Aerosol delivery device with improved atomizer

Abstract

To provide an aerosol delivery device prepared utilizing a vapor-forming unit configured for improved vapor formation and / or improved integration with a power unit.SOLUTION: An aerosol delivery device 800 provides atomizers and elements thereof, such as a combined wick and heater 834 configured to improve vaporization response time, particularly on porous, monolithic wicks 836. The wick can have a tapered end that engages the interior of a substantially basket-shaped wire heater coil. The heater also may be in the form of a conductive mesh that is present on a portion of the wick.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery devices, such as smoking articles, and more particularly to aerosol delivery devices (e.g., smoking articles commonly referred to as e-cigarettes) that may utilize electrically generated heat for the generation of an aerosol. The smoking article may be configured to heat an aerosol precursor, which may be made from tobacco, derived from tobacco, or may otherwise incorporate materials that may incorporate tobacco, and the precursor can form an inhalable substance for human consumption. [Background technology]

[0002] Many smoking devices have been proposed for many years as an improvement or replacement for smoking products that require tobacco to be burned for use.Many of these devices are designed to provide the sensation associated with smoking cigarettes, cigars or pipes, but are said to not deliver a significant amount of incomplete combustion and pyrolysis products resulting from tobacco combustion.For this purpose, many smoking products, flavor generators and medicinal inhalers have been proposed, which utilize electrical energy to vaporize or heat volatile materials, or to provide the sensation of smoking cigarettes, cigars or pipes without significantly burning tobacco.For example, see the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, Griffith Jr. et al., U.S. Patent Application Publication No. 2013 / 0255702 and Sears et al., U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrical heating sources referenced by trade names and commercial sources set forth in U.S. Patent Application No. 14 / 170,838 to Bless et al., filed February 3, 2014, which is incorporated herein by reference. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0096781 [Patent Document 4] U.S. Patent Application No. 14 / 170,838 Summary of the Invention [Problem to be solved by the invention]

[0004] It would be desirable to provide a vapor-forming unit for an aerosol delivery device that is configured to improve vapor formation and / or improve integration with a power supply unit. It would also be desirable to provide an aerosol delivery device manufactured utilizing such a vapor-forming unit. [Means for solving the problem]

[0005] The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. The aerosol delivery device and, in particular, a ceramic wick can be integrated to form a vapor forming unit, which can be combined with a power supply unit to form the aerosol delivery device.

[0006] In one or more embodiments, the present disclosure may relate to a nebulizer particularly useful for aerosol delivery devices. The nebulizer may include, among other things, at least a fluid transport element and a heater. The fluid transport element may be formed from a hard material, particularly a porous monolith such as a porous ceramic or porous glass. The combination of the heater and the fluid transport element may exhibit improved vapor formation, depending on the specific configuration of the individual materials.

[0007] In some embodiments, an exemplary sprayer can include a fluid transport element in the form of a rigid, porous monolith having a tapered first end and a second end, and a substantially conical-shaped heater including an interior region that receives and substantially conforms to the tapered first end of the fluid transport element. In further embodiments, such a sprayer can be defined in terms of one or more of the following statements, which can be combined in any number and order:

[0008] The rigid porous monolith can be formed from porous ceramic or porous glass.

[0009] The fluid transport element may not include fibrous materials.

[0010] The fluid transport element can have a body having a longitudinal length extending between tapered first and second ends, the body having a substantially constant diameter along its longitudinal length.

[0011] The tapered first end of the fluid transport element can form between about 5% and about 50% of the total length of the fluid transport element.

[0012] The tapered first end can taper (i.e., gradually decrease) from a first diameter that is approximately the same as the diameter of the body to a second diameter that is no more than about 50% of the diameter of the body of the fluid transport element.

[0013] The sprayer can be defined by the following: the heater can have an upper end with a diameter substantially the same as the diameter of the body of the fluid transport element; the heater can have a height substantially the same as the length of the tapered first end of the fluid transport element; and the heater can have a lower end with a diameter that is about 50% or less of the diameter of the upper end of the heater.

[0014] The present disclosure may also relate to a sprayer that includes a fluid transport element in the form of a rigid porous monolith having a first end and a second end, and a heater in the form of a conductive mesh contacting at least a portion of an outer surface of the fluid transport element. In further embodiments, such a sprayer may be defined in terms of one or more of the following statements, which may be combined in any number and order:

[0015] The conductive mesh may be formed from a plurality of intersecting conductive filaments.

[0016] The conductive mesh can have a regular pattern of conductive filaments that form a parallelogram (or other geometric shape) that encloses an insulating space.

[0017] The insulating space may be open or at least partially closed.

[0018] The insulating spaces can have an average individual area of ​​about 0.01 μm to about 0.5 μm.

[0019] The fluid transport element can have a total longitudinal length, and the conductive mesh can be present on about 10% to about 80% of the total longitudinal length of the fluid transport element.

[0020] The conductive mesh can be present over about 30% to about 70% of the total longitudinal length of the fluid transport element.

[0021] In one or more embodiments, the present disclosure may relate to an aerosol delivery device, particularly one including a nebulizer as described elsewhere herein. Specifically, such an aerosol delivery device can include a reservoir containing an aerosol precursor composition, and a second end of a fluid transport element from the nebulizer can extend into the reservoir to contact the aerosol precursor composition. The fluid transport element can siphon or otherwise transport the aerosol precursor composition from the reservoir to a heater (having any configuration described elsewhere herein) that is thermally connected to the fluid transport element. The heater is positioned external to the reservoir to vaporize at least a portion of the aerosol precursor composition transported from the reservoir through the fluid transport element. The formed vapor can combine with air drawn into the aerosol delivery device to form an aerosol, which flows to the mouthpiece of the aerosol delivery device and exits the aerosol delivery device. An aerosol delivery device including a nebulizer can be a single, integrated structure that houses all of the elements described herein useful for forming an aerosol (e.g., power, control, and vaporization elements). The aerosol delivery device can be a cartridge or tank that does not include power elements (e.g., does not include batteries) and / or does not include control elements (e.g., does not include a printed circuit board having sensors or other electronic controls thereon).

[0022] The present disclosure includes, but is not limited to, the following embodiments.

[0023] Embodiment 1: A sprayer comprising: a fluid transport element in the form of a rigid, porous monolith having a tapered first end and a second end; and a substantially conical-shaped heater including an interior region that receives and substantially coincides with the tapered first end of the fluid transport element.

[0024] Embodiment 2: The atomizer of any preceding embodiment, wherein the rigid porous monolith is formed from porous ceramic or porous glass.

[0025] Embodiment 3: The atomizer of any preceding embodiment, wherein the fluid transport element does not comprise fibrous material.

[0026] Embodiment 4: The sprayer of any preceding embodiment, wherein the fluid transport element has a body having a longitudinal length extending between tapered first and second ends, the body having a substantially constant diameter along its longitudinal length.

[0027] Embodiment 5: The sprayer of any preceding embodiment, wherein the tapered first end of the fluid transport element forms between about 5% and about 50% of the total length of the fluid transport element.

[0028] Embodiment 6: The sprayer of any preceding embodiment, wherein the tapered first end tapers from a first diameter that is approximately the same as the diameter of the body to a second diameter that is no more than about 50% of the diameter of the body of the fluid transport element.

[0029] Embodiment 7: The sprayer of any preceding embodiment, wherein the heater has an upper end with a diameter substantially the same as the diameter of the body of the fluid transport element, the heater has a height substantially the same as the length of the tapered first end of the fluid transport element, and the heater has a lower end with a diameter that is no greater than about 50% of the diameter of the upper end of the heater.

[0030] Embodiment 8: An aerosol delivery device comprising a nebulizer according to any preceding embodiment.

[0031] Embodiment 9: The aerosol delivery device of any preceding embodiment, comprising a reservoir containing an aerosol precursor composition, wherein the second end of the fluid transport element extends into the reservoir so as to contact the aerosol precursor composition.

[0032] Embodiment 10: A sprayer comprising a fluid transport element in the form of a rigid porous monolith having a first end and a second end, and a heater in the form of a conductive mesh in contact with at least a portion of the outer surface of the fluid transport element.

[0033] Embodiment 11: The atomizer of any preceding embodiment, wherein the conductive mesh is formed from a plurality of intersecting conductive filaments.

[0034] Embodiment 12: The sprayer of any preceding embodiment, wherein the conductive mesh has a regular pattern of conductive filaments forming a parallelogram that encloses the insulating space.

[0035] Embodiment 13: The sprayer of any preceding embodiment, wherein the insulating space is open.

[0036] Embodiment 14: Heat insulating space is about 0.01 μm 2 ~approximately 2mm 2 3. The atomizer of any preceding embodiment, having an average individual area of

[0037] Embodiment 15: The sprayer of any preceding embodiment, wherein the fluid transport element has a total longitudinal length and the conductive mesh is present on about 10% to about 80% of the total longitudinal length of the fluid transport element.

[0038] Embodiment 16: The sprayer of any preceding embodiment, wherein the conductive mesh is present on about 30% to about 70% of the total longitudinal length of the fluid transport element.

[0039] Embodiment 17: An aerosol delivery device comprising a nebulizer according to any preceding embodiment.

[0040] Embodiment 18: The aerosol delivery device of any preceding embodiment, comprising a reservoir containing an aerosol precursor composition, wherein the second end of the fluid transport element extends into the reservoir so as to contact the aerosol precursor composition.

[0041] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more of the above-described embodiments, as well as combinations of any two, three, four, or more features or elements described in the present disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosure, in any of its various aspects and embodiments, appear as intended to be combinable, unless the context clearly dictates otherwise.

[0042] The present disclosure having been described in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0043] [Figure 1] FIG. 1 is a partial cutaway view of an aerosol delivery device including a cartridge and a power supply unit that includes various elements that may be utilized in the aerosol delivery device, according to various embodiments of the present disclosure. [Figure 2A] 1A-1C are views of fluid transport elements according to various embodiments of the present disclosure including tapered ends. [Figure 2B] FIG. 2B is a cross-sectional view of the fluid transport element through line AA from FIG. 2A, showing its cross-sectional shape. [Figure 3] 1 is a diagram of a heater according to various embodiments of the present disclosure, the heater having a substantially conical shape with a diameter at the top end of the heater greater than the diameter at the bottom end of the heater. [Figure 4] 1A-1C are diagrams of a sprayer according to various embodiments of the present disclosure, the sprayer including a fluid transport element having a tapered end and including a heater having a substantially conical shape, the heater engaging the tapered end of the fluid transport element. [Figure 5]FIG. 10 is a diagram of a comparative atomizer having a single-strand heating wire wrapped around substantially the center of a fluid transport element having a substantially constant diameter along its entire length. [Figure 6] 1A-1C are diagrams of a sprayer according to various embodiments of the present disclosure, the sprayer including a fluid transport element and a conductive mesh heater surrounding a portion of the fluid transport element. [Figure 7] 1A and 1B are enlarged cross-sectional views of conductive mesh heaters according to various embodiments of the present disclosure. [Figure 8] 1 is a partial cutaway view of an aerosol delivery device including a tank containing a reservoir and a nebulizer, according to various embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0044] The present disclosure will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0045] As described below, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat materials (preferably without significant combustion and / or significant chemical changes to the materials) to form inhalable substances, and components of such systems most preferably have the form of items small enough to be considered handheld devices. That is, preferred aerosol delivery system components do not produce smoke (i.e., from by-products of tobacco combustion or pyrolysis); rather, preferred systems produce vapors resulting from the volatilization or vaporization of certain components incorporated therein. In preferred embodiments, the aerosol delivery system components may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver the tobacco-derived components in aerosol form.

[0046] The aerosol-generating components of certain preferred aerosol delivery systems can provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, organoleptic effects, physical sensations, modes of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of an aerosol-generating component of the present disclosure can hold and use the component, draw on one end of the component to inhale the aerosol generated by the component, take puffs at selected time intervals, etc., in the same way as a smoker would use a conventional type of smoking article.

[0047] The aerosol delivery device of the present disclosure can also be characterized as a vapor product or drug delivery article. Accordingly, such articles or devices can be configured to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance can be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible and whether or not in a form that can be considered smoky.

[0048] The aerosol delivery device of the present disclosure generally includes many components disposed within an outer body or shell, which may be referred to as a housing. The overall design of the outer body or shell can vary, and the type or configuration of the outer body can vary, which can define the overall dimensions and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, integral housing, or the elongated housing can be formed from two or more separable bodies. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and can resemble the shape of a traditional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are contained within a single housing. Alternatively, the aerosol delivery device can include two or more joined and separable housings. For example, an aerosol delivery device may have a control body (or power unit) at one end that includes a housing that houses one or more components (e.g., a battery and various electronics for controlling the operation of the item) and a removably attached outer body or shell at the other end that houses the aerosol-forming components (e.g., one or more aerosol precursor ingredients such as flavors and aerosol-forming agents, one or more heaters, and / or one or more wicks).

[0049] The aerosol delivery device of the present disclosure can be formed from an outer housing or shell that is not substantially tubular but can be formed substantially to relatively large dimensions. The housing or shell can be configured to include a mouthpiece and / or can include consumable elements such as a liquid aerosol former, and can be configured to receive a separate shell (e.g., a cartridge or tank) that can include a vaporizer or atomizer.

[0050] The aerosol delivery device of the present disclosure most preferably includes some combination of a power source (i.e., an electrical drive source), at least one control component (e.g., a means (e.g., a microcontroller or microprocessor) for activating, controlling, regulating, and terminating power for heat generation, such as by controlling the flow of current from the power source to other components of the article), a heater or heat-generating member (e.g., an electrical resistance heating element or other component that, alone or in combination with one or more additional elements, may commonly be referred to as an "atomizer"), an aerosol precursor composition (e.g., a liquid that can generally generate an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece and mouthpiece region that allows the aerosol delivery device to be drawn upon for aerosol inhalation (e.g., a defined air flow path through the article so that the generated aerosol may be drawn therethrough by inhalation).

[0051] More specific forms, configurations, and arrangements of components within the aerosol delivery systems of the present disclosure will become apparent in light of the further disclosure provided below. Moreover, the selection and arrangement of various aerosol delivery system components can be understood in light of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure.

[0052] An exemplary embodiment of an aerosol delivery device 100 illustrating components that may be utilized in an aerosol delivery device according to the present disclosure is shown in FIG. 1. The aerosol delivery device 100 may include a power supply unit 102 and a cartridge 104, which may be permanently or removably aligned in functional relationship, as seen in the cutaway view shown therein. Engagement between the power supply unit 102 and the cartridge 104 may be press-fit (as shown), threaded, interference fit, magnetic, or the like. Specifically, connection components as further described herein may be used. For example, the power supply unit may include a coupler configured to engage with a connector on the cartridge.

[0053] In certain embodiments, one or both of the power supply unit 102 and the cartridge 104 may be referred to as disposable or reusable. For example, the power supply unit may have a replaceable or rechargeable battery and, therefore, may be combined with any type of recharging technology, including connection to a typical electrical outlet, a car charger (i.e., cigarette lighter socket), and a computer via a Universal Serial Bus (USB) cable or the like. For example, an adapter including a USB connector on one end and a power supply unit connector on the opposite end is disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference. Furthermore, in some embodiments, the cartridge may include a disposable cartridge such as that disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference.

[0054] As shown in FIG. 1 , power supply unit 102 can be formed from power supply unit shell 101 that can include control components 106 (e.g., a printed circuit board (PCB), integrated circuits, memory components, a microcontroller, etc.), a flow sensor 108, a battery 110, and an LED 112, which can be variably aligned. In addition to or as an alternative to the LED, additional indicators (e.g., tactile feedback components, audio feedback components, etc.) can be included. Additional representative types of components or indicators that provide visual cues, such as light-emitting diode (LED) components, and their construction and use, are described in U.S. Pat. No. 5,154,192 to Sprinkel et al., U.S. Pat. No. 8,499,766 to Newton, U.S. Pat. No. 8,539,959 to Scatterday, U.S. Pat. App. No. 2015 / 0020825 to Galloway et al., and U.S. Pat. App. No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference. It will be understood that none of the illustrated elements are required. For example, the LEDs may be absent or replaced with a different indicator, such as a vibrating indicator. Similarly, the flow sensor may be replaced with a manual actuator, such as a push button.

[0055] The cartridge 104 can be formed from a cartridge shell 103 enclosing a reservoir 144 in fluid communication with a liquid transport element 136 configured to wick or otherwise transport the aerosol precursor composition stored in the reservoir housing to the heater 134. The liquid transport element can be formed from one or more materials configured to transport liquid, such as by capillary action. The liquid transport element can be formed from, for example, fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose cloth, glass fiber), porous ceramic, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillaries, etc. Thus, the liquid transport element can be any material that includes an open pore network (i.e., multiple interconnected pores such that fluid can flow from one pore to another in multiple directions through the element). As discussed further herein, some embodiments of the present disclosure may specifically relate to the use of non-fibrous transport elements. As such, fibrous transport elements may be explicitly excluded. Alternatively, a combination of fibrous and non-fibrous transport elements may be utilized. Various embodiments of materials configured to generate heat upon the application of an electric current may be used to form the resistive heating element 134. Examples of materials from which the wire coil may be formed include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi), molybdenum silicide (MoSi), aluminum doped molybdenum disilicide (Mo(Si,Al)), titanium, platinum, silver, palladium, alloys of silver and palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), conductive inks, boron-doped silica, and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0056] An opening 128 may be present in the cartridge shell 103 (e.g., at the mouthpiece) to allow the formed aerosol to be released from the cartridge 104. Such components are representative of components that may be present in a cartridge and are not intended to limit the scope of cartridge components encompassed by this disclosure.

[0057] Cartridge 104 may also include one or more electronic components 150, which may include integrated circuits, memory components, sensors, etc. Electronic components 150 may be configured to communicate with control component 106 and / or external devices by wired or wireless means. Electronic components 150 may be located anywhere within cartridge 104 or its base 140.

[0058] Although the control component 106 and the flow sensor 108 are illustrated separately, it is understood that the control component and the flow sensor may be combined as an electronic circuit board with the air flow sensor directly attached. Furthermore, the electronic circuit board may be positioned horizontally relative to the view of FIG. 1 , in that the electronic circuit board may be longitudinally parallel to the central axis of the power supply unit. In some embodiments, the air flow sensor may include its own circuit board or other base element to which it may be attached. In some embodiments, a flexible circuit board may be utilized. The flexible circuit board may be configured in various shapes, including a substantially tubular shape. For example, printed circuit board and pressure sensor configurations are described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., the disclosure of which is incorporated herein by reference.

[0059] The power supply unit 102 and the cartridge 104 may include components configured to facilitate fluid engagement therebetween. As shown in FIG. 1 , the power supply unit 102 may include a coupler 124 having a cavity 125 therein. The cartridge 104 may include a base 140 configured to engage with the coupler 124 and may include a protrusion 141 configured to fit within the cavity 125. Such engagement may facilitate a stable connection between the power supply unit 102 and the cartridge 104 as well as establish an electrical connection between the battery 110 and control components 106 in the power supply unit and the heater 134 in the cartridge. Additionally, the power supply unit shell 101 may include an air inlet 118, which may be a notch in the shell that connects to the coupler 124, allowing ambient air around the coupler to pass into the shell, then through the cavity 125 of the coupler, and into the cartridge via the protrusion 141.

[0060] Useful couplers and bases according to the present disclosure are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference. For example, as seen in FIG. 1 , the coupler may define an outer periphery 126 configured to mate with an inner periphery 142 of a base 140. In one embodiment, the inner periphery of the base may define a radius substantially equal to or slightly greater than the radius of the outer periphery of the coupler. Additionally, the coupler 124 may define one or more protrusions 129 on the outer periphery 126 configured to engage with one or more recesses 178 defined in the inner periphery of the base. However, various other embodiments of structures, shapes, and components may be used to couple a base to a coupler. In some embodiments, the connection between the base 140 of the cartridge 104 and the coupler 124 of the power supply unit 102 may be substantially permanent, while in other embodiments, the connection therebetween may be releasable, for example, so that the power supply unit may be reused with one or more additional cartridges, which may be disposable and / or refillable.

[0061] In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped, or substantially tubular, or substantially cylindrical. Other embodiments encompass additional shapes and dimensions, such as rectangular or triangular cross-sections, polyhedral shapes, etc. Specifically, the power unit 102 may not be rod-shaped, but rather may have a substantially rectangular, circular, or any other shape. Similarly, the power unit 102 may be substantially larger than a power unit that would be expected to be substantially the size of a conventional cigarette.

[0062] The reservoir 144 shown in FIG. 1 can be a container (e.g., formed from walls substantially impermeable to the aerosol precursor composition) or a fibrous reservoir. The container walls can be flexible and collapsible. Alternatively, the container walls can be substantially rigid. The container is preferably substantially sealed to prevent passage of the aerosol precursor composition other than through any specific openings expressly provided for passage of the aerosol precursor composition, such as through a transport element described elsewhere herein. In an exemplary embodiment, the reservoir 144 can comprise one or more layers of nonwoven fibers substantially formed in the shape of a tube that surrounds the interior of the cartridge shell 103. The aerosol precursor composition can be held in the reservoir 144. For example, a liquid component can be sorbently held by the reservoir 144 (i.e., if the reservoir 144 includes a fibrous material). The reservoir 144 can be fluidly connected to the liquid transport element 136. In this embodiment, the liquid transport element 136 can transport the aerosol precursor composition stored in the reservoir 144 via capillary action to the heating element 134, which is in the form of a metal wire coil. Thus, the heating element 134 is in a heating configuration with the liquid transport element 136.

[0063] In use, when a user draws on the article 100, airflow is detected by the sensor 108, activating the heating element 134, which vaporizes the components of the aerosol precursor composition. When drawing on the mouthpiece of the article 100, ambient air enters the inlet 118 and passes through the cavity 125 in the coupler 124 and the central opening in the protrusion 141 of the base 140. In the cartridge 104, the drawn-in air combines with the formed vapor to form an aerosol. The aerosol is blown, inhaled, or otherwise drawn through the heating element 134 and exits through the mouth opening 128 in the mouthpiece of the article 100. Alternatively, in the absence of an airflow sensor, the heating element 134 may be activated manually, such as by a push button.

[0064] The aerosol delivery device may include an input element (which may replace or complement the airflow or pressure sensor). The input may be included to allow a user to control the device's functions and / or output information to the user. Any component or combination of components may be utilized as an input to control the device's functions. For example, one or more push buttons may be used, as described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touchscreen may be used, as described in U.S. Patent Application No. 14 / 643,626 to Sears et al., filed March 10, 2015, which is incorporated herein by reference. As an additional example, a component adapted for gesture recognition based on specific movements of the aerosol delivery device may be used as an input. See U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference.

[0065] In some embodiments, the input may comprise a computer or computing device such as a smartphone or tablet. Specifically, the aerosol delivery device may be hardwired to a computer or other device, such as via a USB cord or similar protocol. The aerosol delivery device may also communicate with the computer or other device acting as input via wireless communication. See, for example, the systems and methods for controlling a device via readout requests, such as those described in U.S. Patent Application Publication No. 2016 / 0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference. In such embodiments, an application or other computer program may be used in conjunction with a computer or other computing device to input control instructions to the aerosol delivery device, including, for example, the ability to form an aerosol of a specific composition by selecting the nicotine content and / or the content of additional flavors to be included.

[0066] The various components of the aerosol delivery device according to the present disclosure can be selected from those described in the art and commercially available. An example of a battery that can be used according to the present disclosure is described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference.

[0067] The aerosol delivery device can incorporate a sensor or detector for controlling the supply of power to the heating element when aerosol generation is desired (e.g., when inhaled during use). Thus, for example, a manner or method is provided for turning off the power supply to the heating element when the aerosol delivery device is not being inhaled during use, and turning on the power supply to activate or cause heat generation by the heating element during inhalation. Additional representative types of sensing or detection mechanisms, their structure and configuration, their components, and their general operating methods are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr., U.S. Patent No. 5,372,148 to McCafferty et al., and WO 2010 / 003480 to Flick, which are incorporated herein by reference.

[0068] Most preferably, the aerosol delivery device incorporates a control mechanism for controlling the amount of power to the heating element during inhalation. Representative types of electronic components, their structure and configuration, their features, and their general methods of operation are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, U.S. Pat. App. Pub. No. 2009 / 0230117 to Fernando et al., U.S. Pat. App. Pub. No. 2014 / 0060554 to Collet et al., and U.S. Pat. App. Pub. No. 2014 / 0270727 to Ampolini et al., and U.S. Pat. App. Pub. No. 2015 / 0257445 to Henry et al., which are incorporated herein by reference.

[0069] Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014 / 0261487 to Chapman et al. and 2014 / 0059780 to Davis et al., and U.S. Patent Application Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference. Additionally, various wicking materials and the construction and operation of those wicking materials within particular types of electronic cigarettes are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference.

[0070] In aerosol delivery systems characterized as electronic cigarettes, the aerosol precursor composition most preferably incorporates tobacco or tobacco-derived components. In some respects, tobacco may be provided as tobacco parts or pieces, such as finely ground, crushed, or powdered tobacco flakes. For example, tobacco beads, pellets, or other solid forms may be included, as described in U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al., the disclosure of which is incorporated herein by reference. In other respects, tobacco may be provided in the form of an extract, such as a spray-dried extract incorporating many of the water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of a relatively high-concentration nicotine-containing extract that also incorporates small amounts of other extracted components derived from tobacco. In other respects, tobacco-derived components may be provided in a relatively pure form, such as certain flavoring agents derived from tobacco. In some respects, a component derived from tobacco that may be used in a highly purified or essentially pure form is nicotine (e.g., pharmaceutical-grade nicotine).

[0071] Aerosol precursor compositions, also referred to as vapor precursor compositions, may contain a variety of ingredients, including, for example, polyhydric alcohols (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorants. Representative types of aerosol precursor ingredients and formulations are also described and characterized in U.S. Patent No. 7,217,320 to Robinson et al. and U.S. Patent Application Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Application Publication No. 2013 / 0213417 to Chong et al., U.S. Patent Application Publication No. 2014 / 0060554 to Collett et al., U.S. Patent Application Publication No. 2015 / 0020823 to Lipowicz et al. and U.S. Patent Application Publication No. 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those incorporated into RJ Reynolds Vapor Company's VUSE® products, Lorillard Technologies' BLU® products, Mistic Ecigs' MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. Also desirable are so-called "smoke juices" for e-cigarettes, available from Johnson Creek Enterprises LLC.

[0072] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol-generating component provides acceptable sensation and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material (e.g., glycerin and / or propylene glycol) be used to generate a visible mainstream aerosol that resembles in many respects the appearance of cigarette smoke. The amount of aerosol precursor in the aerosol-generating system may depend on factors such as the desired number of puffs per aerosol-generating component. In one or more embodiments, about 1 ml or more, about 2 ml or more, about 5 ml or more, or about 10 ml or more of the aerosol precursor composition may be included.

[0073] Still other features, controls or components that can be incorporated into the aerosol delivery systems of the present disclosure are described in U.S. Pat. No. 5,967,148 to Harris et al., U.S. Pat. No. 5,934,289 to Watkins et al., U.S. Pat. No. 5,954,979 to Counts et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 8,365,742 to Hon, U.S. Pat. No. 8,402,976 to Fernando et al. ... U.S. Patent Application Publication No. 2010 / 0163063, U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent Application Publication No. 2013 / 0298905 to Leven et al., U.S. Patent Application Publication No. 2013 / 0180553 to Kim et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., and U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al.

[0074] The above description of the use of the article may be applied to the various embodiments described herein through minor modifications that may be apparent to those skilled in the art in light of the further disclosure provided herein. However, the above description of use is not intended to limit the use of the article, but is provided to comply with all necessary disclosure requirements of the present disclosure. Any of the elements shown in FIG. 1 or in the articles described above may be included in an aerosol delivery device according to the present disclosure.

[0075] In one or more embodiments, the present disclosure may relate specifically to an aerosol delivery device configured to increase vapor production. Such an increase may result from a variety of factors. In some embodiments, the liquid transport element (i.e., the wick or wicking element) may be partially or completely formed from a porous monolith, such as a porous ceramic, porous glass, or the like. Exemplary monolithic materials suitable for use with embodiments of the present disclosure are described, for example, in U.S. Patent Application No. 14 / 988,109, filed January 5, 2016, and U.S. Patent Application Publication No. 2014 / 0123989 to LaMothe, the disclosures of which are incorporated herein by reference. The porous monolith may form a substantially solid wick. In particular, the transport element may be a substantially single monolithic material, rather than a bundle of individual fibers as known in the art.

[0076] The use of rigid porous monoliths as fluid transport elements is beneficial for improving heating uniformity and reducing the likelihood of carbonization of the fluid transport element if uneven heating occurs. It may also be desirable to eliminate the presence of fibrous materials within the aerosol delivery device. Despite these advantages, porous monoliths present certain challenges for successful implementation as fluid transport elements. These challenges stem in part from the different material properties of porous monoliths (e.g., porous ceramics) compared to fibrous wicks. For example, alumina has both a higher thermal conductivity and a higher heat capacity than silica. These thermal properties result in heat being lost from the aerosol precursor composition at the wick-heater interface, which may require a relatively higher initial energy output to achieve comparable fluid vaporization. The present disclosure provides a means to overcome these challenges.

[0077] In some embodiments using a porous monolith, the energy required for vaporization when using a porous monolith can be minimized, reducing the heat flux density (Watts per square meter (W / m)) at the surface of the porous monolith fluid transport element. 2The vaporization response time can be improved by increasing the heat flux density (measured in units of 1000 kJ / cm2). This disclosure describes embodiments that are particularly well suited to providing such an increase in heat flux density.

[0078] In one or more embodiments, the present disclosure may relate to atomizer configurations in which a porous monolithic fluid transport element has a specific shape that is combined with a heater having a substantially matching shape. For example, a fluid transport element 236 is shown in FIG. 2A, where the fluid transport element 236 is in the form of a substantially rigid porous monolith. As seen in FIG. 2B, the fluid transport element has a substantially circular cross-section, although other cross-sectional shapes are also encompassed. The fluid transport element 236 has a body 236a, a tapered first end 236b, and a second end 236c. While the fluid transport element 236 is shown as being substantially straight, other configurations, such as having one or more bends or being curved, are also encompassed. The body 236a of the fluid transport element 236 has a substantially constant diameter d along the longitudinal length of the body 236a. The second end 236c can have a diameter substantially the same as the diameter d of the body 236a. However, the diameter of second end 236c may be smaller or larger than diameter d of main body 236a. As shown, tapered end 236b of transport element 236 forms approximately 25% of the total length L of the transport element. In various embodiments, tapered end 236b forms approximately 5% to 50%, approximately 10% to 40%, or approximately 15% to 35% of the total length L of transport element 236. Tapered end 236b of transport element 236 is configured to begin with a diameter approximately the same as diameter d of main body 236a and then gradually narrow to point 236d. While point 236d is shown as a sharp point, such a configuration is not required. Preferably, point 236d has a diameter of approximately 50% or less, approximately 35% or less, approximately 20% or less, or approximately 10% or less of diameter d of main body 236a, with an exemplary lower range being approximately 5% or approximately 1% of the main body diameter d. In some embodiments, point 236d can be substantially rounded or flat.

[0079] The heater 234 is shown in FIG. 3 as being formed from a heating wire 235a shaped to substantially match the tapered end 236b of the transport element 236. As shown, the heater 234 is substantially squirrel-cage shaped. To substantially match the tapered end 236b of the transport element 236, the heater 234 can have dimensions substantially similar to those of the transport element 236. In an exemplary embodiment, the heater 234 has an upper end 234a with a diameter A that is substantially the same as the diameter d of the body 236a of the transport element 236. "Substantially the same" indicates that the diameter A of the upper end 234a of the heater 234 is within ±10% of the diameter d of the body 236a of the transport element 236. The heater 234 also has a height C that is substantially the same as the length of the tapered end 236b of the transport element 236. Substantially the same indicates that the height C of the heater 234 is within ±10% of the length of the tapered end 236b of the transport element 236. In some embodiments, the height C of the heater 234 is equal to or less than the length of the tapered end 236b of the transport element 236. For example, the height C of the heater 234 can be about 50% to about 100%, about 60% to about 99%, or about 65% to about 98% of the length of the tapered end 236b of the transport element 236. The heater 234 can also have a lower end 234b with a diameter D that is smaller than the diameter A of the upper end 234a of the heater. The diameter D of the lower end 234b of the heater 234 is preferably equal to or less than about 50%, about 35%, about 20%, or about 10% of the diameter A of the upper end 234a of the heater. For example, diameter D can be about 1% to about 50%, about 2% to about 40%, or about 5% to about 30% of diameter A. The diameter of heater 234 can gradually decrease from diameter A at upper end 234a of the heater to diameter D at lower end 234b of the heater. Heater 234 has an open interior region configured to receive tapered end 236b of transport element 236.

[0080] The heater 234 can further include electrical leads (235b, 235c) for providing positive and negative electrical connections to the heater. The electrical leads (235b, 235c) can be integrally formed with the heating wire 235a or can be separate elements that can be attached to the heating wire (e.g., by welding or using a connector). The heater 234 can have an overall width B that can include the overall width of the coil formed by the heating wire 235a and the length of the electrical leads (235b, 235c).

[0081] A combination of a transport element 236 and a heater 234 is shown in FIG. 4. As can be seen there, the sprayer 275 is formed from a transport element 236 in the form of a rigid, porous monolith and a heater 234 wrapped around the tapered end of the transport element. The heater 234 comprises a nine-turn coil of heater wire 235a. As can be seen, the heater 234 is substantially conical in shape and includes an interior region that receives and substantially conforms to the tapered end of the fluid transport element. In this configuration, energy from the heater 234 is concentrated on a relatively small surface area at the tapered end of the wick. In comparison, as shown in FIG. 5, a heater 234' formed from a nine-turn coil of heater wire 235a' wrapped around a constant diameter portion of a fluid transport element 236' covers a significantly larger surface area of ​​the fluid transport element, thus reducing energy concentration. In such a comparative atomizer, the heat flux density is significantly reduced compared to when the heater wire is wrapped around a relatively small surface area, as shown in FIG.

[0082] In one or more embodiments, alternative heater configurations can be used to increase heat flux density and thus improve heating and vapor formation. For example, as shown in FIG. 6, a mesh or screen heater 334 may be used, which can be effective in increasing the heater surface area coverage on the porous monolithic fluid transport element 336. The heater is preferably configured to contact at least a portion of the outer surface of the fluid transport element, and the heater is in the form of a conductive mesh. As used herein, the terms mesh and screen are interchangeable and are specifically meant to refer to a network of intersecting conductive filaments 335a. Thus, a conductive mesh can be interpreted as a network and / or entangled structure of conductive filaments. The conductive filaments 335a can be formed from any suitable conductive material, such as those listed elsewhere herein for forming heaters. In one or more embodiments, the conductive filaments 335a can be at least partially interwoven with non-conductive filaments 383 or similar materials, which can be effective in improving the direction of current flow between fasteners 338a and 338b.

[0083] The conductive mesh heater 334 can circumferentially surround at least a portion of the outer surface of the fluid transport element 336. In some embodiments, the conductive mesh heater 334 can only partially surround at least a portion of the outer surface of the fluid transport element 336. The conductive mesh heater 334 can include a first end 334a and a second end 334b, where the extent of the conductive mesh heater on the outer surface of the fluid transport element 336 terminates. The first end 334a and the second end 334b ​​of the conductive mesh heater 334 can include respective first and second fasteners 338a and 338b that can secure the conductive mesh heater to the fluid transport element and / or serve as an electrical connection between the conductive mesh heater and a power source.

[0084] As seen in FIG. 7 , the conductive mesh heater 334 can include a plurality of intersecting conductive filaments 335a. The conductive mesh heater 334 can define a regular pattern of the conductive filaments 335a forming a parallelogram 339 or other shape consistent with a mesh configuration. The conductive filaments 335a can, among other things, surround an insulating space 381. The insulating space 381 can be open (e.g., insulated by air) or at least partially filled with insulating material. The insulating space 381 can be configured to have a defined area so that the heating capacity of the conductive mesh heater 334 is maximized and the amount of power delivery to the conductive mesh heater is minimized. In some embodiments, the insulating space is approximately 0.01 μm 2 ~approximately 2mm 2 In a further embodiment, the insulating spaces may have an average individual area of ​​about 0.05 μm 2 ~about 1.5mm 2 , about 0.1μm 2 ~about 1mm 2 , about 0.25μm 2 ~about 0.5mm 2 or about 0.5 μm 2 ~about 0.1mm 2 In some embodiments, the insulating spaces can have an average individual area of ​​about 0.005 mm 2 ~approximately 2mm 2 , approximately 0.01 mm 2 ~about 1.5mm 2 or approximately 0.02 mm 2 ~about 1mm 2 In some embodiments, the insulating spaces may have an average individual area in the upper range of about 0.01 μm 2 ~about 10μm 2 , about 0.02μm 2 ~approximately 5 μm 2 or approximately 0.05 μm 2 ~about 1μm 2 and the like.

[0085] 6, the conductive mesh heater 334, as shown, covers approximately 30% of the total longitudinal length of the fluid transport element 336. In further embodiments, the conductive mesh heater 334 can be present on between about 10% and about 80%, between about 15% and about 75%, or between about 20% and about 70% of the total longitudinal length of the fluid transport element 336. The conductive mesh heater 334 can be positioned substantially adjacent to one end of the fluid transport element 336, or the conductive mesh heater can be substantially centrally positioned along the longitudinal length of the fluid transport element.

[0086] In further embodiments, a nebulizer (275, 375) as shown in Figures 4 and / or 6 may be included in an aerosol delivery device (100) as shown in Figure 1. Accordingly, any of the relevant elements from aerosol delivery device 100 of Figure 1 may be included in an aerosol delivery device including a nebulizer (275 and / or 375) described herein. As an exemplary embodiment, aerosol delivery device 800 is shown in Figure 8. Aerosol delivery device 800 includes a tank (or cartridge) 804 defined by an outer body or shell 803. Tank 804 includes a reservoir 844 at least partially filled with an aerosol precursor composition 845. Reservoir 844 is configured as a closure having a single opening 846 configured to sealingly engage a porous monolithic fluid transport element 836, among other features. Thus, fluid transport element 836 is in fluid communication or other contact with aerosol precursor composition 845 and extends or protrudes into reservoir 844 to transport the aerosol precursor composition to heater 834. When heater 834 is activated, the aerosol precursor composition is vaporized, at least partially filling vaporization zone 809 within tank 804. Air drawn through air inlet 818 transports the formed vapor (e.g., in the form of an aerosol where the formed vapor mixes with air) from vaporization zone 809 to mouth 827. As shown, reservoir 844 is located substantially in the center of tank 804, and the aerosol passes around the reservoir. However, other configurations of elements are also encompassed. Tank 804 includes connector 840 for connecting the tank to a control body or power unit (e.g., element 102 in FIG. 1 ). Connector 840 may have a structure similar to base 140 shown in Figure 1, or may have any additional structure suitable for connecting tank 804 to a control body / power unit. Although not shown, it is understood that electrical connections are included to provide electrical connection between heater 834 and a battery (e.g., element 110 in Figure 1) or other power delivery device. In addition to, or as an alternative to, the heater 834 and fluid transport element 836 combination shown in Figure 8, sprayer 375 shown in Figure 6 may be used.

[0087] The heaters described herein may generally be disposed around the exterior of the fluid transport element. However, in one or more embodiments, the heater may be disposed at least partially inside the fluid transport element. For example, a ceramic fluid transport element may be formed in the presence of the heater such that the ceramic fluid transport element and heater are monolithic. In such embodiments, at least a sufficient amount of the heater suitable for forming electrical contact is disposed on the exterior of the fluid transport element. In some embodiments, the fluid transport element may be at least partially hollow, i.e., include an open space into which the heater may be disposed. In this manner, heating may proceed from the inside out, with maximum vapor generation occurring outward from the fluid transport element. If desired, the heaters described herein may be disposed at least partially inside the fluid transport element. In some embodiments, the heaters described herein may be disposed on the exterior surface of the fluid transport element, and a second heater may be disposed at least partially inside the fluid transport element as described above.

[0088] The use of at least two separate heaters can be beneficial for improving vapor generation. Specifically, a first heater can be used to preheat the liquid for vaporization within the liquid transport element, and a second heater can be used to actually vaporize the liquid. Preheating can reduce the total power and / or absolute temperature and / or heating time required to provide a desired amount of vapor. For example, the internal heater can be a preheater, and the external heater can be a vaporization heater. Alternatively, at least two separate heaters can be disposed on the exterior surface of the liquid transport element. One heater can function as a preheater, and the other heater can function as a vaporization heater. For example, as shown in FIG. 8, a preheater (not shown) can be disposed between heater 834 (which can function as a vaporization heater) and reservoir 844. The preheater may preheat the liquid aerosol precursor composition 845 flowing from the reservoir 844 to the vaporization heater 834, so that the vaporization heater can more easily achieve vaporization as described above, and / or the preheater may reduce the viscosity of the liquid aerosol precursor composition to improve the flow of liquid from the reservoir to the vaporization heater. A similar heater combination may be applied to the liquid transport element 336 in FIG. 6. In FIG. 8, the second heater disposed between the heater 834 and the reservoir 844 may be a mesh heater as described herein, a simple wire coil, or any other type of heater useful for preheating liquid in a liquid transport element. In FIG. 6, the second heater on the liquid transport element 336 may be an additional mesh heater, a simple wire coil, or any other type of heater useful for preheating liquid in a liquid transport element. For example, a heater coil 234' as shown in Figure 5 may be added as a second heater in combination with the wire mesh heater (see Figure 6) or squirrel cage heater (see Figure 4) described herein.

[0089] In one or more instances, a value set forth herein may be characterized by the word "about." When a value is "about" a stated amount, it is understood to indicate that the stated amount may be exactly the stated value, or may vary from the stated value by up to 5%, up to 2%, or up to 1%.

[0090] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A sprayer comprising: a fluid transport element in the form of a rigid porous monolith having a tapered first end and having a second end; a substantially conical shaped heater including an interior region that receives and substantially conforms to the tapered first end of the fluid transport element; Including a sprayer.

2. 10. The atomizer of claim 1, wherein the rigid porous monolith is formed from a porous ceramic or porous glass.

3. 3. The atomizer of claim 1 or claim 2, wherein the fluid transport element does not include fibrous material.

4. 4. The sprayer of claim 1, wherein the fluid transport element has a body having a longitudinal length extending between tapered first and second ends, the body having a substantially constant diameter along its longitudinal length.

5. 5. The atomizer of claim 4, wherein the tapered first end of the fluid transport element forms between about 5% and about 50% of the overall length of the fluid transport element.

6. 5. The sprayer of claim 4, wherein the tapered first end tapers from a first diameter that is approximately the same as the diameter of the body to a second diameter that is no greater than about 50% of the diameter of the body of the fluid transport element.

7. 5. The sprayer of claim 4, the heater has an upper end with a diameter substantially the same as the diameter of the body of the fluid transport element; the heater has a height substantially the same as the length of the tapered first end of the fluid transport element; An atomizer in which the heater has a lower end having a diameter that is no greater than about 50% of the diameter of the upper end of the heater.

8. 8. An aerosol delivery device comprising the nebulizer of any one of claims 1 to 7.

9. 10. The aerosol delivery device of claim 8, comprising a reservoir containing the aerosol precursor composition, the second end of the fluid transport element extending into the reservoir so as to contact the aerosol precursor composition.

10. 1. A sprayer comprising: a fluid transport element in the form of a rigid porous monolith having a first end and a second end; a heater in contact with at least a portion of the exterior surface of the fluid transport element and in the form of a conductive mesh; Including a sprayer.

11. 11. The atomizer of claim 10, wherein the conductive mesh is formed from a plurality of intersecting conductive filaments.

12. 12. The atomizer of claim 10 or claim 11, wherein the conductive mesh has a regular pattern of conductive filaments forming a parallelogram that encloses the insulating space.

13. 13. The atomizer of claim 12, wherein the insulating space is open.

14. The heat insulating space is approximately 0.01 μm ２ ~ approx. 2 mm ２ 14. The atomizer of claim 12 or claim 13, having an average individual area of

15. 15. The sprayer of any one of claims 10-14, wherein the fluid transport element has a total longitudinal length and the conductive mesh is present on between about 10% and about 80% of the total longitudinal length of the fluid transport element.

16. 16. The atomizer of claim 15, wherein the conductive mesh is present on about 30% to about 70% of the total longitudinal length of the fluid transport element.

17. 17. An aerosol delivery device comprising the nebulizer of any one of claims 10 to 16.

18. 18. The aerosol delivery device of claim 17, comprising a reservoir containing the aerosol precursor composition, the second end of the fluid transport element extending into the reservoir so as to contact the aerosol precursor composition.

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