Electronic cigarette

Abstract

To provide an electric smoking material from which more saturated palatability can be obtained from steam output.SOLUTION: An electronic smoking material 60 includes: a liquid supply part having a liquid material; a heater 14 that can act to heat the liquid material to a temperature that is enough to vaporize the liquid material and form aerosol; a core 28 communicated with the liquid material and also communicated with the heater, by which the liquid material is delivered to the heater; at least one air inlet that can act to deliver air to an air flow passage 20 in the center upstream of the heater; and a fiber element 300 located downstream of the heater.SELECTED DRAWING: Figure 19

Description

[Technical Field]

[0001] The present invention relates to electronic cigarettes.

[0002] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application is related to U.S. Provisional Patent Application No. 61 / 593,004, filed January 31, 2012, and claims priority under 35 U.S.C. § 119 to these provisional applications, the disclosures of which are incorporated herein by reference as if set forth in their entirety. [Background technology]

[0003] Electronic cigarettes or electronic cigars (collectively referred to as "smoking articles") are provided that include a heater element that vaporizes a liquid material to produce an aerosol or "vapor." The heater element preferably includes a resistive heater coil having a wick extending the entire length of the heater coil. The heater coil is configured and made of materials that prevent hot spots or excessive temperatures from occurring during a puff.

[0004] Preferably, the electronic smoking article includes a mouth insertion end having at least two dispersion outlets to provide a fuller mouthfeel from the vapor output. Preferably, the mouth insertion end having multiple outlets is coupled with an arrangement that decelerates the air immediately upstream of the mouth insertion end to substantially avoid a "hot" sensation at or around the "smoker's" lips.

[0005] The electronic smoking article preferably has a metal canister portion and a precision-molded main portion, i.e., an air inlet port located along the metal canister portion, preferably along the metal sidewall portion of the smoking article. The air inlet port is precision-molded within close tolerances and sized to be the dominant pressure drop source along the air communication path between the air inlet port and the vapor source (heater). This configuration ensures that the RTD remains essentially the same from puff to puff and from one smoking article to the next. To further enhance consistent performance, the RTD of the smoking article is tested during manufacturing of the smoking article and during corrective action, if necessary. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a plan view showing an electronic smoking article according to a first embodiment of the present invention. [Figure 2] 2 is a cross-sectional side view of the electronic smoking article shown in FIG. 1. FIG. [Figure 3A] 3A is an exploded perspective view of an element having a cartridge section of the electronic smoking article shown in FIG. 1. FIG. [Figure 3B] 3B is a detailed view showing the air inlet port of the cartridge section of the electronic smoking article shown in FIG. [Figure 4] 4 is a perspective view of the mouth insertion end of the electronic smoking article shown in FIG. 1. FIG. [Figure 5] FIG. 5 is a cross-sectional view taken along line A-A of the mouth insertion end of FIG. [Figure 6] FIG. 6 is a perspective view showing another embodiment of the mouth insertion end of the electronic smoking article shown in FIG. [Figure 7] 7 is a cross-sectional view taken along line BB of the mouth insertion end of FIG. [Figure 8] FIG. 8 is an enlarged detailed view of the heater assembly of the electronic smoking article shown in FIG. [Figure 9A] FIG. 9A is an enlarged view of the inner tube with the heater coil and wick assembly before the sealing ring is placed. [Figure 9B]FIG. 9B is an enlarged view of the inner tube with the heater coil and wick assembly after the sealing ring has been placed. [Figure 10] FIG. 10 is a cross-sectional view showing yet another (third) embodiment of a mouth insertion end for use with the electronic smoking article of FIG. [Figure 11] FIG. 11 is an exploded view of the mouth insertion end of FIG. [Figure 12] FIG. 12 is a detailed view showing an assembly of another coupling arrangement for use with the electronic smoking article of FIG. [Figure 13] FIG. 13 is a perspective view showing a second embodiment of a connector cathode having a notch. [Figure 14A] FIG. 14A is an illustration of a third embodiment of a connector cathode having angled holes. [Figure 14B] FIG. 14B is an illustration of a third embodiment of a connector cathode having angled holes. [Figure 14C] FIG. 14C is an illustration of a third embodiment of a connector cathode having angled holes. [Figure 15] FIG. 15 is a cross-sectional view of a connector cathode and anode where the anode is shortened to achieve vent communication through the air inlet port. [Figure 16] FIG. 16 is a perspective view of a fourth embodiment of a mouth insertion end for use with an electronic smoking article. [Figure 17] FIG. 17 is a cross-sectional view of an electronic smoking article according to a first embodiment, further including a sleeve assembly. [Figure 18] FIG. 18 is a side view showing an electronic smoking article according to another embodiment. [Figure 19] FIG. 19 is a cross-sectional view of another embodiment of an electronic smoking article having a fiber element at the mouth end of the electronic smoking article. [Figure 20] FIG. 20 is a cross-sectional view of another embodiment of an electronic smoking article having a fiber element at the mouth end of the electronic smoking article. [Figure 21]FIG. 21 is a cross-sectional view of another embodiment of an electronic smoking article having a fiber element at the mouth end of the electronic smoking article. [Figure 22] FIG. 22 is a cross-sectional view of another embodiment of an electronic smoking article having an open mouth end. [Figure 23] 23 is a perspective view of a fiber element for insertion into the open mouth end of the electronic smoking article of FIG. 22. FIG. [Figure 24] FIG. 24 is a perspective view of a detachable fiber element for use with an electronic smoking article. [Figure 25] 25 is a cross-sectional view of an alternative embodiment of an electronic smoking article having a mouth insertion end and the detachable fiber element of FIG. 24. FIG. [Figure 26] FIG. 26 is a cross-sectional view of another embodiment of an electronic smoking article having a mouth insertion end and a fiber element. [Figure 27] FIG. 27 is a cross-sectional view of an electronic smoking article having a mouth insertion end and a removable sleeve. [Figure 28] FIG. 28 is a cross-sectional view showing another embodiment of an electronic smoking article having a carbon dioxide tank. [Figure 29] FIG. 29 is a plan view showing an electronic smoking article having aromatic strips on the outer surface of the electronic smoking article. DETAILED DESCRIPTION OF THE INVENTION

[0007] (Layout of electronic smoking devices) 1 and 2, a novel electronic smoking article (electronic cigarette or cigar) 60 is illustrated, comprising a replaceable cartridge (i.e., first section) 70 and a reusable fixture (i.e., second section) 72, which in preferred embodiments are adapted to be joined together by a threaded connection 205 or other convenient means such as a slip fit, detent, clamp, and clasp, or any combination thereof. Generally, the second section 72 contains a puff sensor 16 responsive to air drawn into the second section 72 through an air inlet port 45 adjacent the free or tip end of the electronic smoking article 60, a battery 1, and control circuitry. The disposable first section 70 contains a liquid supply region 22 and a heater 14 that atomizes liquid drawn from the liquid supply region 22 through a wick 28. Once the threaded connection 205 is achieved, the battery 1 can be connected to the electric heater 14 in the first section 70 during operation of the puff sensor. Air is drawn into the first section 70 primarily through one or more air inlet ports 44.

[0008] In a preferred embodiment, only the first section 70 is replaced when the cartridge liquid is depleted. Other configurations may include disposing of the entire electronic smoking article 60 once the liquid supply is exhausted. In such cases, the battery type and other features may be designed to be simple and inexpensive, but will generally embody the same concepts as the preferred embodiment in which the second section is reused and / or recharged.

[0009] In a preferred embodiment, the electronic smoking article 60 is approximately the same size as a regular cigarette. In one embodiment, the electronic smoking article 60 may be about 80 mm to about 110 mm long, preferably about 80 mm to about 100 mm long, and have a diameter of about 7 mm to about 8 mm. In a preferred embodiment, for example, the electronic smoking article may be about 84 mm long and have a diameter of about 7.8 mm.

[0010] At least one adhesive-backed label is preferably applied to the outer tube 6. This label completely surrounds the electronic smoking article 60 and may be colored and / or textured to provide the look and / or feel of a conventional cigarette. The label may be perforated with holes sized and positioned to avoid blocking the air inlet port 44.

[0011] The outer tube 6 and / or the inner tube 62 may be formed from any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites comprising one or more of these materials, or thermoplastics suitable for the food or pharmaceutical industries, such as polypropylene, polyetheretherketone (PEEK), ceramic, and polyethylene. Preferably, these materials are lightweight and non-brittle.

[0012] (Cartridge structure) 1, 2, and 3, the first section 70 includes a longitudinally extending outer tube (or casing) 6 and an inner tube (or chimney) 62 coaxially disposed within the outer tube 6. The nose portion 61 (see FIG. 3A) of an upstream gasket (or seal) 15 preferably fits within the upstream end 65 of the inner tube 62, while simultaneously sealing the outer periphery 67 of the gasket 15 with the inner surface of the outer tube 6. The upstream gasket 15 also includes a central, longitudinal air passage 20 that opens into the interior of the inner tube 62, which defines a central passage 21. A transverse passage 33 at the rear of the gasket 15 intersects and communicates with the central passage 20 of the gasket 15. This passage 33 establishes communication between the central passage 20 and a space 35 (see FIG. 2) formed between the gasket 15 and the cathode connector piece 37. In a preferred embodiment, the cathode connector piece 37 has a threaded section to achieve connection via a threaded connection 205 .

[0013] The cathode connector piece 37 has opposing notches 38 and 38' along its periphery that align with the locations of two RTD-controlled air inlet ports 44 and 44', respectively, within the outer tube (casing) 6 when the cathode connector piece 37 is inserted therein. In one embodiment, such alignment can be depicted as shown in FIG. 3B (detailed view). This alignment allows the air inlet ports 44 and 44' to be positioned close to the threaded connection 205 without being blocked by the presence of the cathode connector piece 37. This arrangement also reinforces the areas of the air inlet ports 44 and 44', facilitating precision drilling of the air inlet ports 44 and 44'.

[0014] (Air intake port and suction resistance control) In a preferred embodiment, at least one air inlet port 44 is formed within the outer tube 6, preferably adjacent the threaded connection 205, to minimize the risk of a smoker's fingers blocking one of these air inlet ports and to control resistance to draw (RTD) during smoking. Each of the RTD-controlling air inlet ports 44 and 44' is preferably machined into the outer tube 6 with precision tooling so that their diameters are closely controlled and can be replicated from one electronic smoking article 60 to the next during manufacture of the electronic smoking article. The air inlet ports 44 and 44' are preferably drilled with a carbide drill bit and / or other high-precision tools and / or techniques. Additionally, the outer tube 6 is preferably formed from a metal or alloy that will not change the size and shape of the air inlet ports 44 and 44' during manufacturing, packaging, and smoking. Thus, the air inlet ports 44 and 44' provide a consistent RTD. In a preferred embodiment, air inlet ports 44 and 44' are sized and shaped so that electronic smoking article 60 has an RTD in the range of about 60 mmH2O to about 150 mmH2O, more preferably about 90 mmH2O to about 110 mmH2O, and even more preferably about 100 mmH2O to about 130 mmH2O.

[0015] The RTD-controlled air inlet ports 44 and 44' are the critical orifices (i.e., smallest orifices) along the path from the air inlet ports 44 and 44' and the central passageway 21 of the inner tube 62 (through which the heater 14 atomizes the liquid). Thus, the air inlet ports 44 and 44' control the level of resistance to draw of the electronic smoking article 60, which can be set to a level similar to the draw level of a conventional cigarette when lit.

[0016] 1, another aspect of maintaining accurate and repeatable resistance to draw is the use of a metallic material for the outer tube 6, which leads to precise tooling and techniques. If another material is desired for the outer tube 6 (such as plastic for a softer feel), the air inlet ports 44 and 44' can alternatively be formed in a metal plate fixture (or insert) 43 at the location of the air inlet ports 44 and 44' to maintain the precision of the air inlet ports 44 and 44'.

[0017] It is contemplated that sheet metal inserts 43 may also be provided when outer tube 6 is made of metal, in which case such an arrangement would allow air inlet ports 44 and 44' to be formed and inspected separately (off-line) in a group of blank sheet metal inserts. If any completed sheet metal insert 43 fails to meet the standards or specifications for air inlet port diameter (and RTD), it is advantageous to discard the failed sheet metal insert rather than use it in the entire cartridge assembly (first section) 70.

[0018] Referring again to FIG. 1 , the metal sheet insert 43 may comprise a separate piece secured to the outer surface of the outer tube 6 or completely within the outer tube 6, preferably with an oversized hole that can overlap beyond the area of ​​the air inlet port 44. It is also contemplated that the metal sheet insert may be secured flush with the contour of the outer tube 6 or completely within it (within the outer tube 6) using a snap fit and / or adhesive material between the metal sheet insert and the outer tube 6. The shape and location of the air inlet port 44 in the metal sheet insert 43 are preferably symmetrical so that the air inlet port 44 remains fully operational when the metal sheet insert 43 is positioned as shown in FIG. 1 or rotated 180 degrees. Furthermore, the metal sheet insert 43 may be located on the inner or outer surface of the outer tube 6. The metal sheet insert 43 may extend completely or partially around the circumference of the electronic smoking article 60. If the metal plate insert 43 extends partially around the periphery of the electronic smoking article 60, multiple metal plate inserts 43 may be used, each corresponding to a single air intake port 44 or 44'.

[0019] In a preferred embodiment, the second section 72 includes an air inlet port 45 at the upstream end 5 of the electronic smoking article 60, the air inlet port 45 being sized just large enough to properly operate a nearby puff sensor 16. Drawing action at the mouth insertion end 8 is conducted to the air inlet port 45 through a central flow passage provided within the anode post 47c of the first section 70 and the anode connection post 47b of the second section 72, and along the space 13 between the battery 1 and the canister of the second section 72. These flow passages, and the air inlet port 45 itself, are sized so that the air flow therethrough is significantly less than the air flow through the air inlet ports 44 and 44', minimizing the effect on the RTD and maintaining consistency in the RTD. For example, each air inlet port may be less than about 2.0 mm wide and less than about 1.5 mm deep. For example, each air inlet port may be approximately 0.7 mm to approximately 0.8 mm wide and approximately 0.7 mm to approximately 0.8 mm deep. In a preferred embodiment, 95% of the air introduced into the electronic smoking article 60 passes through the air inlet ports 44 and 44', while only 5% of the total air flow enters through the air inlet port 45 at the upstream end 5 of the electronic smoking article 60. The flow rate is preferably determined by making the central passage 34 of the anode post 47b of the second section 72 small enough to provide a pressure drop significantly greater than the pressure drop across the air inlet ports 44 and 44'. For example, the central passage 34 of the anode post 47b may be sized to provide a pressure drop of approximately 2000 mm of water (as opposed to a nominal pressure drop of 100 mm of water through the combination of the air inlet ports 44 and 44').

[0020] 18, to ensure that a consistent RTD is maintained throughout the product, a removable protective cover 601 may be applied to the air inlet ports 44 and 44' as shown in FIG. 18 to prevent deterioration from dust and dents during manufacturing, packaging, shipping, and retail handling, and otherwise. A circumferential wrapper or tape 601 may be wrapped around the outer tube 6 at the air inlet ports 44 and 44' to maintain a consistent RTD until consumption. Alternatively or additionally, the electronic smoking article 60 may be provided with a reusable protective cover to achieve the same or additional protection as described above.

[0021] Furthermore, current manufacturing techniques for electronic smoking articles may be modified to incorporate testing for consistent RTDs. In other words, understanding how to achieve a consistent RTD in a product (as discussed above) needs to be coupled with understanding how to test this RTD during the product's manufacturing (as discussed below). Achieving a consistent RTD from one electronic smoking article to the next promotes consistent performance and delivery levels, and enhances the smoking experience by satisfying smokers' expectations that smoking an electronic smoking article be similar to smoking a lit cigarette or cigar. The latter procedure may include testing the metal plate insert 43 before installation as described above, or alternatively or additionally, may include testing the completed first section 70 by fastening a nominal, but inactivated, second section 72 to the newly manufactured first section 70 to form a harmless, inert test mechanism that accurately reproduces the airflow events but does not risk activating the heater, and applying a predetermined suction to the test mechanism while measuring the pressure drop. By way of non-limiting example, a fully assembled electronic smoking article may be drawn through the test mechanism while the pressure drop is measured using a Model PV10 pressure drop measuring device manufactured by Borgwaldt KC of Chesterfield, Virginia. The appropriate pressure drop test method for electronic smoking articles is adapted from the standard method in ISO 6565:2011, entitled "Tobacco and tobacco products - Draw Resistance of Cigarettes and Pressure Drop of Filter Rods - Standard Conditions and Measurement," and is applicable to equipment capable of measuring pressure drop over a diameter range of 5.0 mm to 9.0 mm and an operating range of 50 mmWG (mm water gauge) to 1900 mmWG. The test can be completed in a few seconds, and the equipment can be calibrated for a range of 50 mmWG to 300 mmWG.

[0022] Instead of using a deactivated second section 72, it is contemplated that a releasable test body could be used to serve the same purpose as a harmless (inert) test mechanism. This test body would be configured to replicate the nominal effect of the actual reusable second section 72 on the RTD, but could be optimized for machine handling and high speed automated coupling and decoupling of a newly manufactured and test-ready first section 70.

[0023] The provision of threaded connection 205 does not facilitate automated high-speed machining and performance of RTD testing. Referring to FIG. 12, other connection 205' may include a connection with pin 501 and releasable detents 503 and / or an electrical bearing surface 505 with releasable detents, rotational locking devices, or the like. In the illustrated embodiment, detents 503 cooperate with raised annular portion 509. In other examples, one or more bias balls may be used in place of or in addition to raised annular portion 509. Such a configuration facilitates automated machining, increases capacity for rapid and accurate testing of RTDs, and facilitates automated RTD testing. It is contemplated that drilling performance control may include a feedback loop to monitor RTD test results to detect trends toward out-of-specification and allow corrective action, such as replacing a worn drill bit.

[0024] 3A and 3B, the cathode connector piece 37 preferably has opposing notches 38 and 38' along its circumference 39 such that, upon insertion of the cathode connector piece 37 into the outer tube 6, these notches align with the respective locations of two or more RTD-controlled air inlet ports 44 and 44' in the outer tube 6. In some embodiments, more than two air inlet ports 44, 44' (e.g., three, four, five, six, seven, eight, nine, ten, or more) can be provided. Alternatively, a single air inlet port 44 can be provided. In one example, such an alignment can be depicted as shown in FIG. 3B. This alignment allows the air inlet ports 44 and 44' to be positioned close to the threaded connection 205 without being blocked by the presence of the cathode connector piece 37. This arrangement can also serve to reinforce the areas of the air inlet ports 44 and 44', thereby facilitating precision drilling of the air inlet ports 44 and 44'. As explained below, other arrangements may also be used.

[0025] In another embodiment, as shown in FIG. 13 , the cathode connector piece 37 can have one or more slits 300 formed in the periphery 39 of the cathode connector piece 37. The outer tube 6 of the cartridge (first section) 70 slides over the unthreaded end of the connector piece 37 until it reaches a stop (or edge) 307, opening a predetermined end of the slit 300 to the exterior of the cartridge 70 to admit air. The admitted air can travel along the slit 300 to the interior of the cartridge 70. The slit 300 can be used as a critical orifice and can be used in place of the air inlet ports 44 and 44′. In another embodiment, the slit 300 can be used in addition to the air inlet ports 44 and 44′.

[0026] In yet another embodiment, as shown in FIGS. 14A, 14B, and 14C, the cathode connector piece 37 can be formed with angled holes 301 that communicate with one or more slots 302 in the cathode connection fixture 49b. Preferably, the cathode connection fixture 49b can have a hollow annular space 303 within its interior portion that communicates with one or more slots 302. Air is drawn into the slots 302 and moves into the annular space 303, and from there into the angled holes 301. Therefore, it is not necessary to align the slots 302 with the angled holes 301, because air will move around the annular space 303 and into the angled holes 301 even if the holes 301 and slots 302 are not aligned with one another. This configuration offers manufacturing advantages because it is not necessary to align the angled holes 301 with the slots 302.

[0027] 15, anode post 47c can be shorter than anode post 47c of FIG. 2, thereby increasing the air gap behind cathode connector piece 37. Air enters through slots 302' (not shown in FIG. 15 except in their relative positions), is drawn through internal air inlet port 44 via annular space 303, and then flows linearly into the air gap, through central passage 34 of anode post 47c, into central passage 20, and on to heater 14.

[0028] (liquid supply area, heater and wick) The nose portion 93 of the downstream gasket 10 preferably fits within the downstream end 81 of the inner tube 62. The outer periphery 82 of the gasket 10 forms a substantially airtight seal with the inner surface 97 of the outer tube 6. The downstream gasket 10 has a central passage 84 disposed between the central passage 21 of the inner tube 62 and the interior of the port insertion end 8, and the central passage 84 transmits the aerosol from the central passage 21 to the port insertion end 8.

[0029] The resulting space between gaskets 10 and 15 and between outer tube 6 and inner tube 62 defines the boundary of liquid application region 22. Liquid application region 22 contains a liquid material and, optionally, a liquid storage medium 210 that serves to store the liquid material therein. Liquid storage medium 210 may include cotton gauze or other fibrous material wrapped around inner tube 62.

[0030] In a preferred embodiment, the liquid supply region 22 is contained within the outer annulus 620 between the inner and outer tubes 62 and 63, and between the gaskets 10 and 15, such that the liquid supply region 22 at least partially surrounds the central air flow passage 21. The heater 14 extends across the central flow passage 21 between opposing portions of the liquid supply region 22.

[0031] The liquid storage medium 210 is preferably a fibrous material comprising cotton, polyethylene, polyester, rayon, or any combination thereof. The fibers preferably have a diameter ranging from about 6 microns to about 15 microns (e.g., from about 8 microns to about 12 microns or from about 9 microns to about 11 microns). The liquid storage medium 210 can be a sintered porous or foam material. The fibers are preferably non-breathable and can have a cross-sectional shape of a Y, cross, clover, or any other suitable shape. Alternatively, the liquid supply area 22 can include a filled tank containing only the liquid material without the fibrous storage medium 210.

[0032] The liquid material also preferably has a boiling point suitable for use in the electronic smoking article 60. If the boiling point is too high, the heater 14 will not be able to vaporize the liquid in the wick 28. However, if the boiling point is too low, the liquid may vaporize even when the heater 14 is not activated.

[0033] The liquid material preferably includes a tobacco-containing material having volatile tobacco flavor compounds that are released from the liquid upon heating, and these compounds can include nicotine. The liquid material can be a tobacco flavor-containing material or a nicotine-containing material without a tobacco flavor. Alternatively, or in addition, the liquid material can include non-tobacco materials or other flavoring materials, and can be nicotine-free. For example, the liquid material can include water, solvents, ethanol, plant extracts, and natural or artificial flavors. Preferably, the liquid material further includes an aerosol former. Examples of suitable aerosol formers are glycerin and propylene glycol. The liquid material can also include preservatives or pH adjusters, such as organic and inorganic acids.

[0034] Referring also to FIG. 8, during use, liquid material migrates from the liquid supply region 22 and / or the liquid storage medium 210 near the heater 14 by capillary action of the wick 28. In one embodiment, as shown in FIG. 8, the wick 28 has a first end 29 and a second end 31. The first end 29 and the second end 31 extend into opposite sides of the liquid storage medium 210 and are adapted to contact the liquid contained therein. The heater 14 also preferably at least partially surrounds a central portion 113 of the wick 28 so that, when the heater 14 is activated, the liquid in the central portion 113 of the wick 28 is vaporized by the heater 14 to form an aerosol. The wick 28 preferably comprises a filament capable of drawing liquid, more preferably a bundle of glass (or ceramic) filaments, most preferably windings of glass filaments, preferably a bundle having groups of three windings, all of which are capable of drawing liquid by capillary action through the interstices between the filaments. Preferably, the core 28 is flexible and has three strands, each having a plurality of filaments. It should further be noted that the ends 29 and 31 of the core 28 are flexible and can be folded within the boundaries of the liquid supply area 22.

[0035] Advantageously, the liquid material in the liquid dispensing region 22 is protected from oxygen (since oxygen generally cannot enter the liquid dispensing region 22 through the wick 28). In certain embodiments, the liquid material is also protected from light, significantly reducing the risk of deterioration of the liquid material. Thus, shelf life and cleanliness may be maintained at a high level.

[0036] In a preferred embodiment, the liquid supply area 22 is sized and shaped to hold sufficient liquid material such that the electronic smoking article 60 is operable for smoking for at least about 200 seconds, preferably at least about 250 seconds, more preferably at least about 300 seconds, and most preferably at least about 350 seconds. The liquid supply area 22 therefore corresponds to a conventional pack of cigarettes. Furthermore, the electronic smoking article 60 may be configured so that each puff lasts up to about 5 seconds.

[0037] (Mouth insertion end) 2, 3A, 4, 5, 6, 7, and 17, the first section 70 includes a mouth insertion end 8 having at least two dispersive outlet passages 24 (e.g., three, four, five, or more, preferably two to ten, or more, more preferably two to six, and even more preferably four). These outlet passages 24 are preferably arranged off-axis and angled outward (i.e., diverging) from the central passage 21 of the inner tube 62. The mouth insertion end (or flow guide) 8 also preferably has outlet passages 24 uniformly distributed around the circumference of the mouth insertion end 8 to substantially uniformly distribute the aerosol within the smoker's mouth during use and enhance the smoker's perception of mouth fullness. In this case, as the aerosol is directed into the smoker's mouth, it moves in various directions as it enters the smoker's mouth, creating a mouthful of mouthfulness. In contrast, electronic smoking articles with a single on-axis exit passage tend to direct their aerosol as a single high velocity jet toward a more restricted location within the smoker's mouth.

[0038] Furthermore, diverging outlet passages 24 are positioned and have interior surfaces 83 such that droplets of unatomized liquid material, if any, that might become entrained in the aerosol strike the interior surface of mouth insertion end 8, or the portions of wall 305 defining diverging outlet passages 24, or both, so that such droplets are substantially removed or dispersed, improving the quality of the aerosol.

[0039] In a preferred embodiment, the diverging outlet passages 24 are angled at an angle of about 5° to about 60° relative to the longitudinal axis of the outer tube 6 to more completely distribute the aerosol throughout the smoker's mouth during use and to remove droplets. In a preferred embodiment, there are four diverging outlet passages 24, each angled at an angle of about 40° to about 50°, more preferably at an angle of about 40° to about 45°, and most preferably at an angle of about 42°, relative to the longitudinal axis of the outer tube 6.

[0040] The diameter of each of the diverging outlet channels 24 ranges from about 0.015 inches to about 0.090 inches. (e.g., in the range of about 0.020 inches to about 0.040 inches, or about 0.028 inches to about 0.038 inches). The size of the diverging exit passages 24 and the number of diverging exit passages 24 may be selected to adjust the resistance to draw (RTD) of the electronic cigarette 60 as desired.

[0041] In one embodiment shown in FIG. 16, diverging outlet channels 24 and on-axis outlet channels 26 may be provided at the port insertion end 8 .

[0042] As shown in FIG. 2, the inner surface 83 of the mouth insertion end 8 can have a generally dome-shaped surface. Alternatively, as shown in FIG. 7, the annular inner surface 83' of the mouth insertion end 8 can be generally cylindrical or frusto-conical with a flat end face. Preferably, the inner surface 83 is substantially uniform across its entire surface. Furthermore, the inner surface 83 can be symmetrical about the longitudinal axis of the mouth insertion end 8. However, in other embodiments, the inner surface 83 can have an irregular shape and / or other shapes.

[0043] In a preferred embodiment, a hollow section 911 is located within the port insertion end 8 at the point where the diverging outlet flow paths 24 converge.

[0044] The port insertion end 8 may be integrally secured within the outer tube 6 of the cartridge 70. Additionally, the port insertion end 8 may be formed from a polymer selected from the group consisting of low density polyethylene, high density polyethylene, polypropylene, polyvinyl chloride, polyether ether ketone (PEEK), and any combination thereof. The port insertion end 8 may also be colored if desired.

[0045] As previously mentioned, the multiple outlet mouth insertion end 8 disperses and redirects the aerosol when the electronic smoking article is inhaled, resulting in a fuller mouthfeel. Once aerosol is generated, it passes through the central passage 21 within the inner tube 62 and the central passage 84 within the downstream gasket 10. Panelists testing early prototypes reported experiencing a "burn" sensation on the lips when smoking an electronic smoking article configured with a mouth insertion end having multiple diverging outlet passages 24 and a central passage having a diameter of approximately 1.3 mm. However, when the inner diameter of the central passage 84 was increased to approximately 2.6 mm, the reported "burn" sensation essentially disappeared.

[0046] Dynamic modeling of the downstream gasket 10 and the area at and around the mouth insertion end 8 determined that a small, 1 mm-wide central passage 84 in the gasket 10 tends to produce a peak aerosol velocity of approximately 12 meters per second (m / s) exiting the mouth insertion end. In contrast, modeling of a system with a 5 mm-wide central passage 84 indicates that a peak velocity of only 2.5 m / s is achieved at the exit of the diverging exit passages 24 at the mouth insertion end 8, representing a nearly five-fold reduction in air velocity. As can be seen from the above testing and modeling, by increasing the diameter of the central passage 84 to prevent acceleration of the aerosol stream prior to being drawn through the exit of the diverging exit passages 24 at the multiple-exit mouth insertion end 8, further improvements in the organoleptic experience of the electronic smoking article are achieved.

[0047] Therefore, it is advantageous to provide an electronic smoking article with a downstream gasket 10 having a central passageway 84 with a diameter sufficient to prevent acceleration of the aerosol stream before it reaches the mouth insertion end 8. Preferably, the diameter of the central passageway 84 is about 2.0 mm to about 3.0 mm, more preferably about 2.4 mm to about 2.8 mm. In this case, the mouth insertion end 8 divides the output stream from the central passageway 84 into multiple divergent streams with reduced velocity, thereby providing a full mouthfeel and avoiding a "hot" sensation.

[0048] Inasmuch as proper sizing of the central passage 84 of the gasket 10 serves to substantially prevent aerosol acceleration, this function can be further enhanced by forming a sloped rim (not shown) on the exit face of the exit orifice to further reduce the aerosol velocity before it reaches the mouth insertion end 8.

[0049] In other embodiments, the port insertion end 8 and downstream gasket 10 may be integrally formed as a single piece to provide greater consistency of performance and ease of manufacturing.

[0050] In another embodiment, as shown in Figures 10 and 11, the electronic smoking article 60 of Figure 1 can be provided with a mouth insertion end 8 having a fixed piece 27 and a rotatable piece 25. Exit passages 24 and 24' are located in each of the fixed piece 27 and the rotatable piece 25. These exit passages 24 and 24' are aligned as shown to allow aerosol to enter the smoker's mouth. However, the rotatable piece 25 can be rotated within the mouth insertion end 8 to at least partially block one or more exit passages 24 within the fixed mouth insertion end 8. Thus, the consumer can adjust the amount of aerosol inhaled with each puff. The exit passages 24 and 24' can be formed within the mouth insertion end 8 such that they diverge to provide a more satisfying mouthfeel during inhalation of the aerosol.

[0051] (Alloys and circuits for improved heater performance consistency, hot spot and carbonyl mitigation) In a preferred embodiment, power source 1 includes a battery positioned within electronic smoking article 60 such that anode 47a is below cathode 49b. Battery anode post 47b of second section 72 preferably contacts battery anode 47a.

[0052] More specifically, electrical connection between the anode 47a of the battery 1 and the heater coil 14 in the first section 70 is achieved via the battery anode connection post 47b in the second section 72 of the electronic smoking article 60, the anode post 47c of the cartridge (first section) 70, and an electrical lead 47d connecting the rim portion of the anode post 47c to the electrical lead 109 of the heater element 14 (see FIG. 8). Similarly, electrical connection between the cathode 49a of the battery 1 and the other electrical lead 109' of the heater coil 14 is achieved via a threaded connection 205 between the cathode connection fixture 49b in the second section 72 and the cathode connector piece 37 of the first section 70, and from there via an electrical lead 49c electrically connecting the fixture 37 to the opposite electrical lead 109' of the heater coil 14.

[0053] Preferably, electrical leads 47d and 49c and heater leads 109 and 109' are highly conductive and heat resistant, while coil section 110 of heater 14 is highly resistive so that heat generation occurs primarily along coil section 110 of heater 14. Also, electrical lead 47d is preferably connected to heater lead 109 by crimping. Similarly, electrical lead 49c is connected to heater lead 109' by crimping. In other embodiments, electrical leads 47d and 49c can be attached to heater leads 109 and 109' by soldering. Crimping is preferred for increased manufacturing speed.

[0054] The battery may be a lithium ion battery or a variant thereof, such as a lithium ion polymer battery. Alternatively, the battery may be a nickel metal hydride battery, nickel cadmium battery, lithium manganese battery, lithium cobalt battery, or fuel cell, preferably allowing the electronic smoking article 60 to be used by the smoker until the energy in the power source is depleted or, in the case of a lithium polymer battery, until a minimum voltage cut-off level is reached.

[0055] Alternatively, power source 1 may be rechargeable and may include circuitry that allows the battery to be charged by an external charging device. In this case, the circuitry preferably provides power for a predetermined number of puffs when charged, after which the circuitry must be reconnected to the external charging device. A USB charger or other suitable charger assembly may be used to recharge electronic smoking article 60.

[0056] The electronic smoking article 60 also preferably includes a control circuit having a puff sensor 16. The puff sensor 16 is operable to detect a drop in air pressure and initiate application of voltage from the power supply 1 to the heater 14. The control circuit may also include a heater activation light 48, as shown in FIG. 2, operable to illuminate when the heater 14 is activated. The heater activation light 48 preferably comprises an LED and is located at the upstream end of the electronic smoking article 60 so that the heater activation light 48 indicates that coal is burning during a puff. The heater activation light 48 may be positioned so that it is visible to the smoker. The heater activation light 48 may also be used to diagnose the electronic smoking article system or to indicate that a recharge is in progress. The heater activation light 48 may also be configured to allow the smoker to activate the heater activation light 48 or to disable activation during a smoke, if desired, for secrecy.

[0057] Preferably, at least one air inlet port 45 (FIG. 1) is located adjacent to a puff sensor 16 that detects airflow indicating that the smoker is puffing and activates a power supply 1 and a heater activation light 48 to indicate that the heater 14 is operating.

[0058] The control circuit is preferably integral with the puff sensor 16 and provides power to the heater 14 in response to the puff sensor 16, which preferably has a maximum duration limiter.

[0059] Alternatively, the control circuit may include a manual switch that allows the smoker to initiate a puff. The duration for which current is supplied to the heater may be preset depending on the amount of liquid desired to be vaporized. Alternatively, the control circuit may provide power to the heater 14 as long as the puff sensor 16 detects a pressure drop.

[0060] Preferably, when activated, heater 14 heats the portion of wick 28 surrounded by heater 14 for a period of less than about 10 seconds, more preferably less than about 7 seconds. Thus, the power cycle (or maximum puff length) can be in the range of about 2 seconds to about 10 seconds (e.g., about 3 seconds to about 9 seconds, about 4 seconds to about 8 seconds, or about 5 seconds to about 7 seconds).

[0061] The heater 14 is preferably a wire coil surrounding a core 28. Examples of suitable electrically resistive materials include titanium, zirconium, tantalum, and metals selected from the platinum group. Examples of suitable metal alloys include stainless steel, alloys containing nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, and iron, and superalloys based on nickel, iron, cobalt, and stainless steel. Depending on the energy transfer kinetics and the required external physicochemical properties, the heater can be formed from, for example, nickel aluminide, a material having an alumina layer on its surface, iron aluminide, or other composite material, and the electrically resistive material can optionally be embedded in, encapsulated, or coated with an insulating material, or vice versa. The heater 14 preferably comprises at least one material selected from the group consisting of stainless steel, copper, copper alloys, nickel-chromium alloys, superalloys, and any combination thereof. In a preferred embodiment, heater 14 is formed from a nickel-chromium alloy or an iron-chromium alloy, although the latter is not preferred for reasons explained below. In another embodiment, heater 14 may be a ceramic heater having an electrically resistive layer on its outer surface.

[0062] In other embodiments, heater 14 may be constructed from iron aluminides (e.g., FeAl or FeAl) or nickel aluminides (e.g., NiAl), as described in commonly owned U.S. Pat. No. 5,595,706 to Sikka et al., filed Dec. 29, 1994. Iron aluminides are advantageous because they exhibit high resistivity. FeAl exhibits a resistance of approximately 180 microohms, while stainless steel exhibits a resistance of approximately 50-91 microohms. The higher resistance reduces the current draw or load on power source (battery) 1.

[0063] In a preferred embodiment, the heater coil 14 is formed from a nickel-chromium alloy that is substantially free of iron. Experiments have shown that heater coils constructed from iron-chromium alloys are subject to oxidation of their iron content when the alloy comes into contact with water during manufacturing processing, storage, and / or operation of the device.

[0064] Heating glycerin and / or propylene glycol above certain temperatures is known to produce carbonyls (including formaldehyde). Iron oxide tends to catalyze these reactions so that carbonyls form at lower temperatures. By using alloys that are substantially iron-free, this catalysis is avoided, minimizing the potential for carbonyl and other compounds.

[0065] Additionally, certain considerations and measures are taken in the manufacture and design of the preferred embodiment to avoid the development of unintentional "hot spots" in the heater coil 14 during the heating cycle of the heater coil 14. Hot spots can cause excessive peak temperatures that can result in undesirable effects that would otherwise be avoided.

[0066] Without wishing to be bound by theory, it is believed that if the turns of the coil heater 14 are altered so that the spacing between loops of the coil 14 is locally reduced, this reduction in spacing creates hot spots which are believed to cause peak temperatures to exceed desired levels. It is also believed that by maintaining uniform spacing along the turns of the heater coil 14 and taking steps to maintain the original uniform spacing between the turns of the heater coil 14, the effects of "hot spots" are avoided.

[0067] 8, it is believed that producing consistent coil spacing 111 throughout the coil section 110 of a given heater coil 14 may be achieved by a method that includes using an automatic winder to wind the coil around a core 28 and using the core 28 as the axis for the winding process. In a preferred embodiment, 3 to 8 turns are preferred, and 3 to 5 turns are more preferred.

[0068] The uniformity of the coil spring 111, once established, is maintained throughout the design and manufacture of the preferred embodiment.

[0069] 9A, the opposed slots 63 in the inner tube 62 facilitate positioning of the heater 14 and core 28 within the inner tube 62 without creating impact between the edges of the slots 63 and the coil sections 110 (shown in FIG. 8) of the heater 14. Thus, the edges of the slots 63 do not affect or change the coil spacing 111 of the heater 14, which would otherwise cause hot spots.

[0070] 9B, the sealing ring 69 is positioned so that it is closest to or in contact with the core 28, but care is taken not to press against the core. Such positioning avoids imposing a bending moment on the heater coil 14 and bending the heater coil 14, which could otherwise compress the coil spacing 111 and create a hot spot along one side of the reduced coil 14. Therefore, the upstream edge 114 of the sealing ring 69 is positioned close to the core 28, but not beyond it to avoid the potential bending effect mentioned above. When positioned as shown in FIG. 9B, the sealing ring 69 seals off the remainder of the available space between the heater coil assembly and the slot 63.

[0071] In a preferred embodiment, the inner tube 62 and sealing ring 69 are formed from woven fiberglass.

[0072] In a preferred embodiment, the inner tube 62 has a diameter of about 4 mm, and each of the opposing slots 63 has minor and major dimensions of about 2 mm by about 4 mm.

[0073] In one embodiment, the heater 14 comprises a wire coil at least partially surrounding the core 28. In this embodiment, the wire is preferably a metal wire, or the heater coil extends along the entire length of the core 28, or along a portion of it, or both. The heater coil 14 can extend completely or partially around the core 28. In other embodiments, the heater coil does not contact the core 28.

[0074] Preferably, the heater 14 heats the liquid within the wick 28 by thermal conduction. Alternatively, heat from the heater 14 may be transferred to the liquid by a heat-conducting element, or the heater 14 may transfer heat to incoming ambient air that is drawn through the electronic smoking article during use, thereby heating the liquid by convection with this ambient air.

[0075] In one embodiment, wick 28 comprises a ceramic wick of ceramic filaments capable of drawing liquid. As discussed above, wick 28 is at least partially surrounded by heater 14. Furthermore, in a preferred embodiment, wick 28 extends through opposing slots 63 within inner tube 62 such that each end of wick 28 contacts liquid application area 22 (shown in FIG. 2).

[0076] In a preferred embodiment, the wick 28 includes a filament and a bundle of glass filaments. For example, the wick 28 may include multiple filaments. These filaments or threads may generally be aligned perpendicular (orthogonal) to the longitudinal direction of the electronic smoking article. Preferably, the wick 28 includes 1 to 8 filaments, more preferably 2 to 6 filaments. In a preferred embodiment, the wick 28 includes three strands, each of which includes multiple twisted glass filaments.

[0077] In a preferred embodiment, the wick 28 is comprised of filaments that allow capillary action to transfer the liquid through the filaments to the heater 14. The wick 28 may comprise filaments having a cross section that may generally be cross-shaped, clover-shaped, Y-shaped, or any other suitable shape.

[0078] The wick 28 preferably comprises any suitable material or combination of materials. Examples of suitable materials include glass, ceramic, or graphite-based materials. Furthermore, the wick 28 may have any suitable capillary attraction to accommodate aerosol-generating liquids having various liquid physical properties, such as density, viscosity, surface tension, and vapor pressure. The capillary properties of the wick 28, combined with the properties of the liquid, ensure that the wick 28 remains wet in the area of ​​the heater 14, preventing overheating of the heater 14.

[0079] Instead of using a wick 28, the heater 14 can be a porous material incorporating a resistive heater made of a material with high electrical resistance that can generate heat quickly.

[0080] Preferably, the core 28 and the fibrous medium of the liquid region 22 are constructed from glass fibers.

[0081] (Sleeve assembly) 17, the electronic smoking article 60 may also be provided with a sleeve assembly 87 that is removably and / or rotatably positioned around the first section 70 of the electronic smoking article 60. Additionally, the sleeve assembly 87 insulates at least a portion of the first section 70 to maintain the temperature of the aerosol before it is delivered to the smoker. In a preferred embodiment, the sleeve assembly 87 is rotatable around the electronic smoking article 60 and has slots 88 spaced about its periphery in a direction transverse to the sleeve assembly that are aligned with the air inlet ports 44 and 44' in the first section 70 to allow air to enter the electronic smoking article 60 as the smoker takes a puff. Before or during smoking, the smoker may rotate the sleeve assembly 87 as desired so that the air inlet ports 44 and 44' are at least partially blocked by the sleeve assembly 87, thereby adjusting the resistance to draw and / or ventilation of the electronic smoking article 60.

[0082] The sleeve assembly 87 is preferably formed from silicone or other flexible material to provide a soft mouthfeel to the smoker. However, the sleeve assembly 87 may be formed from one or more pieces and may be formed from a variety of materials, including plastic, metal, and combinations thereof. In a preferred embodiment, the sleeve assembly 87 is a single piece formed from silicone. The sleeve assembly 87 may be removed and reused in other electronic smoking articles or may be disposed of along with the first section 70. The sleeve assembly 87 may be any suitable color, or may have images or other indicia, or both.

[0083] (Aroma Delivery) As shown in FIG. 29 , the electronic cigarette 60 can also include an aroma strip 89 located on the outer surface 91 of at least one of the first section 70 and the second section 72. Alternatively, the aroma strip 89 can be located on a portion of the sleeve assembly 87. The aroma strip 89 is preferably located between the device's battery and the heater 14 so that the aroma strip 89 is adjacent to the smoker's nose during smoking. The aroma strip 89 can include a gel, film, or solution containing a fragrance or flavoring material that is released before smoking, during smoking, or both. In one embodiment, the flavor aroma of either or any combination of gel, fluid, and / or solution can be released by a puffing action that can open a vent (not shown) on the aroma strip when located within the first section 70. Alternatively, the aroma can be released by heat generated by the heater 14.

[0084] In one embodiment, the aroma strips 89 may comprise a tobacco flavor extract. Such an extract may be obtained by grinding tobacco material into small pieces and extracting it with an organic solvent. The extract may then be filtered, dried (e.g., with sodium sulfate), and concentrated. Alternatively, the extract may be obtained using techniques known in the field of flavor chemistry, such as the SAFE (Solvent Assisted Flavor Extraction) distillation technique (Engel et al., 1999), which separates the volatile and non-volatile fractions. Additionally, pH fractionation and chromatographic methods may be used for further separation and / or isolation of specific compounds.

[0085] The aroma carrier 89 may be a polymer or paper strip to which an extract or flavoring material is applied, for example, with a paintbrush or by impregnation. The flavoring material may be natural or artificial. Alternatively, the extract or flavoring material may be encapsulated in the paper ring and / or strip and manually released by the smoker, for example, by scratching the aroma strip while smoking.

[0086] (fiber element) As shown in Figures 19, 20 and 21, the electronic smoking article 60 may be provided with a fibrous element, i.e., filter 300 or 300', downstream of the heater 14 instead of the mouth insertion end 8 (as shown in Figure 2). In another embodiment, shown in Figures 25 and 26, a fibrous element 300 may be provided downstream of the heater in addition to the mouth insertion end 8. The fibrous element 300, 300' may be located between the heater 14 and the mouth insertion end 8, as shown in Figure 26, or downstream of the mouth insertion end 8, as shown in Figure 25.

[0087] The addition of the fiber elements 300, 300' can help adjust the resistance to draw of the electronic smoking article 60. Furthermore, the fiber elements 300, 300' can change the characteristics of the aerosol by adding additives, or can provide additional flavor and change the mouthfeel of the aerosol during smoking, or both. The fiber elements 300, 300' can be configured to resemble filters used in conventional smoking articles.

[0088] Preferably, fiber element 300 is manufactured as a permanent part of first section 70 and is therefore disposed of along with the disposable first section. In other embodiments, fiber element 300' can be a detachable fiber element, as shown in Figures 23 and 24.

[0089] In a preferred embodiment, the fibrous elements 300, 300' comprise a low-efficiency filter material. The fibrous elements 300, 300' may include a bundle of fibrous material formed into a plug. The fibrous material may be any of a variety of fibrous materials suitable for use in filter elements in conventional smoking articles. The fibrous material may comprise cellulose acetate fibers, polyester fibers, polypropylene fibers, paper, or the like. For example, the fibrous elements 300, 300' may comprise cellulose acetate tow and, if desired, may be wrapped in a paper material.

[0090] Various filter structures can be used to form the filter element. Exemplary filter structures include mono-filters, dual-filters, triple-filters, cavity filters, recessed filters, free-flow filters, or any combination thereof. Mono-filters typically have cellulose acetate tow or cellulose paper materials. Dual filters typically have a cellulose acetate mouth end plug and pure cellulose or cellulose acetate segments. The length and pressure drop of these segments, which may relate to the type of material used to construct the fibrous elements 300, 300', can be adjusted to produce the desired filtration and resistance to draw (RTD).

[0091] The length of the fibrous elements 300, 300' can be between about 3 mm and about 10 mm. Preferably, the diameter of the fibrous elements 300, 300' is approximately the same as or smaller than the diameter of the electronic smoking article 60.

[0092] As shown in FIG. 20, the fiber elements 300, 300′ may be plug-space-plug fiber elements having an upstream plug 342 of fiber material, a downstream plug 340 of fiber material, and a space 344 therebetween. An additive 348 may be disposed within the space 344. Alternatively, if a space is provided within the fiber element 300, 300′, in addition to including the additive 348 within the space, the additive 348 may be dispersed throughout or throughout the fiber material used to form one or more plugs of fiber material within the fiber element 300, 300′, as shown in FIG. 21. Thus, for example, the additive may be dispersed within the upstream plug 342 and the downstream plug 340 of the fiber element 300, 300′, as desired.

[0093] The detachable fiber elements 300' can be purchased in packs containing multiple fiber elements 300', each containing the same or a different additive 348, allowing the smoker to select the fiber element 300' and additive 348 of their choice. The detachable fiber elements 300' can be inserted into or otherwise attached to an electronic smoking article 60. For example, in one embodiment, the fiber elements 300 can be inserted into the mouth-open end 346 of the electronic smoking article 60 shown in FIG. 22. Alternatively, as shown in FIGS. 24 and 25, the fiber elements 300, 300' of the electronic smoking article 60 can be paired with a sleeve 325 that can be removably slid onto the mouth-end 8 of the electronic smoking article 60, if desired. The sleeve 325 can have a snap-fit ​​mechanism or can simply be held in place by a friction fit.

[0094] In one embodiment, in addition to the additive 348 contained in the fiber element 300, 300', the outer surface of the mouth end of the electronic smoking article and / or the outer surface of the fiber element 300, 300' may be impregnated with an additive, or may contain an additive-containing microcapsule coating 370 (shown in FIGS. 22 and 25) or other flavor and / or aroma components in addition to the additive 348 contained within the fiber element 300, 300'. The additive 348 may be released in response to moisture from the smoker's mouth and lips, and these additives may be encapsulated with water-soluble materials having varying degrees of water solubility to control the release of the additive over a period of time. The coating material may contain the same additive 348 as contained in the fiber element 300, 300' or a different additive 348. By providing an impregnated additive 348 or an additive-containing coating 370 together with the additive 348 in the fiber element 300, 300', the release of the additive 348 during smoking can be staggered, or multiple additives can be released, or both.

[0095] As used herein, the term "additive" refers to any material or composition that alters the characteristics of the electronic smoking article 60 when the electronic smoking article is smoked. Any suitable additive material, or any combination of such materials, may be included within the fiber element 300, 300'. Such additive materials include flavoring materials, aroma materials, pH modifiers, chemical sensates including cooling and heating agents, carbon dioxide formers, commercially available flavor systems, nicotine in liquid, salt or powder form, and other smoke modifiers. Additionally, additive materials may include diluents or solvents that may affect the sensory characteristics of the aerosol. For example, the fiber element 300, 300' may include Carbosation® (available from Ogawa Fragrance Co., Ltd.), which may enhance or create a carbonation-filled mouthfeel, or both.

[0096] The diluent, if included, may be an aerosol forming agent such as glycerin or propylene glycol.

[0097] As used herein, the term "flavoring material" refers to any liquid or solid flavor containing material or formulation capable of releasing flavor and / or aroma into an aerosol stream. Suitable flavors or flavorings include, but are not limited to, menthol, mints such as peppermint and spearmint, chocolate, licorice, citrus and other fruit flavors, gamma-octalactone, vanillin, ethyl vanillin, breath freshener flavors, spice flavors such as cinnamon, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, ginger oil, and tobacco flavor. Other suitable flavors may include flavor compounds selected from the group consisting of acids, alcohols, esters, aldehydes, ketones, pyrazines, combinations or mixtures thereof, and the like.

[0098] The flavoring materials can be in the form of particles, granules, fibers, capsules, microcapsules, powders, crushed plant material, aromatic bark, seeds, pieces of dried fruit and / or roots, or any other suitable form. The flavoring materials can include, for example, tobacco beads, flavor beads, menthol-containing flavor beads, flavor capsules, and other flavoring materials such as those used in conventional cigarette smoke filters.

[0099] Suitable flavorants may be non-volatile or volatile and may be delivered to the mouth via condensation of the aerosol in a filter and subsequent encapsulation, or dissolution of the flavorant in droplets, or deposition of the droplets on the smoker's tongue during a puff, or any combination thereof. The droplets may be composed of the ingredients used to form the aerosol, including polyethylene glycol, glycerin, water, and optionally nicotine. The flavorant may be released within the aerosol, or may be delivered to the smoker's mouth via contact with moisture from the smoker's lips, or both.

[0100] The flavouring material may be made to impart a bitter taste. Suitable compounds that impart a bitter taste include, but are not limited to, caffeine, denatonium benzoate, theobromine, quinine and naringin.

[0101] The flavoring material may also impart a sour taste. Suitable compounds that impart a sour taste include, but are not limited to, citric acid, malic acid, succinic acid, and tartaric acid.

[0102] The flavoring material may also impart a salty flavor. Suitable compounds that impart a salty flavor include, but are not limited to, sodium chloride and potassium chloride.

[0103] The flavoring material may also impart a sweet taste. Suitable compounds that impart a sweet taste include, but are not limited to, carbohydrates, including sucrose, and high intensity sweeteners, including sucralose and saccharin.

[0104] Flavoring materials may also be used to impart umami and mouthfeel. Suitable compounds that impart umami and mouthfeel include, but are not limited to, monosodium glutamate, gamma-glutamyl peptides such as gamma-glutamycysteine-beta-alanine, and (R)-strombine.

[0105] In one embodiment, the additive can be a chemosensory agent, or can be selected to alter the mouthfeel of the aerosol, or to achieve both. For example, the additive can be a chemosensory agent that produces a warming, tingling, or cooling sensation, or any combination thereof. Alternatively, to produce a "fatty" mouthfeel, the additive can be a medium-chain triglyceride, triacetin, or an edible oil such as Neobee® M-5. In another embodiment, the additive can be tannic acid to produce an "astringent" mouthfeel. Additives such as capsaicin, piperine, α-hydroxy-sanshool, and (8)-gingerol can be included to produce a warming, tingling, or burning sensation. To produce a cooling sensation, additives can be included, including menthol, menthyl lactate, WS-3 (N-ethyl-p-menthane-3-carboxamide), WS-23 (2-isopropyl-N,2,3-trimethylbutyramide), and Evercool 180®. Additionally, additives can include extracts such as coffee extract, red pepper extract, ginger extract, and peppermint oil.

[0106] In other embodiments, additives can be used to reduce the unpleasant properties of nicotine in the aerosol, or otherwise alter the properties of the aerosol, or both. For example, the additive can be an acidic solution containing an edible acid. The acidic solution can be added to the fiber elements 300, 300′ so that the acid reacts with nicotine in the aerosol stream to form nicotinic acid and reduce the amount of volatile nicotine free base in the aerosol that may cause throat irritation during smoking. Suitable acids for inclusion in the acidic solution include, but are not limited to, citric acid, malic acid, lactic acid, hydrochloric acid, and any combination thereof. In addition to the acidic solution, an ionic resin or absorbent can be included within the fiber elements 300, 300′ to absorb nicotine from the vapor phase and reduce irritation. Suitable absorbents include activated carbon and silica gel.

[0107] In yet another embodiment, the additive may include an aromatic material that is volatile and capable of releasing a vapor during a puff and that is perceptible via the post-nasal passages.

[0108] In a preferred embodiment, the fiber elements 300, 300' may contain multiple fiber materials and / or additives, each having a different pH value. The aerosol passing through the fiber elements 300, 300' may be modified depending on the pH value of the materials used to form the fiber elements 300, 300' and the additives 348 contained therein. For example, the fiber elements 300, 300' may be formed from cellulose acetate treated with an additive. The additive may include a pH modifier added as an acidic solution. A suitable acidic solution may be about 20 mg to about 150 mg of propylene glycol, glycerol, and water in a mixture. It has 2% citric acid and a pH of about 4. This solution, when added to fiber plugs 300, 300' and used in electronic smoking articles 60, has been found to provide a milder, less irritating smoking experience than electronic smoking articles that do not have such treated fiber elements.

[0109] Alternatively, the additive 348 may be a pH-modifying material applied as a solution to the fiber material of the fiber elements 300, 300'. The solution may have about 20 mg to about 150 mg of 2% sodium bicarbonate in a mixture of propylene glycol, glycerol, and water, and a pH of about 10. Such a solution, when added to a fiber element 300, 300' placed within an electronic smoking article, has been shown to increase the throat impact and irritation of a smoker compared to an electronic smoking article having a fiber element 300, 300' that has not been treated with such a solution.

[0110] During smoking, the additive in the form of a finely divided solid may be entrained in the aerosol and delivered to the smoker. If the additive includes a volatile material, such as menthol or other volatile flavor, the additive may diffuse into the aerosol as it passes through the fibrous elements 300, 300'. Eventually, a portion of the aerosol may be deposited or condensed within the fibrous elements 300, 300', causing the additive to dissolve therein. Thus, when the smoker takes a puff on the electronic smoking article 60, the additive is delivered.

[0111] As mentioned above, the additive can contribute carbon dioxide to the aerosol stream. It is believed that adding carbon dioxide to the aerosol stream can enhance the flavor and mouthfeel of the aerosol. It is believed that some aerosols can be artificial, off-flavored, lack character, or any combination thereof, compared to smoke produced by conventional cigarettes. Therefore, adding an additive capable of contributing carbon dioxide to the aerosol stream can enhance the flavor or mouthfeel.

[0112] In one embodiment, the additive 348 can include sodium bicarbonate and one or more acids, such as citric acid, to enhance the carbon dioxide concentration above that of atmospheric carbon dioxide. The sodium bicarbonate and citric acid can generate and / or release carbon dioxide in the presence of an aerosol carrier, such as propylene glycol.

[0113] Alternatively, the additive 348 can be a salt such as ammonium bicarbonate that releases a desired amount of carbon dioxide in the presence of heat from the aerosol. The salt can be disposed within the fiber element or on a screen 401 (shown in Figures 21 and 27). In one embodiment shown in Figure 27, the screen 401 can be attached to a sleeve 325 that can be attached to the mouth end of the outer tube 6 during manufacture or immediately prior to smoking. Alternatively, the screen 401 can be disposed within the electronic smoking article 60 upstream of the fiber element 300, as shown in Figure 21.

[0114] In another embodiment, shown in Figure 28, the electronic smoking article 60 may include a carbon dioxide tank 403. The control system of the electronic smoking article 60 may be programmed to selectively release small amounts of carbon dioxide from the tank 403 with each puff to enhance the palatability of the aerosol, if desired.

[0115] In another embodiment, the additive 348 is nicotine in liquid, salt, or powder form. Nicotine may be contained solely within the fiber element 300, 300', such that the liquid material is nicotine-free and contains only the aerosol formers of propylene glycol or glycerin, water, and, optionally, flavors. Alternatively, nicotine may be contained in the liquid supply (region) in addition to the nicotine contained as an additive within the fiber element 300, 300'. As the aerosol passes through the fiber element, nicotine may be extracted and delivered to the smoker along with the aerosol. Additional additives may be contained within the fiber element 300, 300' along with the nicotine, if desired.

[0116] Preferably, the nicotine is held in liquid suspension within the fiber elements 300, 300'. Alternatively, the nicotine can be held in a polymeric film such as a pectin film, within the fiber elements 300, 300', or within the plug-space-plug fiber elements 300, 300'. In addition to or instead of the fiber elements 300, 300', a resin can be disposed downstream of the heater. This resin can be an ion-exchange resin, e.g., polyacrylex, and the nicotine can be bound within the resin. Various fiber elements 300, 300' are available commercially, each with a different nicotine content, as desired.

[0117] Advantageously, forming the nicotine into the aerosol appears to reduce throat irritation and chest effects, but adding the nicotine to the aerosol after it is formed appears to reduce any throat effects that the nicotine may have.

[0118] The additive 348 is preferably added in an amount sufficient to provide additional flavor and / or aroma, or to enhance or alter the mouthfeel of the aerosol. For example, the fiber element 300 may contain from about 0.05 mg to about 100 mg of the additive.

[0119] When the term "about" is used in this specification and claims in connection with a numerical value, this term means that the associated numerical value includes a tolerance of ±10% before and after the numerical value. Furthermore, when reference is made to %, the % is by weight, i.e., % by weight.

[0120] Furthermore, when the terms "generally" and "substantially" are used in connection with geometric shapes, these terms mean that precision of the geometric shape is not required, but that a margin of error for the shape is within the scope of the disclosure. When used in connection with geometric terms, these terms "generally" and "substantially" encompass not only features that meet the exact definition, but also features that closely approximate the exact definition.

[0121] It is apparent that the present specification has provided a new, improved, and non-obvious electronic smoking article with sufficient description to be particularly understood by those skilled in the art. Furthermore, as will be apparent to those skilled in the art, various modifications, variations, substitutions, and equivalent arrangements may be made to the features of the electronic smoking article without substantially departing from the spirit and scope of the present invention. It is therefore intended that the appended claims encompass all such modifications, variations, substitutions, and equivalent arrangements that fall within the spirit and scope of the present invention as defined by the appended claims.

Claims

1. An electronic smoking article, comprising: a longitudinally extending outer tube; An inner tube within this outer tube, a liquid supply having a liquid material contained within an outer annulus between the outer tube and the inner tube; a heater located within the inner tube; a wick in communication with the liquid supply and surrounded by the heater, the wick supplying a liquid material to the heater and heating the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol within the inner tube; and a fiber element located downstream of said heater.

2. 10. The electronic smoking article of claim 1, further comprising a mouth insertion end, the mouth insertion end having at least two outlet dispersion channels operable to direct aerosol through the smoker's mouth during a puff.

3. 3. The electronic smoking article of claim 2, wherein each of the at least two outlet dispersion channels is at an angle of about 5 degrees to about 60 degrees relative to a longitudinal axis of the electronic smoking article.

4. 10. The electronic smoking article of claim 1, wherein the fibrous elements comprise a low efficiency filter material.

5. 10. The electronic smoking article of claim 1, wherein the fiber element comprises a fiber material selected from the group consisting of cellulose acetate, polyester, polypropylene, paper, and any combination thereof.

6. 10. The electronic smoking article according to claim 1, wherein the fiber element further comprises at least one additive.

7. 7. The electronic smoking article of claim 6, wherein the at least one additive is selected from the group consisting of a flavorant, an aroma material, a pH modifier, a chemical sensate, a carbon dioxide former, a smoke modifier, a diluent, an aerosol former, nicotine, and any combination thereof.

8. 10. The electronic smoking article of claim 1, wherein the length of the fiber elements is within the range of about 3 mm to about 10 mm.

9. 10. The electronic smoking article of claim 1, wherein the fibrous element comprises an upstream plug of fibrous material, a downstream plug of fibrous material, and a space therebetween.

10. 10. The electronic smoking article of claim 9, wherein at least one additive is contained within the space.

11. 2. The electronic smoking article according to claim 1, wherein the fiber element is removable.

12. 12. The electronic smoking article of claim 11, wherein the fiber element has a sleeve attachable to the mouth end of the outer tube.

13. 12. The electronic smoking article according to claim 11, wherein the electronic smoking article is an electronic cigarette having a recess at its mouth end into which the fiber element can be inserted.

14. 10. The electronic smoking article of claim 1, wherein the fiber element has a coating thereon.

15. 8. The electronic smoking article according to claim 7, wherein the additive is selected from the group consisting of caffeine, denatonium benzoate, theobromine, quinine, naringin, citric acid, malic acid, succinic acid, tartaric acid, sodium chloride, potassium chloride, sucrose, fructose, sucralose, saccharin, monosodium glutamate, gamma-glutamyl peptide, medium-chain fatty acid triglyceride, triacetin, neobee, tannic acid, and any combination thereof.

16. 8. The electronic smoking article of claim 7, wherein the chemical sensory agent is selected from the group consisting of capsaicin, piperine, alpha-hydroxy-sanshool and (8)-gingerol, menthol, menthyl lactate, and any combination thereof.

17. 8. The electronic smoking article of claim 7, wherein the pH modifier is selected from the group consisting of citric acid, malic acid, lactic acid, hydrochloric acid, and any combination thereof.

18. 10. The electronic smoking article of claim 1, further comprising at least one absorbent selected from the group consisting of activated carbon, silica gel, and any combination thereof.

19. 8. The electronic smoking article of claim 7, wherein the aerosol former is selected from the group consisting of propylene glycol, glycerin, and any combination thereof.

20. 8. The electronic smoking article of claim 7, wherein the carbon dioxide former is selected from the group consisting of sodium bicarbonate, citric acid, and any combination thereof.

21. 7. The electronic smoking article according to claim 6, wherein the additive is contained in the fiber element in an amount ranging from about 0.05 mg to about 100 mg.

22. 2. An electronic smoking article as described in claim 1, comprising a first section attachable to a second section, the first section containing the wick, the liquid supply and the fiber element, and a power source operable to apply a voltage across the heater contained within the second section.

23. 2. The electronic smoking article of claim 1, wherein the electronic smoking article has a single outer tube, and the wick, the liquid supply section, the fiber element, the heater, and the power source are housed within the outer tube.

24. 7. The electronic smoking article of claim 6, wherein the at least one additive is substantially uniformly dispersed throughout the fiber elements.

25. 8. The electronic smoking article according to claim 7, wherein the additive is nicotine and the liquid material does not contain nicotine.

26. An electronic smoking kit, comprising: (a) Electronic smoking articles, which are: a longitudinally extending outer tube; An inner tube within this outer tube, a liquid supply having a liquid material contained within an outer annulus between the outer tube and the inner tube; a heater located within the inner tube; the electronic smoking article comprising: a wick in communication with the liquid supply and surrounded by the heater, the wick supplying a liquid material to the heater and causing the heater to heat the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol within the inner tube; and (b) an electronic smoking kit comprising a plurality of detachable fiber elements, each detachable fiber element having at least one additive;

27. 27. The electronic smoking kit of claim 26, wherein the at least one additive is selected from the group consisting of a flavorant, an aroma material, a pH modifier, a chemical sensate, a carbon dioxide former, a smoke modifier, a diluent, an aerosol former, nicotine, and any combination thereof.

28. 28. The electronic smoking kit of claim 27, wherein the additive is nicotine, and the nicotine content of each of the plurality of detachable fiber elements differs from one another.

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