Aerosol supply device

Abstract

To provide an aerosol supply device.SOLUTION: A housing defines a first opening on a first end of the housing, and receives an aerosol generation material through the first opening, and the housing defines a second opening on a second end of the housing. At least one heater is arranged in the housing, and heats the aerosol generation material received in the housing, for generating an aerosol. A hollow member is arranged in the housing and extends at least partially between the second and first openings. The hollow member has an end facing the second opening, and promotes formation of droplets.SELECTED DRAWING: Figure 9A

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device. [Background technology]

[0002] Smoking articles such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these smoking articles that burn tobacco by creating products that release compounds without burning. An example of such a product is a heating device that releases compounds by heating a material rather than burning the material. The material may be, for example, tobacco or other non-tobacco products that may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present disclosure, An aerosol delivery device comprising a housing, at least one heater, and at least one hollow member, a housing defining a first opening at a first end thereof for receiving the aerosol-generating material through the first opening and a second opening at a second end thereof; at least one heater is disposed within the housing and configured to generate an aerosol by heating the aerosol-generating material received within the housing; a hollow member disposed within the housing and extending at least partially between the second opening and the first opening; An aerosol delivery device is provided in which the hollow member has an end facing the second opening and is configured to inhibit capillary flow adjacent the end.

[0004] According to a second aspect of the present disclosure, An aerosol delivery device comprising a housing, at least one induction heater, and at least one hollow member, a housing defining a first opening at a first end thereof for receiving the aerosol-generating material through the first opening and a second opening at a second end thereof; at least one induction heater is disposed within the housing and configured to generate an aerosol by heating the aerosol-generating material received within the housing; a hollow member disposed within the housing and extending at least partially between the second opening and the first opening; The hollow member is a first end in a direction toward the first opening and a second end in a direction toward the second opening; a decreasing inner diameter toward the second end; a minimum inner diameter located less than about 50% of the distance from the second end to the first end; An aerosol delivery device is provided having the following structure:

[0005] According to a third aspect of the present disclosure, An aerosol delivery device comprising a housing, at least one heater, and at least one hollow member, a housing defining a first opening at a first end thereof for receiving the aerosol-generating material through the first opening and a second opening at a second end thereof; at least one heater is disposed within the housing and configured to generate an aerosol by heating the aerosol-generating material received within the housing; a hollow member disposed within the housing and extending at least partially between the second opening and the first opening; An aerosol delivery device is provided, wherein the hollow member has an interior surface with one or more ridges or grooves, the one or more ridges or grooves configured to impede liquid flow along the interior surface towards the second opening.

[0006] Other characteristics and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, made with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a front view of an example of an aerosol delivery device. [Diagram 2] FIG. 2 is a front view of the aerosol delivery device of FIG. 1 with the outer cover removed. [Diagram 3] 2 is a cross-sectional view of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 3 is an exploded view of the aerosol delivery device of FIG. 2. [Diagram 5] FIG. 5A is a cross-sectional view of a heating assembly in an aerosol delivery device, and FIG. 5B is an enlarged view of a portion of the heating assembly of FIG. 5A. [Figure 6A] FIG. 2 is a perspective view of the bottom end of the aerosol delivery device having a door providing access to a second opening. [Figure 6B] FIG. 2 is a perspective view of the bottom end of the aerosol delivery device with the door omitted. [Figure 7] FIG. 1 is a perspective view of an aerosol delivery device with certain components omitting the heating assembly. [Figure 8] 13A is a cross-sectional view of a hollow member that is not configured to promote droplet formation. FIG. [Figure 9A] FIG. 2 illustrates a cross-sectional view of a first exemplary hollow member configured to promote droplet formation. [Figure 9B] FIG. 2 illustrates a cross-sectional view of a first exemplary hollow member configured to promote droplet formation. [Figure 10A] FIG. 13 is a cross-sectional view of a second exemplary hollow member configured to promote droplet formation. [Figure 10B] FIG. 13 is a cross-sectional view of a second exemplary hollow member configured to promote droplet formation. [Figure 11] FIG. 13 illustrates a diagrammatic representation of a cross-sectional view of a third exemplary hollow member configured to promote droplet formation. [Figure 12]FIG. 13 is a diagrammatic representation of a cross-sectional view of a fourth exemplary hollow member configured to promote droplet formation. [Figure 13] FIG. 12 shows a diagrammatic representation of the example of FIG. 11 in combination with an absorbent material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] As used herein, the term "aerosol-forming material" includes materials that provide a component that volatilizes upon heating, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials can also include other non-tobacco products that may or may not contain nicotine depending on the product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, and the like. Aerosol-forming materials may be, for example, a combination or blend of materials. Aerosol-forming materials are also known as "smoking materials."

[0009] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, typically forming an aerosol that can be inhaled without burning, i.e., combusting, the aerosol-generating material. Such devices are sometimes described as "aerosol-generating devices," "aerosol delivery devices," "non-combustion heating devices," "tobacco heating product devices," or "tobacco heating devices," or similar. Similarly, there are so-called e-cigarette devices that typically vaporize an aerosol-generating material in liquid form, which may or may not contain nicotine. The aerosol-generating material may be provided in the form of, or as part of, a rod, cartridge, or cassette, etc., that can be inserted into the device. A heater for heating and volatilizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0010] The aerosol delivery device can accept an article that includes an aerosol-generating material for heating. An "article" in this context is a component that includes or contains an aerosol-generating material that is heated during use to volatilize the aerosol-generating material, and optionally other components during use. A user can insert an article into the aerosol delivery device before it is heated to generate an aerosol that is then inhaled by the user. The article can be, for example, an article of a predetermined size or a particular size configured to be placed within a heating chamber of a device sized to accept the article.

[0011] A first aspect of the present disclosure defines an aerosol delivery device that includes a hollow member disposed within the device to suppress capillary flow near the end. It has been found that when an article containing an aerosol-generating material is heated within the device, the aerosol can cool and condense inside the device. For example, the aerosol can condense on the inner surface of the chamber that receives the aerosol-generating material. The liquid can flow down the inside of the chamber and can flow by capillarity near the end of the hollow member disposed at one end of the chamber. For example, an existing hollow member can have a flat rim or flange, and the liquid can flow down the inner surface of the hollow member and along the bottom end of the flat rim or flange. The liquid can then flow into other areas of the device.

[0012] It may be useful to reduce capillary flow of liquid throughout the device. In some examples, the ends of the hollow members may be configured to promote the formation of droplets. This may direct the liquid into a receptacle. Modified end portions of hollow members or chambers may thus be provided that restrict capillary flow within the device by promoting the formation of droplets at the ends of the device. In other examples, droplets may not be formed but capillary flow near the ends may nevertheless be prevented, for example, by ensuring that the force of gravity on the liquid is greater than the force from surface tension that drives capillary flow.

[0013] In a first example, the hollow member has a thin wall thickness at the end. Thus, rather than having a flat rim or flange, the hollow member has a thin or "sharp" end to reduce the possibility of capillary flow near the end of the hollow member. The liquid will collect at the end of the hollow member where the wall thickness is thinnest. The force of gravity applied to the liquid is sufficient to inhibit capillary flow near the end surface. As the amount of liquid at the end increases, it can form a drop and overcome the surface tension of the liquid at the end surface of the hollow member so that the liquid drips off the end of the hollow member. The area of ​​reduced wall thickness can provide an air gap between the hollow member and other components in the device. Because the liquid at the end of the hollow member cannot flow by capillary action across the air gap, the amount of liquid increases until a drop drips off the end of the hollow member.

[0014] An exemplary aerosol delivery device includes a housing, the housing / device defining a first opening at a first end through which the aerosol generating material is received. The housing / device further defines a second opening at a second end of the housing / device. The second opening allows a user to access and clean the device. The housing may be at least partially defined, for example, by an exterior cover and one or more end members. The first opening may be located at a mouth end of the device. The second opening may be located at a distal end of the device. The second end may be opposite the first end.

[0015] The hollow member may be located within the housing adjacent to the second opening or at the second opening, such that one end of the hollow member faces the second opening but need not be contiguous with the second opening. The hollow member extends at least partially between the first opening and the second opening, i.e. the hollow member may extend completely from the second opening to the first opening or may extend only a portion of the distance between the second opening and the first opening.

[0016] The hollow member can define an axis, e.g., a longitudinal axis. An outer wall of the hollow member at an end of the hollow member has a first wall thickness measured in a direction perpendicular to the axis. A portion of the hollow member disposed closer to the first end of the housing than the end of the hollow member has a second wall thickness measured in a direction perpendicular to the axis. The first wall thickness is thinner than the second wall thickness.

[0017] Thus, the thinnest wall thickness of the hollow member may be located at an end of the hollow member.

[0018] The hollow member may be tubular. The hollow member includes a through hole extending in an axial direction through the hollow member. The through hole has an inner diameter / inner width measured in a direction perpendicular to the longitudinal axis. The hollow member has an interior surface (provided by the through hole) along which liquid can flow. When a user puffs on the device, air can be drawn through the second opening and through the hollow member towards the first opening.

[0019] The hollow member can form at least a portion of a chamber extending through the housing between the first opening and the second opening. The susceptor can form another portion of the chamber. The hollow member can also be known as a tube, cleanout tube or support. An end of the hollow member can define the second opening. The hollow member can support a susceptor at the other end of the hollow member.

[0020] In some examples, the wall thickness of at least a portion of the hollow member thins / reduces toward the second opening. For example, an end portion of the hollow member can have a wall thickness that tapers from the second wall thickness to the first wall thickness. The end portion can have a tapered wall thickness that thins along the length of the end portion. The thinnest wall thickness is near or at the end of the hollow member. In some examples, the end portion is disposed adjacent to the second opening.

[0021] A tapered wall thickness can provide a stronger hollow member because the hollow member can have a reduced wall thickness at its end, rather than having an end portion with a constant / uniform wall thickness, which can be fragile if the wall thickness is thin. A tapered wall thickness can also be easier to manufacture.

[0022] The end portion of the hollow member comprises an end of the hollow member facing the second opening. The portion of the hollow member located closer to the first end may be located directly adjacent to the end portion.

[0023] The tapered wall thickness may have a constant taper, or the tapered wall thickness may have a non-constant or varying taper.

[0024] The end surface or face of the hollow member may be flat in some instances. In other instances, the end surface or face of the hollow member may be curved with a constant or varying radius of curvature. If the end surface is curved, the maximum radius of curvature may be about 0.25 mm.

[0025] The wall thickness can be reduced by reducing the outer width / diameter of the hollow member toward the end of the hollow member. Thus, in some examples, the second opening lies in a plane perpendicular to the longitudinal axis, and the exterior surface of the hollow member is inclined relative to the plane such that the wall thickness of the end portion is reduced toward the second opening. In other words, the end portion of the hollow member can be hollow frustum.

[0026] In one example, the hollow frustum has a taper angle that is less than about 70°. That is, the angle between the longitudinal axis and the exterior surface of the hollow member that extends across the longitudinal axis is less than about 70°. This angle may also be referred to as a draft angle or taper angle. It has been found that the effect of capillary flow near the end surface of the hollow member may be reduced if the end portion has a taper angle of less than about 70° because gravity acts to reduce capillary flow along the sloped surface. By way of comparison, existing hollow members may have a flat rim or flange, and the angle between the longitudinal axis and the end surface of the flat rim or flange is about 90°. A sloped exterior surface of less than about 70° is sufficient for liquid to accumulate at the end of the hollow member such that the force of gravity of the liquid overcomes the surface tension of the liquid, thereby promoting the formation of droplets at the end of the hollow member.

[0027] The angle of inclination of the frustum can be less than about 45°, less than about 30°, or less than about 25°. The smaller the angle of inclination, the more effective the end profile is at reducing capillary flow because gravity has a greater effect on reducing capillary flow on an inclined surface. The smaller the angle of inclination, the more effective the end profile is at reducing capillary flow, regardless of the velocity of the liquid at the end of the hollow member.

[0028] The frustum may be a right frustum, such as a right circular cone frustum.

[0029] The end portion of the hollow member has a length dimension measured in a direction parallel to the longitudinal axis, which length dimension is between about 0.5 mm and about 5 mm, such as between about 0.5 mm and about 2 mm. It has been found that having a reduced wall thickness region of this length provides a good balance between overcoming the effects of capillary flow (by ensuring that the wall thickness is reduced over a sufficient length) and ensuring that the hollow member is not too fragile (by ensuring that the wall thickness is not reduced over too wide an area). In instances where the end portion is a hollow frustum, this length will also depend on the taper angle.

[0030] The first wall thickness can be less than about 0.5 mm. A wall thickness of less than 0.5 mm has been found to promote the formation of droplets at the ends of the hollow member, thereby promoting reduced capillary flow effects. In some examples, the first wall thickness can be less than about 0.25 mm or less than about 0.1 mm.

[0031] The first wall thickness can be less than about 50% of the second wall thickness, thus providing an air gap along the edge of the end portion, which can reduce or eliminate the effects of capillary flow. In some examples, the first wall thickness can be greater than about 10% of the second wall thickness to help provide structural integrity to the end portion.

[0032] In a second example, the hollow member defines an axis, such as a longitudinal axis, and the hollow member includes an end portion disposed adjacent the second opening and having an outer width dimension perpendicular to the axis that decreases or narrows toward the end. The reduced width of the end portion can provide an air gap between the end portion of the hollow member and other components within the device. Liquid at the end of the hollow member cannot cross the air gap and therefore remains at the end, possibly forming droplets as the amount of liquid increases.

[0033] The width dimension is measured between the opposing exterior surfaces of the hollow member.

[0034] The end portions may be hollow frustum.

[0035] The end portions may have a constant wall thickness or a non-constant wall thickness.

[0036] In any of the above examples, the device may include an absorbent material arranged to receive liquid from the end of the hollow member. The absorbent material may reduce the likelihood of liquid leaking out of the device, for example through the air inlet. Once absorbed by the absorbent material, the liquid may evaporate during the storage period or may be substantially retained within the absorbent member. The absorbent material may be removed from the device so that it can be cleaned and replaced within the device, the absorbent material may be emptied and replaced within the device, the absorbent material may be emptied, cleaned and replaced within the device, or the absorbent material may be discarded and replaced with a new absorbent member.

[0037] In some examples, the bottom of the device includes a cover or door, also known as a clean-out door, that allows a user access to the hollow member for cleaning. The cover can be moved between a first position in which the second opening is blocked by the door and a second position in which the second opening is unblocked, and the cover includes a recess that is positioned adjacent to the second opening when the cover is in the first position to receive liquid droplets from the end of the hollow member. When the user opens the cover, liquid can be poured out of the recess. The second opening is not blocked as long as access to the second opening is possible, e.g., the second opening can still be partially blocked or covered by the cover. In some examples, in the second position, access to the opening is substantially unimpeded by the cover.

[0038] In some examples, the door / cover can be separated from the device. This can allow easier disposal of the absorbent material by the user and / or for the user to pour excess liquid out of the recess. The cover can be completely separated from the device.

[0039] In some examples, the recess includes an absorbent material at least partially disposed in the recess for absorbing liquid.

[0040] In one example, the cover defines one or more openings for allowing air to pass therethrough, which openings may be located outside the recessed portion of the cover, thereby inhibiting leakage of liquid from the cover even if the absorbent material becomes full or the recessed portion contains liquid. The one or more openings are also known as air inlets.

[0041] During use, the absorbent material can be at least partially disposed between the aerosol-generating material and the cover, i.e. the absorbent material and the aerosol-generating material can be disposed simultaneously within the device. For example, the aerosol-generating material can be disposed in a first section of the chamber and the absorbent material can be disposed in a second section of the chamber, or the absorbent material can be disposed in a recess in the cover. This allows for absorption of liquid when the device is in use (i.e. during a heating session).

[0042] The absorbent material may include foams such as polyurethane foam or high density polyurethane foam, sponge, paper or cellulose acetate. These materials are light absorbents and relatively inexpensive to manufacture.

[0043] The absorbent material may include a thread-like tow material, also called a fibrous material, which may include cellulose acetate fiber tow. The thread-like tow may be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly 1-4 butanediol succinate (PBS), poly butylene adipate-co-terephthalate (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The thread-like tow may be plasticized using an appropriate plasticizer for the tow, such as triacetin, where the material is cellulose acetate tow, or the tow may be unplasticized. Unless otherwise stated, the tows can have any suitable specifications, such as fibers having a "Y" shape or fibers having other cross-sections, such as an "X" shape, a thread-like fineness value between 2 and 20 finenesses per thread, e.g., between 4 and 14 finenesses per thread, and a total fineness value between 5,000 and 50,000, e.g., between 10,000 and 40,000.

[0044] The absorbent material may have a capacity to absorb at least 7 grams of water per gram of absorbent material. In other examples, the absorbent capacity may be at least 10 grams per gram, or at least 15 grams per gram. Absorbent capacity measures the weight of liquid that can be maintained by the material without leaking. A higher capacity is preferred to ensure that the absorbent material can hold a sufficient amount of liquid that may be encountered during use without leaking. For example, a higher absorbent capacity allows for more use of the aerosol delivery device before the absorbent material needs to be emptied or replaced. In some examples, a hydrophilic polyurethane foam is used that is commercially available under the trade name Freudenberg 1012 from Freudenberg Performance Materials, headquartered in Weinheim, Germany. It has an absorbent capacity of 20 grams per gram.

[0045] Absorbent capacity in this case is measured by pouring water onto a test piece of absorbent material, such as a piece of foam with a flat top surface. The test piece is placed on the surface of a scale, without restraint, e.g., the test piece is free to expand in size. Water is added until the water is observed to leak out of the absorbent material or until it forms a puddle on top of the absorbent material, indicating that the foam is full and absorbent capacity has been reached. The weight at this point is recorded and this weight is used to calculate the absorbent capacity based on the known weight of the dry foam tested.

[0046] In one example, the absorbent material forms at least a portion of the brush. The brush thus comprises the absorbent material. The brush thus acts as an absorbent member to hold / retain liquid. The brush may also retain solid particles, such as loose tobacco.

[0047] The brush may include absorbent material in the form of bristles or threads. The brush may include absorbent material in the form of a mesh. Bristles, threads and mesh are absorbent materials because they hold / maintain droplets within their structure. For example, droplets may be trapped in the spaces between the bristles / threads. Similarly, the mesh may include a structure of intertwined or woven strands that hold / maintain droplets in the spaces between them.

[0048] The brush may include an absorbent material supported by a substrate, which may form a "backbone" to which the bristles, threads or mesh are attached.

[0049] As with the other examples, the absorbent member can be removed from the device and either discarded or cleaned and replaced in its original location in the device.

[0050] In examples including an absorbent material, at least a portion of the absorbent material may be configured to provide a visual indication to indicate when the absorbent material may be replaced or cleaned, for example, when a predetermined amount of liquid has been absorbed by the absorbent material or when the absorbent material has been used for a predetermined length of time.

[0051] In one example, the visual indication is a change in color of a portion of the absorbent material, for example, the absorbent material can be configured to change from a first color to a second color, where the first color and the second color are different (or at least distinct from one another).

[0052] In some instances, the liquid has a third color and the second color is different from the third color, and thus the absorbent material may not change color to the same color as the liquid.

[0053] The color change may occur non-uniformly throughout the absorbent material. For example, the end of the absorbent material closest to the aerosol-generating material may change color first, and the end furthest from the aerosol-generating material may change color at a later time. A user may clean or replace the absorbent material once the entire absorbent material has changed color. In other examples, the color change may occur substantially uniformly throughout the absorbent material. A user may clean or replace the absorbent material once the color tone suggests doing so.

[0054] In one example, the color change is caused by a change in pH value. Thus, the absorbent material may include a chemical indicator, such as a dye, to provide a visual indication. Thus, in one example, the absorbent material changes color as a result of the pH value of the liquid.

[0055] In another example, the color change is caused by a change in temperature, thus the absorbent material may change color upon exposure to heat, such as the heat of a liquid.

[0056] In one example, the absorbent material includes a capsule that includes a colored indicator within a shell, and the shell is configured to break and release the colored indicator to provide a visual indication. The shell may therefore break down over time. In one example, the shell is dissolvable and dissolves upon exposure to a liquid. The colored indicator, such as a dye, may then leak out of the capsule as the shell dissolves. In one example, the shell dissolves in the presence of water or in the presence of glycerol in the liquid. The shell is preferably dissolved in the presence of glycerol, rather than water, to ensure that the shell does not break down outside of the device and / or does not break down due to moisture in the air when not in use. In another example, the shell breaks down due to a chemical reaction with one or more chemicals in the liquid. In yet another example, the shell breaks down due to exposure to heat within the device. In a particular example, there are multiple capsules that each include a colored indicator within their shell, and each shell is configured to break down at a different time. For example, a first capsule can release a first color chemical indicator after one heating session and a second capsule can release a second chemical indicator after another heating session. Individual capsules can have different shell thicknesses such that the shells break at different times.

[0057] In one example, a first portion of the absorbent material is configured to provide a visual indication to indicate that the absorbent material can be replaced or cleaned at any time, and a second portion of the absorbent material can provide a different visual indication, or the second portion of the absorbent material may not provide a visual indication.

[0058] In some examples, the first portion can be configured to change from a first color to a second color, and the first and second colors are different (or at least distinct from one another). The liquid can have a third color, and the second portion can be configured to change from a fourth color to the third color. Thus, in some examples, the first portion is configured to change to a color different from that of the liquid, and the second portion is simply naturally colored by the liquid and therefore does not change to the same color as the first portion.

[0059] In a particular example, the first portion is disposed at a first end of the absorbent material and the second portion is disposed at a second end of the absorbent material, the first end being the end furthest from the aerosol-generating material (i.e., at the distal end of the absorbent material) and the second end being the end closest to the aerosol-generating material (i.e., at the proximal end). This can be useful because it indicates that liquid has penetrated the entire length of the absorbent material and therefore indicates that the absorbent material can be cleaned or replaced at any time.

[0060] In some examples, one or more of the chemical indicators or dyes are Generally Recognized As Safe (GRAS) by the U.S. Food and Drug Administration (FDA). For example, the dyes may be acceptable foods and, optionally, food-grade materials. Thus, the chemical indicators may be non-toxic and safe for consumption. This is useful because the indicators can be heated and aerosolized, and therefore inhaled or ingested by a user.

[0061] In one example, the visual indication includes the appearance of a particular pattern. For example, one or more marks or indications may appear when the absorbent material can be replaced or cleaned. In some examples, the pattern changes from a first pattern to a second pattern when the absorbent material can be replaced or cleaned. The appearance of a particular pattern can also include a change in color.

[0062] In some examples, the visual indications are viewable from the outside of the device, such as through a window or opening in an exterior cover of the device, while in other examples, the visual indications may be viewable by opening the cover.

[0063] At least a portion of the absorbent material may be gas permeable. The gas permeable absorbent material may allow the passage of gas through the gas permeable absorbent material, for example in a direction toward the portion of the chamber configured to receive the aerosol generating material. The pressure drop caused by drawing through the absorbent material is preferably less than about 200 Pa (20 mm H2O), more preferably less than about 100 Pa (10 mm H2O) or less than 50 Pa (5 mm H2O). This will depend on the dimensions and material properties of the absorbent material in the flow path, and will be tested by determining the difference in pressure drop across the aerosol delivery device with and without the absorbent material in place.

[0064] The absorbent member may cover one or more of the air inlets. The absorbent member may thus eliminate or reduce the possibility of liquid leaking through the air inlets. As mentioned, the air inlets may be openings formed in the cover.

[0065] In any of the above examples, the device may additionally or alternatively include a hydrophobic material, such as a hydrophobic layer or membrane, disposed at least partially in the recess. The hydrophobic material provides a liquid impermeable layer that stops liquids from seeping through the absorbent material and out of the door. The hydrophobic material may include polyethylene terephthalate (PET). PET is lightweight, flexible, inexpensive, and has a high melting point (to avoid deformation of the hydrophobic material during the heating session).

[0066] In a particular example, the absorbent material is disposed above the hydrophobic material, such that the absorbent material is closer to the first opening than the hydrophobic material (i.e., the absorbent member is disposed between the hydrophobic material and the aerosol-generating material), such that the hydrophobic material can stop liquid from seeping through the absorbent member.

[0067] In one alternative, the hydrophobic material is positioned closer to the first opening than the absorbent material (ie, the hydrophobic material is positioned between the absorbent material and the aerosol-forming material).

[0068] In some examples, at least a portion of the hollow member is hydrophobic or includes a hydrophobic coating to promote liquid flow. Liquid can be directed to flow toward the absorbent material and / or the hydrophobic material.

[0069] In some examples, at least a portion of the hollow member is formed from polypropylene or polyethylene. A portion of the hollow member may be coated with a layer of polypropylene or polyethylene in certain examples. Polypropylene and polyethylene are examples of hydrophobic materials.

[0070] In a particular example, at least a portion of the surface of the hollow member is modified to make the surface more hydrophobic. One example of modifying a surface is polishing the surface, such that the surface is a polished surface.

[0071] In any of the above examples, the hollow member can have an inner diameter that decreases toward the end. The inner diameter is measured in a direction perpendicular to the longitudinal axis. Thus, the interior surface of the hollow member is tapered. This decreasing inner diameter can increase the time it takes for liquid to condense and flow toward the end of the hollow tube. Increasing this time increases the temperature of the hollow member so that the condensate can be reheated and evaporated. This reduces the amount of liquid in the device and also reduces the chance of leakage.

[0072] Preferably, the hollow member has a smallest inner diameter at an end of the hollow member. In other examples, the smallest inner diameter is located less than about 50% of the length of the hollow member away from the end of the hollow member. The smallest inner diameter may be located less than about 25%, less than about 10%, or less than about 5% of the length of the hollow member away from the end of the hollow member.

[0073] Such hollow members are particularly useful in aerosol delivery devices having induction heaters, which typically heat up much more quickly than resistive heaters, which can mean that condensation is more of a problem in resistive heating systems.

[0074] An angle of greater than about 1° may be subtended between the interior surface of the hollow member and the longitudinal axis of the hollow member. It has been found that even small inclinations can have an effect on the amount of liquid that escapes the hollow member, thereby shortening the time it takes for the liquid to flow to the end of the hollow member.

[0075] In any of the above examples, the hollow member can have an interior surface with one or more ridges or grooves configured to impede liquid flow along the interior surface toward the second opening. By providing the hollow member with a "rough" or contoured surface, it takes longer for liquid to flow toward the end of the hollow member. In one example, the interior surface of the hollow member includes a spiral passageway formed around the interior surface.

[0076] In another aspect, a hollow member for an aerosol delivery device is provided. The hollow member can have any of the features described above. For example, the end portions of the hollow member can be hollow frustum and have a wall thickness that tapers toward the end of the hollow member.

[0077] In yet another aspect, an aerosol delivery device includes a housing, at least one induction heater, and a hollow member. The housing defines a first opening at a first end of the housing for receiving an aerosol-generating material through the first opening and a second opening at a second end of the housing. The at least one induction heater is disposed within the housing and configured to generate an aerosol by heating the aerosol-generating material received within the housing. The hollow member is disposed within the housing and extends at least partially between the second opening and the first opening. The hollow member has a first end in a direction toward the first opening and a second end in a direction toward the second opening. An inner diameter of the hollow member decreases toward the second end. A minimum inner diameter of the hollow member is disposed less than about 50% of the distance from the second end to the first end. In other examples, the minimum inner diameter can be disposed less than about 25%, less than about 10%, or less than about 5% of the distance from the second end to the first end. In this manner, the minimum inner diameter is closer to the second end than to the first end.

[0078] Another aspect of the present disclosure defines an aerosol delivery device comprising a housing defining a first opening at a first end thereof for receiving an aerosol-generating material therethrough and a second opening at a second end thereof. The device further comprises a chamber disposed between the second opening and the first opening, at least a portion of the chamber configured to receive the aerosol-generating material. The device further comprises at least one heater disposed within the housing and configured to generate an aerosol by heating the aerosol-generating material received within the chamber. The device further comprises a removable cover configured to receive liquid from the chamber, the removable cover attachable to the aerosol delivery device in a position where the second opening is blocked by the cover.

[0079] The device thus comprises a removable / separable cover / door. The cover is thus configured to receive liquid from the chamber and can be separated to allow collected liquid to be discarded. A separable cover allows the user to more easily discard the liquid and / or absorbent / hydrophobic material (if present). The separable nature of the cover also allows it to be cleaned, which is particularly useful if the device itself is not water resistant.

[0080] In some examples, the cover comprises a liquid reservoir for receiving liquid. The cover can be configured to (i) allow liquid to flow into the reservoir and (ii) substantially restrict liquid from flowing out of the reservoir. For example, the cover can comprise a one-way valve to stop liquid from leaking out of the reservoir. Alternatively, the reservoir can have an opening shaped to allow liquid to enter but restrict liquid from exiting.

[0081] In some examples, the cover includes an absorbent material. For example, the cover may include a recess, with the absorbent material at least partially disposed in the recess. In some examples, the absorbent material is removably adhered to the cover. A user may remove the absorbent material and clean or discard the removed absorbent material before adhering clean absorbent material back to the cover. In yet other examples, the absorbent material is not removable / separable from the cover. The door may be separated, thus allowing the absorbent material to be cleaned.

[0082] In some examples, the cover includes a hydrophobic material. For example, the cover can include a recess, with the hydrophobic material at least partially disposed in the recess. In some examples, the hydrophobic material is removably adhered to the cover. A user can remove the hydrophobic material and clean or discard the removed hydrophobic material before adhering clean hydrophobic material back onto the cover.

[0083] In some examples, at least a portion of the chamber is hydrophobic or includes a hydrophobic coating to promote the flow of liquid towards the cover.

[0084] According to another aspect, an aerosol delivery device is provided that includes a housing defining a first opening at a first end of the housing for receiving an aerosol-generating material through the first opening and a second opening at a second end of the housing. The device further includes a chamber disposed between the second opening and the first opening, at least a portion of the chamber configured to receive the aerosol-generating material. The device further includes at least one heater disposed within the housing and configured to generate an aerosol by heating the aerosol-generating material received within the chamber. The device further includes a brush configured to receive and retain residue from the chamber. In use, the aerosol is drawn through the chamber along a flow path toward the first opening, the brush being disposed at least partially upstream of a portion of the chamber configured to receive the aerosol-generating material.

[0085] In some examples, the brush receives and retains liquid residue from the chamber. In other examples, the brush receives and retains solid residue from the chamber. The brush can be removed from the device and cleaned or discarded. The brush can be completely disposed within the chamber or can be partially disposed within the chamber. In some examples, the cover / door comprises a recess and the brush is at least partially disposed within the recess.

[0086] In one example, the brush includes an absorbent material, so that the brush acts as an absorbent member and is capable of absorbing / retaining liquid.

[0087] In another aspect, a system comprises an aerosol delivery device as described above and also includes an aerosol-generating material contained at least partially within the housing.

[0088] 1 illustrates an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. Broadly speaking, the device 100 can be used to heat an exchangeable item 110 that contains an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device is a tobacco heating device, also known as a non-combustion heating device.

[0089] The device 100 comprises a housing 102 (defined at least in part by an exterior cover) that encloses and houses the various components of the device 100. The device 100 or housing 102 has a first opening 104 at one end into which an item 110 can be inserted for heating by the heating assembly. In use, the item 110 can be fully or partially inserted into the heating chamber where it can be heated by one or more components of the heater / heater assembly.

[0090] The device 100 in this example includes a first end member 106 with a lid 108 that can be moved relative to the first end member 106 to close the first opening 104 when the item 110 is not in place. In Figure 1, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "A."

[0091] Device 100 may also include user-operable controls 112, such as buttons or switches that, when pressed, operate device 100. For example, a user may power on device 100 by operating switch 112.

[0092] Device 100 may also include electrical components, such as a socket / port 114 that can accept a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0093] Figure 2 depicts the device 100 of Figure 1 with the outer cover 102 removed and without the presence of the item 110. The device 100 defines a longitudinal axis 134.

[0094] 2, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member and the second end member 106, 116 together at least partially form an end surface of the device 100. For example, a bottom surface of the second end member 116 at least partially forms a bottom surface of the device 100. In this example, the lid 108 also forms a portion of a top surface of the device 100. The first end member and the second end member 106, 116 are part of the device housing such that the housing defines the first opening 104.

[0095] Because the end of the device 100 closest to the first opening 104 is closest to the user's mouth during use, this end of the device 100 closest to the first opening 104 is also known as the proximal end (or mouth end) of the device 100. During use, a user inserts an article 110 into the first opening 104, activates a user control 112 to initiate heating of the aerosol-generating material, and puffs the aerosol generated in the device, which causes the aerosol to flow through the device 100 and along a flow path toward the proximal end of the device 100.

[0096] The other end of the device furthest from the first opening 104 is also known as the distal end of the device 100, as this is the end furthest from the user's mouth during use. When a user puffs on the aerosol generated in the device, the aerosol flows away from the distal end of the device 100.

[0097] The device 100 further comprises a power source 118. The power source 118 may be a battery, such as a rechargeable or non-rechargeable battery. The battery is electrically coupled to the heating assembly to provide power under the control of a controller (not shown) when required to heat the aerosol generating material. In this example, the battery is connected to a central support 120 that maintains the battery 118 in place.

[0098] The device further comprises at least one electronic module 122. The electronic module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also comprise one or more electrical tracks for electrically connecting together the various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power may be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via electrical tracks.

[0099] In the exemplary device 100, the heating assembly is an induction heating assembly, which includes various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly can include an induction element, for example one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The variable current in the induction element results in a variable magnetic field. The variable magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by the variable orientation of the magnetic dipoles in the magnetic material as a result of magnetic hysteresis losses in the susceptor, i.e., alignment of the magnetic dipoles with the variable magnetic field. In comparison with, for example, heating by conduction, in induction heating, heat is generated inside the susceptor and therefore can heat up quickly, and furthermore, no physical contact between the induction heater and the susceptor is required, thus facilitating freedom of construction and application.

[0100] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil and the second inductor coil 124, 126 are made of a conductive material. In this example, the first inductor coil and the second inductor coil 124, 126 are made of a multi-strand wire, such as a Litz wire / cable, wound in a generally helical manner to provide the inductor coils 124, 126. The Litz wire includes multiple wire strands that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect loss of the conductor. In the exemplary device 100, the first inductor coil and the second inductor coil 124, 126 are made of copper Litz wire having a rectangular cross section. In other examples, the Litz wire can have other shaped cross sections.

[0101] The first inductor coil 124 is configured to generate a first variable magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second variable magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is side-by-side with the second inductor coil 126 in a direction parallel to a longitudinal axis 134 of the device 100. Ends 130 of the first and second inductor coils 124, 126 may be connected to the PCB 122.

[0102] It will be appreciated that the first and second inductor coils 124, 126 can have at least one characteristic that differs from one another in some examples. For example, the first inductor coil 124 can have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 can have a different inductance value than the second inductor coil 126. In FIG. 2, the first and second inductor coils 124, 126 are of different lengths such that the first inductor coil 124 is wound over a shorter section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 can have a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 can be constructed of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0103] The susceptor 132 in this example is hollow and thus defines at least a portion of a chamber for receiving the aerosol-generating material. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular and has a circular cross-section.

[0104] The susceptor 132 and the first and second inductor coils 124, 126 may form at least a portion of a heater / heater assembly. The heated susceptor 132 thus heats the aerosol-generating material received within the housing / device.

[0105] 2 further includes an insulating member 128 that may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyether ether ketone (PEEK). The insulating member 128 may help insulate the various components of the device 100 from heat generated within the susceptor 132.

[0106] The insulating member 128 may also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 2, the first and second inductor coils 124, 126 are disposed about the insulating member 128 and are in contact with a radially outwardly facing surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0107] In a particular example, the susceptor 132 , the insulating member 128 and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0108] 3 shows a side view, partially in cross section, of device 100. In this example, outer cover 102 is present.

[0109] The device 100 further includes a hollow member 136 that engages one end of the susceptor 132 to maintain the susceptor 132 in place. The hollow member 136 is connected to the second end member 116. The hollow member 136 is also known as a support, tube or cleanout tube. The hollow member is positioned adjacent to the second opening and extends toward the first opening.

[0110] The device may also include a second printed circuit board 138 associated with the control element 112 .

[0111] The device 100 further comprises a cover or door 140 and a spring 142 disposed towards a distal end of the device 100. The spring 142 can open the door 140 to provide access to a second opening formed in the housing. The second opening can be defined, for example, by an end of the hollow member 136. A user can access the chamber through the second opening to clean the susceptor 132 and / or the hollow member 136. Thus, the device 100 or housing 102 defines a second opening at a second end of the device / housing. Similarly, the device 100 or housing 102 defines a first opening 104 at a first end of the device / housing. The first end and the second end can be opposite each other. A chamber or passageway is formed between the door 140 and the first opening 104. For example, the chamber / passageway can be at least partially defined by the hollow member 136 and the susceptor 132. The door 140 can be moved between two positions: in the first position, the second opening is covered by the door 140, and in the second position, the second opening is not covered by the door 140.

[0112] The device 100 further includes an extension chamber 144 that extends away from the proximal end of the susceptor 132 toward the first opening 104 of the device. A retaining clip 146 is at least partially disposed within the extension chamber 144 and maintains the article 110 in abutment when the article 110 is received within the device 100. The extension chamber 144 is connected to the end member 106. The extension chamber 144 may also define at least a portion of a chamber / passageway.

[0113] FIG. 4 is an exploded view of the device 100 of FIG. 1 with the outer cover 102 omitted.

[0114] FIG 5A depicts a cross-section of a portion of the device 100 of FIG 1. FIG 5B depicts an enlarged view of a region of FIG 5A. FIGs 5A and 5B show an article 110 received within a susceptor 132, with the article 110 sized such that an exterior surface of the article 110 abuts an interior surface of the susceptor 132. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 can also include other components, such as a filter, wrapping material, and / or cooling structure.

[0115] 5B shows that the exterior surface of the susceptor 132 is spaced from the interior surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 mm to 3.5 mm, or about 3.25 mm.

[0116] 5B further shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm such that the inductor coils 124, 126 are in abutting contact with the insulating member 128.

[0117] In one example, the susceptor 132 has a wall thickness 154 of about 0.025 mm to 1 mm, or about 0.05 mm.

[0118] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0119] In one example, the insulating member 128 has a wall thickness 156 of about 0.25 mm to 2 mm, 0.25 mm to 1 mm, or about 0.5 mm.

[0120] Figure 6A depicts the distal / lower end of device 100. In Figure 6A, door 140 is disposed in a first position in which the second opening to chamber / hollow member 136 is closed. One or more openings 160 form an air inlet in door 140. Air can be drawn into chamber / hollow member 136, through device 100, through openings 160 toward first opening 104.

[0121] 6B depicts the distal / bottom end of the device 100 with the door 140 omitted. The spring 142 and the bottom end of the hollow member 136 are visible. The end of the hollow member 136 and / or the second end member 116 define a second opening 162. The hollow member 136 and susceptor 132 can be cleaned through the second opening 162. For example, a cleaning tool can be introduced into the chamber.

[0122] 7 illustrates a perspective view of aerosol delivery device 100 with certain components of the heating assembly omitted, such as second inductor coil 126. Susceptor 132 and hollow member 136 at least partially define a chamber through which air and aerosol can flow. Susceptor 132 can form a first section of the chamber that receives the aerosol-generating material. Hollow member 136 supports one end of susceptor 132 and can form a second section of the chamber.

[0123] It has been found that when an article containing an aerosol-generating material is heated within the chamber of the device 100, the aerosol may cool and condense inside the device. For example, the aerosol may condense on the interior surface of the hollow member 136, which is cooler than the susceptor 132. Condensation may also occur on the susceptor 132 as it cools after use or when different parts of the susceptor are heated to different temperatures. This condensate, or liquid, may run down the inside of the chamber and collect at the bottom of the device. For example, the liquid may collect on the door 140. The liquid may then leak out of the opening 160 formed in the door 140 or around the door. Additionally, the liquid may leak out even when the door 140 is open.

[0124] In some examples, liquid may flow by capillary action along the end of hollow member 136 and onto other components of the device, such as the underside of second end member 116. Arrows 164 in FIG. 6B show the path that liquid may take as it emerges from the bottom end of hollow member 136. If the liquid takes this path, it may be more likely to leak around door 140.

[0125] FIG. 8 shows a cross-sectional view of the hollow member 136 of FIGS. 6B and 7. The hollow member in this example has a flat end surface 166 provided by a flange. Arrows 168 indicate the flow path of liquid as it flows down the interior surface 170 of the hollow member 136 and along the end surface 166 by capillary flow. Liquid may even flow along the underside of the second end member 116. If enough water flows along the second end member 116, the water flow may bypass the door 140 instead of flowing into a receptacle 172 formed in the door 140 as desired. Liquid that bypasses the door 140 may leak out of the device.

[0126] Thus, it is also useful to reduce or stop capillary flow of liquid near the ends of hollow member 136 in order to reduce or stop leakage of liquid from device 100. Thus, modified hollow members can be provided that restrict capillary flow by promoting the formation of droplets at the ends of the hollow member.

[0127] 9A and 9B depict cross-sectional views of a modified hollow member 236 configured to reduce capillary flow within device 100. Fig. 9B is an enlarged view of a portion of Fig. 9A. Hollow member 236 may be used in device 100 in place of hollow member 136 depicted in Fig. 8.

[0128] The hollow member 236 has a thin wall thickness at the ends 238 of the hollow member 236. The wall thickness of the hollow member 236 is measured in a direction perpendicular to the longitudinal axis 200 defined by the hollow member 236. Thus, instead of having a flat rim or flange (as in FIG. 7), the hollow member 236 has thin or "sharp" ends 238 to reduce the possibility of capillary flow near the ends of the hollow member 236.

[0129] The end 238 of the hollow member 236 facing the second opening 240 has a first wall thickness 242, and a portion 244 of the hollow member 236 located closer to the first end of the housing has a second wall thickness 246. The first wall thickness 242 is thinner than the second wall thickness 246 to provide a sharp edge. In this example, the thinnest wall thickness throughout the hollow member 236 is the first wall thickness 242. The portion 244 is located directly adjacent to the end portion 248, which extends away from the end 238 of the hollow member 236 and has a thinner wall thickness than the second wall thickness 246. The end portion 248 located adjacent to the second opening has a wall thickness that tapers from the second wall thickness 246 to the first wall thickness 242. Thus, the wall thickness tapers toward the end 238 of the hollow member 236.

[0130] End portion 248 thus has the form of a hollow frustum with an inclination angle 250 subtended between an exterior surface 252 of end portion 248 and longitudinal axis 200. In this particular example, inclination angle 250 is approximately 60°.

[0131] Arrows 254 in FIG. 9B show the flow path of liquid as it flows down the inner surface 256 of hollow member 236 towards the end 238 of hollow member 236. As liquid flows down the inner surface 256 of hollow member 236, the narrow end of hollow member reduces the capillary flow of liquid along the end surface of hollow member 236. As a result, liquid cannot flow by capillary action along the underside of hollow member 236 and second end member 116 (not shown in FIG. 9B for clarity). Thus, liquid forms droplets more easily at end 238 of hollow member 238 where the wall thickness is thinnest. Thus, the force of gravity on the droplet can overcome the surface tension of the liquid so that the droplet drips off end 238 of hollow member. The reduced wall thickness of end portion 248 may mean that an air gap 258 is formed between end portion 248 of hollow member 236 and second end member 116. Because the liquid at the end 238 of the hollow member 236 cannot wick across the air gap 258 , the amount of liquid increases until a droplet drips out of the end 238 of the hollow member 236 .

[0132] As shown most clearly in Figure 9B, the door 140 can include a recess 172 that is disposed adjacent the end 238 of the hollow member 236 when the door is in the first position (i.e., the closed position of Figure 9B) so that liquid can drip into the recess 172. In the example of Figure 9B, an absorbent material 260 is disposed in the recess to absorb liquid and stop it from passing through the one or more air inlets 160 (shown in Figure 6B).

[0133] End portion 248 has a length dimension 262 measured in a direction parallel to longitudinal axis 200. In this example, the length dimension is about 3 mm.

[0134] The hollow member 236 has an inner diameter that decreases toward the end 238 of the hollow member 236. The inner diameter is measured in a direction perpendicular to the longitudinal axis 200. FIG. 9A shows that the inner diameter 264 at the end 238 of the hollow member 236 is smaller than the inner diameter 268 at a point closer toward the first opening 104. The hollow member 236 thus has a tapered inner surface 256. As mentioned, this can increase the time it takes for liquid to flow toward the end 238 of the hollow member. In this example, an angle 270 of approximately 1 degree is subtended between the inner surface 256 of the hollow member and the longitudinal axis 200.

[0135] In some examples, the hollow member 236 has an interior surface 256 with one or more ridges or grooves (not shown) to increase the time it takes for liquid to flow toward the end 238 of the hollow member.

[0136] 10A and 10B depict cross-sectional views of another modified hollow member 336 configured to reduce capillary flow within device 100. Figure 10B is an enlarged view of a portion of Figure 10A. Hollow member 336 can be used in device 100 in place of hollow member 136 depicted in Figure 8.

[0137] The hollow member 336 in Figures 10A and 10B differs from the hollow member depicted in Figures 9A and 9B in that the hollow member 336 has a smaller inclination angle 350. In this example, the inclination angle is about 25°. Additionally, the end portion 348 has a longer length dimension 362. In this example, the length dimension 362 is about 5 mm.

[0138] 10A and 10B also depict a hydrophobic layer 360 disposed within recess 172 of door 140. Liquid can flow over hydrophobic layer 360 and remain there until a user opens door 140 to pour the liquid out.

[0139] 11 is a diagrammatic representation of a cross-sectional view of a modified hollow member 436 configured to reduce capillary flow within device 100. Hollow member 436 can be used in device 100 in place of hollow member 136 depicted in FIG.

[0140] The hollow member 436 has a thin wall thickness at the ends 438 of the hollow member 436. The wall thickness of the hollow member 436 is measured in a direction perpendicular to the longitudinal axis 400 defined by the hollow member 436. Thus, instead of having a flat rim or flange (as in FIG. 7), the hollow member 436 has a thin or "sharp" end 438 to reduce the possibility of capillary flow near the ends of the hollow member 436.

[0141] An end 438 of the hollow member 436 located adjacent to the second opening has a first wall thickness 442, and a portion 444 of the hollow member 436 located closer to the first end of the housing has a second wall thickness 446. The first wall thickness 442 is thinner than the second wall thickness 446 to provide a sharp edge. In this example, the thinnest wall thickness throughout the hollow member 436 is the first wall thickness 442. The portion 444 is located directly adjacent to the end portion 448, which extends away from the end 438 of the hollow member 436 and has a thinner wall thickness than the second wall thickness 446. Unlike the examples of Figures 9A, 9B, 10A and 10B, the end portion 448 has a constant / uniform wall thickness and forms a step on the outer surface of the transition between the two wall thicknesses. In other examples, the step can be formed on the inner surface of the transition between the two wall thicknesses.

[0142] Arrows 454 indicate the flow path of liquid as it flows down the interior surface 456 of hollow member 436 towards the end 438 of hollow member 436. As liquid flows down the interior surface 456 of hollow member 436, the narrow end of hollow member reduces the capillary flow of liquid along the end surface of hollow member 436. As a result, liquid cannot flow by capillary action along the underside of hollow member 436 and second end member 116. Thus, droplets form more easily at end 438 of hollow member 436 where the wall thickness is thinnest. Thus, the force of gravity on the droplet can overcome the surface tension of the liquid so that the droplet drips off end 438 of hollow member 436. The reduced wall thickness of end portion 448 may mean that an air gap 458 is formed between end portion 448 of hollow member 436 and second end member 116. Because the liquid at the end 438 of the hollow member 436 cannot wick across the air gap 458 , the amount of liquid increases until a droplet drips out of the end 438 of the hollow member 436 .

[0143] As already mentioned, the door 140 may include a recess 172 that is located adjacent the end 438 of the hollow member 436 when the door is in the first position (i.e., the closed position of FIG. 11). Liquid may therefore drip into the recess 172. In the example of FIG. 11, the recess is empty. However, the recess may also include an absorbent material and / or a hydrophobic layer as discussed above with reference to FIGS. 9 and 10.

[0144] End portion 448 has a length dimension 462 measured in a direction parallel to longitudinal axis 400. In this example, the length dimension is about 1 mm.

[0145] The hollow member 436 in this example has an inner diameter that is constant / uniform throughout the hollow member 436. In other examples, the inner diameter may decrease towards the end 438 of the hollow member 436.

[0146] Figure 13 further depicts another example that is the same as the example described above with reference to Figure 11, except for the addition of an absorbent material 660 disposed in the door recess. The absorbent material has a thickness that is greater than the distance between the end of the hollow member and the bottom of the recess. This can further reduce capillary flow due to the wicking action provided by the absorbent material 660. For example, the end of the hollow member can be between 1 mm and 5 mm from the bottom of the recess, or between 1 mm and 3 mm from the bottom of the recess.

[0147] In the example of FIG. 13, the flow path is through absorbent material 660, as opposed to the example of FIG. 9B where the flow path is around absorbent material 260.

[0148] It will be appreciated that the absorbing material configuration of FIG. 13 is not limited to end profiles according to FIG. 11, but may also be applied to any other end profiles described herein.

[0149] 12 is a diagrammatic representation of a cross-sectional view of a modified hollow member 536 configured to reduce capillary flow within device 100. Hollow member 536 can be used in device 100 in place of hollow member 136 depicted in FIG.

[0150] 9A, 9B, 10A, 10B, and 11, the hollow member 536 in this example has a uniform wall thickness along the length of the hollow member 536. The wall thickness of the hollow member 536 is measured in a direction perpendicular to the longitudinal axis 500 defined by the hollow member 536. Instead of having end portions with reduced wall thickness, the hollow member has end portions with a reduced width dimension (the width dimension is measured in a direction perpendicular to the longitudinal axis 500). As with the previous examples, this can reduce the likelihood of capillary flow near the ends of the hollow member 536.

[0151] The hollow member has an end portion 548 having a width dimension that decreases toward the end 538 of the hollow member 536. For example, the end portion 548 has a first width dimension 542 where the end portion 548 meets another portion 544 located closer to the first end of the housing than the end 538 of the hollow member, and the end portion 548 has a second, smaller width dimension 546 at the end 538 of the hollow member 536. In some examples, the another portion 544 has a substantially constant width dimension. The end portion 548 is located at the end 538 of the hollow member 536, and the end portion 548 is a region having a reduced width dimension.

[0152] The reduced width of end portion 548 can provide an air gap 558 between end portion 548 of the hollow member and other components within the device. Arrows 554 indicate the flow path of liquid as it flows down interior surface 556 of hollow member 536 toward end 538 of hollow member 536. The liquid at the end of the hollow member cannot cross air gap 558 and the amount of liquid increases until a droplet drips off the end of the hollow member.

[0153] As already mentioned, the door 140 may comprise a recess 172 that is arranged adjacent the end 538 of the hollow member 536 when the door is in the first position (i.e. the closed position of FIG. 11 ). Liquid may therefore drip into the recess 172. In the example of FIG. 12 the recess is empty. However, the recess may also comprise an absorbent material and / or a hydrophobic layer as described above with reference to FIGS. 9 and 10 .

[0154] End portion 548 has a length dimension 562 measured in a direction parallel to longitudinal axis 500. In this example, the length dimension is about 2 mm.

[0155] The hollow member 536 in this example has an inner diameter that decreases toward an end 538 of the hollow member 536 .

[0156] As mentioned, in the example of Figure 12, the hollow member has a width dimension that decreases towards the ends of the hollow member. Note that the examples depicted in Figures 9A, 9B, 10A, 10B and 11 also have hollow members with width dimensions that decrease towards the ends of the hollow member.

[0157] In the variation of Figure 12, the end portion can have a width dimension that increases toward the end of the hollow member. In other words, rather than tapering toward the end, the end portion can be flared or otherwise enlarged. This can also promote the formation of a drop if the wall thickness of the end portion is substantially constant.

[0158] The above embodiments should be understood as illustrative examples of the invention. Other embodiments of the invention are contemplated. It should be understood that any feature described in connection with any one embodiment can be used alone or in combination with other features described, and can also be used in combination with one or more features of any other embodiment, or in any combination of any other embodiment. Moreover, equivalents and modifications not described above can also be used without departing from the scope of the invention, as defined in the appended claims.

Claims

1. An aerosol delivery device comprising a housing, at least one heater, and at least one hollow member, the housing defines a first opening at a first end of the housing for receiving an aerosol-forming material through the first opening and a second opening at a second end of the housing; the at least one heater is disposed within the housing and configured to generate an aerosol by heating the aerosol-forming material received within the housing; the hollow member is disposed within the housing and extends at least partially between the second opening and the first opening; The aerosol delivery device, wherein the hollow member has an end facing the second opening and is configured to inhibit capillary flow adjacent the end.

2. The aerosol delivery device of claim 1 , wherein the end facing the second opening is configured to promote droplet formation.

3. the hollow member defines an axis; an outer wall of the hollow member at the end of the hollow member has a first wall thickness measured in a direction perpendicular to the axis; a portion of the hollow member disposed closer to the first end of the housing than the end of the hollow member has a second wall thickness measured in a direction perpendicular to the axis; the first wall thickness being less than the second wall thickness; 3. The aerosol delivery device of claim 1 or 2.

4. The aerosol delivery device of claim 3 , wherein an end portion of the hollow member has a wall thickness that tapers from the second wall thickness to the first wall thickness.

5. 4. The aerosol delivery device of claim 3, wherein the end portion is a hollow frustum, the inclination angle of the frustum being less than about 70 degrees.

6. 6. The aerosol delivery device of claim 4 or 5, wherein the end portion has a length dimension measured in a direction parallel to the axis, the length dimension being between about 0.5 mm and about 5 mm.

7. The aerosol delivery device of any one of claims 3 to 6, wherein the first wall thickness is less than about 0.5 mm.

8. The aerosol delivery device of any one of claims 3 to 7, wherein the first wall thickness is less than about 50% of the second wall thickness.

9. the hollow member defines an axis; The hollow member is an end portion disposed adjacent to the second opening and having a width dimension perpendicular to the axis that decreases toward the end; 3. The aerosol delivery device of claim 1 or 2, comprising:

10. 10. The aerosol delivery device of claim 9, wherein the end portion is a hollow frustum.

11. An aerosol delivery device according to any preceding claim, comprising an absorbent material arranged to receive liquid from the end of the hollow member.

12. 12. The aerosol delivery device of claim 11, wherein at least a portion of the hollow member is hydrophobic or includes a hydrophobic coating to promote liquid flow toward the absorbent material.

13. 13. The aerosol delivery device of any one of claims 1 to 12, wherein the device comprises a cover, the cover being movable between a first position in which the second opening is blocked by the cover and a second position in which the second opening is not blocked, the cover comprising a recess disposed adjacent the second opening when the cover is in the first position to receive liquid from the end of the hollow member.

14. The aerosol delivery device of claim 13 , comprising an absorbent material disposed at least partially in the recess for absorbing liquid.

15. 15. The aerosol delivery device of claim 13 or 14, comprising a hydrophobic material disposed at least partially in the recess.

16. The aerosol delivery device of claim 14 or 15, wherein the absorbent material is disposed on the hydrophobic material.

17. The aerosol delivery device of any one of claims 1 to 16, wherein the hollow member has an inner diameter that decreases towards the end.

18. 18. The aerosol delivery device of any one of claims 1 to 17, wherein the hollow member has an interior surface with one or more ridges or grooves, the one or more ridges or grooves configured to impede liquid flow along the interior surface toward the second opening.

19. 1. An aerosol delivery device comprising a housing, at least one induction heater, and at least one hollow member, the housing defines a first opening at a first end of the housing for receiving an aerosol-forming material through the first opening and a second opening at a second end of the housing; the at least one induction heater is disposed within the housing and configured to generate an aerosol by heating the aerosol-forming material received within the housing; the hollow member is disposed within the housing and extends at least partially between the second opening and the first opening, the hollow member comprising: a first end in a direction toward the first opening and a second end in a direction toward the second opening; a decreasing inner diameter toward the second end; a minimum inner diameter located less than about 50% of the distance from the second end to the first end; An aerosol delivery device comprising:

20. An aerosol delivery device according to any one of claims 1 to 19; an aerosol-forming material at least partially contained within the housing; A system comprising:

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