Aerosol delivery device sensing system including an infrared sensor and related methods - Patents.com

Abstract

An aerosol delivery device sensing system is provided. The system may include an outer body, an atomizer, and an infrared sensor. The atomizer, housed within the outer body, may include a heating element. The infrared sensor may be configured to measure infrared radiation generated by the atomizer. The infrared sensor may be located inside or outside the outer body. In this regard, by way of example, the infrared sensor may be configured to provide feedback for control purposes, or the infrared sensor may be employed for testing purposes. A fiber optic cable may extend from the infrared sensor to a component to sense radiation emitted therefrom.

Description

[Technical field]

[0001] The present disclosure relates to aerosol delivery devices, such as electronic cigarettes, and more particularly to aerosol delivery devices that include an atomizer that may be configured to heat an aerosol precursor composition made from, extracted from, or incorporating tobacco to form an inhalable substance for human consumption. [Background technology]

[0002] Many devices have been proposed over the years as improvements or replacements for smoking products that require the burning of tobacco for use. Many of these devices are purportedly designed to provide the sensations associated with cigarette, cigar or pipe smoking without the significant amounts of incomplete combustion and pyrolysis products that result from the burning of tobacco. To this end, a number of alternative smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile substances or that attempt to provide the sensations of cigarette, cigar or pipe smoking without burning tobacco to any significant extent. See, for example, the various alternative smoking articles, aerosol delivery devices and heat generating sources described in the background art set forth in U.S. Patent No. 8,881,737 to Collett et al., U.S. Patent Application Publication No. 2013 / 0255702 to Griffith Jr. et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., U.S. Patent Application Publication No. 2014 / 0096782 to Ampolini et al., and U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al., which are incorporated by reference in their entireties. See also, for example, the various embodiments of products and heating configurations described in the background art sections of U.S. Patent No. 5,388,594 to Count et al. and U.S. Patent No. 8,079,371 to Robinson et al., which are incorporated by reference in their entireties. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Pat. No. 8,881,737 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0000638 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2014 / 0096782 [Patent Document 6] US Patent Application Publication No. 2015 / 0059780 [Patent Document 7] U.S. Pat. No. 5,388,594 [Patent Document 8] U.S. Pat. No. 8,079,371 Summary of the Invention [Problem to be solved by the invention]

[0004] However, it may be desirable to monitor conditions within the aerosol delivery device while the aerosol delivery device is in operation. Accordingly, improvements regarding sensors for aerosol delivery devices may be desirable. [Means for solving the problem]

[0005] The present disclosure relates to an aerosol delivery device configured to generate an aerosol, which in some embodiments may be referred to as an e-cigarette. In one aspect, an aerosol delivery device sensing system is provided. The aerosol delivery device sensing system may include an outer body. Further, the aerosol delivery device sensing system may include an atomizer that includes a heating element and is housed within the outer body. The aerosol delivery device sensing system may additionally include an infrared sensor. The infrared sensor may be configured to measure infrared radiation generated by the atomizer.

[0006] In some embodiments, the aerosol delivery device sensing system may further include a fiber optic cable having a first end positioned proximate to the infrared sensor and a second end positioned proximate to the atomizer. The infrared sensor may be configured to measure infrared radiation received from the atomizer via the fiber optic cable. The aerosol delivery device sensing system may additionally include a shielding device coupled to the infrared sensor and extending around a sensor opening defined by the infrared sensor. The first end of the fiber optic cable may be coupled to the shielding device. The shielding device may be substantially completely sealed when engaged with the first end of the fiber optic cable and the infrared sensor, thereby substantially preventing infrared radiation not passing through the fiber optic cable from entering the sensor opening. The fiber optic cable may include a shielding layer configured to substantially prevent infrared radiation from entering the fiber optic cable at locations other than the second end.

[0007] In some embodiments, the infrared sensor may be housed in the outer body. The delivery device sensing system may include the aerosol delivery device. The system is adapted to control the current supplied to the atomizer in response to a signal from the infrared sensor. The aerosol delivery device sensing system may further include a controller configured to The electronic components may be disposed within the cartridge. and a controller configured to removably engage the cartridge. When the cartridge is engaged with the control body, the power source may be in communication with the controller. The controller can receive signals from the infrared sensor via the electronic components. can.

[0008] In some embodiments, the infrared sensor may be located outside the outer body. The aerosol delivery device sensing system may include a temperature testing unit including an infrared sensor, and an aerosol delivery device including an outer body and an atomizer.

[0009] In a further aspect, a method of monitoring the temperature of an aerosol delivery device is provided. The method may include providing an outer body and an atomizer including a heating element. The atomizer may be housed in the outer body. The method may further include providing an infrared sensor. Additionally, the method may include measuring infrared radiation generated by the atomizer with the infrared sensor.

[0010] In some embodiments, the method may further include disposing a first end of the fiber optic cable proximate to an infrared sensor. The method may additionally include disposing a second end of the fiber optic cable proximate to the atomizer. Measuring the infrared radiation generated by the atomizer with the infrared sensor may include measuring infrared radiation received from the atomizer through the fiber optic cable.

[0011] In some embodiments, the method may further include coupling the shielding device to the sensor assembly such that the shielding device extends around a sensor opening defined by the infrared sensor. Additionally, the method may include coupling the shielding device to a first end of the fiber optic cable. Coupling the shielding device to the sensor assembly and the first end of the fiber optic cable may include nearly completely sealing the shielding device to substantially block infrared radiation not passing through the fiber optic cable from entering the sensor opening. Additionally, the method may include substantially blocking infrared radiation from entering the fiber optic cable at locations other than the second end, which has a shielding layer.

[0012] In some embodiments, the method may further include disposing an infrared sensor within the outer body. Measuring the infrared radiation generated by the atomizer with the infrared sensor may include controlling a current supplied to the atomizer in response to a signal from the infrared sensor. The method may additionally include providing a controller. Controlling a current supplied to the atomizer in response to a signal from the infrared sensor may include controlling a current supplied to the atomizer with the controller.

[0013] In some embodiments, the method may additionally include disposing an infrared sensor outside the outer body. Positioning the second end of the fiber optic cable proximate to the atomizer may include inserting the fiber optic cable into the outer body.

[0014] Thus, the present disclosure includes, without limitation, the following example implementations.

[0015] Exemplary implementation form 1: An aerosol delivery device sensing system comprising an outer body, an atomizer including a heating element and housed in the outer body, and an infrared sensor, the infrared sensor configured to measure infrared radiation generated by the atomizer.

[0016] Exemplary Implementation 2: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein the aerosol delivery device sensing system further includes a fiber optic cable having a first end positioned proximate to the infrared sensor and a second end positioned proximate to the atomizer, and the infrared sensor is configured to measure infrared light received from the atomizer via the fiber optic cable.

[0017] Exemplary Implementation 3: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein the aerosol delivery device sensing system further includes a shielding device coupled to the infrared sensor and extending around a sensor opening defined by the infrared sensor, and a first end of the optical fiber cable is coupled to the shielding device.

[0018] Exemplary implementation 4: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, in which the shielding device is almost completely sealed when engaged with the first end of the fiber optic cable and the infrared sensor, thereby substantially preventing infrared radiation that is not passing through the fiber optic cable from entering the sensor opening.

[0019] Exemplary Implementation 5: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein the fiber optic cable includes a shielding layer configured to substantially prevent infrared light from entering the fiber optic cable at locations other than the second end.

[0020] Exemplary implementation 6: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which the infrared sensor is housed in the outer body.

[0021] Exemplary Implementation 7: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein the aerosol delivery device sensing system includes an aerosol delivery device.

[0022] Exemplary implementation 8: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein the aerosol delivery device sensing system further includes a controller configured to control the current supplied to the atomizer in response to a signal from the infrared sensor.

[0023] Exemplary implementation 9: An aerosol delivery device sensing system includes an electronic component, an electrical source, and and wherein the electronic components are disposed within the cartridge, and the power supply and the controller is disposed within the control body configured to removably engage the cartridge, When the bridge engages the control body, the power source communicates with the controller, which in turn communicates with the electronic components. 10. The method of claim 1, further comprising: receiving a signal from an infrared sensor using the infrared sensor; An aerosol delivery device sensing system of any combination of the exemplary implementations of.

[0024] Exemplary implementation 10: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein the infrared sensor is positioned on the outside of the outer body.

[0025] Exemplary implementation 11: An aerosol delivery device sensing system of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, including a temperature testing unit including an infrared sensor and an aerosol delivery device including an outer body and an atomizer.

[0026] Exemplary implementation 12: A method for monitoring the temperature of an aerosol delivery device, comprising: providing an outer body and an atomizer including a heating element and housed within the outer body; providing an infrared sensor; and measuring infrared radiation generated by the atomizer using the infrared sensor.

[0027] Exemplary implementation 13: A method for monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, further comprising positioning a first end of the fiber optic cable in proximity to an infrared sensor and positioning a second end of the fiber optic cable in proximity to an atomizer, wherein measuring the infrared radiation generated by the atomizer using the infrared sensor comprises measuring the infrared radiation received from the atomizer via the fiber optic cable.

[0028] Exemplary implementation 14: A method for monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, further comprising coupling a shielding device to the sensor assembly such that the shielding device extends around a sensor opening defined by the infrared sensor, and coupling the shielding device to a first end of the optical fiber cable.

[0029] Exemplary implementation 15: A method of monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein coupling a shielding device to the sensor assembly and the first end of the fiber optic cable includes nearly completely sealing the shielding device to substantially prevent infrared radiation that is not passing through the fiber optic cable from entering the sensor opening.

[0030] Exemplary implementation 16: A method for monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, further comprising providing a shielding layer to substantially block infrared radiation from entering the optical fiber cable at locations other than the second end.

[0031] Exemplary implementation 17: A method for monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, further comprising disposing an infrared sensor within the outer body.

[0032] Exemplary implementation 18: A temperature monitoring method of an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein measuring infrared radiation generated by the atomizer using an infrared sensor includes controlling a current supplied to the atomizer in response to a signal from the infrared sensor.

[0033] Exemplary Implementation 19: A method for monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, further comprising providing a controller, and controlling the current supplied to the atomizer in response to a signal from the infrared sensor comprises controlling the current supplied to the atomizer by the controller.

[0034] Exemplary implementation 20: A method for monitoring the temperature of an aerosol delivery device of any of the exemplary implementations described above, or of any combination of any of the exemplary implementations described above, wherein the method for monitoring the temperature of the aerosol delivery device further includes positioning an infrared sensor on the outside of the outer body.

[0035] Exemplary implementation 21: A method for monitoring the temperature of an aerosol delivery device of any of the preceding exemplary implementations, or of any combination of any of the preceding exemplary implementations, wherein positioning the second end of the fiber optic cable in proximity to the atomizer includes inserting the fiber optic cable into the outer body.

[0036] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements described in the present disclosure, regardless of whether such features or elements are explicitly combined in a particular exemplary implementation described herein or whether they are otherwise recited. The present disclosure is intended to be read in its entirety such that any separable features or elements of the disclosure are deemed combinable, in any of its aspects and exemplary implementations, unless the context of the disclosure clearly dictates otherwise.

[0037] It will therefore be appreciated that this brief summary has been provided solely for the purpose of summarizing some exemplary implementations to provide a basic understanding of some aspects of the present disclosure. It will therefore be appreciated that the above exemplary implementations are merely examples and should not be construed in any way to narrow the scope or spirit of the present disclosure. Other exemplary implementations, aspects, and advantages will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of some described exemplary implementations.

[0038] Having thus described the present disclosure in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0039] [Figure 1] FIG. 1 is a side view of an aerosol delivery device including a cartridge and a regulator according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 illustrates the control body of FIG. 1 in an exploded configuration, according to an exemplary embodiment of the present disclosure. [Diagram 3] 2 illustrates the cartridge of FIG. 1 in an exploded configuration, according to an exemplary embodiment of the present disclosure. [Figure 4] 1 is a schematic diagram of an aerosol delivery device sensing system including an external infrared sensor according to an exemplary embodiment of the present disclosure. [Diagram 5] FIG. 1 is a schematic diagram of an aerosol delivery device sensing system including an external infrared sensor and a fiber optic cable according to an exemplary embodiment of the present disclosure. [Figure 6A] 6 is a cross-sectional view through the fiber optic cable of FIG. 5 according to an exemplary embodiment of the present disclosure. [Figure 6B] 6B is a cross-sectional view of an optical fiber of the fiber optic cable of FIG. 6A according to an exemplary embodiment of the present disclosure. [Figure 7] 1 is a schematic diagram of an aerosol delivery device sensing system including an external infrared sensor, a shielding device, and a fiber optic cable according to an exemplary embodiment of the present disclosure. [Figure 8] 1 is a schematic diagram of an aerosol delivery device sensing system including an internal infrared sensor according to an exemplary embodiment of the present disclosure. [Figure 9] 1 is a schematic diagram of an aerosol delivery device sensing system including an internal infrared sensor and a fiber optic cable according to an exemplary embodiment of the present disclosure. [Figure 10] 1 is a schematic diagram of a method for monitoring the temperature of an aerosol delivery device according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] The present disclosure is more fully described below with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein, but 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 variations unless the context clearly dictates otherwise.

[0041] This disclosure provides a description of an aerosol delivery device. The aerosol delivery device can use electrical energy to heat a material (preferably without burning the material to any significant degree) to form an inhalable substance, and such an article is most preferably compact enough to be considered a "handheld" device. The aerosol delivery device can provide some or all of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, flavor and flavor types, sensory effects, physical sensations, usage habits, visual cues such as those provided by a visible aerosol, etc.) without any substantial degree of burning of any component of the article or device. Most preferably, the aerosol delivery device does not generate smoke in the sense of an aerosol resulting from the by-products of tobacco combustion or pyrolysis, but rather, the article or device generates vapors (including vapors in an aerosol that can be considered visible, which may appear to be described as smoke-like) resulting from the volatilization or vaporization of certain components of the article or device, although in other embodiments the aerosol may be invisible. In highly preferred embodiments, the aerosol delivery device may incorporate tobacco and / or tobacco-derived components, and as such, the aerosol delivery device may be characterized as an electronic smoking article, such as an electronic cigarette or "e-cigarette."

[0042] Although the system is generally described herein with respect to embodiments relating to aerosol delivery devices, such as so-called "e-cigarettes," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of articles. For example, the description provided herein may be employed with traditional smoking article (e.g., cigarettes, cigars, pipes, etc.), heated tobacco, and related packaging embodiments of any of the products disclosed herein. Thus, the description of the features, components, features, and methods disclosed herein are described with respect to embodiments relating to aerosol delivery devices by way of example only, and may be embodied and used in a variety of other products and methods.

[0043] The aerosol delivery device of the present disclosure can also be characterized as being a vapor-generating article or a drug delivery article. Thus, such an article or device can be adapted to provide one or more substances (e.g., flavorings and / or medicament active ingredients) in an inhalable form or state. For example, the inhalable substance can be substantially in the form of a vapor (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible, and whether or not in a form that can be considered similar to smoke.

[0044] During use, the aerosol delivery device of the present disclosure may undergo many of the physical actions taken by an individual when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is utilized by lighting tobacco and inhaling the tobacco). For example, a user of the aerosol delivery device of the present disclosure may hold the article in a manner very similar to a traditional type of smoking article, draw on one end of the article for inhalation of the aerosol generated by the article, puff at selected time intervals, etc.

[0045] The aerosol delivery device of the present disclosure generally includes several components disposed within an outer shell or body. The overall design of the outer shell or body may vary, and the form or configuration of the outer body may vary, which may define the overall size and shape of the aerosol delivery device. Typically, the elongated body resembling the shape of a cigarette or cigar may be formed from a single, integral shell, or the elongated body may be formed of two or more separable sections. For example, the aerosol delivery device may include an elongated shell or body that may be substantially tubular in shape and may itself resemble the shape of a conventional cigarette or cigar. However, in other embodiments, various other shapes and configurations (e.g., rectangular or fob shaped) may be employed.

[0046] In one embodiment, all components of the aerosol delivery device are housed within one outer body or shell. Alternatively, the aerosol delivery device can include two or more shells that are joined and separable. For example, the aerosol delivery device can have a control body with a shell that houses one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the article) at one end, and a shell that includes a disposable portion (e.g., a disposable flavor-containing cartridge) removably attached thereto at the other end. More specific forms, configurations and arrangements of components within a single-shell type unit or within a multi-part separable shell type unit will be apparent in light of the further disclosure provided herein. Furthermore, the design and arrangement of components of various aerosol delivery devices can be understood by considering commercially available electronic aerosol delivery devices.

[0047] The aerosol delivery device of the present disclosure most preferably comprises: a power source (i.e., an electrical supply); at least one controller (e.g., a means for activating, controlling, regulating, and / or terminating electrical power to generate heat by controlling the flow of electrical current from the power source to other components of the aerosol delivery device); a heater or heat generating component (e.g., an electrical resistance heating element, or a component commonly referred to as part of an "atomizer"); a precursor composition (e.g., a liquid that can generate an aerosol upon application of sufficient heat, such as the components commonly referred to as "smoke juice," "e-liquid," and "e-juice"); a mouth area or tip that allows for utilization of the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the article through which generated aerosol can be drawn upon inhalation); has some combination of:

[0048] The arrangement of components within the aerosol delivery device of the present disclosure may vary. In certain embodiments, the aerosol precursor composition may be located near an end of the aerosol delivery device, such as configured to be located proximal to the mouth of the user, to maximize aerosol delivery to the user. However, other configurations are not excluded. In general, the heating element may be located close enough to the aerosol precursor composition such that heat from the heating element can volatilize the aerosol precursor (and one or more flavorants, agents, etc., that may also be provided for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, emitted, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are meant to mean that references to emit, emitting, emitting, or emitted are interchangeable to include forming or generating, forming or generating, forming or generating, or formed or generated. Specifically, inhalable substances are released in the form of vapors or aerosols, or mixtures thereof, and such terms are also used interchangeably herein, unless otherwise specified.

[0049] As mentioned above, the aerosol delivery device may incorporate a battery or other power source (e.g., a capacitor) to provide sufficient current to provide various functions to the aerosol delivery device, such as powering the heater, powering the control system, and powering the indicators. The power source may take various embodiments. Preferably, the power source is capable of delivering sufficient power to rapidly heat the heating element to form an aerosol and power the aerosol delivery device by use for a desired period of time. The power source is preferably sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Additionally, the preferred power source is lightweight enough so as not to impair the desired smoking experience.

[0050] More specific forms, configurations, and arrangements of components within the aerosol delivery device of the present disclosure will be apparent in light of the further disclosure provided below. Furthermore, the selection of components of various aerosol delivery devices can be understood in consideration of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device can also be understood in consideration of commercially available electronic aerosol delivery devices. Examples of commercial manufacturers and commercially available products whose components, their methods of operation, materials contained therein, and / or other attributes may be included in the device of the present disclosure are described in U.S. Patent Application No. 15 / 222,615, filed July 28, 2016, to Watson et al., which is incorporated herein by reference in its entirety.

[0051] One exemplary embodiment of an aerosol delivery device 100 is shown in FIG. 1. In particular, FIG. 1 shows the aerosol delivery device 100 including a control body 200 and a cartridge 300. The control body 200 and the cartridge 300 can be permanently or removably aligned in a functional relationship. Various mechanisms can connect the cartridge 300 to the control body 200 to provide threaded engagement, press-fit engagement, interference fit, magnetic engagement, and the like. In some embodiments, when the cartridge 300 and the control body 200 are in an assembled configuration, the aerosol delivery device 100 can be substantially rod-shaped, substantially tubular, or substantially cylindrical in shape. However, as mentioned above, other embodiments can employ various other configurations, such as a rectangular or fob shape. Additionally, although the aerosol delivery device is generally described herein as resembling the size and shape of a traditional smoking article, other embodiments may employ different configurations and larger volume reservoirs that can be referred to as "tanks."

[0052] In certain embodiments, one or both of the cartridge 300 and the controller 200 may be referred to as disposable or reusable. For example, the controller 200 may have replaceable or rechargeable batteries and / or capacitors and thus may be combined with any type of charging technology, including connection to a typical AC electrical outlet, connection to an automobile charger (i.e., cigarette lighter socket), connection to a computer, such as via a Universal Serial Bus (USB) cable, etc. Additionally, in some embodiments, the cartridge 300 may include a disposable cartridge as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0053] 2 shows an exploded view of a control 200 of the aerosol delivery device 100 (see FIG. 1) according to an exemplary embodiment of the present disclosure. As shown, the control 200 may include a coupler 202, an outer body 204, a sealing member 206, an adhesive member 208 (e.g., KAPTON® tape), a flow sensor 210 (e.g., a puff sensor or pressure switch), a controller 212, a spacer 214, an electrical supply 216 (e.g., a capacitor and / or a battery that may be rechargeable), a circuit board having an indicator 218 (e.g., a light emitting diode (LED)), a connector circuit 220, and an end cap 222. An example of a power source is described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0054] With respect to the flow sensor 210, representative current regulation components and other current control components including various microcontrollers, sensors, and switches for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. See also the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0055] In one embodiment, the indicator 218 may include one or more light emitting diodes. The indicator 218 may be in communication with the controller 212 via the connector circuit 220 and may be illuminated while a user is drawing on a cartridge coupled to the coupler 202, for example, as detected by the flow sensor 210. The end cap 222 may be configured to make the illumination provided thereunder by the indicator 218 visible. Thus, the indicator 218 may be illuminated during use of the aerosol delivery device 100 to mimic the lighting end of a smoking article. However, in other embodiments, the indicators 218 may be provided in various numbers, may take different shapes, or may even be openings in the outer body (such as for the emission of sound when such an indicator is present).

[0056] Additional components may still be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses a smoking article indicator; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouthpiece of a device to detect a user's lip motion associated with taking a puff and then trigger heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy to a heating load array in response to a pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes a recognition device that detects non-uniformity in infrared transmittance of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes a defined viable power cycle having multiple differential phases; and U.S. Pat. No. 5,934,289 to Counts et al. discloses photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for varying the resistance of draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and WO 2010 / 003480 to Flick discloses a fluid flow sensing system to indicate puffs in an aerosol generation system, all of the foregoing disclosures are incorporated herein by reference in their entireties.Further exemplary components that disclose materials or components related to electronic aerosol delivery articles and that may be used herein include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 8,156,944 and No. 8,375,957 to Hon, U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Pat. ... US Patent Publication Nos. 2006 / 0196518 and 2009 / 0188490, U.S. Patent Publication No. 2010 / 0024834 to Oglesby et al., U.S. Patent Publication No. 2010 / 0307518 to Wang, WO 2010 / 091593 to Hon, and WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Various materials disclosed by the aforementioned documents can be incorporated into the device in various embodiments, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0057] 3 illustrates a cartridge 300 of the aerosol delivery device 100 (see FIG. 1) in an exploded configuration. As illustrated, the cartridge 300 can include a base 302, electronic component terminals 304, electronic components 306, such as a printed circuit board (PCB), a flow director 308, an atomizer 310, a reservoir 312 (e.g., a reservoir base), an outer body 314, a mouthpiece 316, a label 318, and first and second heating terminals 320, 321, according to an exemplary embodiment of the present disclosure.

[0058] In some embodiments, the first and second heating terminals 320, 321 may be embedded in or otherwise coupled to the flow director 308. For example, the first and second heating terminals 320, 321 may be insert molded into the flow director 308. Thus, the flow director 308 and the first and second heating terminals are collectively referred to herein as a flow director assembly 322. Additional description of the first and second heating terminals 320, 321 and the flow director 308 is provided in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., which is incorporated herein by reference in its entirety.

[0059] The atomizer 310 can include a liquid transport element 324 and a heating element 326. The cartridge may additionally include a base shipping plug fitted to the base and / or a mouthpiece shipping plug fitted to the mouthpiece to protect the base and mouthpiece and prevent contaminants from being introduced therein prior to use, as disclosed, for example, in U.S. Patent No. 9,220,302 to Depiano et al., which is incorporated herein by reference in its entirety.

[0060] The base 302 is coupled to a first end of the outer body 314, and the mouthpiece 316 is coupled to an opposite second end of the outer body to substantially or completely enclose other components of the cartridge 300 therein. For example, the electronics terminals 304, the electronics 306, the flow director 308, the atomizer 310, and the reservoir 312 may be substantially or completely retained within the outer body 314. A label 318 may at least partially surround the outer body 314, and optionally the base 302, and may include information thereon, such as a product identifier. The base 302 may be configured to engage with the coupler 202 (see, e.g., FIG. 2) of the control body 200. In some embodiments, the base 302 may include an anti-rotation mechanism that substantially prevents relative rotation between the cartridge and the control body, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0061] Reservoir 312 may be configured to hold an aerosol precursor composition. Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat. No. 8,881,737 to Collett et al., and U.S. Pat. No. 9,254,002 to Chong et al., U.S. Patent Application Publication No. 2013 / 0008457 to Zheng 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 can be used include the aerosol precursors incorporated in the VUSE® products by RJ Reynolds Vapor Company, the BLU products by Lorillard Technologies, the MISTIC MENTHOL products by Mistic Ecigs, and the VYPE products by CN Creative Ltd. Also desirable is the so-called "smoke juice" for electronic cigarettes available from Johnson Creek Enterprises LLC. Embodiments of effervescent materials can be used with aerosol precursors, as described, for example, in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which is incorporated herein by reference.Further, the use of foamable materials is described in, for example, U.S. Pat. No. 4,639,368 to Niazi et al., U.S. Pat. No. 5,178,878 to Wehling et al., U.S. Pat. No. 5,223,264 to Wehling et al., U.S. Pat. No. 6,974,590 to Pather et al., U.S. Pat. No. 7,381,667 to Bergquist et al., U.S. Pat. No. 8,424,541 to Crawford et al., U.S. Pat. No. 8,627,828 to Strickland et al., and U.S. Pat. No. 9,307,787 to Sun et al., as well as U.S. Patent Application Publication No. 2010 / 0018539 to Brinkley et al., and PCT Publication No. WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference. Further description of embodiments of the aerosol precursor compositions, including additional description of tobacco or components extracted from tobacco contained therein, are provided in U.S. Patent Application Nos. 15 / 216,582 and 15 / 216,590, each to Davis et al., filed July 21, 2016, which are incorporated by reference in their entireties herein.

[0062] As shown in FIG. 3, the reservoir 312 may include multiple layers of non-woven fibers formed in the shape of a tube that surrounds the interior of the outer body 314 of the cartridge 300. Thus, for example, the liquid component may be sorptively retained by the reservoir 312. The reservoir 312 is in fluid communication with a liquid transport element 324. Thus, the liquid transport element 324 may be configured to transport the liquid from the reservoir 312 to the heating element 326 via capillary action or other liquid transport mechanisms. In further embodiments, the reservoir 312 may be in the form of a container formed with walls that are substantially impermeable to the e-liquid. See, for example, a container such as those described in U.S. Patent Application Publication No. 2015 / 0144145 to Chang et al., which is incorporated herein by reference in its entirety. In other embodiments, the cartridge 300 may be substantially replaced by a tank-type component, in which case the e-liquid may be stored in an annular space between the outer wall of the tank and an inner flow tube that runs through the tank. Exemplary devices are described in U.S. Patent Application Serial No. 15 / 202,947, filed July 6, 2016, which is incorporated by reference in its entirety.

[0063] As shown in FIG. 3, the liquid transport element 324 may be in direct contact with the heating element 326. As further shown in FIG. 3, the heating element 326 may have a wire defining multiple coils wound around the liquid transport element 324. In some embodiments, the heating element 326 may be formed by winding a wire around the liquid transport element 324, as described in U.S. Pat. No. 9,210,738 to Ward et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the wire may define a variable coil spacing, as described in U.S. Pat. No. 9,277,770 to DePiano et al., which is incorporated herein by reference in its entirety. Various embodiments of materials configured to generate heat when an electric current is applied therethrough may be employed to form the heating element 326. Examples of materials from which the wire coil can be formed include Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum doped molybdenum disilicide (Mo(Si,Al)2), graphite and graphite based materials, and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0064] However, various other embodiments of methods can be used to form the heating element 326, and various other embodiments of heating elements may be used within the atomizer 310. For example, stamped heating elements may be used in the atomizer, as described in U.S. Patent Application Publication No. 2014 / 0270729 to DePiano et al., which is incorporated herein by reference in its entirety. In addition to the above, additional exemplary heating elements and materials for use therein can be found in U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 ... Sprinkel et al., and U.S. Patent No. 5,311,623 to DePiano et al. No. 5,228,460 to Jr, U.S. Patent No. 5,322,075 to Deevi et al., U.S. Patent No. 5,353,813 to Deevi et al., U.S. Patent No. 5,468,936 to Deevi et al., U.S. Patent No. 5,498,850 to Das et al., U.S. Patent No. 5,659,656 to Das et al., U.S. Patent No. 5,498,855 to Deevi et al., U.S. Patent No. 5,530,225 to Hajaligol, U.S. Patent No. 5,665,262 to Hajaligol, U.S. Patent No. 5,573,692 to Das et al., and U.S. Patent No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties. Additionally, in other embodiments, chemical heating may be employed. Various additional examples of heaters and materials used to form the heaters are described in U.S. Pat. No. 8,881,737 to Collett et al., as noted above, which is incorporated herein by reference in its entirety.

[0065] A variety of heater components can be used in the aerosol delivery device. In various embodiments, one or more microheaters or similar solid-state heaters can be used. Microheaters suitable for use in the presently disclosed device, and atomizers incorporating microheaters, are described in U.S. Patent No. 8,881,737 to Collett et al., which is incorporated herein by reference in its entirety.

[0066] The first heating terminal 320 and the second heating terminal 321 (e.g., a negative heating terminal and a positive heating terminal) are configured to engage opposing ends of the heating element 326 and form an electrical connection therewith when the cartridge 300 is connected to the controller 200 (e.g., see FIG. 2). Furthermore, when the controller 200 is coupled to the cartridge 300, the electronics 306 can form an electrical connection with the controller via the electronics terminals 304. The controller 200 can thus use the controller 212 (see FIG. 2) to determine whether the cartridge 300 is genuine, to control the direction of current to the cartridge 300, and / or to perform other functions. Additionally, various examples of electronics and functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference in its entirety.

[0067] During use, a user can suck on the mouthpiece 316 of the cartridge 300 of the aerosol delivery device 100 (see FIG. 1). This can draw air through an opening in the control body 200 (see, e.g., FIG. 2) or the cartridge 300. For example, in one embodiment, an opening can be defined between the coupler 202 and the outer body 204 (see, e.g., FIG. 2) of the control body 200, as described in U.S. Pat. No. 9,220,302 to DePiano et al., which is incorporated herein by reference in its entirety. However, in other embodiments, the flow of air can be received through other portions of the aerosol delivery device 100. As described above, in some embodiments, the cartridge 300 can include a flow director 308. The flow director 308 can be configured to direct the flow of air received from the control body 200 to the heating element 326 of the atomizer 310.

[0068] A sensor in the aerosol delivery device 100 (e.g., flow sensor 210 in the controller 200, see FIG. 2) can sense the puff. When the puff is sensed, the controller 200 can pass a current through a circuit including a first heating terminal 320 and a second heating terminal 321 to a heating element 326. The heating element 326 can thus vaporize the aerosol precursor composition directed from the reservoir 312 to the aerosolization zone by the liquid transport element 324. The mouthpiece 326 can thus permit the passage of air and entrained vapor (i.e., components of the aerosol precursor composition in an inhalable form) from the cartridge 300 to a consumer inhaling thereon.

[0069] Various other details regarding components that may be included in cartridge 300 are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., which is incorporated herein by reference in its entirety. Additional components that may be included in cartridge 300 and details regarding same are provided, for example, in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., which is incorporated herein by reference in its entirety.

[0070] The various components of the aerosol delivery device according to the present disclosure can be selected from those described and commercially available in the art, see, for example, the reservoir and heater system for controllable delivery of a wide variety of aerosolizable materials in electronic smoking articles disclosed in U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0071] In another embodiment, the cartridge can be formed substantially entirely from one or more carbon materials, which can provide the advantages of being biodegradable and wire-free. In this regard, the heating element can include carbon foam, the reservoir can include a carbonized fabric, and graphite can be employed to form electrical connections with the power source and controller. Exemplary embodiments of carbon-based cartridges are provided in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., which is incorporated herein by reference in its entirety.

[0072] Thus, as described above, the aerosol delivery device 100 (see FIG. 1) can use the atomizer 310 to generate heat to atomize the aerosol precursor composition held in the reservoir 312. As further explained above, the controller 212 (see FIG. 2) can control the flow of electrical current from the electrical source 216 (see FIG. 2) to the atomizer 310 in response to a signal from the flow sensor 210 (see FIG. 2) that is indicative of draw in the aerosol delivery device. However, during development of the aerosol delivery device and / or during its normal use, it may be desirable to monitor conditions within the aerosol delivery device 100 in other ways.

[0073] In this regard, Figure 4 illustrates an aerosol delivery device sensing system 400 according to an exemplary embodiment of the present disclosure. As illustrated, the aerosol delivery device sensing system 400 may include an aerosol delivery device, such as the aerosol delivery device 100 described above, or may include a portion thereof, such as only a cartridge 300. As shown diagrammatically, the cartridge 300 of the aerosol delivery device 100 may include an atomizer 310 housed within an outer body 314. Thus, by way of example, the atomizer 310 may include a heating element 326 and a liquid transport element 324 (see Figure 3).

[0074] Additionally, the aerosol delivery device sensing system 400 may include a temperature testing unit 402. The temperature testing unit 402 may include an infrared sensor 404. The infrared sensor 404 may be configured to measure infrared radiation. Thereby, for example, the infrared sensor 404 may be configured to measure infrared radiation generated by the atomizer 310. An exemplary embodiment of an infrared sensor is disclosed in U.S. Pat. No. 5,169,234 to Bohm et al., which is incorporated herein by reference in its entirety. Additionally, infrared sensors are commercially available from RAYTEK, Inc., Santa Cruz, Calif., OMEGA ENGINEERING, Norwalk, Conn., and MICRO-EPSILON MESSTECHNIK GmbH&Co.KG, Ortenburg, Germany.

[0075] As can be appreciated, the infrared radiation detected by the infrared sensor 404 may be received directly from the atomizer 310, or may be received indirectly from the atomizer via other components of the aerosol delivery device 100 that are heated by the atomizer. Thus, the infrared sensor 404 may be configured as desired to or otherwise aim to receive infrared radiation from one or more components of the aerosol delivery device 100.

[0076] In this regard, the infrared sensor 404 can define a sensor aperture 406. The sensor aperture 406 can thereby be directed toward a component from which it is desired to measure infrared radiation emitted therefrom. For example, in the illustrated embodiment, the sensor aperture 406 is directed toward the atomizer 310. The infrared sensor 404 can thereby detect infrared radiation received directly from the atomizer 310. Furthermore, in some embodiments, the infrared sensor can be specifically directed toward a component of the atomizer 310, such as the heating element 326 or the liquid transport element 324 (see FIG. 3), to determine how much heat is being emitted from that particular portion of the atomizer. Alternatively, as noted above, the infrared sensor 404 can be directed toward one or more other components of the aerosol delivery device 100 that can be heated by the atomizer 310.

[0077] In embodiments in which the infrared sensor 404 is disposed outside (i.e., partially outside or completely outside) the aerosol delivery device 100 to detect infrared radiation emitted from components within the outer body of the aerosol delivery device 100 (e.g., within the outer body 314 of the cartridge 300), the infrared sensor can sense infrared radiation emitted through an opening defined in the aerosol delivery device. In some embodiments, the aerosol delivery device 100 may include one or more pre-existing openings that align with one or more of its internal components. For example, the mouthpiece 316 may include a through hole 316A that may align with some of the internal components of the aerosol delivery device. However, other components may not directly align with pre-existing openings in the aerosol delivery device 100. Thus, it may be necessary to form an opening in the aerosol delivery device 100 to provide access to one or more components from which it is desired to sense infrared radiation emitted therefrom. For example, an opening 314A may be formed (e.g., drilled) in the outer body 314 of the cartridge 300 as shown.

[0078] Thus, the infrared sensor 404 can detect the infrared radiation emitted through an aperture, such as aperture 314A. A signal generated by the infrared sensor 404 can thereby correspond to the received infrared radiation. In some embodiments, the temperature testing unit 402 can further include a controller 408. The controller 408 can be configured to receive a signal from the infrared sensor 404 corresponding to the infrared radiation received from one or more components of the aerosol delivery device 100, which the controller can then convert into a temperature reading. Thus, the temperature of one or more components of the aerosol delivery device 100 can be monitored and / or recorded such that operating parameters of the aerosol delivery device can be adjusted and / or the components can be designed or redesigned to accommodate the temperature conditions.

[0079] However, infrared radiation may follow a nearly straight path. In this regard, infrared radiation radiates from a given source. Thus, it may be difficult or impossible to receive infrared radiation from some components within the aerosol delivery device 100 that are located remotely therein and / or surrounded by other components. Furthermore, in some embodiments, the outer body 314 may define a tubular configuration, the ends of which may be sealed to some extent by the mouthpiece 316 and the base 302. Thus, direct access to most internal components of the aerosol delivery device 100 may require modifying the aerosol delivery device, such as by drilling holes in the outer body and / or otherwise disassembling and / or modifying components. Furthermore, as a result of the modifications required for testing, the infrared radiation monitored under test conditions may not reflect the actual use conditions associated with the aerosol delivery device. Furthermore, as discussed above, it may not be possible to provide a direct, clear path between the infrared sensor 404 and each component of the aerosol delivery device 100, such that infrared radiation emanating therefrom is not received through the sensor aperture 406, thereby preventing the infrared radiation from monitoring infrared radiation emitted from each component of the aerosol delivery device 100. Therefore, it may be desirable to provide the aerosol delivery device sensing system with additional functionality configured to address the above-noted problems with the "line of sight" sensing capabilities of the infrared sensor.

[0080] In this regard, Figure 5 illustrates an embodiment of an aerosol delivery device sensing system 400' substantially similar to the aerosol delivery device sensing system of Figure 4. However, the aerosol delivery device sensing system 400' further includes a fiber optic cable 410. The fiber optic cable 410 may extend between a first end 410A and a second end 410B. The first end 410A of the fiber optic cable 410 may be positioned proximate the infrared sensor 404, and the second end 410B of the fiber optic cable 410 may be positioned proximate a component of the aerosol delivery device 100 from which it is desired to measure infrared radiation. The infrared radiation may enter the fiber optic cable 410 at the second end 410B and travel therethrough to the infrared sensor 404 with substantially no loss. Although the fiber optic cable 410 is shown extending through a through hole 316A defined in the mouthpiece 316, the fiber optic cable 410 may not completely block the through hole so as not to impede the flow of aerosol therethrough, or the fiber optic cable may extend through a different opening.

[0081] In this regard, as shown in FIG. 6A, the fiber optic cable 410 may include one or more optical fibers 412. Each optical fiber 412 may include a core 412A and a cladding layer 412B, as shown in FIG. 6B. Total internal reflection may occur within each optical fiber 412 due to the difference in refractive index between the core and the cladding layer, so that little loss of infrared radiation occurs therefrom, as described above. Furthermore, in some embodiments, the fiber optic cable 410 may further include a shielding layer 414 configured to substantially prevent infrared radiation from entering the fiber optic cable at any location other than the second end 410B (see FIG. 5). Thereby, the infrared sensor 404 (see FIG. 5) may receive approximately the same amount of infrared radiation as if the infrared sensor were placed directly adjacent to the component without the use of the fiber optic cable 410 to ensure an accurate reading thereof.

[0082] In the embodiment of the aerosol delivery device sensing system 400′ shown in FIG. 5, the first end 410A of the fiber optic cable 410 directly engages the sensor opening 406 of the infrared sensor 404. However, as shown in FIG. 7, in other embodiments, the temperature testing unit 402 of the aerosol delivery device sensing system 400″ may further include a shielding device 416. The shielding device 416 may be coupled to the infrared sensor 404. In this regard, the shielding device 416 may extend around the sensor opening 406 defined by the infrared sensor 404. Furthermore, the first end 410A of the fiber optic cable 410 may be coupled to the shielding device 416. The shielding device 416 may be substantially completely sealed when the shielding device 416 engages the first end 410A of the fiber optic cable 410 and the infrared sensor 404 to substantially prevent infrared light that has not passed through the fiber optic cable from entering the sensor opening 406. Thus, the shielding devices 416 can be used to convert an infrared sensor 404 not configured for use with a fiber optic cable 410 for use therewith. Additionally, the shielding devices 416 may be used to allow the infrared sensor 404 to be used with a variety of fiber optic cables 410 having different sizes and / or shapes by providing each shielding device with an appropriately sized opening configured to receive the first end 410A of an optical cable fiber. Thus, the shielding devices 416 may be characterized as being a particular size and / or shape adapter.

[0083] Thus, the infrared sensor 404 can be used to detect infrared radiation emitted from one or more components of the aerosol delivery device 100. As described above, the infrared sensor 404 may be configured to receive the infrared radiation directly, but in other embodiments, the fiber optic cable 410 may be used to receive the infrared radiation and direct the infrared radiation to the infrared sensor. The use of the fiber optic cable 410 may provide an advantage in that it allows access to various components within the aerosol delivery device 100 that may not otherwise be accessible or may only be accessible through modifications of the aerosol delivery device. The modifications of the aerosol delivery device described above may be irreversible and may affect sensor readings and / or may prevent testing of other components. Additionally, the use of the fiber optic cable 410 may allow for precise control over the target at which the infrared radiation is received. In this regard, to provide an accurate reading, the fiber optic cable 410 may be specifically aimed at a single component or portion thereof by placing its second end 410B in close proximity to the component, so that the radiation received by the infrared sensor 404 will be substantially emitted only from that one component or portion thereof. In contrast, using the infrared sensor 404 without the fiber optic cable 410 may allow for the reception of some infrared radiation from other components or sources that may affect the accuracy of the reading provided by the infrared sensor. However, if it is desired to obtain a temperature measurement of a larger area (e.g., an area surrounding the atomizer) rather than a specific point, in some embodiments the fiber optic cable 410 and / or the infrared sensor 404 may be configured to receive infrared radiation from such a larger area, for example, by using a lens. In this regard, as an example, it may be useful to know the temperature of the area surrounding the atomizer, which may define a peak temperature that is significantly lower than the peak temperature of the atomizer to allow for rapid heating and cooling of the atomizer.In this regard, conditions in this area around the atomizer may be monitored to ensure that the temperature remains below a desired safe threshold.

[0084] This may allow infrared radiation to be received from one or more components such that, for example, the temperature of the components may be determined by the controller 408. For example, as shown in FIG. 4, the sensor aperture 406 may be directed toward the atomizer 410, or as shown in FIGS. 5 and 7, the second end 410B of the fiber optic cable 410 may be positioned proximate the atomizer 310 to detect infrared radiation emitted from the atomizer. This allows the infrared sensor 404 to measure infrared radiation received from the atomizer 310. In this regard, it may be desirable to obtain and record information regarding the temperature of the atomizer 310 during operation so that the operation of the atomizer may be improved. For example, insufficient heating of the atomizer 310 may result in less aerosol being produced than desired. Conversely, excessive heat generation in the atomizer 310 may consume electrical current and thereby deplete the electrical supply 216 (see FIG. 2) unnecessarily quickly. Furthermore, excessive heat generation can damage components of the aerosol delivery device 100 and / or cause other problems. Additionally, the rate at which the atomizer 310 heats and cools may be monitored to ensure that aerosol is generated for the desired duration for each puff. Furthermore, too much heat can degrade the aerosol precursor composition and / or the generated aerosol and / or adversely affect its flavor. Thus, monitoring the atomizer 310 may be employed to ensure that it generates the desired amount of heat and heats / cools at the desired rate.

[0085] Thus, as described above, the infrared sensor 404 can be included in the temperature test unit 402 as an external device separate from the aerosol delivery device 100 that can be used to analyze its operation. Thus, the temperature test unit 402 can be used to analyze the operation of the aerosol delivery device 100 for purposes such as research and development, and quality control of manufactured aerosol delivery devices. Thereby, for example, the controller 212 (see FIG. 2) can be programmed according to a heating profile configured to generate a desired amount of heat in the atomizer 310 based on infrared radiation received by the infrared sensor during testing. However, variations in the individual components of the aerosol delivery device, ambient conditions, the amount of residual charge in the electrical supply 216 (see FIG. 2), and / or various other factors may cause the actual heat generated by the atomizer 310 to differ from the heat monitored in a laboratory environment.

[0086] 8 thus illustrates an aerosol delivery device sensing system 500 according to an additional embodiment of the present disclosure. As shown, in one embodiment, the aerosol delivery device sensing system 500 can include an aerosol delivery device, which can include some or all of the components of the aerosol delivery device 100 described above. For example, the aerosol delivery device sensing system 500 can include a cartridge 300 and a control 200. As shown, the control 200 can include a controller 212 and an electrical supply 216. The cartridge 300 can include an atomizer 310 housed within an outer body 314.

[0087] Additionally, the cartridge 300 may include an infrared sensor 404 housed within the outer body 314. This allows the infrared sensor to measure infrared radiation received from components within the aerosol delivery device sensing system 500. For example, the infrared sensor 404 may be configured to measure infrared radiation from components within the cartridge 300. As a further example, the infrared sensor 404 may be configured to measure infrared radiation generated by and received therefrom the atomizer 310.

[0088] 8, in some embodiments, the infrared sensor 404 may be positioned such that the sensor opening 406 directly faces the component from which it is desired to measure the infrared radiation emitted therefrom, such as the atomizer 310. However, in other embodiments, the configuration of components within the cartridge 300 may not allow the sensor opening 406 to directly face the component from which it is desired to measure the infrared radiation emitted therefrom.

[0089] 9 shows an embodiment of an aerosol delivery device sensing system 500' in which additional components of the cartridge 300, specifically the reservoir 312 in the illustrated embodiment, are disposed between the infrared sensor 404 and the atomizer 310. As a result, the sensor opening 406 may not directly face the atomizer 310 to receive infrared radiation from the atomizer 310. However, the aerosol delivery device sensing system 500' may further include a fiber optic cable 410. As a result, a first end 410A of the fiber optic cable may be positioned proximate the infrared sensor 404 and a second end 410B may be positioned proximate the atomizer 310. As such, the fiber optic cable 410 may be appropriately positioned such that the second end 410B faces a component from which detection of infrared radiation emitted therefrom is desired. In this regard, the flexibility and relatively small cross-sectional dimensions of the fiber optic cable 410 may enable sensing by the infrared sensor 404 of some or all of the components of the cartridge 300, regardless of their relative placement within the outer body 314. In one embodiment, the fiber optic cable 410 may define a diameter of about 0.25 mm to about 10 mm.

[0090] Regardless of whether the sensor opening 406 faces the atomizer 310 directly or whether the infrared radiation is directed to the infrared sensor 404 via the fiber optic cable 410, the information received from the infrared sensor can be used to control the operation of the atomizer 310. In this regard, the controller 212 can receive a signal from the infrared sensor 404 corresponding to the received infrared radiation. The signal may be received by the controller 212 directly from the infrared sensor 404 or via the electronics 306. Providing a signal from the infrared sensor 404 to the controller 212 via the electronics 306 can simplify the connection between the cartridge 300 and the control body 200 by not requiring the use of an additional connector. In this regard, the signal may be transmitted via the electronics terminals 304 (see FIG. 3).

[0091] This allows the controller 212 to control the supply of electrical current from the electrical supply 216 to the atomizer 310 in response to a signal from the infrared sensor 404. For example, the controller 212 can increase or decrease the supply of electrical current to the atomizer 310 in response to a signal from the infrared sensor 404. As a further example, the supply of electrical current to the atomizer can be decreased or stopped if the signal from the infrared sensor 404 corresponds to the atomizer 310 emitting a predetermined amount of infrared radiation, which corresponds to the atomizer reaching a predetermined temperature.

[0092] This avoids problems with under- or over-supplying current to the atomizer 310. In this regard, the supply of current to the atomizer 310 can be adjusted substantially in real time in response to a signal from the infrared sensor 404. Thus, the supply of current to the atomizer 310 can be adjusted substantially in real time as a function of the temperature of the atomizer, taking into account a signal from the infrared sensor 404 corresponding to the temperature of the atomizer.

[0093] Note that in the embodiment of the aerosol delivery device sensing system 500' shown in Figure 9, the fiber optic cable 410 directly engages the sensor aperture 406. However, as can be appreciated, in other embodiments, a shielding device may engage both the infrared sensor and the fiber optic cable, as described above with respect to Figure 7.

[0094] In a further embodiment, a method for vapor generation using an aerosol delivery device is provided. As shown in FIG. 10, the method may include providing an outer body and an atomizer including a heating element in step 602. The atomizer may be housed in the outer body. Furthermore, the method may include providing an infrared sensor in step 604. Furthermore, the method may include measuring infrared radiation generated by the atomizer with the infrared sensor in step 606.

[0095] The method may further include positioning a first end of the fiber optic cable proximate to the infrared sensor. Additionally, the method may include positioning a second end of the fiber optic cable proximate to the atomizer. In step 606, measuring the infrared radiation generated by the atomizer with the infrared sensor may include measuring infrared radiation received from the atomizer via the fiber optic cable.

[0096] The method may further include coupling the shielding device to the sensor assembly such that the shielding device extends around a sensor opening defined by the infrared sensor. Additionally, the method may include coupling the shielding device to a first end of the fiber optic cable. Coupling the shielding device to the sensor assembly and the first end of the fiber optic cable may include nearly completely sealing the shielding device to substantially block infrared radiation not passing through the fiber optic cable from entering the sensor opening.

[0097] The method may further include substantially preventing infrared radiation from entering the fiber optic cable at locations other than the second end with a shielding layer. The method may further include disposing an infrared sensor within the outer body. In step 606, measuring the infrared radiation generated by the atomizer with the infrared sensor may include controlling a current provided to the atomizer in response to a signal from the infrared sensor.

[0098] The method may further include providing a controller. Controlling the current supplied to the atomizer in response to a signal from the infrared sensor may include controlling the current supplied to the atomizer with the controller. The method may further include disposing the infrared sensor outside the outer body. Additionally, positioning the second end of the fiber optic cable proximate to the atomizer may include inserting the fiber optic cable into the outer body.

[0099] As mentioned above, infrared radiation emitted from a component of the aerosol delivery device may be detected by an infrared sensor, which may be inside or outside the aerosol delivery device, respectively, for control or testing purposes. Such a component from which emitted radiation is sensed may be inside the external body of the aerosol delivery device. It should be understood from the present disclosure that references to components as being within the outer body of the cartridge or the control body of the aerosol delivery device are for illustrative purposes only. In other embodiments, the aerosol delivery device may include a single outer body. Thus, generally speaking, an infrared sensor may sense infrared radiation received from a component within the external body of the delivery device.

[0100] The present disclosure generally describes measuring infrared radiation emitted from the atomizer, not from other components of the aerosol delivery device heated by the atomizer. In other words, the present disclosure generally describes measuring infrared radiation emitted directly by the atomizer. In some embodiments, the infrared sensor may be configured to receive infrared radiation from a portion of the atomizer, such as a heating element or a liquid transport element, by specifically aiming the infrared sensor or fiber optic cable at such a portion. Measuring infrared radiation emitted from a liquid transport element can provide a more accurate reading regarding the temperature conditions experienced by the aerosol precursor composition, while measuring infrared radiation emitted from a heating element can provide information regarding which is the overall hottest component in the aerosol delivery device, so as not to exceed its desired maximum temperature.

[0101] However, in other embodiments, infrared radiation emitted by any of the other components of the aerosol delivery device may be measured by the infrared sensor. This can, for example, ensure that the operation of the aerosol delivery device does not exceed a temperature threshold for one or more components that may be damaged. As a further example, the infrared sensor may detect the temperature of an externally accessible component of the aerosol delivery device (e.g., the external body of the cartridge) to limit the temperature of components of the aerosol delivery device that a user may touch.

[0102] Although the embodiments of the present disclosure generally describe the fiber optic cable as defining a circular cross-section, in other embodiments, the fiber optic cable may define a cross-section having a different shape, such as a rectangle. In this regard, the cross-section of the fiber optic cable may be specifically tailored to match an orifice or space within the aerosol delivery device having an alternative shape. In another embodiment, multiple infrared sensors may be used to simultaneously measure infrared radiation received from multiple locations on the aerosol delivery device and / or on its components. In this regard, each infrared sensor may target a different component or different parts of a component. As can be appreciated, in some embodiments, one or more of the multiple infrared sensors may be engaged with the fiber optic cable to receive infrared radiation from a location where it may be difficult to directly measure radiation emanating therefrom. Thus, multiple fiber optic cables may be used in some embodiments where each fiber optic cable terminates at a different infrared sensor and at a different location within the aerosol delivery device, or multiple fiber optic cables may be connected to a single infrared sensor.

[0103] Although the present disclosure generally relates to using the systems disclosed herein to measure infrared radiation emitted from components of an aerosol delivery device, in other embodiments, the systems disclosed herein may be used to measure infrared radiation emitted from any other device. In this regard, the use of fiber optic cables may be particularly advantageous in any device where tight tolerances and / or a substantially unbroken outer body preclude direct access to components therein.

[0104] Many modifications and other aspects of the present disclosure will come to mind to those skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. It is therefore to be understood that the present disclosure should not be limited to the specific aspects disclosed herein, and that modifications and other aspects 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. An outer body; a heating element housed in the outer body and powered by a power source; an infrared sensor configured to measure infrared radiation generated by a component within the outer body, the component being a heating element powered by a power source; and a fiber optic cable having a first end positioned proximate to the infrared sensor and a second end positioned proximate to a component within the outer body that generates the infrared radiation; Equipped with An aerosol delivery device sensing system, wherein the infrared sensor is configured to measure infrared radiation received from a component within the outer body that generates the infrared radiation via the fiber optic cable.

2. a shielding device coupled to the infrared sensor and extending around a sensor opening defined by the infrared sensor; The aerosol delivery device sensing system of claim 1 , wherein a first end of the fiber optic cable is coupled to the shielding device.

3. The aerosol delivery device sensing system of claim 2, wherein the shielding device is almost completely sealed when engaged with the first end of the fiber optic cable and the infrared sensor, thereby substantially preventing infrared light that is not passing through the fiber optic cable from entering the sensor opening.

4. The aerosol delivery device sensing system of claim 3 , wherein the fiber optic cable includes a shielding layer configured to substantially prevent infrared light from entering the fiber optic cable at locations other than the second end.

5. The aerosol delivery device sensing system of claim 1 , wherein the infrared sensor is housed within the outer body.

6. The aerosol delivery device sensing system of claim 1 , further comprising a controller programmed with a heating profile configured to cause the heating element to generate a heat quantity based on infrared radiation measured by the infrared sensor.

7. The aerosol delivery device sensing system of claim 1 , wherein the infrared sensor is disposed on the outside of the outer body.

8. 10. The aerosol delivery device sensing system of claim 1, comprising a temperature testing unit including an infrared sensor and an aerosol delivery device including an outer body and a heating element.

9. providing an outer body and a heating element housed within the outer body and powered by a power source; Providing an infrared sensor; positioning a first end of a fiber optic cable proximate to an infrared sensor; positioning a second end of the fiber optic cable proximate to a component within the outer body that generates infrared radiation, the component being a heating element powered by a power source; measuring infrared radiation generated by components within the outer body with an infrared sensor; Including, A method for monitoring the temperature of an aerosol delivery device, wherein infrared light is received from a component via a fiber optic cable.

10. coupling a shielding device to the sensor assembly such that the shielding device extends around a sensor opening defined by the infrared sensor; coupling a shielding device to a first end of a fiber optic cable; 10. The method of claim 9, further comprising:

11. The method for monitoring the temperature of an aerosol delivery device of claim 10, wherein coupling the shielding device to the sensor assembly and the first end of the fiber optic cable includes almost completely sealing the shielding device to substantially prevent infrared light that is not passing through the fiber optic cable from entering the sensor opening.

12. 12. The method for monitoring the temperature of an aerosol delivery device of claim 11, further comprising: using a shielding layer to substantially block infrared radiation from entering the fiber optic cable at locations other than the second end.

13. 10. The method of claim 9, further comprising disposing an infrared sensor within the outer body.

14. 10. The method of claim 9, further comprising programming the controller with a heating profile configured to cause the heating element to generate a heat quantity based on the infrared radiation measured by the infrared sensor.

15. 10. The method of claim 9, further comprising disposing an infrared sensor on the exterior of the outer body.

16. The method for monitoring the temperature of an aerosol delivery device of claim 15, wherein positioning the second end of the fiber optic cable proximate to a component within the outer body that generates infrared radiation includes inserting the fiber optic cable into the outer body.

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