Aerosol delivery device including ceramic core material element

Abstract

To provide aerosol delivery devices, methods of forming such devices, and elements of such devices.SOLUTION: The present disclosure provides vapor-forming units for aerosol delivery devices, the vapor-forming units including a ceramic wick that is in contact with a heater and in contact with an aerosol precursor composition. The vapor-forming units are connectable to a power unit.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] 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 article can be configured to heat an aerosol precursor, which can incorporate tobacco-based or tobacco-derived materials or can incorporate tobacco, and the precursor can form an inhalable substance for human consumption. [Background technology]

[0002] Many smoking devices have been proposed over the years as an improvement or replacement for smoking products that require tobacco to be burned for use. Many of these devices are said to be purposely designed to provide the sensations associated with cigarette, cigar, or pipe smoking, but without delivering significant amounts of incomplete combustion and pyrolysis products resulting from tobacco combustion. To this end, many smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile substances or attempt to provide the sensations of cigarette, cigar, or pipe smoking without significantly burning tobacco. 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. 7,726,320 to Robinson et al., U.S. Patent Application Publication No. 2013 / 0255702 to Griffith Jr. et al., and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrical heat sources referenced by product name and commercial source in U.S. patent application Ser. No. 14 / 170,838, filed Feb. 3, 2014, by Bless et al., which is incorporated by reference in its entirety.

[0003] It would be desirable to provide a vapor forming unit of an aerosol delivery device that is configured to improve vapor formation and / or improve integration with a power unit. It would also be desirable to provide an aerosol delivery device made utilizing such a vapor forming unit. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 1] US Patent Application Publication No. 2013 / 0255702 [Patent Document 1] US Patent Application Publication No. 2014 / 0096781 Summary of the Invention [Means for solving the problem]

[0005] The present disclosure relates to an aerosol delivery device, a method for forming such a device, and elements of such a device. The aerosol delivery device may in particular incorporate a ceramic wick to form a vapor forming unit. The vapor forming unit may be combined with a power unit to form the aerosol delivery device.

[0006] In one or more embodiments, the present disclosure may provide an aerosol delivery device including at least a vapor forming unit. The vapor forming unit may function in a manner similar to cartridges and / or tanks known for use in aerosol delivery devices. In an exemplary embodiment, the vapor forming unit of the aerosol delivery device may include: a housing defined at least in part by an outer wall; a flow tube disposed inside an outer wall of the housing; an annular space defined between an outer wall of the housing and the flow tube; an air flow path through the device between the connector end of the housing and the mouth end of the housing and at least partially through the flow tube; an atomizer formed from a heater in combination with a ceramic wick, the ceramic wick in sealing engagement with the flow tube such that at least a portion of the ceramic wick is in an airflow path and such that at least a portion of the ceramic wick is in fluid communication with an annular space defined between an outer wall of the housing and the flow tube; and a sealing member disposed between the ceramic core and the flow tube and configured to form a sealed engagement.

[0007] In various embodiments, the aerosol delivery device can be configured as a generally tubular or cylindrical body. In particular, the airflow path through the vapor formation unit can be substantially aligned with the longitudinal axis of the reservoir (e.g., annular space). Thus, the aerosol delivery device can be further defined with respect to one or more of the following statements, which can be combined in any number or order.

[0008] The flow tube can include at least one vent configured in a wall thereof, the at least one vent adapted to allow air flow therethrough and substantially prevent liquid flow therethrough. In particular, the at least one vent configured in a wall of the flow tube can be located proximate to the mouth end of the housing.

[0009] The aerosol delivery device may further include a mouthpiece that engages the mouth end of the housing and engages the end of the flow tube.

[0010] The aerosol delivery device may further include a connector that engages the connector end of the housing.

[0011] The ceramic core may be substantially solid.

[0012] The heater may be a resistive heating wire disposed around the exterior surface of a substantially solid ceramic core.

[0013] The substantially solid ceramic core may have a longitudinal axis that is substantially perpendicular to the longitudinal axis of the housing.

[0014] The substantially solid ceramic core can extend transversely across the flow tube between the first and second ceramic core ends, and the sealing member can be in sealing engagement with the ceramic core proximate the first and second ceramic core ends.

[0015] The ceramic core can have a hollow interior defining a passageway extending between a first end of the ceramic core and a second end of the ceramic core.

[0016] The heater may be disposed within a passage defined in the hollow interior of the ceramic core.

[0017] The second end of the hollow ceramic core can be engaged with the free end of the flow tube.

[0018] The first end of the hollow ceramic core is connectable with a connector that mates with the connector end of the housing.

[0019] The sealing member can form a sealed engagement between the free end of the flow tube and the second end of the ceramic core, and the second sealing member can form a sealed engagement between the first end of the hollow ceramic core and the connector.

[0020] In one or more embodiments, the aerosol delivery device disclosed herein can include a vapor formation unit, where the reservoir and the airflow path through the vapor formation unit are not substantially aligned. More specifically, the reservoir can be offset from the airflow path through the vapor formation unit. As an exemplary embodiment, the vapor formation unit of the aerosol delivery device can include: a housing including an air inlet and an air outlet; a liquid reservoir within a housing formed from a flexible outer wall and having an opening formed therein; The atomizer can include an atomizer in a housing having a ceramic wick including an end that engages an opening formed in the liquid storage container and a generally central portion that engages a heater, the generally central portion of the ceramic wick and the heater being in an air flow path between an air flow inlet and an air flow outlet of the housing.

[0021] In further embodiments, the aerosol delivery device may be further defined with respect to one or more of the following statements, which may be combined in any number or order.

[0022] The ceramic core may be generally rod-shaped.

[0023] The ceramic wick may have a longitudinal axis, the liquid reservoir may have a longitudinal axis, and the longitudinal axes of the ceramic wick and the liquid reservoir may be substantially parallel.

[0024] A longitudinal axis of the ceramic wick and liquid reservoir may be substantially perpendicular to a longitudinal axis of an air flow path between the air flow inlet and the air flow outlet of the housing.

[0025] The air flow outlet may include a mouthpiece extending outwardly from the housing.

[0026] The housing may comprise a body substantially aligned with the axis of the airflow path and a projection extending generally perpendicularly from the body, the projection including a liquid reservoir.

[0027] The aerosol delivery device may further comprise a power unit connectable to the housing, the power unit including a power source.

[0028] The power unit may be connectable with the housing such that the power unit is external to the housing when connected.

[0029] The power unit may be connectable with the housing such that the housing is completely internal to the power unit when connected.

[0030] The power unit may include a mouthpiece.

[0031] The housing for insertion into the power unit can be configured so that the air flow outlet of the housing is substantially aligned with the aerosol inlet to the mouthpiece.

[0032] The mouthpiece can be movable between an open position, which allows the passage of the generated aerosol, and a closed position, which substantially prevents the passage of the generated aerosol.

[0033] The present invention includes, but is not limited to, the following embodiments: Embodiment 1: An aerosol delivery device comprising: a housing defined at least in part by an outer wall; a flow tube disposed inside an outer wall of the housing; an annular space defined between an outer wall of the housing and the flow tube; an air flow path through the device between the connector end of the housing and the mouth end of the housing and at least partially through the flow tube; an atomizer formed from a heater in combination with a ceramic wick, the ceramic wick in sealing engagement with the flow tube such that at least a portion of the ceramic wick is in an airflow path and such that at least a portion of the ceramic wick is in fluid communication with an annular space defined between an outer wall of the housing and the flow tube; a sealing member disposed between the ceramic core and the flow tube and configured to form a sealed engagement; An aerosol delivery device comprising:

[0034] Embodiment 2: The aerosol delivery device of any of the previous embodiments, wherein the flow tube includes at least one vent configured in its wall, the at least one vent allowing air flow therethrough and substantially preventing liquid flow therethrough.

[0035] Embodiment 3: The aerosol delivery device of any of the previous embodiments, wherein at least one vent hole configured in the wall of the flow tube is positioned proximate to the mouth end of the housing.

[0036] Embodiment 4: The aerosol delivery device of any of the previous embodiments, further comprising a mouthpiece that engages with the mouth end of the housing and engages with an end of the flow tube.

[0037] Embodiment 5: The aerosol delivery device of any of the previous embodiments, further comprising a connector that engages with the connector end of the housing.

[0038] Embodiment 6: The aerosol delivery device of any of the previous embodiments, wherein the ceramic core is substantially solid.

[0039] Embodiment 7: The aerosol delivery device of any of the previous embodiments, wherein the heater is a resistive heating wire disposed around the exterior surface of the ceramic core.

[0040] Embodiment 8: The aerosol delivery device of any of the previous embodiments, wherein the ceramic core has a longitudinal axis that is approximately perpendicular to the longitudinal axis of the housing.

[0041] Embodiment 9: The aerosol delivery device of any of the previous embodiments, wherein the ceramic wick extends transversely across the flow tube between the first ceramic wick end and the second ceramic wick end, and the sealing member is in sealing engagement with the ceramic wick proximate to the first ceramic wick end and the second ceramic wick end.

[0042] Embodiment 10: The aerosol delivery device of any of the previous embodiments, wherein the ceramic core has a hollow interior defining a passageway extending between the first end of the ceramic core and the second end of the ceramic core.

[0043] Embodiment 11: The aerosol delivery device of any of the previous embodiments, wherein the heater is disposed within a passageway defined within the hollow interior of the ceramic core.

[0044] Embodiment 12: The aerosol delivery device of any of the previous embodiments, wherein the second end of the ceramic wick is engaged with the free end of the flow tube.

[0045] Embodiment 13: The aerosol delivery device of any of the previous embodiments, wherein a first end of the ceramic wick is connected to a connector that engages with a connector end of the housing.

[0046] Embodiment 14: The aerosol delivery device of any of the previous embodiments, wherein a sealing member forms a sealing engagement between the free end of the flow tube and the second end of the ceramic wick, and a second sealing member forms a sealing engagement between the first end of the ceramic wick and the connector.

[0047] Embodiment 15: An aerosol delivery device comprising: a housing including an air inlet and an air outlet; a liquid storage container within the housing formed from a flexible outer wall and having an opening formed therein; and an atomizer within the housing having a ceramic wick including an end that engages the opening formed in the liquid storage container and an approximately central portion that engages a heater, wherein the approximately central portion of the ceramic wick and the heater are in the air flow path between the air inlet and the air outlet of the housing.

[0048] Embodiment 16: The aerosol delivery device of any of the previous embodiments, wherein the ceramic core is generally rod-shaped.

[0049] Embodiment 17: The aerosol delivery device of any of the previous embodiments, wherein the ceramic wick has a longitudinal axis and the liquid reservoir has a longitudinal axis, and the longitudinal axes of the ceramic wick and the liquid reservoir are approximately parallel.

[0050] Embodiment 18: The aerosol delivery device of any of the previous embodiments, wherein the longitudinal axis of the ceramic wick and the liquid storage vessel is approximately perpendicular to the longitudinal axis of the air flow path between the air flow inlet and the air flow outlet of the housing.

[0051] Embodiment 19: The aerosol delivery device of any of the previous embodiments, wherein the air flow outlet comprises a mouthpiece extending outwardly from the housing.

[0052] Embodiment 20: The aerosol delivery device of any of the previous embodiments, wherein the housing comprises a body substantially aligned with the axis of the airflow path and a protrusion extending approximately perpendicularly from the body, the protrusion including a liquid storage container.

[0053] Embodiment 21: The aerosol delivery device of any of the previous embodiments, further comprising a power unit connectable to the housing, the power unit including a power source.

[0054] Embodiment 22: The aerosol delivery device of any of the previous embodiments, wherein the power unit is connectable to the housing such that the housing is external to the power unit when connected.

[0055] Embodiment 23: The aerosol delivery device of any of the previous embodiments, wherein the power unit is connectable to the housing such that the housing is completely internal to the power unit when connected.

[0056] Embodiment 24: The aerosol delivery device of any of the previous embodiments, wherein the power unit comprises a mouthpiece.

[0057] Embodiment 25: The aerosol delivery device of any of the previous embodiments, wherein the housing is configured for insertion into the power unit such that the air flow outlet of the housing is substantially aligned with the aerosol inlet to the mouthpiece.

[0058] Embodiment 26: The aerosol delivery device of any of the previous embodiments, wherein the mouthpiece is movable between an open position through which the formed aerosol can pass and a closed position in which the passage of the formed aerosol is substantially prevented.

[0059] These and other features, aspects, and advantages of the present disclosure will become apparent from reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, as well as any combination of two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure, in any of its various aspects and embodiments, is intended to be read as a whole such that any separable features or elements of the disclosed invention should be considered as combinable unless the context clearly dictates otherwise.

[0060] Having thus described the 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]

[0061] [Figure 1] FIG. 1 is a partial cross-sectional view of an aerosol delivery device including a cartridge and a power unit including various elements that can be utilized in an aerosol delivery device according to various embodiments of the present disclosure. [Diagram 2] FIG. 1 illustrates a generally tubular or cylindrical shaped vapor formation unit for use in an aerosol delivery device according to various embodiments of the present disclosure. [Diagram 3] 1 is a partial cross-sectional view of a steam formation unit showing its internal structure according to various embodiments of the present disclosure. [Figure 4] 1 is a partial view of a steam formation unit showing the relationship between a flow tube, a connector, and a wick according to various embodiments of the present disclosure. [Diagram 5]1 is a partial cross-section of a steam formation unit showing the internal structure according to various embodiments of the present disclosure. [Figure 6] FIG. 1 is a diagram of a power unit useful in combination with a steam formation unit according to various embodiments of the present disclosure. [Figure 7] FIG. 1 illustrates an aerosol delivery device according to various embodiments of the present disclosure, including a power unit and a vapor formation unit. [Figure 8] FIG. 1 illustrates an aerosol delivery device according to various embodiments of the present disclosure, including a power unit and a vapor formation unit. [Figure 9] 1 is a cutaway view of the interior of a steam formation unit showing the internal structure according to various embodiments of the present disclosure; FIG. [Figure 10] 1 is a cutaway view of the interior of a steam formation unit showing the internal structure according to various embodiments of the present disclosure; FIG. [Figure 11] 1 is a cutaway view of an aerosol delivery device according to various embodiments of the present disclosure showing a vapor formation unit combined with a power unit. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0062] The present disclosure will be described more fully below 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.

[0063] As described below, embodiments of the present disclosure relate to an aerosol delivery system. The aerosol delivery system according to the present disclosure uses electrical energy to heat a material (preferably without burning the material to any significant extent and / or without significantly chemically altering the material) to form an inhalable substance, and the components of such a system most preferably have the form of an article that is compact enough to be considered a handheld device. That is, the use of the components of the preferred aerosol delivery system does not result in the production of smoke - i.e., from the by-products of the combustion or pyrolysis of tobacco, but rather, the use of those preferred systems results in the production of vapor resulting from the volatilization or vaporization of certain components incorporated therein. In a preferred embodiment, the components of the aerosol delivery system 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.

[0064] The aerosol-generating components of certain preferred aerosol delivery systems can provide many of the sensations (e.g., inhalation and exhalation patterns, taste or flavor types, organoleptic effects, physical feel, mode of use, visual cues such as those provided by a visible aerosol, etc.) of a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke) without any significant degree of combustion of any of its components. 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, draw on one end of the component to inhale the aerosol generated by the component, take puffs or draws at selected time intervals, etc.

[0065] The aerosol delivery device of the present disclosure can also be characterized as being a vapor product or drug delivery article. Thus, such an article or device can be configured to provide one or more substances (e.g., flavorings and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance can 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 can 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 in a form that can be considered as smoke.

[0066] The aerosol delivery device of the present disclosure generally includes a number of components disposed within an outer body or shell, sometimes referred to as a housing. The overall design of the outer body or shell can vary, and the type or configuration of the outer body can vary, which can define the overall size and shape of the aerosol delivery device. Typically, the elongated body resembling the shape of a cigarette or cigar can be formed from a single, unitary housing, or the elongated housing can be formed from two or more separable bodies. For example, the aerosol delivery device can be generally tubular in shape and thus comprise an elongated shell or body resembling the shape of a traditional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are contained within one housing. Alternatively, the aerosol delivery device can comprise two or more housings that are joined and separable. For example, an aerosol delivery device can have a control body (or power unit) with a housing containing one or more components (e.g., a battery and various electronics for controlling the operation of the article) at one end and a removably attached outer body or shell containing aerosol-forming components (e.g., one or more aerosol precursor components such as flavorants and aerosol formers, one or more heaters, and / or one or more wicks) at the other end.

[0067] The aerosol delivery device of the present disclosure can be formed from an outer housing or shell that is not generally tubular in shape, but can be formed to a substantially larger dimension. The housing or shell can be configured to contain a mouthpiece and / or can contain consumable elements such as a liquid aerosol former, and can be configured to receive a separate shell (e.g., a cartridge or tank) that can contain a vaporizer or atomizer.

[0068] The aerosol delivery device of the present disclosure most preferably comprises some combination of a power source (i.e., a power source), at least one control component (e.g., a means for activating, controlling, regulating, and terminating power for heat generation, such as by controlling the current power supply 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, which, alone or in combination with one or more additional elements, may be commonly referred to as an "atomizer"), an aerosol precursor composition (e.g., a liquid that can 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 or mouth area (e.g., a defined air flow path through the article such that the generated aerosol may be drawn therefrom upon inhalation) that allows for inhalation of the aerosol delivery device for aerosol inhalation.

[0069] 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. Moreover, the selection and arrangement of various aerosol delivery system components can be understood in light of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure.

[0070] An exemplary embodiment of an aerosol delivery device 100 illustrating components that may be utilized in an aerosol delivery device according to the present disclosure is provided in FIG. 1. As seen in the illustrated cross-sectional view, the aerosol delivery device 100 may comprise a power unit 102 and a cartridge 104 that may be permanently or removably aligned in a functional relationship. Engagement between the power unit 102 and the cartridge 104 may be press-fit (as shown), threaded, interference fit, magnetic, etc. In particular, connection components as further described herein may be used. For example, the power unit may include a coupler adapted to engage a connector on the cartridge.

[0071] In certain embodiments, one or both of the power unit 102 and the cartridge 104 may be referred to as disposable or reusable. For example, the power unit may have a replaceable or rechargeable battery and thus may be combined with any type of recharging technology, including connection to a typical electrical outlet, connection to an automobile charger (i.e., cigarette lighter socket), and connection to a computer via a Universal Serial Bus (USB) cable or the like. For example, an adapter including a USB connector on one end and a power unit connector on the opposite end is disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the cartridge may comprise a disposable cartridge, as disclosed in U.S. Patent Application No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0072] As shown in FIG. 1, the power unit 102 can be formed from a power unit shell 101 that can include a control component 106 (e.g., a printed circuit board (PCB), integrated circuit, memory component, microcontroller, etc.), a flow sensor 108, a battery 110, and an LED 112, which can be variably aligned. Additional indicators (e.g., haptic feedback components, audio feedback components, etc.) can be included in addition to or as an alternative to the LED. Additional representative types of components that generate visual stimuli or indicators, such as light emitting diode (LED) components, and their construction and use 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. App. Pub. No. 2015 / 0020825 to Galloway et al.; and U.S. Pat. App. Pub. No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference.

[0073] The cartridge 104 can be formed of a cartridge shell 103 enclosing a reservoir 144 in fluid communication with a liquid transport element 136 adapted to wick or otherwise transport the aerosol precursor composition stored in the reservoir housing to the heater 134. The liquid transport element can be formed of one or more materials configured to transport liquids by capillary action or the like. The liquid transport element can be formed, for example, from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, glass fiber), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillaries, and the like. Thus, the liquid transport element can 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). Various embodiments of materials configured to generate heat when an electric current is passed through them can be used to form the resistive heating element 134. Examples of materials from which the wire coil can be formed include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum doped molybdenum disilicide (Mo(Si,Al)2), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0074] An opening 128 may be present in the cartridge shell 103 (e.g., at the mouth end) to allow the formed aerosol to exit the cartridge 104. Such components are representative of components that may be present in a cartridge and are not intended to limit the scope of cartridge components included in this disclosure.

[0075] The cartridge 104 may also include one or more electronic components 150, which may include integrated circuits, memory components, sensors, etc. The electronic components 150 may be configured to communicate with the control component 106 and / or external devices by wired or wireless means. The electronic components 150 may be located anywhere within the cartridge 104 or its base 140.

[0076] Although the control component 106 and the flow sensor 108 are shown separately, it is understood that the control component and the flow sensor can be combined as an electronic circuit board to which the air flow sensor is directly attached. Furthermore, the electronic circuit board can be positioned horizontally relative to the view of FIG. 1 in that the electronic circuit board can be longitudinally parallel to the central axis of the power unit. In some embodiments, the air flow sensor can include its own circuit board or other base element to which it can be attached. In some embodiments, a flexible circuit board can be utilized. The flexible circuit board can be configured in a variety of shapes, including a generally tubular shape.

[0077] The power unit 102 and the cartridge 104 can include components adapted to facilitate fluid engagement therebetween. As shown in FIG. 1, the power unit 102 can include a coupler 124 having a cavity 125 therein. The cartridge 104 can include a base 140 adapted to engage with the coupler 124 and can include a protrusion 141 adapted to fit within the cavity 125. Such engagement can facilitate a stable connection between the power unit 102 and the cartridge 104 as well as establish an electrical connection between the battery 110 and the control components 106 in the power unit and the heater 134 in the cartridge. Additionally, the power unit shell 101 can include an air inlet 118, which can be a notch in the shell that communicates with the coupler 124 that allows air to pass around the coupler and enter the shell, and then within the shell, where ambient air passes through the cavity 125 of the coupler and into the cartridge via the protrusion 141.

[0078] Useful couplers and bases according to the present disclosure are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. For example, a coupler as seen in FIG. 1 may define an outer periphery 126 configured to mate with an inner periphery 142 of a base 140. In one embodiment, the inner periphery of the base may define a radius that is approximately equal to or slightly greater than the radius of the outer periphery of the coupler. Additionally, the coupler 124 may define one or more protrusions 129 on the outer periphery 126 configured to engage with one or more recesses 178 defined in the inner periphery of the base. However, various other embodiments of structures, shapes, and components may be used to couple a base to a coupler. In some embodiments, the connection between the base 140 of the cartridge 104 and the coupler 124 of the power unit 102 can be generally permanent, while in other embodiments the connection therebetween may be releasable, for example, so that the power unit can be reused with one or more additional cartridges, which can be disposable and / or refillable.

[0079] The aerosol delivery device 100 can be generally rod-like or tubular in shape or generally cylindrical in shape in some embodiments. Other embodiments include additional shapes and dimensions, such as rectangular or triangular cross-sections, multi-sided shapes, etc. In particular, the power unit 102 can be non-rod-like, but rather can have a generally rectangular, circular, or some other shape. Similarly, the power unit 102 can be substantially larger than a power unit that would be expected to be substantially the size of a conventional cigarette.

[0080] The reservoir 144 shown in FIG. 1 can be a container (e.g., formed from a wall that is substantially impermeable to the aerosol precursor composition) or can be a fibrous reservoir. The container wall can be flexible and collapsible. Alternatively, the container wall can be substantially rigid. In an exemplary embodiment, the reservoir 144 can include one or more layers of nonwoven fibers formed substantially in the shape of a tube that surrounds the interior of the cartridge shell 103. The aerosol precursor composition can be held in the reservoir 144. For example, a liquid component can be sorbently held by the reservoir 144 (i.e., when the reservoir 144 includes a fibrous material). The reservoir 144 can be in fluid communication with the liquid transport element 136. The liquid transport element 136 can transport the aerosol precursor composition stored in the reservoir 144 via capillary action to the heating element 134, which in this embodiment is in the form of a metal wire coil. Thus, the heating element 134 is in a heating arrangement with the liquid transport element 136.

[0081] In use, when a user inhales on the article 100, airflow is detected by the sensor 108, activating the heating element 134, and the components of the aerosol precursor composition are vaporized by the heating element 134. When the mouth end of the article 100 is inhaled, ambient air enters the inlet 118 and passes through the cavity 125 of the coupler 124 and the central opening of the protrusion 141 of the base 140. In the cartridge 104, the inhaled air mixes with the formed vapor to form an aerosol, which is swept, sucked, or otherwise drawn away from the heating element 134 and out the mouth opening 128 at the mouth end of the article 100.

[0082] The aerosol delivery device may include an input device element. An input device may be included to allow the user to control the device's functions and / or to output information to the user. Any component or combination of components may be utilized as an input device for controlling the device's functions. For example, one or more push buttons may be used, as described in U.S. Patent Application Publication No. 2015 / 0245658 by Worm et al., which is incorporated herein by reference. A touch screen may be used, as described in U.S. Patent Application No. 14 / 643,626, filed March 10, 2015 by Sears et al., which is incorporated herein by reference. As a further example, a component adapted for gesture recognition based on designated movements of the aerosol delivery device may be used as an input device. See U.S. Patent Application Publication No. 2016 / 0158782 by Henry et al., which is incorporated herein by reference.

[0083] In some embodiments, the input device can comprise 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 the computer or other device that serves as the input device via wireless communication. See, for example, the systems and methods for controlling a device via a read request described in U.S. Patent Application Publication No. 2016 / 0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference. In such embodiments, an 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 additional flavoring content to be included.

[0084] 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 Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference.

[0085] The aerosol delivery device can incorporate a sensor or detector for controlling the power supply to the heating element when aerosol generation is desired (e.g., when inhaling during use). Thus, for example, a manner or method is provided for turning off the power supply to the heating element when the aerosol delivery device is not being inhaled during use, and turning on the power supply to activate or trigger the heating element to generate heat during inhalation. Further representative types of sensing or detection mechanisms, their structures and configurations, their components, and the general method of their operation are described in U.S. Patent No. 5,261,424 by Sprinkel, Jr.; U.S. Patent No. 5,372,148 by McCafferty et al.; and WO 2010 / 003480 by Flick, which are incorporated herein by reference.

[0086] 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. Patent Application Publication Nos. 2009 / 0230117 to Fernando et al., 2014 / 0060554 to Collet et al., and 2014 / 0270727 to Ampolini et al.; and U.S. Patent Application Publication No. 2015 / 0257445 to Henry et al., which are incorporated herein by reference.

[0087] Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014 / 0261487 to Chapman et al. and 2014 / 0059780 to Davis et al., and U.S. Patent Application Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference. Additionally, various suction materials, and the configuration and operation of these 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.

[0088] In the case of an aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition most preferably incorporates tobacco or a component derived from tobacco. In one aspect, the tobacco may be provided as a portion or piece of tobacco, such as finely ground, crushed or powdered tobacco flakes. In another aspect, 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 that also incorporates small amounts of other extracted components derived from tobacco. In another aspect, the component derived from tobacco may be provided in a relatively pure form, such as a particular flavoring derived from tobacco. In one aspect, a component derived from tobacco that can be used in a highly purified or essentially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[0089] The aerosol precursor composition, also referred to as a vapor precursor composition, may include a variety of ingredients including, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extract, and / or flavorings. Representative types of aerosol precursor compositions and formulations are also described and characterized in U.S. Pat. No. 7,217,320 to Robinson et al. and U.S. Pat. Appl. Pub. No. 2013 / 0008457 to Zheng et al.; U.S. Pat. Appl. Pub. No. 2013 / 0213417 to Chong et al.; U.S. Pat. Appl. Pub. No. 2014 / 0060554 to Collett et al.; U.S. Pat. Appl. Pub. No. 2015 / 0020823 to Lipowicz et al.; and U.S. Pat. Appl. Pub. No. 2015 / 0020830 to Koller, the disclosures of which are incorporated herein by reference, and WO 2014 / 182736 to Bowen et al. Other aerosol precursors that may be used include those 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.

[0090] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating component provides acceptable sensory characteristics and desirable performance characteristics. For example, it is highly preferred to use a sufficient amount of aerosol forming material (e.g., glycerin and / or propylene glycol) to provide visible mainstream aerosol generation that resembles in many ways 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. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system, and particularly into the aerosol generating component, is less than about 2 g, generally less than about 1.5 g, often less than about 1 g, and frequently less than about 0.5 g.

[0091] Still other features, controls or components that can be incorporated into the aerosol delivery system of the present disclosure are described 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. Pat. No. 8,402,976 to Fernando et al. ... No. 2010 / 0163063 to Tucker et al.; U.S. Patent Application Publication No. 2013 / 0192623 to Leven et al.; U.S. Patent Application Publication No. 2013 / 0298905 to Leven et al.; U.S. Patent Application Publication No. 2013 / 0180553 to Kim et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., and U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al.

[0092] The above description of the use of the article can be applied to various embodiments described herein through minor modifications that may be apparent to those skilled in the art in light of the further disclosure provided herein.However, the above description of use is not intended to limit the use of the article, but is provided to meet all the necessary requirements of the present disclosure.Any of the elements shown in FIG. 1 or the above-mentioned article may be included in the aerosol delivery device according to the present disclosure.

[0093] In one or more embodiments, the present disclosure may relate to an aerosol delivery device that is specifically configured to provide increased vapor production. Such an increase may result from a variety of factors. In some embodiments, the liquid transport element (i.e., the wick or wicking element) may be partially or completely formed from a ceramic material, particularly a porous ceramic. Exemplary ceramic materials suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application No. 14 / 988,109, filed Jan. 5, 2016, and U.S. Patent Application Publication No. 2014 / 0123989 by LaMothe, the disclosures of which are incorporated herein by reference. The porous ceramic may form a substantially solid wick, i.e., a single monolithic material rather than a bundle of individual fibers as known in the art.

[0094] In some embodiments, the heating element can be configured to increase vaporization, for example, by increasing the heating temperature that can be tolerated due to the use of a ceramic wick, or by increasing the heating surface (e.g., having a greater number of coils of resistive heating wire wrapped around the ceramic wick). In some embodiments, increased vapor production can relate to a larger reservoir capacity, i.e., a larger volume of the aerosol precursor composition, allowing for increased total vapor production of the cartridge or tank.

[0095] In some embodiments, the present disclosure may relate to an aerosol delivery device, in particular a vapor-forming unit. The vapor-forming unit may be referred to as a tank in view of its ability to store a relatively large volume of aerosol precursor composition in its reservoir. The term "tank" should not be construed as limiting, and the unit may be characterized as a cartridge. In general, the vapor-forming unit may be combined with a power unit. Alternatively, the vapor-forming unit may have a power-generating element included therein.

[0096] 2, the device may include a steam forming unit 204 that may comprise a housing 203 at least partially defined by an outer wall 205. The steam forming unit 204 may further comprise a connector 240 that may be disposed at a connector end 243 of the housing 203. The mouthpiece 227 may be disposed at a mouth end 230 of the housing 203.

[0097] The internal structure of the vapor formation unit 204 is evident in FIG. 3. In particular, the flow tube 245 is disposed inside the outer wall 205 of the housing 203. The flow tube 245 can be formed from any suitable material, such as a metal, a polymer, a ceramic composition, and the like. The flow tube 245 is preferably formed from a material that does not degrade at the temperatures reached near the heater, and thus is thermally stable. The arrangement of the flow tube 245 and the outer wall 205 of the housing 203 can define an annular space 247 therebetween. The annular space 247 can effectively function as a reservoir for the aerosol precursor composition. The annular space 247 can be substantially devoid of other materials other than the aerosol precursor composition. However, in some embodiments, a fibrous material can be included in the annular space 247 if it is desired to sorptively retain at least a portion of the aerosol precursor composition. An air flow path 257 can be present through the vapor formation unit 204, and in particular, can be present between the connector end 243 of the housing 203 and the mouth end 230 of the housing 203. Airflow path 257 extends at least partially through flow tube 245. However, airflow path 257 may also extend through additional elements of the device, such as interior channel 228 of mouthpiece 227 and / or connector 240. Connectors suitable for use in accordance with the present disclosure and airflow paths therethrough are described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference.

[0098] The vapor formation unit 204 of FIG. 3 may further include a heater 234 and a wick 236, which may be collectively characterized as an atomizer or atomizer unit. The heater 234 and wick 236 interact with the flow tube 245 such that the aerosol precursor composition in the annular space 247 is transported via the wick to the heater where the aerosol precursor composition is vaporized within the flow tube or within a space in fluid communication with the flow tube (e.g., directly adjacent to an end of the flow tube). Thus, at least a portion of the wick 236 is within the airflow path 257 and at least a portion of the wick is in fluid communication with the annular space 247. The interaction between the wick 236 and the flow tube 245 may be characterized as a sealed engagement in that the wick may pass through an opening 246 formed in the flow tube such that the aerosol precursor composition from the annular space 247 is substantially prevented from passing through the opening apart from the passage of the wick itself.

[0099] In some embodiments, the sealing engagement can be facilitated by the use of a sealing member 248 that can be disposed between the core 236 and the flow tube 247. The sealing member 248 can engage the core 236 and the flow tube 245 in a variety of ways, and only a single sealing member or multiple sealing members can be utilized. The arrangement of the core 236, flow tube 245, sealing member 248, and connector 240 is shown in FIG. 4. In the illustrated embodiment, the core 236 is disposed essentially between the flow tube 245 and the connector 240. The opening 246 (see FIG. 3) in the flow tube 245 is in the form of a cutout in the end of the flow tube wall. A corresponding cutout may be formed in the connector 240. The core 236 passes through the cutout on one or both sides of the flow tube 245, and the sealing member 246 fills the space between the outer surface of the core and the inner surface of the cutout in the flow tube (and connector, if necessary). As shown, the sealing member 246 also functions as a seal between the end of the flow tube 245 and the connector 240, effectively sealing the connection of the two elements. In other words, the flow tube 245 can extend completely between the mouthpiece 227 and the connector 240. The sealing member 248 can be formed from any suitable sealant, such as silicone, rubber, or other resilient material.

[0100] Returning to FIG. 3, the flow tube 245 can include a vent, which can be formed by one or more vents or vent openings 251. The vents 251 can be configured to equalize pressure within the annular space as liquid is depleted from the annular space 247. In some embodiments, the vents 251 can include a vent cover 252. The vent cover 252 can be formed from a microporous material. Preferably, the vent cover 252 is effective to allow the passage of gas (e.g., air) while generally preventing the passage of liquid. The vents can be located at various positions along the flow tube 245, particularly proximate to the interconnection between the flow tube and the mouthpiece 227. The flow tube 245 can engage or abut the mouthpiece 227 at a first end of the flow tube and engage or abut the connector 240 at a second end of the flow tube.

[0101] In one or more embodiments, the heater 234 may be specifically in the form of a resistive heating wire that may be coiled or otherwise disposed around an exterior surface of the wick 236. In this manner, vapor is formed around the outside of the wick 236 and swept away by air passing through the wick and heater 234 and into the airflow path 257. The wick 236 may specifically have a longitudinal axis that is generally perpendicular to the longitudinal axis of the housing 203. In some embodiments, the wick 236 may extend transversely across the flow tube 245 between the first wick end 236a and the second wick end 236b. Additionally, a sealing member 248 may be in sealing engagement with the wick 236 proximate the first wick end 236a and the second wick end 236b. The first and second wick ends (236a, 236b) may extend beyond the sealing member 248 or may be substantially flush with the sealing member, so long as the aerosol precursor composition in the annular space 247 can achieve fluid connection with the wick ends.

[0102] Electrical terminals (234a, 234b) may be electrically connected to the heater 234 and may extend through the connector 240 to facilitate electrical connection to a power source. A printed circuit board (PCB) 250 or the like may be included in the vapor formation unit 204 and may be specifically disposed within the connector 240 to effectively isolate the electronic components from the liquid in the annular space 247 and the vapor (and possible condensate) in the flow tube 245. The PCB 250 may provide control functions for the vapor formation unit and / or may send / receive information to a controller (see element 106 in FIG. 1 ), which may be in a further body to which the vapor formation unit may be connected.

[0103] Further embodiments of the steam formation unit 304 are encompassed by the present disclosure with reference to the exemplary embodiment shown in Fig. 5. As can be seen therein, the steam formation unit 304 is in many respects similar to the steam formation unit 204 shown in Fig. 3. In particular, the steam formation unit 304 includes a housing 303 formed at least in part by an outer wall 305. The steam formation unit 304 may further include a connector 340 that may be disposed at a connector end 343 of the housing 303. The mouthpiece 327 may be disposed at a mouth end 330 of the housing 303.

[0104] The steam forming unit 304 also includes a ceramic wick 336 having a hollow interior defining an open passageway 337 extending between a first end 336a of the wick and a second end 336b of the wick. The wick 336 and the open passageway 337 therethrough can have a longitudinal axis generally parallel to the longitudinal axis of the housing 303.

[0105] The heater 334 may be disposed within the open passage 337 of the wick 336, and may be in a heating arrangement with the inner surface 336c of the wick in particular. The heater 334 may be in the form of a wire coil, or may assume any further arrangement suitable for heating the aerosol precursor composition transported from the annular space 347 between the flow tube 345 and the outer wall 305 of the housing 303.

[0106] The flow tube 345 in the illustrated embodiment extends from a first end 345a that engages the mouthpiece 327 to a second end 345b (i.e., the free end) that engages a second end 336b of the wick 336. The first end 336a of the wick 336 likewise engages the connector 340. In this manner, the outer surface 336d of the wick 336 is exposed to the annular space 347 and thus the aerosol precursor composition stored therein, such that the aerosol precursor composition is passed through the wall of the wick to the heater 334 residing in the hollow interior of the wick.

[0107] The core 336 can be in sealing engagement with one or both of the flow tube 345 and the connector 340. As shown in Figure 5, a first sealing member 348a is circumferentially disposed between the core 336 and the connector 340. Similarly, a second sealing member 348b is circumferentially disposed between the core 336 and a portion of the flow tube 345 (e.g., proximate the second end 345b of the flow tube). The first sealing member 348a and the second sealing member 348b are spaced apart such that an outer surface 336d of the core 336 is exposed therebetween.

[0108] An airflow path 357 may exist through the vapor formation unit 204, and in particular may exist between the connector end 343 of the housing 303 and the mouth end 330 of the housing. The airflow path 357 extends at least partially through the flow tube 345. However, the airflow path 357 may also extend through additional elements of the device, such as the internal channel 328 of the mouthpiece 327 and / or the connector 340. More specifically, the vapor formation unit 304 may be configured such that air, in turn, enters through the connector 340, passes through the open passage 337 via the wick 336, passes through the flow tube 345, and passes through the internal channel 328 of the mouthpiece 327.

[0109] The electrical terminals (334a, 334b) may be electrically connected to the heater 334 and may extend through the connector 340 to facilitate electrical connection to a power source. A printed circuit board (PCB) 350 or the like may be included in the vapor formation unit 304. The printed circuit board (PCB) 350 or the like may be specifically disposed within the connector 340 to effectively isolate the electronic components from the liquid in the annular space 347 and the vapor in the wick 336. The PCB 250 may provide control functions to the vapor formation unit and / or the PCB 350 may send / receive information to a controller (see element 106 in FIG. 1 ), which may be in a further body to which the vapor formation unit may be connected.

[0110] As can be seen in FIG. 1, the cartridge 104 can be configured to be attached to the power unit 102 to form the aerosol delivery device 100, which is generally rod-shaped and particularly resembles a conventional cigarette. In some embodiments, the vapor forming unit described herein can be configured in combination with a relatively large size power unit or multiple power units. In this way, the reservoir of the vapor forming unit can be made larger to hold a larger volume of the aerosol precursor composition. An exemplary embodiment of a power unit 402 is shown in FIG. 6. The power unit 402 can include any or all of the elements described with respect to the power unit 102 shown in FIG. 1. In particular, the power unit 402 can include at least a power source. The power unit 402 can also include a controller (e.g., a PCB including a microcontroller) and / or sensors and / or feedback elements (e.g., light, sound, and / or vibration generating elements) and / or an input screen. The vapor forming unit can be combined with the power unit 402 in various ways. Power units having a similar structure and suitable for use in accordance with the present disclosure are described in U.S. Patent Application Publication No. 2016 / 0050975; U.S. Patent Application No. 14 / 981,051, filed December 28, 2015; and U.S. Patent Application No. 15 / 202,947, filed July 6, 2016, which are incorporated herein by reference.

[0111] FIG. 7 shows an aerosol delivery device 500 comprising a power unit 502 and a connected vapor forming unit 504. The vapor forming unit 504 is generally cylindrical in shape and includes a housing 503, a connector 540 forming a connection with the power unit 502, and a mouthpiece 527. As shown in FIG. 7, it can be seen that compared to FIG. 1, the vapor forming unit 504 is relatively larger in size and can therefore contain a larger amount of aerosol precursor composition. Similarly, the power unit 502 is relatively larger in size and can therefore provide a larger power source. Thus, the aerosol delivery device of FIG. 7 can provide a larger number of puffs of the device and / or a larger total mass of aerosol delivered between charging the power source and refilling or replacing the vapor forming unit 504 compared to the device of FIG. 1.

[0112] The vapor forming unit (204, 304, 504) can be generally cylindrical and elongated, although the unit can take different forms to allow for modifications to its internal structure. For example, FIG. 8 shows an aerosol delivery device 600 comprising a power unit 602 and a connected vapor forming unit 604, where the vapor forming unit is relatively short and includes lateral extensions. Thus, the overall vapor forming unit 604 can have lateral dimensions that more closely approximate the lateral dimensions of the power unit 602. For example, the overall width of the vapor forming unit 604 can be about 50% to about 99%, about 60% to about 98%, or about 70% to about 97% of the overall width of the power unit 602.

[0113] Components of the steam formation unit 604 are further illustrated in FIG. 9. In an exemplary embodiment, the steam formation unit 604 comprises a housing 603 formed from an outer wall 605. The housing 603 includes an air inlet 607 and an air outlet 609. The air inlet 607 can pass through a connector 640 that can be integrally formed with the housing 603. Alternatively, a separate connector can be combined with the housing 603, and the air inlet to the housing can be proximate to the attachment point of the separate connector to the housing. The air outlet 609 can be defined by a wall that can effectively form a flow tube 645. The air outlet 609 can also include a mouthpiece 627 that extends outwardly from the housing 603. In the embodiment illustrated in FIG. 9, the top of the housing 603 is defined by a cap 670 that includes an integrally formed mouthpiece 627 and an integrally formed flow tube 645. However, in other embodiments, the cap 670, mouthpiece 627, and flow tube 645 may each be separate elements that can be combined, the cap 670 may be integrally formed with the mouthpiece 627 while the flow tube 645 is a separate element, the cap 670 may be integrally formed with the flow tube 645 while the mouthpiece 627 is a separate element, or the mouthpiece 627 and flow tube 645 may be integrally formed while the cap is a separate element. If desired, the cap 670 may be integral with the housing 603. In any of the alternatives, the three elements may be combined in any manner to achieve a structure equivalent to that shown in FIG.

[0114] The vapor formation unit 604 shown in the embodiment of Figure 9 further comprises a liquid storage container 644 disposed within the housing 603. The liquid storage container 644 may be formed from a flexible outer wall 653 having an opening 654 formed therein. The flexible outer wall 653 may be formed from a collapsible material capable of holding a desired liquid volume without rupturing and that is otherwise substantially inert to the various components of the aerosol precursor composition stored therein. Non-limiting examples of materials suitable for forming the flexible outer wall include polyvinyl chloride (PVC), urethane, rubberized nylon, polyethylene, polypropylene, and the like.

[0115] The opening 654 of the liquid reservoir 644 can be configured to engage the ceramic wick 636. The wick 636 can be substantially solid, meaning that the wick may be porous but is not hollow in the sense of having a continuous uninterrupted passageway through the wick from one end to the other. In some embodiments, the wick 636 can be substantially rod-shaped. As can be seen in FIG. 9, the wick 636 includes an engagement end 636a that is at least partially inserted into the opening 654 of the liquid reservoir 644. The engagement end 636a of the wick 636 can be held within the opening 654 by frictional forces alone. As shown, the clamp 649 surrounds an outer surface of the liquid reservoir 644 proximate the opening 654 to form a sealed engagement between the wick 636 and the liquid reservoir. In the illustrated embodiment, the wick 636 has a longitudinal axis, the liquid reservoir 644 has a longitudinal axis, and the longitudinal axes of the wick and the liquid reservoir are substantially parallel. The longitudinal axis may be approximately perpendicular to the longitudinal axis of the air flow path between the air flow inlet 607 and the air flow outlet 609 of the housing 603 .

[0116] The heater 634 is disposed at a generally central portion 636c of the wick 636, which is at least partially disposed within an airflow path that includes the airflow inlet 607 and the airflow outlet 609. The airflow path can include a connector 640, a flow tube 645, and a mouthpiece 627. As shown in FIG. 9, a lower end of the flow tube 645 can substantially abut the wick 636 in an area surrounding the central portion 636c of the wick such that substantially all of the vapor generated by the heater 634 vaporizing the aerosol precursor composition passing from the liquid storage container 644 through the wick can be swept through the flow tube without substantially penetrating other areas of the vapor forming unit 604. The wick 636 also includes a free end 636b, which can include a lip 636e that fits snugly against the wick within the housing 603. As in the further embodiment described above, the steam formation unit 604 further includes a PCB 650 and electrical terminals 634a and 634b that connect the heater 634 to a power source.

[0117] 9, the housing 603 of the vapour forming unit 604 can be characterized as including two combined bodies. The body 603a can be substantially aligned with the axis of the airflow path through the housing 603, and the body can include the connector 640, the flow tube 645, and the mouthpiece 627. The housing 603 can also include a protrusion 603b extending generally perpendicularly from the body 603a. The protrusion 603b can include a liquid reservoir 644. The wick 636 can be aligned such that a portion of the wick is within the body 603a and a portion of the wick is within the protrusion 603b.

[0118] As mentioned above, the steam formation unit 604 can be connected to the power unit (see FIG. 8), where the power unit 602 can include, among other things, a power source. In some embodiments, the steam formation unit 604 can be connected to the power unit 602 such that the steam formation is external to the power unit when the power unit is connected. In some embodiments, a portion of the connector 640 can be internal to the power unit 602, while the remaining portion of the body 603a and the extension 603b of the housing 603 remain external to the power unit. However, in other embodiments, the steam formation unit can be connected to the power unit such that the steam formation unit is completely internal to the power unit when the two are connected. Such embodiments are shown in FIGS. 10 and 11.

[0119] The vapor formation unit 704 seen in Figure 10 is configured similarly to the vapor formation unit 604 shown in Figure 9. In particular, the vapor formation unit 704 includes a housing 703 formed from an outer wall 705. The housing 703 includes an air flow inlet 707 and an air flow outlet 709. In some embodiments, the air flow inlet 707 can be formed in a PCB 750 disposed in a notch 705a in the bottom of the outer wall 705. In some embodiments, the PCB 750 may be absent and the notch 705a can be appropriately sized to function as the air flow inlet.

[0120] The vapor formation unit 704 shown in the embodiment of FIG. 10 further comprises a liquid storage container 744 disposed within the housing 703. The liquid storage container 744 may be formed from a flexible outer wall 753 having an opening 754 formed therein. A portion of the flexible outer wall 753 proximate the opening 754 may effectively form a neck 744a sized to receive a ceramic wick 736, which may be substantially solid. Similar to the embodiment shown in FIG. 9, the wick 736 includes an engagement end (not visible in FIG. 10) that is at least partially inserted into the opening 754 defined by the neck 744a of the liquid storage container 744, and the neck 744a may form a seal against the wick 736 by means of a clamp 749.

[0121] In the illustrated embodiment, the wick 736 has a longitudinal axis, the liquid reservoir 744 has a longitudinal axis, and the longitudinal axes of the wick and liquid reservoir are generally parallel. Further, the longitudinal axis may be generally perpendicular to the longitudinal axis of the air flow path between the air flow inlet 707 and the air flow outlet 709 of the housing 703.

[0122] The heater 734 is disposed at a generally central portion 736c of the wick 736, which is at least partially disposed within an airflow path encompassing the airflow inlet 707 and the airflow outlet 709. As shown in FIG. 10, the housing 703 can include isolation walls 705b and 705c extending inwardly from the housing's outer wall 705. The isolation walls (705b, 705c) can include a notch shaped generally corresponding to the outer contour of the wick 736. In some embodiments, three or more isolation walls can be utilized. Alternatively, there can be only a single isolation wall 705c. The isolation walls (705b, 705c) effectively isolate the area surrounding the central portion 736c of the wick 736 such that substantially all of the vapor generated by the heater 734 vaporizing the aerosol precursor composition passing from the liquid storage vessel 744 through the wick can be swept away through the airflow outlet 709 without substantially penetrating other areas of the vapor forming unit 704. The wick 736 also includes a free end 736b, which may include a lip 736e that fits snugly to the wick within the housing 703. As shown, the lip 736e effectively secures the free end 736b of the wick 736 between the outer wall 705 of the housing 703 and one of the isolation walls 705b. The vapor forming unit 704 is shown in FIG. 10 with approximately half of the outer wall 705 of the housing 703 removed to reveal the internal components of the device. The outer wall 705 may, in some embodiments, be formed in two halves that are substantially mirror images thereof. The two halves forming the outer wall 705 may be glued, soldered, or otherwise joined to prevent separation and removal of the internal components of the vapor forming unit 704. Alternatively, the two halves forming the outer wall 705 may be configured to separate so that the wick 736 and / or the heater 734 and / or the liquid storage container 744 can be removed and replaced (or refilled with respect to the liquid storage container).

[0123] Electrical terminals 734a and 734b connect the heater 734 to a PCB 750. The PCB 750 may include corresponding terminals for forming an electrical connection with a power source in the power unit. To this end, the steam formation unit 704 may be configured for insertion into the power unit.

[0124] FIG. 11 illustrates an aerosol delivery device 700 including a vapor forming unit 704 substantially as described in connection with FIG. 10 inserted into a power unit 702 via an opening 781. The vapor forming unit 704 may be replaceable by removal and reinsertion, as indicated by arrow A, via opening 781 of a non-replaceable vapor forming unit inserted during manufacturing, with no option for user removal. The vapor forming unit 704 may be at least partially internal to the power unit when inserted into the power unit 702. In some embodiments, the vapor forming unit 704 may be fully internal to the power unit when inserted into the power unit 702, such that an outer wall 705 forming a housing of the vapor forming unit is fully internal to the power unit. In some embodiments, a tab 792 or similar element may be included in the vapor forming unit 704 to facilitate removal of the vapor forming unit, and at least a portion of such tab or similar element may be located external to the power unit 702, while the housing of the vapor forming unit remains fully internal to the power unit 702.

[0125] The power unit 702 may include electrical connectors 783a, 783b aligned with the steam formation unit 704 and may provide power from a power source 710 in the power unit to the electrical terminals 734a, 734b (e.g., directly or via an intermediate connector on a PCB 750). The power unit 702 may further include a control component 706. The control component 706 may be in the form of a PCB including suitable microcontroller functionality. A sensor 708 may be included in the power unit 702 and may be in fluid communication with an air inlet 785. Through the air inlet 785, air may be drawn from the atmosphere through the power unit 702 and into an air flow inlet 707 of the steam formation unit 704. The sensor 708, sensing the air flow, may activate a power source 710 for powering a heater 734 in the steam formation unit 704. The sensor 708 may be combined with the controller 706.

[0126] The power unit 702 of the aerosol delivery device 700 may include a mouthpiece 727. An aerosol inlet 787 may be formed in the power unit 702 above the airflow outlet 709 of the vapor forming unit 704. Thus, when the vapor forming unit 704 is inserted into the power unit 702, the airflow outlet 709 of the housing 703 is substantially aligned with the aerosol inlet 787. In use, an aerosol precursor composition from the liquid storage container 744 passes through the ceramic wick 736 to the heater 734 where it is vaporized and mixed with air passing through the air inlet 785 and the airflow inlet 707 to form an aerosol that exits the airflow outlet 709 and enters the aerosol inlet 787. From the aerosol inlet 787, the formed aerosol passes through the hollow interior 727a of the mouthpiece 727 and exits the mouth end 727b of the mouthpiece.

[0127] The mouthpiece 727 of the aerosol delivery device 700 can be fixed. In some embodiments, the mouthpiece 727 can be movable between an open position (shown in FIG. 11 ) in which the formed aerosol can pass through the hollow interior 727a to the mouth end 727b of the mouthpiece, and a closed position in which the formed aerosol is substantially prevented from passing. Preferably, the aerosol delivery device 700 can be configured to include a switch 789 so that the aerosol delivery device can be prevented from operating when the mouthpiece 727 is not in a position that allows the passage of the aerosol. In the illustrated embodiment, the mouthpiece 727 is foldable and thus configured to pivot about a central hub 727c to fold substantially flat against the power unit 702 in a closed position and to deploy to an extended position for use. The folding action can substantially seal the aerosol inlet 787 from the hollow interior 727c of the mouthpiece, and the folding action can activate the switch 789, if desired. In the illustrated embodiment of FIG. 11, the power unit 702 includes a receptacle 791 into which the mouthpiece 727 can be substantially seated and which can be configured to substantially cover the mouth end 727b of the mouthpiece to prevent contamination when not in use.

[0128] 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 housing defined at least in part by an outer wall; a flow tube disposed inside an outer wall of the housing, the flow tube including at least one vent hole configured in the wall, the at least one vent hole adapted to allow air flow therethrough and to substantially prevent liquid flow therethrough; a space defined between an outer wall of the housing and the flow tube; an air flow path through the device between the connector end of the housing and the mouth end of the housing and at least partially through the flow tube; an atomizer formed from a heater in combination with a ceramic wick, the ceramic wick in sealing engagement with the flow tube such that at least a portion of the ceramic wick is in an airflow path and such that at least a portion of the ceramic wick is in fluid communication with a space defined between an outer wall of the housing and the flow tube; a sealing member disposed between the ceramic core and the flow tube and configured to form a sealed engagement; An aerosol delivery device comprising:

2. The apparatus of claim 1 , wherein at least one vent hole configured in a wall of the flow tube is located proximate to the mouth end of the housing.

3. 3. The device of claim 1 or 2, further comprising a mouthpiece that engages the mouth end of the housing and engages the end of the flow tube.

4. The device of claim 1 , further comprising a connector that engages a connector end of the housing.

5. 5. The device of claim 1, wherein the ceramic core is substantially solid.

6. 6. The apparatus of claim 5, wherein the heater is a resistive heating wire disposed around the exterior surface of the ceramic core.

7. The device of claim 5 , wherein the ceramic core has a longitudinal axis generally perpendicular to a longitudinal axis of the housing.

8. 6. The apparatus of claim 5, wherein the ceramic core extends transversely across the flow tube between a first ceramic core end and a second ceramic core end, and the sealing member is in sealing engagement with the ceramic core adjacent the first ceramic core end and the second ceramic core end.

9. 9. The apparatus of claim 1, wherein the ceramic core has a hollow interior defining a passageway extending between a first end of the ceramic core and a second end of the ceramic core.

10. The apparatus of claim 9 , wherein the heater is disposed within a passage defined in the hollow interior of the ceramic core.

11. 10. The apparatus of claim 9, wherein the second end of the ceramic wick engages the free end of the flow tube.

12. 12. The device of claim 11, wherein the first end of the ceramic core connects with a connector that mates with a connector end of the housing.

13. 13. The apparatus of claim 12, wherein a sealing member forms a sealing engagement between the free end of the flow tube and the second end of the ceramic core, and a second sealing member forms a sealing engagement between the first end of the ceramic core and the connector.

14. a housing including an air inlet and an air outlet; a liquid reservoir within a housing formed from a flexible outer wall and having an opening formed therein; an atomizer in a housing having a ceramic wick including an end that engages an opening formed in the liquid storage container and a generally central portion that engages a heater, the generally central portion of the ceramic wick and the heater being in an air flow path between an air flow inlet and an air flow outlet of the housing; 1. An aerosol delivery device comprising: An aerosol delivery device, wherein the ceramic wick has a longitudinal axis, the liquid storage container has a longitudinal axis, the longitudinal axes of the ceramic wick and the liquid storage container are approximately parallel, and the longitudinal axes of the ceramic wick and the liquid storage container are approximately perpendicular to the longitudinal axis of an air flow path between an air flow inlet and an air flow outlet of the housing.

15. 15. The device of claim 14, wherein the ceramic core is generally rod-shaped.

16. 20. The device of claim 14 or 18, wherein the air flow outlet includes a mouthpiece extending outwardly from the housing.

17. 17. An apparatus as claimed in any one of claims 14 to 16, wherein the housing comprises a body substantially aligned with the axis of the airflow path and a projection extending generally perpendicularly from the body, the projection including a liquid reservoir.

18. 18. The apparatus of any one of claims 14 to 17, further comprising a power unit connectable to the housing, the power unit including a power source.

19. 20. The apparatus of claim 18, wherein the power unit is connectable with the housing such that the power unit is external to the housing when connected.

20. 20. The apparatus of claim 18, wherein the power unit is connectable with the housing such that the power unit is completely internal to the housing when connected.

21. 20. The device of claim 18, wherein the power unit comprises a mouthpiece.

22. 22. The device of claim 21, wherein the housing is configured for insertion into the power unit such that an airflow outlet of the housing is substantially aligned with the aerosol inlet to the mouthpiece.

23. 22. The aerosol delivery device of claim 21, wherein the mouthpiece is movable between an open position that allows the passage of the formed aerosol and a closed position that substantially prevents the passage of the formed aerosol.

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