Aerosol delivery device and related method

Abstract

To provide an aerosol delivery device functioning without direct contact with or thermal degradation of an aerosol precursor composition.SOLUTION: An aerosol delivery device 100 includes a heating chamber 106 having an aerosol precursor composition 108 disposed therein. A microwave radiation energy emitting device 110 is operably engaged with the heating chamber and is configured to heat the aerosol precursor composition therein with microwave radiation energy to form aerosol from the aerosol precursor composition. An outlet port 118 is formed in a housing of the aerosol delivery device and is in fluid communication with the heating chamber. In response to a suction force applied to the outlet port, the heating chamber causes the aerosol to be drawn out of the housing through the outlet port.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to aerosol delivery devices, and more particularly to microwave radiant heating elements configured to heat an aerosol precursor composition produced from tobacco, derived from tobacco, or otherwise incorporating tobacco-related materials to form an inhalable substance for human consumption. [Background technology]

[0002] Smoking devices have been proposed for many years as an improvement or replacement for smoking products that require the burning of tobacco for use. Many of these devices are designed to provide the sensations associated with smoking a cigarette, cigar, or pipe, but are said to do so without delivering significant amounts of the incomplete combustion and pyrolysis products resulting from the burning of tobacco.

[0003] For this purpose, smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or provide the smoking sensation of cigarettes, cigars or pipes without significant tobacco combustion.See, for example, the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art described in U.S. Patent No. 8,881,737 to Collett et al. and U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al. and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference.

[0004] Among these smoking products, flavor generators, and medicinal inhalers that use electrical energy to generate heat to form smoke or aerosol, a wick and coil configuration is often utilized in combination with a power source such as a battery. More specifically, in this configuration, the coil is in direct contact with the wick and acts as a heating element. The coil is configured to conduct electrical current from the battery and heat a limited amount of the aerosol precursor composition absorbed in the wick by direct contact. However, the wick and coil configuration may cause thermal degradation of the aerosol precursor composition, as direct heating may result in uneven heating of the aerosol precursor composition.

[0005] It is therefore desirable to provide an aerosol delivery device that uses heat generated by an external energy source to heat an aerosol precursor composition to provide the sensation of smoking a cigarette, cigar, or pipe, preferably without direct contact with or thermal degradation of the aerosol precursor composition, in order to extend the useful life of the device and deliver an aerosol with improved uniformity. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Pat. No. 8,881,737 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] US Patent Application Publication No. 2013 / 0255702 [Patent Document 4] US Patent Application Publication No. 2014 / 0000638 [Patent Document 5] US Patent Application Publication No. 2014 / 0096781 Summary of the Invention [Means for solving the problem]

[0007] The present disclosure relates to an aerosol delivery device configured to generate an aerosol for human consumption. In one aspect, the aerosol delivery device comprises: a heating chamber having an aerosol precursor composition disposed therein; a microwave radiant energy emitting device operatively engaged with the heating chamber and configured to heat the aerosol precursor composition therein with microwave radiant energy to form an aerosol from the aerosol precursor composition; a housing having an outlet port and in fluid communication with the heating chamber; Including, The heating chamber responds to suction applied to the exit port to cause the aerosol to be drawn outwardly from the housing through the exit port.

[0008] In another aspect, a method of making an aerosol delivery device includes: operatively engaging a microwave radiant energy emitting device with a heating chamber configured to receive an aerosol precursor composition therein, the microwave radiant energy emitting device configured to heat the aerosol precursor composition with microwave radiant energy emitted thereby to form an aerosol from the aerosol precursor composition; engaging the heating chamber with a housing having an outlet port such that the outlet port is in fluid communication with the heating chamber and such that the heating chamber responds to a suction force applied to the outlet port such that an aerosol is drawn outwardly from the housing through the outlet port; Includes.

[0009] Accordingly, the present disclosure includes, but is not limited to, the following embodiments.

[0010] Embodiment 1: An aerosol delivery device comprising: a heating chamber having an aerosol precursor composition disposed therein; a microwave radiant energy emitting device operatively engaged with the heating chamber and configured to heat the aerosol precursor composition therein with microwave radiant energy to form an aerosol from the aerosol precursor composition; a housing having an outlet port and in fluid communication with the heating chamber; Including, An aerosol delivery device, wherein the heating chamber responds to suction applied to the exit port such that the aerosol is drawn outwardly from the housing through the exit port.

[0011] Embodiment 2: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising an aerosol precursor delivery arrangement operably engaged with the heating chamber and configured to direct the aerosol precursor composition to the heating chamber from a reservoir configured to contain the aerosol precursor composition therein and in fluid communication with the aerosol precursor delivery arrangement.

[0012] Embodiment 3: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein the microwave radiant energy emitting device includes a magnetron extending around the heating chamber and configured to emit microwave radiant energy.

[0013] Embodiment 4: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein the magnetron is disposed within an enclosure configured to substantially surround the heating chamber.

[0014] Embodiment 5: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, comprising two or more reservoirs, each reservoir configured to house a separate aerosol precursor composition therein, each of the two or more reservoirs in fluid communication with the aerosol precursor delivery arrangement, and operable with the aerosol precursor delivery arrangement to direct one of the separate aerosol precursor compositions from a respective one of the two or more reservoirs to the heating chamber.

[0015] Embodiment 6: An aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, comprising an air flow path defined within the housing or enclosure and configured to allow air flow between the heating chamber and outside air outside the housing or enclosure.

[0016] Embodiment 7: An aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein the exit port or air flow path includes an air flow blocking element configured to cooperate with the enclosure to confine microwave radiant energy within the enclosure.

[0017] Embodiment 8: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, comprising a hose member having an engaged proximal end engaged with the outlet port and an opposed distal end engaged with a mouthpiece element, the mouthpiece element and the hose member in fluid communication with the heating chamber via the outlet port to receive an aerosol therefrom in response to a suction force applied to the mouthpiece element.

[0018] Embodiment 9: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, comprising a controller element in communication between the microwave radiant energy emitting device and a sensing element in communication with the aerosol precursor composition in the heating chamber, wherein the sensing element is configured to sense a temperature of the aerosol precursor composition in the heating chamber, and wherein the controller element, in response to the sensed temperature, adjusts microwave radiation output by the microwave radiant energy emitting device to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

[0019] Embodiment 10: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein the aerosol precursor composition is selected from the group consisting of a liquid, a gel, a solid, a capsule, a colloid, a suspension, a botanical derivative, and combinations thereof.

[0020] Embodiment 11: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein one component of the aerosol precursor composition is configured to prevent overheating of the aerosol precursor composition.

[0021] Embodiment 12: An aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, comprising a wick engaged with a heating chamber, the wick in communication with the aerosol precursor composition, and wherein the microwave radiant energy emitting device is configured to heat the wick such that an amount of aerosol formed by the wick is proportional to an amount of the aerosol precursor composition drawn up by the wick.

[0022] Embodiment 13: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein the heating chamber includes a first heated subchamber and a second heated subchamber, one of the first and second heated subchambers having a larger volume for the aerosol precursor composition than the other, the first and second heated subchambers in fluid communication with an outlet port via a selector element, the selector element directing aerosol from a selected one of the first and second heated subchambers to the outlet port in response to a suction force applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction force. Aerosol delivery device.

[0023] Embodiment 14: The aerosol delivery apparatus of any preceding embodiment, or any combination of the preceding embodiments, comprising an aerosol precursor processing unit in fluid communication with the heating chamber and configured to preheat the aerosol precursor composition to a preheat temperature, wherein the preheat temperature is lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is directed to the heating chamber.

[0024] Embodiment 15: The aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein the aerosol precursor processing unit comprises a heating element or an aerosol forming element configured to interact with the aerosol precursor composition.

[0025] Embodiment 16: An aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, comprising an aerosol precursor processing unit in communication with the heating chamber and configured to pre-heat a substrate material with an aerosol precursor composition associated therewith to a pre-heat temperature, wherein the pre-heat temperature is lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the pre-heated substrate material is conducted to the heating chamber.

[0026] Embodiment 17: An aerosol delivery apparatus of any preceding embodiment, or any combination of the preceding embodiments, comprising an aerosol precursor processing unit in communication with a heating chamber and configured to preheat a film comprised of an aerosol precursor composition to a preheat temperature, wherein the preheat temperature is lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated film is conducted to the heating chamber.

[0027] Embodiment 18: A method of manufacturing an aerosol delivery device, comprising: operatively engaging a microwave radiant energy emitting device with a heating chamber configured to receive an aerosol precursor composition therein, the microwave radiant energy emitting device configured to heat the aerosol precursor composition with microwave radiant energy emitted thereby to form an aerosol from the aerosol precursor composition; engaging the heating chamber with a housing having an outlet port such that the outlet port is in fluid communication with the heating chamber and such that the heating chamber responds to a suction force applied to the outlet port such that an aerosol is drawn outwardly from the housing through the outlet port; A manufacturing method comprising:

[0028] Embodiment 19: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising engaging an aerosol precursor delivery arrangement in fluid communication with the heating chamber, the aerosol precursor delivery arrangement configured to direct the aerosol precursor composition from a reservoir having the aerosol precursor composition therein to the heating chamber.

[0029] Embodiment 20: A method of manufacturing an aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein operably engaging the microwave radiant energy emitting device comprises operably engaging a magnetron to the heating chamber, the magnetron extending around the heating chamber and configured to emit microwave radiant energy.

[0030] Embodiment 21: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising disposing a magnetron within an enclosure configured to substantially surround the heating chamber.

[0031] Embodiment 22: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising forming two or more reservoirs within the housing, each reservoir containing a separate aerosol precursor composition therein, each of the two or more reservoirs in fluid communication with the aerosol precursor delivery configuration, and the aerosol precursor delivery configuration operable to direct one of the separate aerosol precursor compositions from a respective one of the two or more reservoirs to the heating chamber.

[0032] Embodiment 23: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising defining an air flow passage within the housing or enclosure, the air flow passage configured to allow air flow between the heating chamber and outside air outside the housing or enclosure.

[0033] Embodiment 24: A method of manufacturing an aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising disposing an airflow blocking element at the exit port or air flow path, wherein the airflow blocking element is configured to cooperate with the enclosure to confine microwave radiant energy within the enclosure.

[0034] Embodiment 25: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising engaging a proximal end of the hose member with the outlet port and engaging an opposite distal end of the hose member with a mouthpiece element, wherein the mouthpiece element and hose member are in fluid communication with the heating chamber via the outlet port to receive an aerosol therefrom in response to suction applied to the mouthpiece element.

[0035] Embodiment 26: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising operably engaging a controller element between the microwave radiant energy emitting device and a sensing element in communication with the aerosol precursor composition in the heating chamber, wherein the sensing element is configured to sense a temperature of the aerosol precursor composition in the heating chamber, and wherein the controller element is configured to adjust microwave radiation output by the microwave radiant energy emitting device in response to the sensed temperature to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

[0036] Embodiment 27: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising selecting an aerosol precursor composition from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, botanical derivatives, and combinations thereof.

[0037] Embodiment 28: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein selecting the aerosol precursor composition further comprises selecting the aerosol precursor composition such that one component of the aerosol precursor composition is configured to prevent overheating of the aerosol precursor composition.

[0038] Embodiment 29: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising engaging the wick with a heating chamber such that the wick is in communication with the aerosol precursor composition, and wherein the microwave radiant energy emitting device is configured to heat the wick such that an amount of aerosol formed by the wick is proportional to an amount of the aerosol precursor composition drawn up by the wick.

[0039] Embodiment 30: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising defining a first heated subchamber and a second heated subchamber within the heating chamber, one of the first and second heated subchambers having a larger capacity for the aerosol precursor composition than the other, the first and second heated subchambers being configured in selective fluid communication with an outlet port via a selector element, the selector element directing aerosol from the heated subchamber in selective communication with the outlet port to the outlet port in response to a suction force applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction force.

[0040] Embodiment 31: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising engaging an aerosol precursor processing unit in fluid communication with the heating chamber, wherein the aerosol precursor processing unit is configured to pre-heat the aerosol precursor composition to a pre-heat temperature, the pre-heat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the pre-heated aerosol precursor composition is directed to the heating chamber.

[0041] Embodiment 32: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, wherein engaging the aerosol precursor processing unit comprises positioning a heating element or an aerosol forming element to interact with the aerosol precursor composition before the pre-heated aerosol precursor composition is directed to the heating chamber.

[0042] Embodiment 33: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising engaging an aerosol precursor processing unit in fluid communication with the heating chamber, wherein the aerosol precursor processing unit is configured to pre-heat a substrate material with an aerosol precursor composition associated therewith to a pre-heat temperature, the pre-heat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the pre-heated substrate material is conducted to the heating chamber.

[0043] Embodiment 34: A method of manufacturing the aerosol delivery device of any preceding embodiment, or any combination of the preceding embodiments, further comprising engaging an aerosol precursor processing unit in fluid communication with the heating chamber, wherein the aerosol precursor processing unit is configured to pre-heat a film comprised of the aerosol precursor composition to a pre-heat temperature, the pre-heat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the pre-heated film is conducted to the heating chamber.

[0044] 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 or elements described in this disclosure or recited in any one or more of the claims, regardless of whether such features or elements are explicitly combined or otherwise recited in the description of a particular embodiment or in the claims herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosure, in any of its aspects and embodiments, appear as intended to be combinable, unless the context of the disclosure clearly dictates otherwise.

[0045] Having described the present disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0046] [Figure 1] 1 shows a side view of an aerosol delivery device including a microwave radiant energy emitting device according to an exemplary embodiment of the present disclosure. [Figure 2A] 1 shows a cross-sectional view of an aerosol generated in a heating chamber of an aerosol delivery device by microwave radiant energy generated by a microwave radiant energy emitting device according to an exemplary embodiment of the present disclosure. [Figure 2B] 1 shows a cross-sectional view of aerosols generated in two heating chambers of an aerosol delivery device by microwave radiant energy generated by a microwave radiant energy emitting device according to an exemplary embodiment of the present disclosure. [Diagram 3] 1 shows a cross-sectional view of an aerosol precursor composition in two different reservoirs of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 4A] 1 illustrates an aerosol precursor processing apparatus according to an exemplary embodiment of the present disclosure. [Figure 4B]1 illustrates an aerosol precursor processing apparatus according to an exemplary embodiment of the present disclosure. [Figure 4C] 1 illustrates an aerosol precursor processing apparatus according to an exemplary embodiment of the present disclosure. [Diagram 5] 1 shows a flow diagram of a method for manufacturing an aerosol delivery device according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] The present disclosure will now be described in further detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided 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.

[0048] The present disclosure relates to an aerosol delivery device that uses microwave radiant energy to heat a material (preferably without significantly burning the material) to form an inhalable substance. In some aspects, the aerosol delivery device is considered a "tabletop" device, configured in a size, shape, etc. similar to that of a traditional hookah. However, in other aspects, the aerosol delivery device is considered a "handheld" device, sized, shaped, etc. to be easily held in a consumer's hand.

[0049] In certain preferred embodiments, the aerosol delivery device is characterized as a smoking article. The term "smoking article" as used herein is intended to mean an article or device that provides some or all of the sensations of smoking a cigarette, cigar, or pipe (e.g., the type of inhalation and exhalation, the type of taste or flavor, the sensory stimulating effect, the physical feel, the type of use, the visual stimuli as provided by a visible aerosol, etc.) without substantially burning any of the components of the article or device. The term "smoking article" as used herein does not necessarily mean that the article or device generates smoke in the sense of an aerosol resulting from the by-products of the combustion or pyrolysis of tobacco during operation, but rather that the article or device generates vapors (including vapors within an aerosol that may be considered as a visible aerosol that may be considered as described as smoke-like) due to the volatilization or vaporization of certain components of the article or device. In some preferred embodiments, an article or device characterized as a smoking article incorporates tobacco and / or tobacco-derived components.

[0050] In various aspects, the article or device of the present disclosure is also characterized as being a vapor product, an aerosol delivery article, or a drug delivery article. Thus, such an article or device is configured to provide one or more substances (e.g., flavors and / or pharmacoactive ingredients) in an inhalable form or state. For example, the inhalable substance is substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance is in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For ease of understanding, 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 they are visible and in a form that can be considered as smoke-like.

[0051] Smoking articles of the present disclosure, when in use, are subject to many of the physical actions employed by an individual when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is used by lighting tobacco and inhaling. For example, a user of a smoking article of the present disclosure manipulates the article as with a traditional type of smoking article, drawing on one mouthpiece element of the article to inhale an aerosol produced by the article, taking puffs for selected time intervals, etc.

[0052] Smoking articles of the present disclosure include some combination of a heat source (i.e., a microwave radiant energy emitting element), at least one control component (e.g., a configuration for activating, controlling, regulating and / or terminating power to the heat source to control heat generation, such as by controlling microwave radiant energy emitted from the heat source to other components of the smoking article), an aerosol precursor composition (e.g., a liquid that can generally generate an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece element (e.g., a defined air flow path through the smoking article such that the generated aerosol may be drawn therefrom by inhalation) that enables drawing on the smoking article (also otherwise referred to herein as an aerosol delivery device) for aerosol inhalation.

[0053] One exemplary embodiment of the aerosol delivery device 100 is provided in FIG. 1. As seen in the side view shown therein, the aerosol delivery device 100 includes a housing 102 and an enclosure 104 that are permanently or removably connected in a functional relationship. The enclosure 104 is configured in size and / or shape to fit around and substantially enclose the first portion of the housing 102 therein. In some examples, the first portion is a lower portion or base of the housing 102. For example, the enclosure 104 is molded to correspond to the exterior contour of the first portion of the housing 102 and is hinged to open and close. In this manner, the first portion of the housing 102 fits into the molded shape of the enclosure 104 when the enclosure is hinged open and is held fixed therein when the enclosure is hinged closed. Other types of engagements or connections between the housing 102 and the enclosure 104 are also contemplated.

[0054] In one embodiment, the heating chamber 106 configured to receive the aerosol precursor composition 108 therein defines a first portion of the housing 102. In some aspects, the enclosure 104 substantially surrounds or encloses the heating chamber 106. The heating chamber 106 is a single heating chamber or, in some embodiments, is further divided into subchambers. For example, in one embodiment shown in FIG. 1 and in further detail in FIG. 2A, a single heating chamber 106 is provided. In another example, as another embodiment shown in FIG. 2B, a first heating subchamber 106A and a second heating subchamber 106B are provided. In such an example, one of the first and second heating subchambers 106A-B is configured to have a larger capacity for the aerosol precursor composition 108 than the other subchamber. In the example shown in FIG. 2B, the second heating subchamber 106B has a larger capacity for the aerosol precursor composition 108 than the first heating subchamber 106A. In other such examples, the first and second heated subchambers 106A-B are configured to have a substantially similar volume for the aerosol precursor composition 108.

[0055] In either example, the heating chamber 106 is operably engaged to a heat source, such as a microwave radiant energy emitting device 110. The microwave radiant energy emitting device 110, in some embodiments, includes a magnetron that generates microwave radiant energy 112. In some embodiments, the magnetron is preferably sized to fit the desired shape, size, etc. of the aerosol delivery device 100 so that the device is easily manipulated without compromising the desired smoking experience. In other embodiments, the microwave radiant energy emitting device 110 includes an antenna, coil, etc. configured to generate microwave radiant energy 112. In such cases, the material to be heated may be in different configurations / orientations relative to the microwave source. For example, in the case of a coil, the material may be in the interior (center) of the coil.

[0056] Thus, microwave radiant energy 112 emitted by microwave radiant energy emitting device 110 is configured to penetrate heating chamber 106 and heat aerosol precursor composition 108 contained therein to form aerosol 114 therefrom. More specifically, in some embodiments, microwave radiant energy 112 rotates polar molecules of aerosol precursor composition 108 to generate thermal energy. As a result, the molecules in the aerosol precursor composition are uniformly excited and heated by microwave radiant energy 112 such that there is minimal thermal degradation of aerosol precursor composition 108 upon formation of aerosol 114 (i.e., there are no superheated particles), and the resulting aerosol 114 has a more consistent vapor chemistry than that generated by other types of heat sources, such as electrical heating elements (e.g., resistive heating coils).

[0057] In some aspects, the microwave radiant energy emitting device 110, as well as other aspects of the aerosol delivery device 100 itself, are powered by a power source. The power source is configured to provide sufficient power, energy, or current to provide various functions of the aerosol delivery device 100, such as heating the aerosol precursor composition via the microwave radiant energy emitting device 110, powering control components or systems, powering indicators, and the like. Preferably, the power source can take various embodiments capable of providing sufficient power to each of the microwave radiant energy emitting devices 110 to rapidly heat the aerosol precursor composition 108 received in the heating chamber 106 and form an aerosol therefrom, and powering other components of the aerosol delivery device 100 throughout use for a desired duration. For example, in some examples, the aerosol delivery device 100, including the microwave radiant energy emitting device 110, is powered via a standard household outlet (e.g., 120 AC volts). In another example, the aerosol delivery device 100 is powered by a battery of sufficient energy density. Thus, when the aerosol delivery device 100 is connected to a power source, the microwave radiant energy emitting device 110 is powered and controllable to heat the aerosol precursor composition 108 contained in the heating chamber 106 .

[0058] The housing 102, enclosure 104 and / or heating chamber 106 are configured to confine the microwave radiant energy 112 emitted by the microwave radiant energy emitting device 110 therein. For example, the housing 102, enclosure 104 and / or heating chamber 106 are similar in material and design to a Faraday cage to prevent the microwave radiant energy from escaping. An exit port or orifice penetrating a surface of the housing 102, enclosure 104 and / or heating chamber 106 and fluidly communicating with the exterior of the housing 102 or enclosure 104 includes a shielding element 116 to confine the microwave radiant energy 112 within the aerosol delivery device 100. In these embodiments, the housing 102 of the aerosol delivery device 100 defines an exit port 118, which is in fluid communication with the heating chamber 106. Thus, the shielding element 116 engages the exit port 118. The air flow passage 120 defined within the housing 102 and / or enclosure 104 also includes a shielding element 116. The shielding element 116 includes at least one layer of a conductive material (e.g., aluminum mesh), although other materials, types and / or configurations of the shielding element 116 are contemplated.

[0059] The outlet port 118 is configured to receive suction force (i.e., from a consumer) at the mouthpiece element 122 such that in response to the suction force, the aerosol 114 is drawn outwardly from the housing 102 through the outlet port 118. The hose member 124 is engageable with the outlet port 118. As shown in FIG. 1, for example, a proximal end of the hose member 122 is engaged with the outlet port 118 and an opposite distal end is engaged with the mouthpiece element 122. In this manner, the mouthpiece element 122 and the hose member 124 are in fluid communication with the heating chamber 106 via the outlet port 118 to receive the aerosol 114 therefrom in response to suction force applied to the mouthpiece element 122. In some embodiments, there are multiple outlet ports 118. For example, as shown in FIG. 1, there are at least two outlet ports 118. In such an example, a hose member 124 having a mouthpiece element 122 is engaged with each available outlet port 118 of the housing 102 such that multiple consumers can use the aerosol delivery device 100 at one time. Otherwise, unused outlet ports are capped or otherwise configured to prevent aerosol from escaping the housing 102 or otherwise entering the housing 102 and diluting the aerosol.

[0060] In some embodiments, one or more heated subchambers 106A-B are configured to selectively fluidly communicate with a respective outlet port 118. For example, a selector element (e.g., a valve, a flange) disposed within one or more heated subchambers 106A-B is configured to automatically respond to suction applied through the outlet port 118 to direct aerosol 114 from the respective heated subchamber 106A-B through the outlet port 118. FIG. 2A illustrates such an example, where the selector element responds to or opens the second heated subchamber 106B in response to suction applied through the respective outlet port. In FIG. 2A, for example, the outlet port through which suction is applied is not engaged with the first heated subchamber 106A, so the selector element is unresponsive or closed and aerosol 114 is not directed therefrom.

[0061] In other examples, the selector element is configured to manually respond to a user selection. In these examples, a switch, button, lever, or other mechanism may be used to selectively control from which heated subchambers 106A-B the aerosol 114 is directed.

[0062] The air flow paths 120 are configured to allow air flow between the heating chamber 106 and the ambient air outside the housing 102 and / or enclosure 104. For example, as shown in FIG. 1 and in more detail in FIG. 2A, a single heating chamber 106 has an air flow path 120 that extends from the interior of the heating chamber 106, through the interior of the enclosure 104, and to the exterior of the housing 102. In another example, as shown in FIG. 2B, two heating chambers 106A-B each have a separate air flow path 120A-B that extends therefrom to the exterior of the housing 102. However, in other examples (not shown), the air flow paths 120A-B are configured to extend from each heating chamber 106A-B and merge into a single flow path within the enclosure 104, with the single flow path extending to the exterior of the housing 102. In examples where there are multiple air flow paths 120, there is a shielding element 116A-B associated with each flow path.

[0063] 1, the aerosol precursor delivery arrangement 126 is operably engaged with the heating chamber 106 and configured to deliver the aerosol precursor composition 108 from a reservoir 128 to the heating chamber 106. The aerosol precursor delivery arrangement 126 is, in various embodiments, an internal flow tube, passageway, or other mechanism. For example, as shown in FIG. 1, the aerosol precursor delivery arrangement 126 is an air flow passageway defined within the housing 102 and configured to direct, by gravity, the aerosol precursor composition 108 dispensed from the reservoir 128 through the housing 102 to the heating chamber 106.

[0064] In other embodiments, the aerosol precursor delivery configuration 126 is also an aerosol delivery configuration, whereby the aerosol formed by the combination of vaporization of the aerosol precursor composition 108 and the ambient air in the heating chamber 106 is delivered to the consumer via the same mechanism that transports the aerosol precursor composition 108 to the heating chamber 106. In these embodiments, the airflow passage 126 is configured to have an interior volume larger than the interior volume of the heating chamber 106 to provide a head space for the generated aerosol to expand and / or age therein. In other embodiments not shown, the airflow passage 126 is configured as a flow tube engaged between the reservoir 128 and the heating chamber 106 to transport the aerosol precursor composition 108 from the reservoir 128 to the heating chamber 106 and to provide a head space for the generated aerosol to expand therein. Other similar mechanisms for delivering the aerosol precursor composition 108 and / or the generated aerosol are also contemplated.

[0065] The reservoir 128 is configured to contain an aerosol precursor composition 108 therein and is configured to be in fluid communication with the aerosol precursor delivery arrangement 126. Figure 1 illustrates the reservoir 128 configured to contain a first aerosol precursor composition 108. However, in some embodiments, illustrated in Figure 3, there are two or more reservoirs 128A-B, each reservoir 128A-B configured to contain a separate aerosol precursor composition 108A-B therein, and each of the two or more reservoirs 128A-B is in fluid communication with and operable with the aerosol precursor delivery arrangement 126.

[0066] In some embodiments, for example, two or more reservoirs 128A-B each contain a different aerosol precursor composition 108A-B therein. In such examples, a manual or automatic actuation mechanism (not shown) can be provided for selectively actuating fluid communication between one or more of the reservoirs 128A-B and the aerosol precursor delivery arrangement 126.

[0067] In other embodiments, for example, each of the two or more reservoirs 128A-B contains the same or substantially similar aerosol precursor composition 108A-B, and a first reservoir 128A of the two or more reservoirs is a primary reservoir and a second reservoir 128B of the two or more reservoirs is a secondary reservoir. In this example, the first or primary reservoir 128A is configured to be in fluid communication with the aerosol precursor delivery configuration 126, and the second or secondary reservoir 128B is configured to be in fluid communication with the aerosol precursor delivery configuration 126 only upon depletion of the aerosol precursor composition 108A contained within the first reservoir 128A. In these examples, a manual or automatic actuation mechanism (not shown) can be provided to sense depletion of the aerosol precursor composition 108A contained in the first reservoir 128A and actuate fluid communication between the second reservoir 128B containing the aerosol precursor composition 108B and the aerosol precursor delivery configuration 126.

[0068] Thereby, the aerosol precursor delivery arrangement 126 is configured to deliver any of the separate aerosol precursor compositions 108A-B, individually or in combination, from a respective one of the two or more reservoirs 128A-B to the heating chamber 106. For example, two different aerosol precursor compositions 108A-B contained within respective reservoirs 128A-B are simultaneously, but independently, delivered to respective heating sub-chambers 106A-B. In such an example, each reservoir 128A-B is in fluid communication with a separate aerosol precursor delivery arrangement, heating chamber, and exit port. As a result of such a configuration, when multiple consumers use the aerosol delivery device 100 simultaneously, the aerosol delivery device 100 is configured to be customizable for each consumer, such that each consumer can select their own aerosol precursor composition 108 (e.g., menthol, crema, etc.) for a personalized experience.

[0069] In other such embodiments, for example, two different aerosol precursor compositions 108A-B contained within respective reservoirs 128A-B can be delivered simultaneously to the same heating chamber 106, such that the two different aerosol precursor compositions 108A-B can be combined within the heating chamber 106 before, during and / or after aerosolization. As a result of such configurations, the aerosol delivery device 100 can be configured to be customizable for a single consumer or multiple consumers, such that the combination of the various aerosol precursor compositions 108A-B results in a unique experience.

[0070] The reservoir 128 is configured as either a reusable reservoir or a removable and disposable reservoir. In one example, the reservoir 128 is reusable, and additional amounts of the aerosol precursor composition 108 are added to the reservoir 128 when needed. In another example, the reservoir 128 is removed when the aerosol precursor composition 108 contained therein is used up. A new reservoir 128 containing an additional amount of the aerosol precursor composition is then engaged with the housing 102, where the reservoir 128 is a disposable reservoir or a refillable and reusable reservoir. In either case, the reservoir 128 can be engaged with the housing 102 via a threaded engagement, a press-fit engagement, a magnetic engagement, or the like. Otherwise, the reservoir 128 is securely engaged with the housing 102 such that the reservoir 128 cannot be removed from the housing 102 (i.e., in the case of a refillable or reusable reservoir). In any event, the reservoir 128 is in fluid communication with the aerosol precursor delivery arrangement 126 such that the aerosol precursor composition 108 is delivered therefrom to the heating chamber 106 .

[0071] To meter the amount of aerosol precursor composition 108 delivered to the heating chamber 106, one embodiment of the reservoir 128 includes a screen 130 having a grid structure that is fine enough to prevent all of the aerosol precursor composition 108 from being delivered to the heating chamber 106 at once, but large enough to allow the composition particles to flow at a limited rate. For example, as shown in FIG. 1, the screen 130 is configured to span substantially the entire or entire inner diameter of the housing 102 and is positioned adjacent to the reservoir 128. In another example, as shown in FIG. 3, the screen 130 is positioned adjacent to both reservoirs 128A-B. However, a screen for each reservoir 128A-B is also contemplated.

[0072] In some embodiments, the aerosol precursor composition 108, which may also be referred to as a vapor precursor composition, includes one or more distinct components. The distinct components of the aerosol precursor composition 108 are selected from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, botanicals, and combinations thereof, dispersed in a porous matrix or individual packets (e.g., substrates). In some non-limiting examples, one of the components of the aerosol precursor composition 108 includes a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Additional representative types of aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., PCT Publication WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (1988) by R. J. Reynolds Tobacco Company Monograph, the disclosures of which are incorporated herein by reference.

[0073] The components of the aerosol precursor composition 108 are combined based on the particular effect that each component contributes to the overall experience of the consumer. In some embodiments, components are selected that enable the aerosol delivery device 100 to provide some or all of the sensation of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation format, type of taste or flavor, sensory stimulant effect, physical feel, format of use, visual stimuli such as those provided by a visible aerosol, etc.). In other embodiments, components are also selected that enable the aerosol delivery device 100 to generate a uniformly heated aerosol 114 from the aerosol precursor composition 108. For example, the aerosol precursor composition 130 can be selected with components that prevent overheating of the aerosol precursor composition 108, such as inert, non-volatile granules (e.g., boiling stones) or other nucleation surfaces that can absorb excess microwave radiation energy 112. Alternatively, the controller element 132 is configured to selectively control the microwave radiation energy emitting device 110 to emit microwave radiation energy 112 at frequencies specific to one or more components of the aerosol precursor composition 108.

[0074] Some embodiments of the aerosol delivery device 100 include a controller element 132 that communicates between the microwave radiant energy emitting device 110 and a sensing element 134 that communicates with the aerosol precursor composition 108 in the heating chamber 106. The controller element 132, in some embodiments, includes a microcontroller. The sensing element 134, in some embodiments, includes a fiber optic probe. As shown in FIG. 1 and in more detail in FIG. 2A, the controller element 132 is disposed within the enclosure 104 and the sensing element 134 is disposed within the heating chamber 106. In another example, as shown in FIG. 2B, a single controller element 132 communicates between the microwave radiant energy emitting device 110 and both sensing elements 134A and 134B disposed in each heating chamber 106A-B.

[0075] In some embodiments, the sensing element 134 is configured to sense a temperature, an air flow rate, a pressure, an aerosol precursor composition element, or any combination thereof, of the aerosol precursor composition 108 in the heating chamber 106. For example, if the sensing element 134 is configured to sense a temperature, the controller element 132 adjusts the microwave radiant energy 112 in response to the sensed temperature to heat the aerosol precursor composition 108 only to the highest desired temperature. In this manner, the controller element 132 in conjunction with the sensing element 134 is configured to prevent overheating, underheating, etc. of the aerosol precursor composition 108.

[0076] In other embodiments, the sensing element 134 is also configured to sense the volume of the amount of aerosol precursor composition 108 contained in the heating chamber 106. For example, if there are two heating chambers 106A-B, the sensing elements 134A-B are each configured to sense the volume of the aerosol precursor composition 108 in the respective heating chamber 106A-B. The controller element 132, in response to the sensed volume, prevents the aerosol precursor delivery arrangement 126 from directing any more aerosol precursor composition 108 to one or both of the heating chambers 106A-B when one or both of the heating chambers 106A-B are at maximum volume. Thus, for example, a valve mechanism in communication with the controller element 132 is configured to limit the amount of aerosol precursor composition 108 delivered to one or both of the heating chambers 106A-B. Alternatively, when one of the heating chambers 106A-B is at maximum capacity, the controller 132 directs the aerosol precursor composition 108 to the other heating chamber 106A-B that is not at maximum capacity in response to the sensed maximum capacity of that chamber.

[0077] Further, in various embodiments, an aerosol precursor composition transport element is disposed in the heating chamber 106 in communication with the aerosol precursor composition 108. For example, as shown in FIGS. 2A-2B, one embodiment of the aerosol precursor composition transport element includes a wick 136 formed from various materials (e.g., cotton and / or fiberglass) configured to transport (i.e., absorb and wick) the aerosol precursor composition 108. Due to the wick material design, the wick 136 is configured to absorb a limited amount (i.e., a puff-sized amount) of the aerosol precursor composition 108 that is delivered to the heating chamber 106. The liquid-absorbed wick is then heated by the microwave radiant energy emitting device 110 to generate the aerosol 114. Additionally, for example, a puff-sized amount of the aerosol precursor composition 108 can be pumped, dripped, or otherwise delivered to the heating chamber 106 and the wick 136. However, the implementation of the wick 136 is optional.

[0078] Thus, during use, when a consumer inhales on the mouthpiece element 122 of the aerosol delivery device 100, the aerosol precursor delivery arrangement 126 directs a quantity of the aerosol precursor composition 108 from the reservoir 128 to the heating chamber 106. Alternatively, the aerosol precursor composition 108 is already placed in the heating chamber 106 prior to inhalation. The microwave radiant energy emitting device 110 is then actuated (e.g., via a puff sensor or sensing element 134, etc.) to vaporize or aerosolize the components of the aerosol precursor composition 108 within the heating chamber 106. In some embodiments, the controller element 132 is communicatively coupled to the microwave radiant energy emitting device 110 to control the microwave radiant energy 112 emitted therefrom. For example, if the sensing element 134 senses an aerosol precursor composition 108 in the heating chamber 106 that requires an increase in microwave radiation energy 112 to aerosolize (e.g., due to the temperature, volume, pressure, etc. of the aerosol precursor composition), the controller element 132 can control the microwave radiant energy emitting device 110 to emit microwave radiation energy 112 sufficient to aerosolize the aerosol precursor composition 108.

[0079] Additionally, drawing on the mouthpiece element 122 of the aerosol delivery device 100 causes ambient air to enter the air flow passage 120 and pass through the heating chamber 106. The drawn in ambient air mixes with the vapor / aerosol formed within the heating chamber 106 and / or aerosol delivery arrangement 126 to transport the aerosol 114. The formed aerosol 114 is drawn from the heating chamber 106, passes through the aerosol delivery arrangement 126, exits through the exit port 118, through the hose member 124, and out of the mouthpiece element 122 of the device 100. In some embodiments, the aerosol 114 that is not drawn through the exit port 118 resides or remains within the aerosol delivery arrangement 126 and is aged therein.

[0080] An exemplary mechanism for providing puff actuation capability includes a model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Ill. Additional components are optionally utilized in the aerosol delivery device 100 of the present disclosure. For example, U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that may be associated with the mouth end of the device to detect a user's lip movement and trigger heating associated with a puff; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a pressure drop through the mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle in a smoking system that includes an identifier that detects non-uniformity in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes a predefined executable power cycle having multiple distinct phases; and U.S. Pat. No. 5,934,289 to Watkins et al. discloses a photonic-optic (photonic-optic) sensor that detects the infrared radiation transmitted through the receptacle and a controller that performs a detection routine when the component is inserted into the receptacle. No. 5,954,979 to Counts et al. discloses means for varying the resistance of draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and WO 2010 / 003480 to Flick discloses a fluid flow sensing system indicative of a puff with an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0081] Additional description of other control components, including microcontrollers, that may be useful in the present smoking articles are provided in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 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., and U.S. Pat. No. 7,040,314 to Nguyen et al., all of which are incorporated by reference in their entireties.

[0082] 4A-4C show schematic diagrams of an exemplary aerosol precursor processing unit. The aerosol precursor processing unit is configured to pre-heat the aerosol precursor composition 108 prior to aerosolization of the aerosol precursor composition 108 by the apparatus 100. Alternatively, the aerosol precursor processing unit is configured to process the aerosol precursor composition 108 after pre-heating of the aerosol precursor composition 108 by the apparatus 100.

[0083] Referring to FIG. 4A, an aerosol precursor processing unit 400A is shown. The aerosol precursor processing unit 400A is configured to be in fluid communication with the heating chamber 106. More specifically, the aerosol precursor processing unit 400A is configured to deliver a processed aerosol precursor composition to the heating chamber via an outlet (not shown) in communication with the heating chamber 106, through an air flow path (e.g., 120, FIG. 2A-2B), or through an aerosol precursor delivery configuration (e.g., 126, FIG. 1). The aerosol precursor processing unit 400A is configured to preheat the aerosol precursor composition 108 to a preheat temperature that is lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition 108 before the processed (i.e., preheated) aerosol precursor composition is delivered to the heating chamber 106. Alternatively, the aerosol precursor composition 108 is preheated in the heating chamber 106 of the aerosol delivery device 100 and removed from the heating chamber 106 prior to vaporization / aerosolization of the aerosol precursor composition 108. At this point, the preheated aerosol precursor composition 108 is delivered (e.g., via the aerosol precursor delivery arrangement 126) to the aerosol precursor processing unit 400A and vaporized. Ambient air supplied via an inlet (not shown) of the aerosol precursor processing unit 400A mixes with the vaporized / aerosolized aerosol precursor composition and transports the aerosol that is ingested by the user.

[0084] In some embodiments, the aerosol precursor processing unit 400A includes a heating element or aerosol forming element configured to interact with the aerosol precursor composition provided thereto. In one example, the heating element includes a hot plate. In another example, the heating element includes a coil heater 402. The coil heater 402 is configured as a resistive heating element that generates heat when an electric current is applied to it. Examples of materials forming the heating element 402 include Kanthal (FeCrAl), Nichrome, Molybdenum Disilicide (MoSi2), Molybdenum Silicide (MoSi), Molybdenum Disilicide doped with Aluminum (Mo(Si,Al)2), and ceramics (e.g., positive temperature coefficient ceramics). To generate heat, the heating element 402 includes conductive heater terminals (e.g., positive and negative terminals) configured to pass an electric current through the heating element 402 and to be attached to suitable wiring or circuitry (not shown) to form an electrical connection between the heating element 402 and a battery or other power source. In other non-limiting examples, the heating element 402 is non-electrical and generates heat to vaporize the aerosol precursor composition 108 via conduction, convection, and / or radiation.

[0085] In other embodiments, the aerosol precursor processing unit 400A includes a microwave radiant energy emitting device configured to interact with the aerosol precursor composition provided thereto and to preheat the aerosol precursor composition using the emitted microwave radiant energy.

[0086] A sensing element 404 disposed within the aerosol precursor processing unit 400A is configured to sense when the aerosol precursor composition 108 has been heated to a pre-heat temperature by the heating element 402. After the sensing element 404 senses that the pre-heat temperature has been reached, the electrical connection with the heating element 402 is disconnected. Additionally, if the aerosol precursor composition is pre-heated in the heating chamber 106 of the apparatus 100, the sensing element 404 is configured to sense when a maximum temperature has been reached, after which the heating element 402 is disconnected.

[0087] 4B, an aerosol precursor processing unit 400B is shown. The aerosol precursor processing unit 400B is configured to be in fluid communication with the heating chamber 106. More specifically, the aerosol precursor processing unit 400B is configured to deliver the processed aerosol precursor composition to the heating chamber 106 via an outlet (not shown) in communication with the heating chamber 106, through an air flow path (e.g., 120, FIG. 2A-2B), or through an aerosol precursor delivery configuration (e.g., 126, FIG. 1). The aerosol precursor processing unit 400B is configured to preheat the substrate material 406 with the aerosol precursor composition 108 to a preheat temperature, the preheat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition 108 before the preheated substrate material 406 is delivered to the heating chamber 106.

[0088] In some embodiments, the aerosol precursor processing unit 400B comprises a conventional microwave oven. Thus, the aerosol precursor processing unit 400B preheats the substrate 406 to a preheat temperature using control and / or sensing components provided in a conventional microwave oven. The preheated substrate 406 is then delivered to the heating chamber 106 for subsequent aerosolization by microwave radiant energy. Alternatively, the substrate 406 is delivered to the reservoir 128 and the aerosol precursor delivery arrangement 126 delivers a limited amount of it to the heating chamber 106.

[0089] FIG. 4C illustrates an aerosol precursor processing unit 400C. The aerosol precursor processing unit 400C is configured to be in fluid communication with the heating chamber 106. More specifically, the aerosol precursor processing unit 400C is configured to deliver the processed aerosol precursor composition to the heating chamber 106 via an outlet (not shown) in communication with the heating chamber 106, through an air flow path (e.g., 120, FIG. 2A-2B), or through an aerosol precursor delivery configuration (e.g., 126, FIG. 1). The aerosol precursor processing unit 400C is configured to preheat a film 408 including the aerosol precursor composition 108 to a preheat temperature, the preheat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition 108, before the preheated film 408 is delivered to the heating chamber 106.

[0090] In some embodiments, the aerosol precursor processing unit 400C comprises a conventional microwave oven and the membrane 408 comprises a disposable or multi-use membrane. In one example, the aerosol precursor composition 108 is provided to the membrane 408. The membrane 408 is sealed and then provided to the aerosol precursor processing unit 400C. The aerosol precursor processing unit 400C thus preheats the membrane 408 to a preheat temperature using control and / or sensing components provided in a conventional microwave oven. The membrane 408 is provided to the aerosol precursor processing unit 400C in a contracted state, but transitions to an expanded state once the aerosol precursor composition 108 therein is vaporized / aerosolized. The preheated, expanded membrane 408 can then be puffed or otherwise attached to the aerosol delivery device 100 via a mouthpiece attachment, allowing for the delivery of the aerosol to a consumer in a controlled manner. After delivery of the aerosol, membrane 408 may be disposed of (ie, single-use) or may be left unsealed and an additional amount of aerosol precursor composition 108 placed therein (ie, multiple use).

[0091] In further embodiments not shown, the aerosol delivery device 100 is utilized to further vaporize the aerosol generated by another mechanism. More specifically, the microwave radiant energy emitting device 110 is configured to reduce the size of the aerosol particles generated by the other mechanism to make the particles small enough for inhalation (e.g., 2 microns in diameter). Some such mechanisms for generating aerosol include an inkjet spraying device, which in various embodiments is configured to spray aerosol particles inside the heated chamber 106 of the aerosol delivery device 100. For example, a thermal printer or a bubble jet printer can spray aerosol particles with a diameter of about 4-40 microns, and a piezoelectric printer can spray aerosol particles with a diameter of about 1-2 microns. Since aerosols composed of particles larger than 2 microns generally cannot be conveniently inhaled, the sprayed aerosol is further vaporized by the microwave radiant energy emitting device 110 to reduce the size of the particles to a respirable diameter, e.g., 2 microns or less.

[0092] Alternatively, a wick and / or coil configuration may be provided within the heating chamber 106 to generate an aerosol comprised of particles having individual diameters of approximately 200-500 nanometers. While an aerosol containing particles of this diameter may be inhaled, in some embodiments, the microwave radiant energy emitting device 110 is configured to further vaporize / aerosolize the aerosol 114.

[0093] 5, a method for manufacturing an aerosol delivery device is shown. The method, generally designated 500, is utilized to manufacture an aerosol delivery device that generates an aerosol via microwave radiant energy of a precursor composition as described above.

[0094] In step 502, a microwave radiant energy emitting device (e.g., 110, FIG. 1) is operably engaged to a heating chamber (e.g., 106, FIG. 1) configured to receive an aerosol precursor composition (e.g., 108, FIG. 1) therein. In some embodiments, the microwave radiant energy emitting device is configured to heat the aerosol precursor composition by microwave radiant energy emitted thereby to form an aerosol from the aerosol precursor composition. The aerosol precursor composition is placed in the heating chamber.

[0095] In step 504, the heating chamber is engaged to a housing (e.g., 102, FIG. 1) having an outlet port (e.g., 118, FIG. 1) such that the outlet port is in fluid communication with the heating chamber and such that the heating chamber responds to suction applied to the outlet port such that the aerosol is drawn outwardly from the housing through the outlet port.

[0096] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains 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 heating chamber having an aerosol precursor composition disposed therein; a microwave radiant energy emitting device operatively engaged with the heating chamber and configured to heat the aerosol precursor composition therein with microwave radiant energy to form an aerosol from the aerosol precursor composition; a housing having an outlet port and in fluid communication with the heating chamber; Including, An aerosol delivery device in which a heating chamber causes an aerosol to be drawn outwardly from the housing through the exit port in response to a suction force applied to the exit port.

2. 10. The apparatus of claim 1, further comprising an aerosol precursor delivery arrangement operably engaged with the heating chamber and configured to direct the aerosol precursor composition to the heating chamber from a reservoir configured to contain the aerosol precursor composition therein and in fluid communication with the aerosol precursor delivery arrangement.

3. The apparatus of claim 2 , wherein the microwave radiant energy emitting device includes a magnetron extending around the heating chamber and configured to emit microwave radiant energy.

4. The apparatus of claim 3 , wherein the magnetron is disposed within an enclosure configured to substantially surround the heating chamber.

5. 5. The apparatus of claim 4, comprising two or more reservoirs, each reservoir configured to contain a separate aerosol precursor composition therein, each of the two or more reservoirs in fluid communication with the aerosol precursor delivery arrangement, the aerosol precursor delivery arrangement operable to direct one of the separate aerosol precursor compositions from a respective one of the two or more reservoirs to the heating chamber.

6. 6. The apparatus of claim 5, including an air flow passage defined within the housing or enclosure and configured to allow air flow between the heating chamber and ambient air outside the housing or enclosure.

7. The apparatus of claim 6 , wherein the exit port or air flow passage includes an airflow blocking element configured to cooperate with the enclosure to confine the microwave radiant energy within the enclosure.

8. 10. The device of claim 1, comprising a hose member having an engaged proximal end engaged with the outlet port and an opposite distal end engaged with the mouthpiece element, the mouthpiece element and the hose member being in fluid communication with the heating chamber via the outlet port to receive aerosol therefrom in response to suction force applied to the mouthpiece element.

9. 13. The apparatus of claim 1, further comprising a controller element in communication between the microwave radiant energy emitting device and a sensing element in communication with the aerosol precursor composition in the heating chamber, the sensing element configured to sense a temperature of the aerosol precursor composition in the heating chamber, and the controller element responsive to the sensed temperature to adjust microwave radiation output by the microwave radiant energy emitting device to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

10. 10. The apparatus of claim 1, wherein the aerosol precursor composition is selected from the group consisting of a liquid, a gel, a solid, a capsule, a colloid, a suspension, a botanical derivative, and combinations thereof.

11. The apparatus of claim 10 , wherein one component of the aerosol precursor composition is configured to prevent overheating of the aerosol precursor composition.

12. 10. The apparatus of claim 1, comprising a wick engaged with the heating chamber, the wick in communication with the aerosol precursor composition, and the microwave radiant energy emitting device configured to heat the wick such that an amount of aerosol formed by the wick is proportional to an amount of the aerosol precursor composition drawn up by the wick.

13. 2. The apparatus of claim 1, wherein the heating chamber includes a first heated subchamber and a second heated subchamber, one of the first and second heated subchambers having a larger capacity for the aerosol precursor composition than the other, the first and second heated subchambers in fluid communication with an outlet port via a selector element, the selector element directing aerosol from a selected one of the first and second heated subchambers to the outlet port in response to a suction force applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction force.

14. 10. The apparatus of claim 1, comprising an aerosol precursor processing unit in fluid communication with the heating chamber and configured to preheat the aerosol precursor composition to a preheat temperature, the preheat temperature being lower than a highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is conducted to the heating chamber.

15. 15. The apparatus of claim 14, wherein the aerosol precursor processing unit comprises a heating element or an aerosol forming element configured to interact with the aerosol precursor composition.

16. 10. The apparatus of claim 1, comprising an aerosol precursor processing unit in communication with the heating chamber and configured to preheat a substrate material with an aerosol precursor composition associated therewith to a preheat temperature, the preheat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated substrate material is conducted to the heating chamber.

17. 10. The apparatus of claim 1, comprising an aerosol precursor processing unit in communication with the heating chamber and configured to preheat a film comprised of the aerosol precursor composition to a preheat temperature, the preheat temperature being lower than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated film is conducted to the heating chamber.

18. 1. A method of manufacturing an aerosol delivery device, comprising: operatively engaging a microwave radiant energy emitting device with a heating chamber configured to receive an aerosol precursor composition therein, the microwave radiant energy emitting device configured to heat the aerosol precursor composition with microwave radiant energy emitted thereby to form an aerosol from the aerosol precursor composition; engaging the heating chamber with a housing having an outlet port such that the outlet port is in fluid communication with the heating chamber and such that the heating chamber responds to a suction force applied to the outlet port such that an aerosol is drawn outwardly from the housing through the outlet port; A manufacturing method comprising:

19. 20. The method of claim 18, further comprising engaging an aerosol precursor delivery arrangement in fluid communication with the heating chamber, the aerosol precursor delivery arrangement configured to direct the aerosol precursor composition from a reservoir having the aerosol precursor composition therein to the heating chamber.

20. 20. The method of claim 19, wherein operably engaging a microwave radiant energy emitting device comprises operably engaging a magnetron to the heating chamber, the magnetron extending around the heating chamber and configured to emit microwave radiant energy.

21. The method of claim 20 , further comprising disposing the magnetron within an enclosure configured to substantially surround the heating chamber.

22. 22. The method of claim 21, further comprising forming two or more reservoirs within the housing, each reservoir containing a separate aerosol precursor composition therein, each of the two or more reservoirs being in fluid communication with the aerosol precursor delivery arrangement, the aerosol precursor delivery arrangement being operable to direct one of the separate aerosol precursor compositions from a respective one of the two or more reservoirs to the heating chamber.

23. 23. The method of claim 22, further comprising defining an air flow passage within the housing or enclosure, the air flow passage configured to allow air flow between the heating chamber and ambient air outside the housing or enclosure.

24. 24. The method of claim 23, further comprising disposing an airflow blocking element in the exit port or air flow path, the airflow blocking element configured to cooperate with the enclosure to confine microwave radiant energy within the enclosure.

25. 20. The method of claim 18, further comprising engaging a proximal end of the hose member with the outlet port and engaging an opposite distal end of the hose member with a mouthpiece element, the mouthpiece element and the hose member being in fluid communication with the heating chamber via the outlet port to receive the aerosol therefrom in response to suction applied to the mouthpiece element.

26. 20. The method of claim 18, further comprising operably engaging a controller element between the microwave radiant energy emitting device and a sensing element in communication with the aerosol precursor composition in the heating chamber, the sensing element configured to sense a temperature of the aerosol precursor composition in the heating chamber, and the controller element configured to adjust microwave radiation output by the microwave radiant energy emitting device in response to the sensed temperature to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

27. 20. The method of claim 18, further comprising selecting the aerosol precursor composition from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, botanical derivatives, and combinations thereof.

28. 30. The method of claim 27, wherein selecting the aerosol precursor composition further comprises selecting the aerosol precursor composition such that one component of the aerosol precursor composition is configured to prevent overheating of the aerosol precursor composition.

29. 20. The method of claim 18, further comprising engaging the wick with a heating chamber such that the wick is in communication with the aerosol precursor composition, and wherein the microwave radiant energy emitting device is configured to heat the wick such that an amount of aerosol formed by the wick is proportional to an amount of the aerosol precursor composition drawn up by the wick.

30. 20. The method of claim 18, further comprising defining a first heated subchamber and a second heated subchamber within the heating chamber, one of the first and second heated subchambers having a larger capacity for the aerosol precursor composition than the other, the first and second heated subchambers being configured in selective fluid communication with an outlet port via a selector element, the selector element directing aerosol from the heated subchamber in selective communication with the outlet port to the outlet port in response to a suction force applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction force.

31. 20. The method of claim 18, further comprising engaging an aerosol precursor processing unit in fluid communication with the heating chamber, the aerosol precursor processing unit configured to preheat the aerosol precursor composition to a preheat temperature, the preheat temperature being less than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is directed to the heating chamber.

32. 32. The method of claim 31 , wherein engaging the aerosol precursor processing unit comprises positioning a heating element or an aerosol forming element to interact with the aerosol precursor composition before the pre-heated aerosol precursor composition is directed to the heating chamber.

33. 20. The method of claim 18, further comprising engaging an aerosol precursor processing unit in fluid communication with the heating chamber, the aerosol precursor processing unit configured to preheat a substrate material with an aerosol precursor composition associated therewith to a preheat temperature, the preheat temperature being less than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated substrate material is conducted to the heating chamber.

34. 20. The method of claim 18, further comprising engaging an aerosol precursor processing unit in fluid communication with the heating chamber, the aerosol precursor processing unit configured to preheat a film comprised of the aerosol precursor composition to a preheat temperature that is less than a maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated film is conducted to the heating chamber.

Images