patent Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference. Additionally, various wicking materials, as well as the configuration and operation of these wicking materials within certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference. In some embodiments, the liquid transport element 321 can be partially or completely formed from a porous monolith, such as a porous ceramic, porous glass, or the like. Exemplary monolithic materials suitable for use with embodiments of the present disclosure are described, for example, in U.S. Patent Application Serial No. 14 / 988,109, filed January 5, 2016 to LaMothe, and U.S. Patent No. 2014 / 0123989, the disclosures of which are incorporated herein by reference. The porous monolith can form a substantially solid core.

[0048] Various embodiments of materials configured to generate heat when an electric current is applied thereto can be employed to form the heater 319. In some embodiments, the heater 319 can be a wire coil. Exemplary materials from which the wire coil may be formed include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)), titanium, platinum, silver, palladium, alloys of silver and palladium, graphite and graphite-based materials (e.g., carbon-based foam materials or threads. In further embodiments, the heater 319 may be formed from conductive ink, boron-doped silica, and / or ceramics (e.g., positive or negative temperature coefficient ceramics). Other types of heaters, such as laser diodes or microheaters, may also be utilized. The laser diodes may be configured to deliver electromagnetic radiation of a particular wavelength or band of wavelengths that may be tuned for vaporization of the aerosol precursor composition and / or tuned for heating a liquid transport element through which the aerosol precursor composition may be provided for vaporization. The laser diodes may be , can be particularly arranged to deliver electromagnetic radiation into the chamber, which can be configured to be radiation trapping (e.g., black body or white body). Suitable micro-heaters are described in U.S. Patent No. 8,881,737 to Collett et al., which is incorporated herein by reference. The micro-heater can include, for example, a substrate (e.g., quartz, silica) having a heater trace thereon (e.g., a resistive element such as Ag, Pd, Ti, Pt, Pt / Ti, boron-doped silicon, or other metal or metal alloy), which can be printed or otherwise applied to the substrate. A passivation layer (e.g., aluminum oxide or silica) can be provided on the heater trace. The heater 319 can be particularly configured to be substantially planar. Such a heater is described in U.S. Patent Application Publication No. 2016 / 0345633 to DePiano et al., which is incorporated herein by reference.

[0049] The outer tank wall 303 can be configured to be at least partially transparent or translucent so that the liquid 323 contained therein can be seen from the outside. Thus, the entire outer tank wall 303 can be transparent or translucent. Alternatively, only a single side of the outer tank wall 303 can be transparent or translucent, while the remaining portion of the outer tank wall can be substantially opaque. In a further embodiment, the outer tank wall 303 can be colored. The color can be configured so that the liquid 323 within the tank 301 is still visible, or the color can be configured so that the outer tank wall 303 is substantially opaque.

[0050] In one or more embodiments, the mouthpiece 309 of the cartridge 300 can be configured to engage with the tank 301. For example, as shown in FIGS. 3 and 4, the distal end 317 of the mouthpiece 309 can include a rim wall 330 at least partially inserted from the outer mouthpiece wall 330, which can be configured to engage with an interior of the proximal end 305 of the outer tank wall 303. The rim wall 330 can have a length of about 1 mm to about 20 mm, about 2 mm to about 18 mm, or about 5 mm to about 15 mm. The rim wall 330 can engage with the outer tank wall 303 via a friction fit only, or the rim wall can be substantially permanently attached to the outer tank wall, such as by welding or adhesive.

[0051] In some embodiments, the mouthpiece 309 may be substantially defined only by an open interior space where the formed vapor may combine with air to form an aerosol for output through the outlet portal 315 of the mouthpiece. In one or more embodiments, the mouthpiece 309 may include one or more additional interior walls that may be configured to define one or more compartments within the mouthpiece. For example, the mouthpiece may include an interior upper wall between the proximal and distal ends of the mouthpiece and may also include an interior lower wall between the inner upper wall and the proximal end of the mouthpiece. More specifically, the mouthpiece 309 may include an interior upper wall 332 between the proximal end 313 and the distal end 317. Additionally, the mouthpiece 309 may include an interior lower wall 334 between the inner upper wall 332 and the distal end 317 of the mouthpiece.

[0052] Two or more walls of the mouthpiece can be configured to define a vaporization chamber in which a heater can be disposed. The outer mouthpiece wall 311, the inner top wall 332, and the inner bottom wall 334 can define a vaporization chamber 342 in which the heater 319 is disposed. One or more electrical contacts 325 can be disposed within a portion of the outer mouthpiece wall 311 that defines the vaporization chamber 342; however, it is understood that one or more electrical leads may extend from the heater 319 to one or more electrical contacts disposed in different portions of the outer mouthpiece wall or disposed in the outer tank wall 303. One or more walls of the mouthpiece may also include one or more openings for the passage of one or more further elements of the cartridge 300 or the passage of the formed vapor / aerosol. For example, the inner top wall 332 can include a vapor opening 333 through which the vapor formed in the vaporization chamber 342 can pass toward the exit portal 315. The vapor opening 333 of the interior top wall 332 can be substantially centered therein and can be substantially aligned with the heater 319 along the longitudinal axis of the cartridge 300. As a further example, the interior bottom wall 334 can include a wick aperture 335 through which a liquid transport element 321 (e.g., a wick) can pass between the heater 319 and the liquid 323 in the tank 301. The wick aperture 335 of the interior bottom wall 334 can be substantially centered therein and can be substantially aligned with the heater 319 along the longitudinal axis of the cartridge 300. If desired, a vaporization chamber can be defined in the lower portion of the tank 301.

[0053] Two or more walls of the mouthpiece can be configured to define a cooling chamber in which the formed aerosol can expand and / or cool before passing through the exit portal. In particular, the outer mouthpiece wall 311 and the interior top wall 332 define a cooling chamber 344 that receives the formed vapor / aerosol from the heater 319, in particular from the vaporization chamber 342. Thus, the formed vapor / aerosol enters the cooling chamber 344 from the vaporization chamber 342 through the vapor opening 333.

[0054] Optionally, mouthpiece 309 can include one or more elements configured to reduce or prevent escape of condensed liquid therefrom. For example, all or a portion of the interior of mouthpiece wall 311 and / or the interior of interior top wall 332 defining cooling chamber 344 can be formed from or include an absorbent or adsorbent material configured to retain liquid. Alternatively or additionally, the interior of mouthpiece wall 311 and / or all or a portion of the interior of interior top wall 332 defining cooling chamber 344 can be configured to direct liquid back toward atomization chamber 342, such as by the addition of microchannels or the like.

[0055] In one or more embodiments, the cartridge 300 can be configured such that the mouthpiece wall 311 can include a flange disposed between its proximal end 313 and distal end 317. For example, the flange 350 can reside and extend circumferentially around substantially the entirety of the mouthpiece 309 from the mouthpiece wall 311. The distance that the flange 350 extends from the mouthpiece wall 311 can be substantially uniform around the entire circumference of the mouthpiece 309. In some embodiments, the distance that the flange 350 extends from the mouthpiece wall 311 can vary at one or more points around the circumference of the mouthpiece 309. The entire cartridge 300 or mouthpiece 309 can be separately defined with respect to a longitudinal axis (L), a first transverse axis (T1) perpendicular to the longitudinal axis, and a second transverse axis (T2) perpendicular to the longitudinal axis and perpendicular to the first transverse axis. Thus, the entire cartridge 300 and / or mouthpiece 309 may be defined in terms of an overall length along the longitudinal axis (L), an overall width along the first transverse axis (T1), and an overall depth along the second longitudinal axis (T2). The length may be greater than the width, and the width may be greater than the depth. The distance that the flange 350 extends away from the mouthpiece wall 311 may be greater along the second transverse axis (T2) than along the first transverse axis (T1). Thus, in alternative embodiments, the total distance between opposing outer edges of the flange 350 across the mouthpiece 309 along the first horizontal axis (T1) may be greater than the total distance between opposing edges of the flange across the mouthpiece along the second horizontal axis (T2); the total distance between opposing outer edges of the flange 350 across the mouthpiece 309 along the first horizontal axis (T1) may be substantially equal to the total distance between opposing edges of the flange across the mouthpiece along the second horizontal axis (T2); or, the total distance between opposing outer edges of the flange 350 across the mouthpiece 309 along the first horizontal axis (T1) may be less than the total distance between opposing edges of the flange across the mouthpiece along the second horizontal axis (T2).In certain embodiments, the distance (d2) between the mouthpiece wall 311 and the outer edge of the flange 350 as measured along the second transverse axis (T2) may be greater than the distance (d1) between the mouthpiece wall and the outer edge of the flange as measured along the first transverse axis (T1). The distances (d1, d2) may in particular be measured approximately at the midpoint of each of the first transverse axis (T1) and the second transverse axis (T2).

[0056] The flange 350 can interact with a corresponding lip on the control device 100 to ensure proper connection of the cartridge 300 with the control device. For example, with reference to FIG. 1 , the device 100 can be configured such that the opening 110 at the device proximal end 108 includes a recess having an inwardly projecting lip 121. The recess can thus include a rim wall 122 that is substantially parallel to the longitudinal axis of the device 100. The rim wall 122 extends downwardly from the proximal end 108 a short distance that can substantially correspond to the thickness of the flange 350 of the cartridge 300 and / or the thickness of additional elements that may be adjacent to the flange.

[0057] The flange 350 and / or the inwardly protruding lip 121 may be configured to bias the cartridge 300 into connection with the device 100. For example, a magnetic connection may be utilized. For example, the cartridge 300 may include a magnet 352 disposed adjacent a bottom surface of the flange 350. The magnet 352 may extend substantially completely around the circumference of the mouthpiece 309, or may be discontinuous so as to be configured as a single or multiple separate magnets. The magnet 352 may be attached to the mouthpiece wall 311, to the flange 350, or to both the mouthpiece wall and the flange. The inwardly protruding lip 121 may be formed of a metal or other material to which the magnet 352 is attracted by magnetic force. In further embodiments, the magnet 352 may be disposed on the device 100. Specifically, the magnet 352 may be attached to the inwardly extending lip 121. In such embodiments, the flange 350 may be formed of a metal or other material to which the magnet 352 is attracted by magnetic force. In further embodiments, magnet 352 may be present on cartridge 300 and device 100. Optionally, magnet 352 may be disposed at distal end 307 of tank wall 303 to interact with magnetic elements disposed within device chamber 112, particularly on bottom wall 114b.

[0058] The device 100 can be configured in some embodiments such that at least a portion of the reservoir 301 is visible when the cartridge 300 is engaged with the device. As described above, at least a portion of the outer reservoir wall 303 can be configured to be at least partially transparent or translucent such that the liquid 323 contained therein is visible from the outside. Thus, the outer wall 104 of the device 100 can be configured to include a window 135 through which the outer reservoir wall 303, and optionally any liquid 323 present within the reservoir 301, is visible when the cartridge 300 is engaged with the device 100. The window 135 can be configured as a cutout in the outer wall 104 of the device 100, or as a notch extending a distance from the proximal end 108 of the outer wall 104 of the device 100 toward the distal end 106 of the device. Further, the window 135 may be completely open, or the window may have a transparent member (e.g., glass or plastic) disposed within the opening defined by the window or covering the window on one or both of the inner and outer surfaces of the exterior wall 104 of the device 100.

[0059] In one or more embodiments, the device 100 may include a light source 139 and at least one opening 137 through the outer wall 104 of the device through which light from the light source is visible. The light source 139 may comprise, for example, one or more light emitting diodes (LEDs) capable of providing illumination of one or more colors. The light source 139 may be located directly on a printed circuit board (PCB) 141, which may include additional control components (e.g., a microcontroller and / or memory components). The opening 137 may be provided in any desired shape, and may be located particularly near the distal end 106 of the device 100. The opening 137 may be completely open, may be filled with a light guiding material or the like, or may be covered with a transparent or translucent member (e.g., glass or plastic) on one or both of the inner and outer surfaces of the outer wall 104 of the device 100. The aerosol delivery device most preferably incorporates a control mechanism for controlling the amount of power to the heating element during inhalation. Representative types of electronic components, their structure and configuration, their features, and their general methods of operation are described in 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. Publication Nos. 2009 / 0230117 to Fernando et al., 2014 / 0060554 to Collet et al., and 2014 / 0270727 to Ampolini et al., and 2015 / 0257445 to Henry et al., which are incorporated herein by reference.

[0060] Airflow sensors, pressure sensors, and the like may also be included in the device. For example, as shown in FIG. 2, device 100 may include sensor 143 on PCB 141. Printed circuit board and pressure sensor configurations are described, for example, in U.S. Patent Publication No. 2015 / 0245658 to Worm et al., the disclosure of which is incorporated herein by reference. Sensor 143 may be located anywhere in device 100 to receive airflow and / or pressure changes that may signal aspiration of the device, thus causing battery 116 to deliver power to heater 319 in cartridge 300. Alternatively, in the absence of an airflow sensor, heater 319 may be manually activated, such as by a push button. Additional representative types of sensing or detection 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 Publication WO 2010 / 003480 to Flick, which are incorporated herein by reference.

[0061] An input element may be included in the aerosol delivery device (and may replace or complement the airflow or pressure sensor). The input may be included to allow a user to control the device's functions and / or for output of information to the user. Any component or combination of components may be utilized as an input to control the functions of the device 100. For example, one or more push buttons may be used as described in U.S. Patent Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touch screen may be used as described in U.S. Patent Application No. 14 / 643,626, filed March 10, 2015 to Sears et al., which is incorporated herein by reference. As a further example, a component adapted for gesture recognition based on specific movements of the aerosol delivery device may be used as an input. See U.S. Patent Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference. As yet another example, a capacitive sensor may be implemented in the aerosol delivery device to allow a user to provide input, such as by touching a surface of the device on which the capacitive sensor is implemented. In another example, a sensor capable of detecting motion relative to the device (e.g., an accelerometer, a gyroscope, a photoelectric proximity sensor, etc.) may be implemented in the aerosol delivery device to allow a user to provide input. Examples of suitable sensors are described in U.S. Patent Application Publication No. 2018 / 0132528 to Sur et al. and U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which are incorporated herein by reference.

[0062] In some embodiments, the input can include a computer or computing device, such as a smartphone or tablet. In particular, the aerosol delivery device can be wired to a computer or other device, such as through the use of a USB cord or similar protocol. The aerosol delivery device can also communicate with a computer or other device acting as an input via wireless communication. See, for example, the systems and methods for controlling a device via read requests described in U.S. Patent Publication No. 2016 / 0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference. In such embodiments, an app (APP) or other computer program can be used in conjunction with a computer or other computing device to input control instructions to the aerosol delivery device, such control instructions including, for example, the ability to form an aerosol of a specific composition by selecting the nicotine content and / or the content of additional flavors included.

[0063] In addition to or as an alternative to the LED, additional indicators (e.g., haptic feedback components, audio feedback components, etc.) may be included. Additional representative types of components that create visual cues or indicators, such as light-emitting diode (LED) components, and their configurations and uses are described in U.S. Pat. No. 5,154,192 to Sprinkel et al.; U.S. Pat. No. 8,499,766 to Newton, and U.S. Pat. No. 8,539,959 to Scatterday, U.S. Pat. Publication No. 2015 / 0020825 to Galloway et al.; and U.S. Pat. Application Publication No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference. It is understood that not all of the illustrated elements are required. For example, the LED may not be present or may be replaced with a different indicator, such as a vibration indicator. Similarly, the flow sensor may be replaced with a manual actuator, such as a push button.

[0064] FIG. 5A illustrates an external connector for use with the aerosol delivery device or vaporization system of the present disclosure, according to some exemplary embodiments of the present disclosure. It will be understood that the external connector illustrated in FIG. 5A is provided by way of example and not limitation. In this regard, the aerosol delivery device according to various embodiments may be used with a variety of external connectors having different shapes and form factors and / or mating interfaces. For example, depending on the shape / form factor of the aerosol delivery device, any corresponding mating interface realized on the aerosol delivery device (e.g., well 106a, etc.), the type and / or location of the device external connection element 118 available on the aerosol delivery device, and / or other factors can be utilized. In one or more embodiments, the vaporization system formed by any combination of the one or more devices and one or more cartridges can further include an external connector 500 configured for electrical contact with the device external connection element 118. The external connector 500 can include a first connector end 503 and a second connector end 505 interconnected by a union 507, which may be, for example, a variable length cord. The first connector end 503 may be configured for electrical and optionally mechanical connection with the device 100. In particular, the first connector end 503 may include an insert wall 503a that may be received within a well present at the distal end 106 of the device 100 (e.g., well 106a of the distal end 106 of the device 100). The external connector 500 may include a plurality of electrical pins 511 within the insert wall 503a configured to make a charging and / or information transfer connection with the device external connection element 118. In some embodiments, the device 100 may include a mechanical connector 119 adjacent the device external connection element 118. The mechanical connector 119 may be a magnet or a metal (or similar element) adapted for magnetic attraction to a magnet. The first connector end 503 may then include a mechanical connection element 513 disposed between the insert wall 503a and the electrical pins 511.The mechanical connection element 513 can be a magnet or a metal (or similar element) adapted for magnetic attraction to a magnet. The second connector end 505 can be configured for connection to a computer or similar electronic device or for connection to a power source. As shown, the second connector end 505 has a Universal Serial Bus (USB) connection; however, a different connection may be provided and / or an adapter may be included as well (e.g., a USB / AC adapter). For example, an adapter including a USB connector on one end and a power supply unit connector on the opposite end is disclosed in U.S. Patent Application Publication No. 2014 / 0261495 by Novak et al., which is incorporated herein by reference.

[0065] FIG. 5B illustrates a charger 518 for use in the aerosol delivery device or vaporization system of the present disclosure, according to some exemplary embodiments of the present disclosure. As shown in FIG. 5B, the charger 518 can include a charger base 520, contacts 521, and a connector end 522 having a USB connection. The charger 518 can be connected to a power source using a USB cable 523. FIG. 5C illustrates a charger 530 for use in the aerosol delivery device or vaporization system of the present disclosure, according to some exemplary embodiments of the present disclosure. The charger 530 can include a charger base 531 and contacts 532. The charger 530 can be connected to a power source using a cable 533. In some embodiments, the charger base 518 and / or 530 can be made of metal (e.g., aluminum) or plastic material.

[0066] In the case of an aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition most preferably incorporates tobacco or tobacco-derived components. In one respect, the tobacco may be provided as tobacco parts or pieces, such as finely ground, crushed, or powdered tobacco lamellae. It may also include tobacco beads, pellets, or other solid forms, as described in U.S. Patent Publication No. 2015 / 0335070 by Sears et al., the disclosure of which is incorporated herein by reference. In another respect, the tobacco may be provided in the form of an extract, such as a spray-dried extract that incorporates many of the water-soluble components of tobacco. Alternatively, the tobacco extract may have the form of a relatively high nicotine content extract, which also incorporates small amounts of other extracted components derived from tobacco. In another respect, the components derived from tobacco, such as certain flavoring agents derived from tobacco, may be provided in a relatively pure form. In one respect, a component derived from tobacco that may be used in a highly purified or essentially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[0067] Aerosol precursor compositions, also referred to as vapor precursor compositions, can include a variety of ingredients, including, by way of example, polyhydric alcohols (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorings. Representative types of aerosol precursor ingredients and formulations are also described and characterized in U.S. Pat. No. 7,217,320 to Robinson et al., and U.S. Pat. Pub. Nos. 2013 / 0008457 to Zheng et al.; 2013 / 0213417 to Chong et al.; 2014 / 0060554 to Collett et al.; 2015 / 0020823 to Lipowicz et al.; and U.S. Pat. Pub. Nos. 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 the aerosol precursors incorporated in VUSE® products by RJ Reynolds Vapor Company, BLU™ products by Lorillard Technologies, MISTIC MENTHOL products by Mistic Ecigs, and VYPE products by CN Creative Ltd. Also desirable are so-called "smoke juices" for e-cigarettes available from Johnson Creek Enterprises LLC.Further example aerosol precursor compositions are sold under the following brand names: BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, MITTEN VAPORS, DR.CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT.BAKER VAPOR, and JIMMY THE JUICE MAN.

[0068] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating component provides acceptable sensory and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol forming material (e.g., glycerin and / or propylene glycol) is used to provide a visible mainstream aerosol production that resembles in many respects the appearance of tobacco smoke. The amount of aerosol precursor in the aerosol generating system may depend on factors such as the number of puffs desired per aerosol generating component. In one or more embodiments, about 1 ml or more, about 2 ml or more, about 5 ml or more, or about 10 ml or more of the aerosol precursor composition may be included.

[0069] Still other features, controls or components that can be incorporated into the aerosol delivery systems of the present disclosure include those disclosed in 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. Patent Publication No. 8,402,976 to Fernando et al.; F No. 2010 / 0163063 to Ernando et al.; U.S. Patent Publication No. 2013 / 0192623 to Tucker et al.; U.S. Patent Application Publication No. 2013 / 0298905 to Leven et al.; 2013 / 0180553 to Kim et al., 2014 / 0000638 to Sebastian et al., 2014 / 0261495 to Novak et al., and 2014 / 0261408 to DePiano et al., which are incorporated herein by reference.

[0070] FIG. 6 illustrates components of the control device 100 shown in FIG. 1 according to an exemplary embodiment of the present disclosure. As shown, the control device 100 includes a rechargeable battery 601. In some examples, the rechargeable battery 601 may correspond to the battery 116 shown in FIG. 2. The control device 100 also includes an electrical connector 602, such as a USB charging connector, configured to interconnect the rechargeable battery 601 with a suitable power source. In some examples, the electrical connector 602 may correspond to the external connector 500, more specifically, the first connector end 503 shown in FIG. 5A. In some embodiments, the electrical connector 602 can be connected to the rechargeable battery 601 via a USB charging circuit 603. The electrical connector 602 and the charging circuit 603 are included in the charging circuit of the control device 100. The electrical connector 602 can be connected to a power source via a charger 604. In some examples, the charger 604 may include a wall transformer or a USB charging source or other source, as otherwise described herein. In some embodiments, the control device 100 may include multiple rechargeable batteries 601.

[0071] In some embodiments, the control device 100 can detect that the charger 604 is connected and begin charging the rechargeable battery 601. When the electrical connector 602 is connected to a power source via the charger 604, the rechargeable battery 601 can be isolated from the power source if a user attempts to puff. To accomplish this, in some embodiments, the control device 100 includes a sensor 605 configured to detect an action by a user using the aerosol delivery device and output a signal indicative of the detection of the action, which can be a puffing action by the user. The control device 100 also includes a microprocessor 606 coupled to a charging circuit, including a USB charging circuit 603, and coupled to the sensor 605.

[0072] In some embodiments, the microprocessor 606 is configured to determine a state of the aerosol delivery device indicative of the occurrence of a passage of electrical current from the power source through the electrical connector 602 to the rechargeable battery 601 in response to receiving a signal from the sensor 605. The microprocessor 606 of some embodiments is configured to interrupt the passage of electrical current from the power source through the electrical connector 602 to the rechargeable battery 601 in response to the determination. In some such embodiments, the microprocessor 606 is configured to interrupt the passage of electrical current using a switch circuit 607 between the electrical connector 602 and the rechargeable battery 601. For example, the switch circuit 607 can be opened to disconnect the electrical connector 602 from the USB charging circuit 603, and thereby from the rechargeable battery 601.

[0073] In some embodiments, the microprocessor 606 is configured to activate the aerosol delivery device after the current from the power source to the rechargeable battery 601 is interrupted. The aerosol delivery device is activated such that power is delivered from the rechargeable battery 601 to a further element of the aerosol delivery device to provide an output in response to an action of using the aerosol delivery device by a user while the electrical connector 602 is connected to the power source. In some embodiments, the further element includes a heating element configured to heat and thereby vaporize a component of the aerosol precursor composition contained within the housing of the aerosol delivery device. Thus, the output in response to the action of using the aerosol delivery device can be the formation of an aerosol for inhalation by a user. For example, the further element can correspond to the heater 319 shown in FIG. 4. Thus, the action of using the device can be puffing on the device and the output in response to puffing on the device can be the formation of an aerosol for inhalation. In some embodiments, the aerosol precursor composition is liquid, or solid, or semi-solid. In further embodiments, the further element may correspond to another functional component of the device, such as a feedback element (e.g., a vibrating or lighting or sound component) configured to provide a status of the device. In this way, power supply to the aerosol delivery device during use of the device (e.g., during formation of the aerosol and / or other use of the device) comes directly from the battery, rather than from a power source to which the electrical connector 602 is connected. In some embodiments, the microprocessor 606 may be configured to simultaneously activate the aerosol delivery device when the current from the power source to the rechargeable battery 601 is interrupted. In some embodiments, the microprocessor 606 may be configured to activate or begin activating the aerosol delivery device before the current from the power source to the rechargeable battery 601 is interrupted.

[0074] The output in response to an action using the aerosol delivery device can be any activity by the device that requires the delivery of power from a battery to further elements of the aerosol delivery device. As described above, the output can be the formation of an aerosol by the delivery of power from a battery to a heater that vaporizes a liquid aerosol precursor composition. In some embodiments, the output can be the activation of a status indicator (e.g., a light, a tactile element, a sound element, a display, etc.) to provide an indication of the status of the device in response to an action using the device, such as shaking the device or touching a capacitive sensor on the device. In such an embodiment, the sensor can include a device (such as a gyroscope or similar element) configured to sense the movement of the device.

[0075] In some embodiments, the above operations may be performed by the microprocessor 606. For example, instructions for the above operations may be stored as computer readable program code in a non-transitory memory. The microprocessor 606 may be configured to execute the computer readable program code to perform the instructions for the above operations. The microprocessor 606 may be several processors, a multi-core processor, or some other type of processor, depending on the particular implementation. Furthermore, the microprocessor 606 may be realized using several heterogeneous processor systems in which a main processor is present along with one or more secondary processors on a single chip. As another illustrative example, the microprocessor 606 may be a symmetric multi-processor system including multiple processors of the same type. In yet another example, the microprocessor 606 may be embodied as or otherwise include one or more ASICs, FPGAs, and the like. Thus, while the microprocessor 606 may execute a computer program to perform one or more functions, various examples of the microprocessor 606 may perform one or more functions without the aid of a computer program. In any case, the microprocessor 606 may be appropriately programmed to perform functions or operations according to the exemplary embodiments of the present disclosure.

[0076] In some embodiments, since there is no current from the power source to the rechargeable battery 601, the heating element is powered only by the remaining power of the rechargeable battery 601, and not by the power source. In this manner, the control device 100 allows the user to smoke while the aerosol delivery device, and more specifically the electrical connector 602, is connected to the charger 604.

[0077] 7(A)-7(C) illustrate a switch circuit 607 in the control device 100 shown in FIG. 1 according to an exemplary embodiment of the present disclosure. As shown in FIG. 7(A), in one embodiment, the switch circuit 607 includes a pair of metal oxide semiconductor field effect transistor (MOSFET) switches respectively coupled to the positive and negative electrical connections of the electrical connector 102. The microprocessor 606 in this embodiment is configured to use the switch circuit 607 to disconnect both the positive and negative electrical connections from the rechargeable battery 601. For example, the microprocessor 606 can control both MOSFET switches to open.

[0078] 7(B), in another embodiment, the switch circuit 607 includes a pair of opto-isolator relays respectively coupled to the positive and negative electrical connections of the electrical connector 102. The microprocessor 606 in this embodiment is configured to use the switch circuit 607 to disconnect both the positive and negative electrical connections from the rechargeable battery 601. For example, the microprocessor 606 can control both opto-isolator relays to open.

[0079] As shown in FIG. 7(C), in another embodiment, the switch circuit 607 includes a MOSFET switch integrated with the charging circuit 603 and another switch external to the charging circuit 603. The microprocessor 606 in this embodiment is configured to use the switch circuit 607 to disconnect the electrical connector 602 from the rechargeable battery 601. For example, the external switch can send an enable signal to the microprocessor 606, and the microprocessor 606 can control the MOSFET switch integrated with the charging circuit 603 to open and the external switch to open based on the enable signal.

[0080] In a further example, the switch circuit 607 is coupled to one or both of the positive and negative electrical connections of the electrical connector 602. The microprocessor in this example is configured to use the switch circuit 607 to disconnect only one of the positive and negative electrical connections from the rechargeable battery 601.

[0081] In some embodiments, the sensor 605 can detect that use has ended an action, such as a puffing action, after current flow from the power source to the rechargeable battery 601 has been interrupted. In response to detecting completion of the action by the sensor 605, the microprocessor 606 in such embodiments is configured to determine that the electrical connector 602 is still connected to the power source despite the absence of current flow from the power source to the rechargeable battery 601. The microprocessor 606 is configured to reconnect the electrical connector 602 to the rechargeable battery 601, thereby reconnecting the power source to the rechargeable battery 601 and charging the rechargeable battery 601. For example, the microprocessor 606 can control the switch circuit 607 to close so that current flows from the power source through the electrical connector 602 to the rechargeable battery 601.

[0082] 8 illustrates a flow chart illustrating a method 800 of charging control according to an exemplary embodiment of the present disclosure. As shown, in such an embodiment, in block 801, the microprocessor 606 may read the pressure sensor status of the sensor 605. In block 802, the microprocessor 606 of such an embodiment may determine whether a puffing action by a user is detected by the sensor 605 based on the output signal from the sensor 605. If a puffing action is not detected, the method 800 may return to block 801 and the microprocessor 606 may continue to monitor the sensor status. On the other hand, if a puffing action is detected, the method 800 may proceed to block 803.

[0083] In block 803, the microprocessor 606 of such an embodiment may determine whether charging is possible. Charging is possible when the microprocessor 606 may determine a state of the aerosol delivery device that indicates the occurrence of the passage of current from the power source through the electrical connector 602 to the rechargeable battery 601. If charging is possible, the microprocessor 606 of such an embodiment may disable the charging connection to interrupt the passage of current from the power source through the electrical connector 602 to the rechargeable battery 601, as described above. After the passage of current is interrupted, the microprocessor 606 may control to activate a vapor mechanism, such as the heater 319, to enable puffing, as shown in block 805. On the other hand, if charging is not possible, the microprocessor 606 of such an embodiment may directly activate a vapor formation mechanism, as shown in block 805.

[0084] The microprocessor 606 of such an embodiment may continue to monitor the sensor status to read the pressure sensor status and determine if the user has terminated the puffing action, as shown in blocks 806 and 807, respectively. If the puffing action is completed, the microprocessor 606 of such an embodiment may determine if the electrical connector 602 is still connected to the power source despite there being no current from the power source to the rechargeable battery 601, as shown in block 808. If a charging source is still present, i.e., the electrical connector 602 is still connected to the power source, the microprocessor 606 of such an embodiment may reconnect the power source to the rechargeable battery 601, as shown in block 809, to reconnect the electrical connector 602 to the rechargeable battery 601, thereby charging the rechargeable battery 601.

[0085] A typical low-battery threshold for a 3.7V e-cigarette battery may be approximately 3.4V. This low-battery threshold may vary between 3.3V and 3.5V depending on the remaining circuitry and vapor / heating mechanism. At this threshold, there is enough power for the microprocessor 606 to continue operating, turn on the LED, etc. However, high amperage heating is inhibited to protect the battery cells from over-discharging. In one example, the battery threshold is set to 3.5V when operating normally with only the rechargeable battery 601. If the voltage of the rechargeable battery 601 is below 3.5V, the user cannot activate the heater 319 and a low battery indication is given by the LED or other method. If the user establishes a charging connection between the aerosol delivery device and a charging device (e.g., charger 604) at this point, the rechargeable battery 601 may take an unacceptably long time to draw enough charging current to rise above the 3.5V threshold and cause the microprocessor 606 to resume allowing puffing activity.

[0086] In some examples, it may be desirable to allow a puff to occur as soon as the aerosol delivery device (with a depleted battery) is connected to a charger, even if the battery level is still below the low battery threshold. By having a different puff prevention voltage threshold (e.g., a lower threshold) when operating on rechargeable battery 601 while connected to charger 604 than the single threshold that may be used when operating on rechargeable battery 601 only, this can be achieved.

[0087] In some embodiments, when the charger 604 is connected to the electrical connector 602, the microprocessor 606 can lower the low battery threshold from 3.5V (e.g., to a voltage in the range of about 3.4V or about 3.3V) to allow the user to activate the heater while the electrical connector 602 is connected to a power source. In other embodiments, other different voltage thresholds both before charging and with the charger connected can be used. In some embodiments, the voltage threshold value can be characterized and adjusted to any combination of voltages depending on the particular battery chemistry, cell capacity, etc., the particular battery manufacturer's charge and discharge curves for the battery's life or number of recharge cycles, the microprocessor, and the heating circuitry, and / or as appropriate for the desired user experience.

[0088] In some embodiments, the control device 100 can include a rechargeable battery 601 and an auxiliary energy storage element, such as a supercapacitor or an auxiliary battery. The auxiliary energy storage element can provide power to the heating element to generate enough aerosol for a predetermined number of puffs, e.g., 10 puffs, or for a predetermined period of time, e.g., 5 minutes. In such an embodiment, if the rechargeable battery 601 can provide enough power to the heating element to generate aerosol for the user to puff, the auxiliary energy storage element may not be used to provide power to the heating element. When the rechargeable battery 601 is connected to the charger 604 for charging, the microprocessor 601 can check the auxiliary energy storage element. If the auxiliary energy storage element can provide power to the heating element to generate enough aerosol for a predetermined number of puffs or for a predetermined period of time, the microprocessor 606 can control the charger 604 to start charging the rechargeable battery 601. During charging, if a user action, e.g., a puffing action, is detected and the rechargeable battery 601 has not recovered enough capacity to provide sufficient power to the heating element, the microprocessor 606 can activate the auxiliary energy storage element to provide power to the heating element to generate enough aerosol for a predetermined number of times or for a predetermined period of time. The power provided by the auxiliary energy storage element can depend on the recovery time of the rechargeable battery 601. The recovery time can be the time that the rechargeable battery 601 needs to be charged to provide the heating element with enough power to generate aerosol for the user for puffing. In such an embodiment, the rechargeable battery 601 and the auxiliary energy storage element can have separate connections to the heating element. Thus, when power from the auxiliary energy storage element is being provided to the heating element, the rechargeable battery 601 can be charged at the same time.

[0089] 9 shows a flow chart illustrating a method 900 of charging control according to another exemplary embodiment of the present disclosure. As shown, in such an embodiment, in block 901, the microprocessor 606 can read the pressure sensor status of the sensor 605. In block 902, the microprocessor 606 in such an embodiment can determine whether a puffing action by a user is detected by the sensor 605 based on the output signal from the sensor 605. If a puffing action is not detected, the method 900 can return to block 901 and the microprocessor 606 can continue to monitor the sensor status. On the other hand, if a puffing action is detected, the method 900 can proceed to block 903.

[0090] In block 903, the microprocessor 606 of such an embodiment can determine whether the voltage of the rechargeable battery 601 is greater than a battery threshold when operating solely on the rechargeable battery 601, such as 3.5V. If the voltage of the rechargeable battery 601 is greater than the battery threshold, the method 900 can proceed directly to block 906, where the microprocessor 606 can enable activation of the heater 319 in the aerosol delivery device to perform a puff action. On the other hand, if the voltage of the rechargeable battery 601 is less than the battery threshold, the method 900 can proceed to block 904.

[0091] In block 904, the microprocessor 606 of such an embodiment may determine whether the electrical connector 602 is connected to a power source via the charger 604. If not, the method 900 may proceed to block 907. As shown in block 907, because the voltage of the rechargeable battery 601 is below the battery threshold and there is no charger connected to charge the rechargeable battery 601, the rechargeable battery 601 may be at a low battery level and the microprocessor 606 of such an embodiment may disable activation of the heater 319 in the aerosol delivery device to perform a puff action.

[0092] On the other hand, if in block 904 the microprocessor 606 of such an embodiment can determine that the electrical connector 602 is connected to a power source via the charger 604, the microprocessor 606 can change the voltage threshold of the rechargeable battery 601 from a higher value to a lower value, for example from about 3.5 V to about 3.3 V. The lower value can be referred to as a charge threshold when operating with the rechargeable battery 601 with the charger 604 connected, which is lower than the battery threshold as discussed above. The method 900 can proceed from block 904 to block 905.

[0093] In block 905, the microprocessor 606 of such an embodiment may perform a comparison between the voltage of the rechargeable battery 601 and a charge threshold of the rechargeable battery 601 (e.g., about 3.3 V) to determine whether the voltage of the rechargeable battery 601 is higher than the charge threshold. If the voltage of the rechargeable battery 601 is higher than the charge threshold (but still lower than the battery threshold of about 3.5 V), the microprocessor 606 of such an embodiment may enable activation of the heater 319 in the aerosol delivery device to perform the puff action, as shown in block 906. On the other hand, if the voltage of the rechargeable battery 601 is lower than the charge threshold, the microprocessor 606 may disable activation of the heater 319 in the aerosol delivery device to perform the puff action, as shown in block 907.

[0094] Methods 800 and 900 can be used together or separately. For example, if the microprocessor 606 determines a state of the aerosol delivery device indicating the occurrence of the passage of current through the electrical connector 602 from the power source to the rechargeable battery 601, the microprocessor 606 can open the switch circuit 607 to interrupt the passage of current and change the voltage threshold of the rechargeable battery 601 from a higher value to a lower value to cause a puff. In another example, if the microprocessor 606 detects a puff action and determines that the electrical connector 602 is connected to the power source (the switch circuit 607 can be opened or closed), the microprocessor 606 can change the voltage threshold of the rechargeable battery 601 from a higher value to a lower value to cause a puff in response to the connection of the aerosol delivery device to the charger 604.

[0095] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol delivery device comprising: A rechargeable battery; Determine the voltage of the rechargeable battery; comparing the voltage of the rechargeable battery to a first low battery threshold and a second low battery threshold, the second low battery threshold being less than the first low battery threshold; outputting a signal indicating a first state of the rechargeable battery if the voltage of the rechargeable battery is less than a first low-voltage threshold, or outputting a signal indicating a second state of the rechargeable battery if the voltage of the rechargeable battery is less than the first low-voltage threshold but greater than a second low-voltage threshold. a microprocessor configured to an indicator operatively coupled to the microprocessor, the indicator being responsive to receiving a signal from the microprocessor to output a status indication of a first state or a second state of the rechargeable battery, the status indications of the first state and the second state of the rechargeable battery being different; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1, wherein in response to the voltage of the rechargeable battery being less than a third low-voltage threshold, the third low-voltage threshold is less than the second low-voltage threshold, the microprocessor deactivates the aerosol delivery device, and power is not delivered from the rechargeable battery to further elements of the aerosol delivery device.

3. 10. The aerosol delivery device of claim 1, wherein the indicator is one or more of a tactile feedback component, an audio feedback component, a light emitting diode (LED) component, and a display component.

4. 10. The aerosol delivery device of claim 1, wherein the values ​​of one or both of the first low voltage threshold and the second low battery threshold can be characterized and adjusted by a user.

5. The aerosol delivery device of claim 1 , wherein the aerosol delivery device is configured to communicate with an external computing device and output information, the information comprising a signal indicative of at least a status of a rechargeable battery.

6. The aerosol delivery device of claim 1, further comprising a charging circuit including an electrical connector configured to interact with a power source, and a sensor configured to detect an action of a user using the aerosol delivery device and output a signal.

7. The aerosol delivery device of claim 6, wherein the microprocessor is operatively coupled to the charging circuit and the sensor, and the microprocessor is configured to determine a charging state indicative of the passage of current from the power source through the electrical connector to the rechargeable battery in response to receiving a signal from the sensor.

8. In response to a user action of using the aerosol delivery device and a determination of the charge state, the microprocessor: activating the aerosol delivery device when the voltage of the rechargeable battery is less than the first low-voltage threshold but greater than the second low-voltage threshold, such that power is delivered from the rechargeable battery to a further element of the aerosol delivery device; If the voltage of the rechargeable battery is less than a second low voltage threshold, deactivating the aerosol delivery device such that power is not delivered from the rechargeable battery to further elements of the aerosol delivery device. The aerosol delivery device of claim 7 , configured to:

9. 10. The aerosol delivery device of claim 8, wherein the microprocessor is further configured to interrupt the passage of electrical current using a switch circuit between the electrical connector and the rechargeable battery.

10. 10. The aerosol delivery device of claim 9, wherein the switch circuit includes a pair of metal oxide semiconductor field effect transistor (MOSFET) switches respectively coupled to the positive and negative electrical connections of the electrical connector, and wherein the microprocessor is configured to interrupt the passage of current includes being configured to disconnect both the positive and negative electrical connections from the rechargeable battery using the switch circuit.

11. The aerosol delivery device of claim 9, wherein the switch circuit includes a pair of optical isolator relays respectively coupled to the positive and negative electrical connections of the electrical connector, and wherein the microprocessor is configured to interrupt the passage of current includes being configured to disconnect both the positive and negative electrical connections from the rechargeable battery using the switch circuit.

12. 10. The aerosol delivery device of claim 9, wherein a switch circuit is coupled to one or both of the positive and negative electrical connections of the electrical connector, and wherein the microprocessor is configured to interrupt the passage of electrical current includes being configured to disconnect only one of the positive and negative electrical connections from the rechargeable battery using the switch circuit.

13. The aerosol delivery device of claim 9, wherein the switch circuit includes a MOSFET switch integrated with the charging circuit and another switch external to the charging circuit, and wherein the microprocessor being configured to interrupt the passage of current includes being configured to use the switch circuit to disconnect the electrical connector from the rechargeable battery.

14. In response to detecting completion of the action by the sensor, the microprocessor: determining that the electrical connector is connected to a power source; Reconnecting the power source to the rechargeable battery to reconnect the electrical connector to the rechargeable battery, thereby charging the rechargeable battery. The aerosol delivery device of claim 6, further configured to:

15. The aerosol delivery device of claim 6 , wherein the action comprises a puffing action by a user.

16. 10. The aerosol delivery device of claim 8, further comprising a heating element configured to heat and thereby vaporize components of an aerosol precursor composition contained within a housing of the aerosol delivery device such that an output in response to an action of using the aerosol delivery device is the formation of an aerosol.

17. 17. The aerosol delivery device of claim 16, wherein the aerosol precursor composition contained therein is liquid, solid, or semi-solid.

18. The microprocessor changing a battery voltage threshold from a first value to a second value lower than the first value; Determining that the voltage of the battery is less than a first value and greater than a second value The aerosol delivery device of claim 8 .

Images