Non-inverting amplifier circuit for an aerosol delivery device - Patent Application 20070123633

Abstract

An aerosol delivery device is provided. The aerosol delivery device includes terminals configured to connect a power source to the aerosol delivery device and a heating element configured to convert electricity into heat, thereby vaporizing components of an aerosol precursor composition. The aerosol delivery device also includes a boost converter configured to step up a voltage from the power source to a higher voltage and an inverter configured to convert the higher voltage to a complementary negative voltage. The aerosol delivery device further includes at least one non-inverting amplifier circuit including an operational amplifier configured to receive the voltage from the power source as an input voltage and receive the higher voltage and the complementary negative voltage as supply voltages. The at least one non-inverting amplifier circuit is configured to amplify the input voltage to an output voltage and provide a continuous output current.

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 can utilize electrically generated heat for the generation of an aerosol. The smoking article can be configured to heat an aerosol precursor, which can incorporate materials that can be produced or extracted from tobacco, or can otherwise incorporate tobacco, and which precursor can form an inhalable substance for human consumption. [Background technology]

[0002] Many smoking articles have been proposed over the years as an improvement or replacement for smoking products that rely on burning tobacco for use. Some exemplary replacements include devices in which a solid or liquid fuel is burned to transfer heat to the tobacco, or a chemical reaction is used to provide such a heat source. Additional exemplary replacements use electrical energy to heat tobacco and / or other aerosol-generating substrate materials, as described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0003] The point of improvement or replacement for smoking articles is typically to provide the sensation associated with cigarette, cigar, or pipe smoking without delivering a significant amount of incomplete combustion products and pyrolysis products.To this end, a number of smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile substances, or attempt to provide the sensation of cigarette, cigar, or pipe smoking without burning tobacco to a significant extent.See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art described in U.S. Patent No. 7,726,320 to Robinson et al.; U.S. Patent Application Publication No. 2013 / 0255702 to Griffith Jr. et al.; and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically-powered heating sources referenced by trade names and commercial sources in U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically-powered heating sources referenced by trade names and commercial sources are listed in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is also incorporated herein by reference.Other representative cigarettes or smoking articles which have been described, and in some instances are commercially available, include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,388,594 to Counts et al. No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; U.S. Patent No. 6,164,287 to White; U.S. Patent No. 6,196,218 to Voges; U.S. Patent No. 6,810,883 to Felter et al.; U.S. Patent No. 6,854,461 to Nichols; U.S. Patent No. 7,832,410 to Hon; U.S. Patent No. 6,832,410 to Kobayashi; No. 7,513,253 to Robinson et al.; U.S. Patent No. 7,726,320 to Robinson et al.; U.S. Patent No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Publication No. 2009 / 0095311 to Hon; U.S. Patent Publication Nos. 2006 / 0196518, 2009 / 0126745, and 2009 / 0188490 to Hon; U.S. Patent Publication No. 2009 / 0188490 to Thorens et al. No. 2009 / 0272379; U.S. Patent Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al.; U.S. Patent Publication Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al.; U.S. Patent Publication No. 2010 / 0307518 to Wang; and WO 2010 / 091593 to Hon, which are incorporated herein by reference.

[0004] Representative products that resemble many attributes of traditional types of cigarettes, cigars or pipes include ACCORD(R) by Philip Morris Incorporated; ALPHA(TM), JOYE 510(TM) and M 4(TM) by InnoVapor LLC; CIRRUS(TM) and FLING(TM) by White Cloud Cigarette; BLU(TM) by Fontem Ventures BV; COHITA(TM), COLIBRI(TM), ELITE CLASSIC(TM), MAGNUM(TM), PHANTOM(TM) and SENSE(TM) by EPUFFER(R) International Inc.; DUOPRO(TM), STORM(TM) and VAPORKING(R) by Electronic Cigarettes, Inc.; EGAR(TM) by Egar Australia; eGo-C(TM) and eGo-T(TM) by Joyetech; ELUSION(TM) by Elusion UK Ltd; EONSMOKE(R) by Eonsmoke LLC; FIN Branding FIN(TM) by Group, LLC; SMOKE(R) by Green Smoke Inc.; HALLIGAN(TM), HENDU(TM), JET(TM), MAXXQ(TM), PINK(TM) and PITBULL(TM) by GREENARETTE(TM), SMOKE STIK(R) by Greenarette LLC; HEATBAR(TM) by Philip Morris International, Inc.; HYDRO IMPERIAL(TM) and LXE(TM) from Crown7; LOGIC(TM) and CUBAN(TM) by LOGIC Technology; LUCI(R) by Luciano Smokes Inc.; METRO(R) by Nicotek, LLC; NJOY(R) and ONEJOY(TM) by Sottera, Inc.; NO. by SS Choice LLC.7(TM);PREMIUM ELECTRONIC CIGARETTE(TM) by PremiumEstore LLC;RAPP E-MYSTICK(TM) by Ruyan America Inc;RED DRAGON(TM) by Red Dragon Products;LLC;RUYAN(R) by Ruyan Group(Holdings)Ltd.;SF(R) by Smoker Friendly International, LLC;GREEN SMART SMOKER(R) by The Smart Smoking Electronic Cigarette Company Ltd.;SMOKE ASSIST(R) by Coastline Products LLC;SMOKING EVERYWHERE(R) by Smoking Everywhere Inc.;V2CIGS(TM) by VMR Products LLC;VAPOR NINE(TM) by VaporNine LLC;VAPOR4LIFE(R) by VAPOR 4 LIFE,Inc.;VEPPO(TM) by E-CigaretteDirect, LLC;VUSE(R) by RJReynolds Vapor Company;MISTIC by Mistic Ecigs and JUUL products by Juul Labs, Inc. Still other motorized aerosol delivery devices, and in particular those devices characterized as so-called electronic cigarettes, are also marketed under trade names such as COOLER VISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®; HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; and SOUTH BEACH SMOKE™. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Pat. No. 9,078,473 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] US Patent Application Publication No. 2013 / 0255702 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2015 / 0220232 [Patent Document 6] US Patent Application Publication No. 2015 / 0245659 [Patent Document 7] U.S. Pat. No. 4,735,217 [Patent Document 8] U.S. Pat. No. 4,922,901 [Patent Document 9] U.S. Pat. No. 4,947,874 [Patent Document 10] U.S. Pat. No. 4,947,875 [Patent Document 11] U.S. Pat. No. 5,060,671 [Patent Document 12] U.S. Pat. No. 5,249,586 [Patent Document 13] U.S. Pat. No. 5,388,594 [Patent Document 14] U.S. Pat. No. 5,666,977 [Patent Document 15] U.S. Patent No. 6,053,176 [Patent Document 16] U.S. Patent No. 6,164,287 [Patent Document 17] U.S. Patent No. 6,196,218 [Patent Document 18] U.S. Patent No. 6,810,883 [Patent Document 19] U.S. Patent No. 6,854,461 [Patent Document 20] U.S. Patent No. 7,832,410 [Patent Document 21] U.S. Patent No. 7,513,253 [Patent Document 22] U.S. Pat. No. 7,896,006 [Patent Document 23] U.S. Patent No. 6,772,756 [Patent Document 24] US Patent Application Publication No. 2009 / 0095311 [Patent Document 25] US Patent Application Publication No. 2006 / 0196518 [Patent Document 26] US Patent Application Publication No. 2009 / 0126745 [Patent Document 27] US Patent Application Publication No. 2009 / 0188490 [Patent Document 28] US Patent Application Publication No. 2009 / 0272379 [Patent Document 29] US Patent Application Publication No. 2009 / 0260641 [Patent Document 30] US Patent Application Publication No. 2009 / 0260642 [Patent Document 31] US Patent Application Publication No. 2008 / 0149118 [Patent Document 32] US Patent Application Publication No. 2010 / 0024834 [Patent Document 33] US Patent Application Publication No. 2010 / 0307518 [Patent Document 34] International Publication No. 2010 / 091593 Summary of the Invention [Problem to be solved by the invention]

[0006] However, it would perhaps be desirable to provide aerosol delivery devices with improved electronics that could extend the usefulness of the device. [Means for solving the problem]

[0007] 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, or a non-combustion heated tobacco product. The present disclosure includes, without limitation, the following illustrative embodiment examples.

[0008] Exemplary embodiment 1: 1. An aerosol delivery device comprising: terminals configured to connect a power source to the aerosol delivery device; a heating element configured to convert electricity into heat to vaporize a component of an aerosol precursor composition; a boost converter configured to step up a voltage from the power source to a higher voltage; an inverter configured to convert the higher voltage to a complementary negative voltage; and at least one non-inverting amplifier circuit coupled to the heating element, the at least one non-inverting amplifier circuit comprising an operational amplifier configured to receive a voltage from the power source as an input voltage and to receive the higher voltage and the complementary negative voltage as supply voltages, the at least one non-inverting amplifier circuit configured to amplify the input voltage to an output voltage and provide a continuous output current from which the heating element is powered. An aerosol delivery device comprising:

[0009] Exemplary embodiment 2: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the power source comprises a single battery or a single battery cell.

[0010] Exemplary embodiment 3: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the power source is or includes a single lithium ion battery (LiB) and the boost converter is configured to step up the voltage from the single LiB to a higher voltage.

[0011] Exemplary embodiment 4: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the continuous output current is at least about 9 amps.

[0012] Exemplary embodiment 5: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the at least one non-inverting amplifier circuit includes a plurality of operational amplifiers each configured to receive a voltage from a power source as an input voltage and a higher voltage and a complementary negative voltage as a supply voltage, the plurality of operational amplifiers configured to amplify the input voltages to respective output voltages and provide respective continuous output currents from which the heating element is powered.

[0013] Exemplary embodiment 6: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the multiple operational amplifiers are configured such that a sum of their respective continuous output currents is provided to the heating element.

[0014] Exemplary embodiment 7: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the multiple operational amplifiers are configured such that a sum of their respective output voltages is provided to the heating element.

[0015] Exemplary embodiment 8: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the aerosol precursor composition comprises a liquid, solid, or semi-solid.

[0016] Exemplary embodiment 9: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the inverter includes a logic gate configured to invert the higher voltage to a complementary negative voltage.

[0017] Example 10: A control body for an aerosol delivery device comprising: a terminal configured to connect a power source to the control body; a heating element configured to convert electricity into heat to vaporize a component of an aerosol precursor composition, or a second terminal configured to connect the heating element to the control body; a boost converter configured to step up a voltage from the power source to a higher voltage; an inverter configured to convert the higher voltage to a complementary negative voltage; and at least one non-inverting amplifier circuit coupled to the heating element or the second terminal, the at least one non-inverting amplifier circuit comprising an operational amplifier configured to receive a voltage from the power source as an input voltage and receive the higher voltage and the complementary negative voltage as supply voltages, the at least one non-inverting amplifier circuit configured to amplify the input voltage to an output voltage and provide a continuous output current from which the heating element is powered.

[0018] Exemplary embodiment 11: A control body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the power source includes a single battery or a single battery cell.

[0019] Exemplary embodiment 12: The control body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the power source is or includes a single lithium ion battery (LiB) and the boost converter is configured to step up the voltage from the single LiB to a higher voltage.

[0020] Exemplary embodiment 13: A control body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the continuous output current is at least about 9 amps.

[0021] Exemplary embodiment 14: A control body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the at least one non-inverting amplifier circuit includes a plurality of operational amplifiers each configured to receive a voltage from a power source as an input voltage and a higher voltage and a complementary negative voltage as a supply voltage, the plurality of operational amplifiers configured to amplify the input voltages to respective output voltages and provide respective continuous output currents from which the heating element is powered.

[0022] Exemplary embodiment 15: The control body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the plurality of operational amplifiers are configured such that a sum of their respective continuous output currents is provided to the heating element.

[0023] Exemplary embodiment 16: The control body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the multiple operational amplifiers are configured such that a sum of their respective output voltages is provided to the heating element.

[0024] Exemplary embodiment 17: The controlled body of any preceding exemplary embodiment, or of any combination of any preceding exemplary embodiment, wherein the aerosol precursor composition is a liquid, solid, or semi-solid.

[0025] Exemplary embodiment 18: an inverter includes a logic gate configured to invert a higher voltage to a complementary negative voltage.

[0026] 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 specific exemplary embodiment described herein or are otherwise recited. The present disclosure is intended to be read as a whole such that any separable features or elements of the present disclosure are deemed combinable, in any of its aspects and exemplary embodiments, unless the context of the disclosure clearly dictates otherwise.

[0027] It should therefore be understood that this brief summary is provided solely for the purpose of summarizing some exemplary embodiments to provide a basic understanding of some aspects of the present disclosure. It should therefore be understood that the above exemplary embodiments are merely examples, and should not be construed in any way to narrow the scope or spirit of the present disclosure. Other exemplary embodiments, 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 embodiments.

[0028] Having thus described aspects of the present disclosure in general terms above, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 is a perspective view of an aerosol delivery device including a cartridge and a control body coupled together according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 is a partial cutaway view of the aerosol delivery device of FIG. 1, with the cartridge and control body separated from each other, according to an exemplary embodiment. [Diagram 3]FIG. 13 is a perspective view of an aerosol delivery device comprising a control body and an aerosol source member coupled to each other according to another exemplary embodiment of the present disclosure. [Figure 4] FIG. 13 is a perspective view of an aerosol delivery device including a control body and an aerosol source member separated from each other according to another exemplary embodiment of the present disclosure. [Diagram 5] FIG. 5 is a front view of the aerosol delivery device of FIGS. 3 and 4 according to an exemplary embodiment. [Figure 6] FIG. 5 is a cross-sectional view of the aerosol delivery device of FIGS. 3 and 4 according to an exemplary embodiment. [Figure 7] FIG. 1 is a circuit diagram of an aerosol delivery device according to various exemplary embodiments of the present disclosure. [Figure 8] FIG. 2 is a circuit diagram of components of an aerosol delivery device according to an exemplary embodiment. [Figure 9] FIG. 2 is a circuit diagram of components of an aerosol delivery device according to an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] The present disclosure will be described more fully below with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the present disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms "a," "an," "the," and the like, include plural referents unless the context clearly dictates otherwise. Also, although quantitative measures, values, geometric relationships, and the like may be referenced herein, unless expressly stated otherwise, any one or more, if not all, of these may be absolute or approximate to account for acceptable variations that may occur due to technical tolerances and the like.

[0031] As described below, exemplary embodiments of the present disclosure relate to aerosol delivery devices. Aerosol delivery devices according to the present disclosure use electrical energy to heat materials to form inhalable substances (preferably without burning the materials to any significant extent), and the components of such systems most preferably have the form of an article that is compact enough to be considered a handheld device. That is, the use of the components of the preferred aerosol delivery device does not result in the production of smoke in the sense that the aerosol is primarily derived from the by-products of tobacco combustion or pyrolysis, but rather the use of such preferred systems results in the production of vapor resulting from the volatilization or vaporization of certain components incorporated therein. In some exemplary embodiments, the components of the aerosol delivery device may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0032] The aerosol-generating components of certain preferred aerosol delivery devices may provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the act of inhaling and exhaling, the type of taste or flavor, the sensory effects, the physical sensations, the act of use, visual cues such as those provided by a visible aerosol) used by a smoker to light and burn tobacco (and thus inhale tobacco smoke) without causing any substantial degree of combustion of any of the components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure may hold and use the component in the same manner as a smoker would use a traditional type of smoking article, drawing on one end of the component for inhalation of the aerosol generated by the component, puffing at selected time intervals, etc.

[0033] Although the system is generally described herein with respect to embodiments related to aerosol delivery devices, such as so-called "electronic cigarettes," "tobacco heating products," and the like, it should be understood that the features, components, features, and methods may be embodied in many different forms and may be associated with a variety of articles. For example, the description provided herein may be used in connection with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustion heated cigarettes, and related packaging embodiments for any of the products disclosed herein. Thus, it should be understood that the description of the features, components, features, and methods disclosed herein are discussed in terms of embodiments related to aerosol delivery devices by way of example only, and may be embodied and used in a variety of other products and methods.

[0034] The aerosol delivery device of the present disclosure may also be characterized as a vapor product article or drug delivery article. Thus, such articles or devices 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 may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may 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 visible or not, and whether in a form that can be considered similar to smoke.

[0035] 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 used 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.

[0036] The aerosol delivery device of the present disclosure generally includes several components provided within an outer housing, which may also be referred to as a body or shell. The overall design of the housing may vary, and the type or configuration of the housing may vary, which may define the overall size and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar may be formed from a single integral housing, or the elongated housing may be formed from two or more separable bodies. For example, the aerosol delivery device may include an elongated housing that may be substantially tubular in shape and thus may resemble the shape of a traditional cigarette or cigar. In one example, all components of the aerosol delivery device are contained within one housing. Alternatively, the aerosol delivery device may include two or more housings that are joined and separable. For example, the aerosol delivery device may have a control body with a housing containing one or more reusable components (e.g., accumulators such as rechargeable batteries, rechargeable supercapacitors, solid state batteries (SSBs), thin film SSBs, lithium ion or hybrid lithium ion supercapacitors, and various electronics for controlling the operation of the article) at one end, and an outer body or shell containing a disposable portion (e.g., a disposable cartridge containing flavor) removably coupleable thereto at the other end. More specific forms, configurations and arrangements of components within a single housing type unit or within a multi-part separable housing type unit will be apparent in light of the further disclosure provided herein. Furthermore, various aerosol delivery device designs and component configurations can be understood in light of commercially available electronic aerosol delivery devices.It will be understood that alternative non-tubular housing form factors may also be used, including device housings having a shape and size generally approximating a cigarette pack and form factor, such as those used in GLO™ by British American Tobacco and IQOS™ by Philip Morris International, Inc.

[0037] As discussed in more detail below, the aerosol delivery device of the present disclosure comprises a power source (i.e., a source of electrical power), at least one control component (e.g., a means for activating, controlling, regulating, and terminating the power of heat generation, such as by controlling the flow of current from the power source to other components of the aerosol delivery device), a heating element (e.g., an electrical resistance heating element or other component and / or an induction coil or other related component and / or one or more radiant heating elements), an aerosol precursor composition (e.g., a solid tobacco material, a semi-solid tobacco material, or a liquid aerosol precursor composition) capable of resulting in an aerosol upon application of sufficient heat, and a mouth-end region or tip (e.g., an air flow path defined through the article such that the generated aerosol can be drawn therefrom upon inhalation) that allows drawing with the aerosol delivery device for aerosol inhalation. In some embodiments, the power source comprises a single battery or a single battery cell. The power source can power a heating element configured to convert electricity into heat, thereby vaporizing the components of the aerosol precursor composition.

[0038] The positioning 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, which may be configured to be positioned near 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 positioned sufficiently near the aerosol precursor composition such that heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorants, medicaments, etc., which may also be provided for delivery to the user) to 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 be interchangeable with one another to include references to emit, emitting, emitting, or emitted, forming or generating, forming or generating, and 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.

[0039] As noted above, the aerosol delivery device may incorporate a battery, supercapacitor, SSB, or other power source to provide a sufficient current flow to provide various functionalities to the aerosol delivery device, such as powering the heating element, powering the control system, and powering the indicators. The power source may take on a variety of embodiments. Preferably, the power source is capable of delivering sufficient power to rapidly activate the heating element to provide aerosol formation and power the aerosol delivery device throughout a desired period of use. The power source is preferably sized to conveniently fit 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.

[0040] More specific forms, configurations, and arrangements of components within the aerosol delivery devices of the present disclosure will be apparent in light of the further disclosure provided below. Moreover, the selection of various aerosol delivery device components can be understood in consideration of commercially available electronic aerosol delivery devices. Moreover, the configuration of components within the aerosol delivery device can also be understood in consideration of commercially available electronic aerosol delivery devices.

[0041] As described below, the present disclosure relates to an aerosol delivery device. The aerosol delivery device may be configured to heat an aerosol precursor composition (sometimes referred to as an inhalable substance medium) to generate an aerosol (inhalable substance). The aerosol precursor composition may include one or more of a solid tobacco material, a semi-solid tobacco material, or a liquid aerosol precursor composition. In some embodiments, the aerosol delivery device may be configured to heat a fluid aerosol precursor composition (e.g., a liquid aerosol precursor composition) and generate an aerosol therefrom. Such an aerosol delivery device may include a so-called electronic cigarette. In other embodiments, the aerosol delivery device may include a non-combustion heating device.

[0042] The liquid aerosol precursor composition, also referred to as a vapor precursor composition or "e-liquid," can include a variety of ingredients including, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorings. In some examples, the aerosol precursor composition includes glycerin and nicotine.

[0043] Some liquid aerosol precursor compositions that may be used in combination with various embodiments may include one or more acids such as levulinic acid, succinic acid, lactic acid, pyruvic acid, benzoic acid, fumaric acid, combinations thereof, etc. Including an acid(s) in a liquid aerosol precursor composition that includes nicotine can provide a protonated liquid aerosol precursor composition that includes nicotine in a salt form. Representative types of liquid aerosol precursor compositions and formulations are described and characterized in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent 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 International Patent Application Publication No. 2014 / 182736 to Bowen et al., and U.S. Patent No. 8,881,737 to Collett et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include aerosol precursors incorporated into any of the several representative products identified above. Also desirable are so-called "smoke juices" for electronic cigarettes available from Johnson Creek Enterprises LLC. Further example aerosol precursor compositions are sold under the brand names BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, MITTEN VAPORS, DR.CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT.BAKER VAPOR, and JIMMY THE JUICE MAN.Embodiments of the foamable material can be used with aerosol precursors and are 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 WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference.

[0044] Representative types of substrates, reservoirs or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014 / 0261487 to Chapman et al., U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al., and U.S. Patent Application Publication No. 2015 / 0216232 to Bless et al., all of which are incorporated herein by reference. Additionally, various wicking materials, as well as the configuration and operation of those wicking materials within certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference.

[0045] In other embodiments, the aerosol delivery device may comprise a non-combustion heating device configured to heat a solid aerosol precursor composition (e.g., an extruded tobacco rod) or a semi-solid aerosol precursor composition (e.g., a glycerin-loaded tobacco paste). The aerosol precursor composition may comprise tobacco-containing beads, tobacco shreds, tobacco pieces, reconstituted tobacco materials, or combinations thereof, and / or mixtures of finely ground tobacco, tobacco extract, spray-dried tobacco extract, or other tobacco forms mixed with optional inorganic materials (such as calcium carbonate), optional flavorings, and aerosol-forming materials to form a substantially solid or moldable (e.g., extrudable) substrate. Representative types of solid and semi-solid aerosol precursor compositions and formulations are disclosed in U.S. Patent No. 8,424,538 to Thomas et al., U.S. Patent No. 8,464,726 to Sebastian et al., U.S. Patent Application Publication No. 2015 / 0083150 to Conner et al., U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al., and U.S. Patent Application Publication No. 2017 / 0000188 to Nordskog et al., all of which are incorporated herein by reference. Further representative types of solid and semi-solid aerosol precursor compositions and configurations include those found in the NEOSTIKS™ consumable aerosol source member of the GLO™ product by British American Tobacco and the HEETS™ consumable aerosol source member of the IQOS™ product by Philip Morris International, Inc.

[0046] In various embodiments, the inhalable substance may specifically be a tobacco component or a tobacco-derived material (i.e., a material found in nature in tobacco that may be directly isolated from tobacco or synthetically prepared). For example, the aerosol precursor composition may include a tobacco extract or a fraction thereof combined with an inert substrate. The aerosol precursor composition may further include unburned tobacco or a composition including unburned tobacco that releases an inhalable substance when heated to a temperature below its combustion temperature. In some embodiments, the aerosol precursor composition may include tobacco condensate or a fraction thereof (i.e., the condensed component of smoke produced by the combustion of tobacco that leaves behind flavor, and possibly nicotine).

[0047] Tobacco materials useful in the present disclosure may vary and may include, for example, flue-cured, burley, oriental or Maryland, dark, dark-fired and rustica tobaccos, as well as other rare or specialty tobaccos, or blends thereof. Tobacco materials may also include so-called "blend" forms and processed forms, such as processed tobacco stems (e.g., cut roll or cut puff stems), volume-expanded tobacco (preferably in the form of cut filler, e.g., expanded tobacco such as dry ice expanded tobacco (DIET)), reconstituted tobacco (e.g., reconstituted tobacco produced using a paper-making or cast sheet type process), and the like. Various representative tobacco types, processed tobacco types, and tobacco blend types are described in U.S. Pat. Nos. 4,836,224 to Lawson et al., 4,924,888 to Perfetti et al., 5,056,537 to Brown et al., 5,159,942 to Brinkley et al., 5,220,930 to Gentry, 5,360,023 to Blakley et al., 6,700,024 to Shafer et al., and 6,800,026 to Wilson et al. No. 7,011,096 to Li et al., and U.S. Patent No. 7,017,585 to Li et al., U.S. Patent No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004 / 0255965 to Perfetti et al., International Patent Application Publication No. WO 02 / 37990 to Bereman, and Bombick et al., Fund. Appl. Toxicol., 39, pp. 11-17 (1997), which are incorporated herein by reference. Further exemplary tobacco compositions that may be useful in smoking devices, including those according to the present disclosure, are disclosed in U.S. Patent No. 7,726,320 to Robinson et al., which is incorporated herein by reference.

[0048] Additionally, the aerosol precursor composition may include an inert substrate having an inhalable substance or its precursor incorporated therein or otherwise deposited thereon. For example, a liquid containing an inhalable substance may be coated onto, or absorbed or adsorbed into, an inert substrate such that upon application of heat, the inhalable substance is released in a form that can be drawn from the inventive article through application of positive or negative pressure. In some embodiments, the aerosol precursor composition may include a flavorful, flavorful tobacco blend in cut filler form. In another embodiment, the aerosol precursor composition may include a reconstituted tobacco material as described in U.S. Pat. No. 4,807,809 to Pryor et al., U.S. Pat. No. 4,889,143 to Pryor et al., and U.S. Pat. No. 5,025,814 to Raker, the disclosures of which are incorporated herein by reference. For more information regarding suitable aerosol precursor compositions, see U.S. Patent Application No. 15 / 916,834 to Sur et al., filed March 9, 2018, which is incorporated herein by reference.

[0049] Regardless of the type of aerosol precursor composition being heated, the aerosol delivery device may include a heating element configured to heat the aerosol precursor composition. In some embodiments, the heating element is an induction heater. Such heaters often comprise an induction transmitter and an induction receiver. The induction transmitter may include a coil configured to create an oscillating magnetic field (e.g., a magnetic field that changes periodically with time) when an alternating current is conducted therethrough. The induction receiver may be at least partially disposed or received within the induction transmitter and may include a conductive material (a ferromagnetic material or an aluminum-coated material). By conducting an alternating current through the induction transmitter, eddy currents may be generated in the induction receiver via induction. The eddy currents flowing through the resistance of the material defining the induction receiver may heat it by Joule heating (i.e., by the Joule effect). The induction receiver may define an atomizer and may be wirelessly heated to form an aerosol from an aerosol precursor composition positioned in proximity to the induction receiver. Various embodiments of an induction heated aerosol delivery device are described in U.S. Patent Application Publication No. 2017 / 0127722 to Davis et al., U.S. Patent Application Publication No. 2017 / 0202266 to Sur et al., U.S. Patent Application No. 15 / 352,153 to Sur et al., filed November 15, 2016, U.S. Patent Application No. 15 / 799,365 to Sebastian et al., filed October 31, 2017, and U.S. Patent Application No. 15 / 836,086 to Sur, all of which are incorporated herein by reference.

[0050] In other embodiments, including those more specifically described herein, the heating element is a conductive heater, such as in the case of an electrical resistance heater. These heaters may be configured to generate heat when an electric current is conducted through them. In various embodiments, the conductive heater may be provided in various forms, such as in the form of a foil, foam, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heaters often include a metallic material and are configured to generate heat as a result of the electrical resistance associated with passing an electric current therethrough. Such a resistive heater may be positioned near the aerosol precursor composition to heat the aerosol precursor composition to generate an aerosol. Various conductive substrates that may be usable with the present disclosure are described in the above-mentioned U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al.

[0051] In some embodiments, the aerosol delivery device may include a control body and a cartridge in the case of a so-called electronic cigarette, or a control body and an aerosol source member in the case of a non-combustion heating device. In either the case of an electronic cigarette or a non-combustion heating device, the control body may be reusable, while the cartridge / aerosol source member may be configured for a limited number of uses and / or may be configured for disposable use. The cartridge / aerosol source member may include an aerosol precursor composition. To heat the aerosol precursor composition, a heating element may be positioned in contact with or in close proximity to the aerosol precursor composition, for example across the control body and cartridge, or within the control body where the aerosol source member may be positioned. The control body may include a power source, which may be rechargeable or replaceable, so that the control body may be reused with multiple cartridges / aerosol source members.

[0052] The control body may also include means for activating the aerosol delivery device, such as a push button for manually controlling the device, a touch-sensitive surface, etc. Additionally or alternatively, the control body may include a flow sensor for detecting when a user draws on the cartridge / aerosol source member, thereby activating the aerosol delivery device.

[0053] In various embodiments, the aerosol delivery device according to the present disclosure may have various overall shapes, including, but not limited to, an overall shape that may be defined as substantially rod-shaped or substantially tubular or substantially cylindrical. In the embodiment shown in and described with reference to the attached figures, the aerosol delivery device has a substantially circular cross section; however, other cross-sectional shapes (e.g., oval, square, rectangular, triangular, etc.) are also encompassed by the present disclosure. Such language describing the physical shape of an article may also apply to its individual components, including the control body and the cartridge / aerosol source member. In other embodiments, the control body may take another handheld shape, such as a small box shape.

[0054] In more specific embodiments, one or both of the control body and the cartridge / aerosol source member may be referred to as disposable or reusable. For example, the control body may have a power source such as a replaceable or rechargeable battery, SSB, thin film SSB, rechargeable supercapacitor, lithium-ion or hybrid lithium-ion supercapacitor. An example of a power source is the TKI-1550 rechargeable lithium-ion battery manufactured by Tadiran Batteries GmbH of Germany. In another embodiment, a useful power source may be the N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Co., Ltd. of Japan. In other embodiments, multiple such batteries may be connected in series, each providing, for example, 1.2 volts.

[0055] In some examples, the power source may then be connected to, and thereby combined with, any type of recharging technology. Examples of suitable chargers include chargers that simply provide constant current or pulsed direct current (DC) power to the power source, fast chargers that add control circuitry, three-stage chargers, inductively powered chargers, smart chargers, kinetically powered chargers, pulse chargers, solar chargers, USB-based chargers, etc. In some examples, the charger includes a power adapter and any suitable charging circuitry. In other examples, the charger includes a power adapter and the control body is equipped with the charging circuitry. In these other examples, the charger is sometimes simply referred to as a power adapter.

[0056] The control body may include any of a number of different terminals, electrical connectors, etc., for connecting to an appropriate charger and, in some examples, for connecting to other peripherals for communication. More specific suitable examples include cylindrical connectors, cigarette lighter connectors, and direct current (DC) connectors such as USB 1.x (e.g., Type A, Type B), USB 2.0 and its updates and additions (e.g., Mini A, Mini B, Mini AB, Micro A, Micro B, Micro AB) and USB 3.x (e.g., Type A, Type B, Micro B, Micro AB, Type C), proprietary connectors such as Apple's Lightning connector. The control body may connect directly to the charger or other peripheral, or the two may connect via a suitable cable, also having appropriate connectors. In examples where the two are connected by a cable, the control body and the charger or other peripheral may have the same or different types of connectors, and the cable may have one type of connector or both types of connectors.

[0057] In examples involving inductively powered charging, the aerosol delivery device may be equipped with inductive wireless charging technology and may include an inductive transmitter and an inductive receiver for connecting with a wireless charger, charging pad, or the like that uses inductive wireless charging (e.g., including wireless charging according to the Qi wireless charging standard from the Wireless Power Consortium (WPC)). Alternatively, the power source may be recharged from a wireless radio frequency (RF) based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some exemplary embodiments for e-cigarettes, the cartridge may include a single-use cartridge as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference.

[0058] One or more connections may be used to connect the power source to the recharging technology, some involving charging cases, cradles, docks, sleeves, etc. More specifically, for example, the control body may be configured to mate with a cradle that includes a USB connector for connecting to a power source. Or in another example, the control body may be configured to fit within and mate with a sleeve that includes a USB connector for connecting to a power source. In these and similar examples, the USB connector may connect directly to the power source, or the USB connector may connect to the power source via a suitable power adapter.

[0059] Examples of power sources are described in U.S. Patent No. 9,484,155 to Peckerar et al., and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the disclosures of which are incorporated herein by reference. With respect to flow sensors, representative current regulating 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, all to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040, No. 560, U.S. Pat. No. 7,040,314 to Nguyen et al., U.S. Pat. No. 8,205,622 to Pan, U.S. Patent Application Publication No. 8,881,737 to Collet et al., U.S. Pat. No. 9,423,152 to Ampolini et al., U.S. Pat. No. 9,439,454 to Fernando et al., and U.S. Patent Application No. 2015 / 0257445 to Henry et al., all of which are incorporated herein by reference.

[0060] An input element may be included with the aerosol delivery device (and may replace or supplement the flow sensor). The input may be included to allow the user to control the device's functions and / or to output information to the user. Any component or combination of components may be utilized as an input 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 touch screen 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 a further 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. As yet another example, a capacitance sensor may be implemented in the aerosol delivery device to allow a user to provide input, such as by touching a surface of the device on which the capacitance sensor is implemented. In another example, a sensor capable of detecting motion associated with the device (e.g., an accelerometer, a gyroscope, a photoelectric proximity sensor, etc.) may be implemented in the aerosol delivery device to allow a user to provide input. Examples of suitable sensors are described in U.S. Patent Application Publication No. 2018 / 0132528 to Sur et al. and U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., the disclosures of which are incorporated herein by reference.

[0061] As indicated above, the aerosol delivery device may include various electronics, such as at least one control component. A suitable control component may include several electronic components, and in some examples, may be formed of a circuit board, such as a printed circuit board (PCB). In some examples, the electronic components include a processing circuit configured to perform data processing, application execution, or other processing, control, or management services, according to one or more exemplary embodiments. The processing circuit may include a processor embodied in various forms, such as at least one processor core, a microprocessor, a coprocessor, a controller, a microcontroller, or various other computing or processing devices, including one or more integrated circuits, such as, for example, an ASIC (application specific integrated circuit), an FPGA (field programmable gate array), some combination thereof, etc. In some examples, the processing circuit may include a memory coupled to or integrated with the processor, and the memory may store data, computer program instructions executable by the processor, some combination thereof, etc.

[0062] In some examples, the control component may include one or more input / output peripherals that may be coupled to or integrated with the processing circuit. More specifically, the control component may include a communication interface to enable wireless communication with one or more networks, computing devices, or other appropriately enabled devices. An example of a suitable communication interface is disclosed in U.S. Patent Application Publication No. 2016 / 0261020 to Marion et al., the contents of which are incorporated herein by reference. Another example of a suitable communication interface is the CC3200 single-chip wireless microcontroller unit (MCU) manufactured by Texas Instruments. Examples of suitable ways in which the aerosol delivery device may be configured to communicate wirelessly according to which are disclosed in U.S. Patent Application Publication No. 2016 / 0007651 to Ampolini et al. and U.S. Patent Application Publication No. 2016 / 0219933 to Henry, Jr. et al., each of which is incorporated herein by reference.

[0063] Further components can also be utilized in the aerosol delivery device of the present disclosure. One example of a suitable component is an indicator, such as a light emitting diode (LED), quantum dot-based LED, etc., that can be illuminated using the aerosol delivery device. Examples of suitable LED components, as well as their construction and use, are described in U.S. Patent No. 5,154,192 to Sprinkel et al., U.S. Patent No. 8,499,766 to Newton, U.S. Patent No. 8,539,959 to Scatterday, and U.S. Patent No. 9,451,791 to Sears et al., all of which are incorporated herein by reference.

[0064] Other indicators of operation are also encompassed by the present disclosure. For example, visual indicators of operation include changes in light color or changes in light intensity to indicate the progress of the smoking experience. Tactile (haptic) indicators of operation and audible (audio) indicators of operation are also encompassed by the present disclosure. Furthermore, combinations of such indicators of operation are also suitable for use in a single smoking article. According to another embodiment, the aerosol delivery device may include one or more indicators or indices, such as, for example, a display, configured to provide information corresponding to the operation of the smoking article, such as, for example, the remaining amount of power of the power source, the progress of the smoking experience, an indication corresponding to activating the heat source, etc.

[0065] Still other components are contemplated. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses a smoking article indicator; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth-end of the device to detect the user's lip activity associated with taking a puff and then trigger heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy to a heat load array in response to a pressure drop through the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier 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. Patent No. 6,040,560 to Fleischhauer et al. describes a defined, executable power cycle with multiple distinct phases; U.S. Patent No. 6,040,560 to Watkins et al. No. 5,934,289 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 certain 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 interfacing means for smoking devices 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 smoking devices; and International Patent Application Publication No. WO 2010 / 003480 by Flick discloses a fluid flow sensing system that indicates a puff in an aerosol generation system; all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0066] Further examples of components relating to electronic aerosol delivery articles and disclosing materials or components 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. 6,772,756 to H. Nos. 8,156,944 and 8,375,957 to on, 8,794,231 to Thorens et al., 8,851,083 to Oglesby et al., 8,915,254 and 8,925,555 to Monsees et al., 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2003-002366 to Hon US Patent Publication Nos. 006 / 0196518 and 2009 / 0188490 to Oglesby et al., US Patent Publication No. 2010 / 0024834 to Wang, WO 2010 / 0307518 to Wang, WO 2010 / 091593 to Hon, and WO 2013 / 089551 to Foo, each of which is incorporated herein by reference. Additionally, US Patent Publication No. 2017 / 0099877 to Worm et al. discloses a capsule that may be included in an aerosol delivery device, and a fob configuration of an aerosol delivery device, which is incorporated herein by reference. Various materials disclosed by the aforementioned documents may be incorporated into the device in various embodiments, and all of the aforementioned disclosures are incorporated herein by reference.

[0067] Still other features, controls or components that may be incorporated into the aerosol delivery devices of the present disclosure include those disclosed 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. 2005 / 0016550 to Katase, U.S. Patent Application Publication No. 2005 / 0016550 to Fernando ... No. 8,689,804 to Tucker et al., U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent Application Publication No. 9,427,022 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 No. 9,220,302 to DePiano et al., all of which are incorporated herein by reference.

[0068] 1 and 2 illustrate an embodiment of an aerosol delivery device including a control body and a cartridge in the case of an electronic cigarette. More specifically, FIG. 1 and FIG. 2 show an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. As shown, the aerosol delivery device may include a control body 102 and a cartridge 104. The control body and the cartridge may be permanently or removably aligned in a functional relationship. In this regard, FIG. 1 shows a perspective view of the aerosol delivery device in a coupled configuration, while FIG. 2 shows a partially cutaway side view of the aerosol delivery device in a decoupled configuration. The aerosol delivery device may be, for example, substantially rod-shaped, substantially tubular-shaped, or substantially cylindrical-shaped in some exemplary embodiments when the control body and the cartridge are in an assembled configuration.

[0069] The control body 102 and the cartridge 104 can be configured to engage with each other by various connections, such as a press-fit (or interference fit) connection, a threaded connection, a magnetic connection, and the like. Thus, the control body can include a first engagement element (e.g., a coupler) adapted to engage with a second engagement element (e.g., a connector) on the cartridge. The first engagement element and the second engagement element can be reversible. As an example, either the first engagement element or the second engagement element can be male threaded and the other can be female threaded. As a further example, either the first engagement element or the second engagement element can be a magnet and the other can be a metal or mated magnet. In certain embodiments, the engagement elements can be directly defined by existing components of the control body and the cartridge. For example, the housing of the control body can define a cavity at its end, the cavity configured to receive at least a portion of the cartridge (e.g., a storage tank or other shell-forming element of the cartridge). In particular, the reservoir of the cartridge may be at least partially received within the cavity of the control body, while the mouthpiece of the cartridge remains exposed outside the cavity of the control body. The cartridge may be retained within the cavity formed by the control body housing, such as by an interference fit (e.g., through the use of detents and / or other features that create an interference engagement between an outer surface of the cartridge and an inner surface of a wall forming the cavity of the control body), magnetic engagement (e.g., through the use of magnets and / or magnetic metals positioned within the cavity of the control body and positioned on the cartridge), or other suitable technique.

[0070] As seen in the cutaway view shown in FIG. 2, the control body 102 and cartridge 104 each include several respective components. The components shown in FIG. 2 are representative of components that may be present in the control body and cartridge, and are not intended to limit the scope of components encompassed by the present disclosure. As shown, for example, the control body can be formed with a housing 206 (sometimes referred to as a control body shell) that can include a control component 208 (e.g., processing circuitry, etc.), a flow sensor 210, a power source 212 (e.g., battery, supercapacitor), and an indicator 214 (e.g., LED, quantum dot-based LED), and such components can be variably aligned. The power source may be rechargeable, and the control component may include a non-inverting amplifier circuit configured to provide a continuous output current.

[0071] The cartridge 104 can be formed with a housing 216 (sometimes referred to as a cartridge shell) that encloses a reservoir 218 configured to hold the aerosol precursor composition and includes a heating element 220 (sometimes referred to as a heater). In various configurations, such a structure can also be referred to as a tank, and thus the terms "cartridge," "tank," and the like can be used interchangeably to refer to a shell or other housing that encloses a reservoir for the aerosol precursor composition and includes a heating element.

[0072] As shown, in some examples, the reservoir 218 may be in fluid communication with a liquid transport element 222 adapted to wick or otherwise transport the aerosol precursor composition stored within the reservoir housing to the heating element 220. In some examples, a valve may be positioned between the reservoir and the heating element and may be configured to control the amount of the aerosol precursor composition that is passed or delivered from the reservoir to the heating element.

[0073] Various exemplary materials configured to generate heat upon application of an electric current may be used to form the heating element 220. The heating elements in these examples may be resistive heating elements such as wire coils, microheaters, and the like. Examples of materials from which the heating elements may be formed include Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tin oxide, tungsten, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum doped molybdenum disilicide (Mo(Si,Al)2), titanium, platinum, silver, palladium, alloys of silver and palladium, graphite and graphite-based materials (e.g., carbon-based foams and threads), conductive inks, boron-doped silica, and ceramics (e.g., ceramics with positive or negative temperature coefficients). The heating elements may be resistive heating elements, or heating elements configured to generate heat through induction. The heating elements may be coated with a thermally conductive ceramic, such as aluminum nitride, silicon carbide, beryllium oxide, alumina, silicon nitride, or composites thereof. Exemplary embodiments of heating elements useful in aerosol delivery devices according to the present disclosure are further described below and can be incorporated into devices as described herein.

[0074] An opening 224 may be present in the housing 216 (eg, at the mouth end) to allow for the exit of the formed aerosol from the cartridge 104 .

[0075] The cartridge 104 may also include one or more electronic components 226, which may include integrated circuits, memory components (e.g., EEPROM, flash memory), sensors, etc. The electronic components may be adapted to communicate with the control component 208 and / or external devices by wired or wireless means. The electronic components may be positioned anywhere within the cartridge or its base 228.

[0076] Although the control component 208 and the flow sensor 210 are shown separately, it is understood that the various electronic components, including the control component and the flow sensor, may be combined on a circuit board (e.g., PCB) that supports and electrically connects the electronic components. Furthermore, the circuit board may be positioned horizontally relative to the view of FIG. 1 in that it may be longitudinally parallel to the central axis of the control body. In some examples, the airflow sensor may include its own circuit board or other base element to which it may be mounted. In some examples, a flexible circuit board may be utilized. The flexible circuit board may be configured in a variety of shapes, including a substantially tubular shape. In some examples, the flexible circuit board may be combined with, layered on, or form part or all of the heater substrate.

[0077] The control body 102 and the cartridge 104 may include components adapted to facilitate fluid engagement therebetween. As shown in FIG. 2, the control body may include a coupler 230 having a cavity 232 therein. The base 228 of the cartridge may be adapted to engage with the coupler and may include a protrusion 234 adapted to fit within the cavity. Such engagement may facilitate a stable connection between the control body and the cartridge and establish an electrical connection between the power source 212 and control component 208 in the control body and the heating element 220 in the cartridge. Additionally, the housing 206 may include an air intake 236, which may be a notch in the housing, in this case, that connects to the coupler and allows the passage of ambient air around the coupler and into the housing, where the air then passes through the cavity 232 of the coupler and through the protrusion 234 into the cartridge.

[0078] Couplers and bases useful according to the present disclosure are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference. For example, the coupler 230 as seen in FIG. 2 may define an outer periphery 238 configured to mate with an inner periphery 240 of the base 228. In one example, the inner periphery of the base may define a radius that is substantially equal to or slightly greater than the radius of the outer periphery of the coupler. Additionally, the coupler may define one or more protrusions 242 on the outer periphery configured to engage with one or more recesses 244 defined in the inner periphery of the base. However, various other examples of structures, shapes and components may be used to couple the base to the coupler. In some examples, the connection between the base of the cartridge 104 and the coupler of the control body 102 may be substantially permanent, while in other examples the connection therebetween may be releasable, such that, for example, the control body may be reusable with one or more additional cartridges, which may be disposable and / or refillable.

[0079] The reservoir 218 shown in FIG. 2 may be a container, as currently described, or may be a fibrous reservoir. For example, in this example, the reservoir may include one or more layers of non-woven fibers formed substantially in a tubular shape surrounding the interior of the housing 216. An aerosol precursor composition may be held in the reservoir. For example, a liquid component may be adsorbed and held by the reservoir. The reservoir may be in fluid communication with a liquid transport element 222. The liquid transport element may transport the aerosol precursor composition stored in the reservoir via capillary action or via a micropump to a heating element 220, which in this example is in the form of a metal wire coil. The heating element is thus in a heating configuration together with the liquid transport element.

[0080] In some examples, a microfluidic chip may be embedded in the reservoir 218, and the amount and / or mass of the aerosol precursor composition delivered from the reservoir may be controlled by a micropump, such as one based on microelectromechanical systems (MEMS) technology. Exemplary embodiments of reservoirs and transport elements useful in aerosol delivery devices according to the present disclosure are further described herein, and such reservoirs and / or transport elements may be incorporated into devices such as those described herein. In particular, certain combinations of heating members and transport elements as further described herein may be incorporated into devices such as those described herein.

[0081] In use, when a user inhales on the aerosol delivery device 100, airflow is detected by the flow sensor 210 and the heating element 220 is activated to vaporize the components of the aerosol precursor composition. Inhaling at the mouth-end of the aerosol delivery device causes ambient air to enter the air intake 236 and pass through the cavity 232 of the coupler 230 and the central opening of the protrusion 234 of the base 228. In the cartridge 104, the inhaled air combines with the formed vapor to form an aerosol. The aerosol is drawn, aspirated, or otherwise drawn away from the heating element and out of the opening 224 at the mouth-end of the aerosol delivery device.

[0082] For further details regarding embodiments of an aerosol delivery device including a control body and a cartridge for an electronic cigarette, see U.S. Patent Application No. 15 / 836,086 to Sur, supra, and U.S. Patent Application No. 15 / 916,834 to Sur et al., as well as U.S. Patent Application No. 15 / 916,696 to Sur, filed March 9, 2018, which are also incorporated by reference herein.

[0083] 3-6 show embodiments of an aerosol delivery device including a control body and an aerosol source member for non-combustion heated devices. More specifically, FIG. 3 shows an aerosol delivery device 300 according to an exemplary embodiment of the present disclosure. The aerosol delivery device may include a control body 302 and an aerosol source member 304. In various embodiments, the aerosol source member and the control body can be permanently or removably aligned in a functional relationship. In this regard, FIG. 3 shows the aerosol delivery device in a coupled configuration, while FIG. 4 shows the aerosol delivery device in a decoupled configuration. Various mechanisms can connect the aerosol source member to the control body to provide a threaded engagement, a press fit engagement, an interference fit, a sliding fit, a magnetic engagement, and the like.

[0084] 4, in various embodiments of the present disclosure, the aerosol source member 304 can include a heated end 406 configured to be inserted into the control body 302 and a mouth end 408 that a user inhales into to create an aerosol. In various embodiments, at least a portion of the heated end can include an aerosol precursor composition 410.

[0085] In various embodiments, the aerosol source member 304 or a portion thereof may be wrapped with an outer overwrap material 412, which may be formed of any material useful for providing additional structure and / or support to the aerosol source member. In various embodiments, the outer overwrap material may include a material that resists the transfer of heat, which may include paper or other fibrous materials, such as cellulosic materials. The outer overwrap material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the outer overwrap may be formed of multiple layers, such as an underlying bulk layer and an overlying layer, such as a typical cigarette wrapper. Such materials may include, for example, lightweight "trash fibers," such as flax, hemp, sisal, rice straw, and / or esparto. The outer overwrap may also include materials commonly used in filter elements of conventional cigarettes, such as cellulose acetate. Additionally, the excess length of overlap at the mouth end 408 of the aerosol source member may function simply to separate the aerosol precursor composition 410 from the consumer's mouth, or may function to provide space for positioning a filter material as described below, or may function to affect inhalation at the article or to affect the flow characteristics of the vapor or aerosol exiting the device during inhalation. Further discussion regarding configurations of overlap materials that may be used in the present disclosure may be found in the above-mentioned U.S. Patent No. 9,078,473 to Worm et al.

[0086] In various embodiments, there may be other components between the aerosol precursor composition 410 and the mouth-end 408 of the aerosol source member 304, where the mouth-end may include a filter 414, which may be made from, for example, a cellulose acetate or polypropylene material. The filter may additionally or alternatively include strands of tobacco-containing material as described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the filter may increase the structural integrity of the mouth-end of the aerosol source member and / or provide filtering capability as needed and / or provide resistance to drawing. In some embodiments, one or any combination of the following may be positioned between the aerosol precursor composition and the mouth-end: an air gap; a phase change material for cooling air; a flavor release medium; ion exchange fibers capable of selective chemical adsorption; aerogel particles as a filter medium; and other suitable materials.

[0087] Various embodiments of the present disclosure use one or more conductive heating elements to heat the aerosol precursor composition 410 of the aerosol source member 304. In various embodiments, the heating elements may be provided in various forms, such as in the form of a foil, foam, mesh, hollow ball, half ball, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating elements often include a metallic material and are configured to generate heat as a result of electrical resistance associated with passing an electric current therethrough. Such resistive heating elements may be positioned in direct contact with or in close proximity to the aerosol source member, particularly the aerosol precursor composition of the aerosol source member 304. The heating elements may be disposed within the control body and / or the aerosol source member. In various embodiments, the aerosol precursor composition may include components embedded in or otherwise part of a substrate portion that may function as or facilitate the function of the heating assembly (i.e., thermally conductive components). Some examples of various heating members and elements are described in U.S. Pat. No. 9,078,473 to Worm et al.

[0088] Some non-limiting examples of various heating element configurations include configurations in which the heating element is placed near the aerosol source member 304. For example, in some examples, at least a portion of the heating element may surround at least a portion of the aerosol source member. In other examples, one or more heating elements may be positioned adjacent to the exterior of the aerosol source member when inserted into the control body 302. In other examples, at least a portion of the heating element may penetrate at least a portion of the aerosol source member when the aerosol source member is inserted into the control body (e.g., one or more prongs and / or spikes penetrate the aerosol source member, etc.). In some examples, the aerosol precursor composition may include a structure in contact with the aerosol precursor composition or a plurality of beads or particles embedded in or otherwise part of the aerosol precursor composition that can function as or facilitate the function of the heating element.

[0089] Figure 5 shows a front view of an aerosol delivery device 300 according to an exemplary embodiment of the present disclosure, and Figure 6 shows a cross-sectional view through the aerosol delivery device of Figure 5. In particular, the control body 302 of the illustrated embodiment may comprise a housing 516 including an opening 518 defined at an engagement end thereof, a flow sensor 520 (e.g., a puff sensor or pressure switch), a control component 522 (e.g., processing circuitry, etc.), a power source 524 (e.g., a battery, a supercapacitor), and an end cap including an indicator 526 (e.g., an LED). The power source may be rechargeable, and the control component may include a non-inverting amplifier circuit configured to provide a continuous output current.

[0090] In one embodiment, the indicator 526 can include one or more LEDs, quantum dot-based LEDs, etc. The indicator is in communication with the control component 522 and, for example, when coupled to the control body 302, can be illuminated when a user draws on the aerosol source member 304 as detected by the flow sensor 520.

[0091] The control body 302 of the illustrated embodiment includes one or more heating assemblies 528 (individually or collectively referred to as heating assemblies) configured to heat the aerosol precursor composition 410 of the aerosol source member 304. While the heating assemblies of various embodiments of the present disclosure can take a variety of forms, in the particular embodiment shown in Figures 5 and 6, the heating assembly includes a barrel 530 and a heating element 532, which in this embodiment comprises a number of heater prongs (the heating assembly, or more specifically the heater prongs, in various configurations may be referred to as heaters) extending from a receiving base 534. In the illustrated embodiment, the barrel comprises a double-walled vacuum tube constructed of stainless steel to maintain heat generated by the heater prongs within the barrel, and more specifically, to maintain heat generated by the heater prongs within the aerosol precursor composition. In various embodiments, the heater prongs may be constructed from one or more electrically conductive materials, including but not limited to copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, or any combination thereof.

[0092] As shown, the heating assembly 528 may extend near the engagement end of the housing 516 and may be configured to substantially surround a portion of the heated end 406 of the aerosol source member 304 containing the aerosol precursor composition 410. In such a manner, the heating assembly may define a generally tubular configuration. As shown in FIGS. 5 and 6, the heating element 532 (e.g., a plurality of heater prongs) is surrounded by the sheath 530 to create a receiving chamber 536. In such a manner, in various embodiments, the sheath may include a non-conductive insulating material and / or a non-conductive insulating structure, including, but not limited to, an insulating polymer (e.g., plastic or cellulose), glass, rubber, ceramic, porcelain, a double-walled vacuum structure, or any combination thereof.

[0093] In some embodiments, one or more portions or components of the heating assembly 528 may be combined, packaged, and / or integrated with (e.g., embedded within) the aerosol precursor composition 410. For example, in some embodiments, the aerosol precursor composition may be formed from the materials described above and may include one or more electrically conductive materials mixed therein. In some of these embodiments, the contacts may be directly connected to the aerosol precursor composition such that when the aerosol source member is inserted into the receiving chamber of the control body, the contacts form an electrical connection with the electrical energy source. Alternatively, the contacts may be integral with the electrical energy source and may extend into the receiving chamber such that when the aerosol source member is inserted into the receiving chamber of the control body, the contacts form an electrical connection with the aerosol precursor composition. Due to the presence of electrically conductive materials in the aerosol precursor composition, applying power from an electrical energy source to the aerosol precursor composition allows an electrical current to flow, thereby generating heat from the electrically conductive material. Thus, in some embodiments, the heating element may be described as integral with the aerosol precursor composition. As a non-limiting example, graphite or other suitable conductive material may be mixed with, embedded within, or otherwise directly on or within the material forming the aerosol precursor composition to create a heating element that is integral with the medium.

[0094] As noted above, in the illustrated embodiment, the sheath 530 may also function to facilitate proper positioning of the aerosol source member 304 when the aerosol source member is inserted into the housing 516. In various embodiments, the sheath of the heating assembly 528 may engage an inner surface of the housing to align the heating assembly relative to the housing, such that, as a result of the fixed coupling between the heating assemblies, the longitudinal axis of the heating assembly may extend substantially parallel to the longitudinal axis of the housing. In particular, a support cylinder may extend from the housing opening 518 to the receiving base 534 to create a receiving chamber 536.

[0095] The heated end 406 of the aerosol source member 304 is sized and shaped for insertion into the control body 302. In various embodiments, the receiving chamber 536 of the control body may be characterized as being defined by a wall having an inner surface and an outer surface, the inner surface defining the interior volume of the receiving chamber. For example, in the illustrated embodiment, the barrel 530 defines an inner surface that defines the interior volume of the receiving chamber. In the illustrated embodiment, the inner diameter of the barrel may be slightly larger or approximately equal to the outer diameter of the corresponding aerosol source member (e.g., to create a snug fit) such that the barrel is configured to guide the aerosol source member into an appropriate position (e.g., lateral position) relative to the control body. Thus, the maximum outer diameter (or other dimension depending on the particular cross-sectional shape of this embodiment) of the aerosol source member may be sized to be smaller than the inner diameter (or other dimension) at the inner surface of the wall of the open end of the receiving chamber of the control body. In some embodiments, the difference in their respective diameters may be small enough that the aerosol source member fits snugly into the receiving chamber and frictional forces prevent the aerosol source member from moving without an applied force, while such difference may be sufficient to allow the aerosol source member to slide in and out of the receiving chamber without the need for excessive force.

[0096] In the illustrated embodiment, the control body 302 is configured such that when the aerosol source member 304 is inserted into the control body, the heating element 532 (e.g., heater prongs) are positioned approximately radially centered on at least a portion of the aerosol precursor composition 410 at the heated end 406 of the aerosol source member. In such a manner, when used in conjunction with a solid, or semi-solid, aerosol precursor composition, the heater prongs may be in direct contact with the aerosol precursor composition. In other embodiments, such as when used in conjunction with an extruded aerosol precursor composition that defines a tubular structure, the heater prongs may be positioned inside a cavity defined by an inner surface of the extruded tubular structure, without contacting the inner surface of the extruded tubular structure.

[0097] During use, a consumer initiates heating of the heating assembly 528, particularly the heating element 532 adjacent to the aerosol precursor composition 410 (or a particular layer thereof). Heating the aerosol precursor composition releases the inhalable substance within the aerosol source member 304 to produce an inhalable substance. When the consumer inhales at the mouth end 408 of the aerosol source member, air is drawn into the aerosol source member through an air intake 538, such as an opening or aperture in the control body 302. As the inhaled substance exits the mouth end of the aerosol source member, a combination of the drawn-in air and the released inhalable substance is inhaled by the consumer. In some embodiments, to initiate heating, a consumer can manually activate a push button or similar component that causes the heating element of the heating assembly to receive electrical energy from a battery or other energy source. The electrical energy may be provided for a predetermined period of time or may be manually controlled.

[0098] In some embodiments, the flow of electrical energy does not proceed substantially between puffs in the device 300 (although the flow of energy may proceed to maintain a baseline temperature above ambient temperature - e.g., a temperature that facilitates rapid heating to an active heating temperature). However, in the illustrated embodiment, heating is initiated by the consumer's act of taking a puff through the use of one or more sensors, such as flow sensor 520. When a puff is discontinued, heating is stopped or reduced. When the consumer has taken a sufficient number of puffs to release a sufficient amount of inhalable substance (e.g., an amount sufficient to equate to a typical smoking experience), the aerosol source member 304 may be detached from the control body 302 and discarded. In some embodiments, additional sensing elements, such as capacitive sensing elements and other sensors, may be used as discussed in U.S. Patent Application Serial No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference.

[0099] In various embodiments, the aerosol source member 304 may be formed of any material suitable for forming and maintaining a reasonable conformation, such as a tubular shape, and for retaining the aerosol precursor composition 410 therein. In some embodiments, the aerosol source member may be formed of a single wall, or in other embodiments, multiple walls, and may be formed of a material (natural or synthetic) that is heat resistant so as to retain its structural integrity - e.g., not deteriorate - at least at the heating temperature provided by the electric heating element, as discussed further herein. In some embodiments, a heat resistant polymer may be used, while in other embodiments, the aerosol source member may be formed of paper, such as a substantially straw-shaped paper. As discussed further herein, the aerosol source member may have one or more layers associated therewith that function to substantially prevent the movement of vapor therethrough. In one exemplary embodiment, an aluminum foil layer may be laminated to one surface of the aerosol source member. A ceramic material may be used. In further embodiments, an insulating material may be used to avoid unnecessarily directing heat away from the aerosol precursor composition. Further exemplary types of components and materials that may be used to provide the above functionality or that may be used as substitutes for the above materials and components may be of the type described in U.S. Patent Application Publication Nos. 2010 / 00186757 to Crooks et al., 2010 / 00186757 to Crooks et al., and 2011 / 0041861 to Sebastian et al., which are incorporated herein by reference.

[0100] In the illustrated embodiment, the control body 302 includes a control component 522 that controls various functions of the aerosol delivery device 300, including providing power to the electric heating element 532. For example, the control component may include a processing circuit connected by conductive wires (not shown) to a power source 524 (which may be connected to additional components as further described herein). In various embodiments, the processing circuit may control when and how the heating assembly 528, particularly the heater prongs, receive electrical energy to heat the aerosol precursor composition 410 for release of an inhalable substance for inhalation by a consumer. In some embodiments, such control may be activated by a flow sensor 520, as described in more detail above.

[0101] 5 and 6, the heating assembly 528 of the illustrated embodiment comprises a barrel 530 and a heating element 532 (e.g., a plurality of heater prongs) extending from a receiving base 534. In some embodiments, such as those in which the aerosol precursor composition 410 comprises a tubular structure, the heater prongs may be configured to extend into a cavity defined by an inner surface of the aerosol precursor composition. In other embodiments, such as the illustrated embodiment in which the aerosol precursor composition comprises a solid or semi-solid, the plurality of heater prongs are configured to penetrate the aerosol precursor composition contained in the heated end 406 of the aerosol source member 304 when the aerosol source member is inserted into the control body 302. In such embodiments, one or more components of the heating assembly, including the heater prongs and / or the receiving base, may be constructed of a non-stick or stick-resistant material, such as certain aluminum, copper, stainless steel, carbon steel, and ceramic materials. In other embodiments, one or more of the components of the heating assembly, including the heater prongs and / or the receiving base, may include other coatings, such as, for example, a non-stick coating including a polytetrafluoroethylene (PTFE) coating such as Teflon®, or a stick-resistant enamel coating, or a ceramic coating such as Greblon® or Thermolon™, or a ceramic coating such as Greblon® or Thermolon™.

[0102] Additionally, it should be noted that while in the illustrated embodiment, there are multiple heater prongs 532 substantially equally distributed around the receiving base 534, in other embodiments, any number of heater prongs may be used, including as few as one, in any other suitable spatial configuration. Furthermore, in various embodiments, the length of the heater prongs may vary. For example, in some embodiments, the heater prongs may comprise small protrusions, while in other embodiments, the heater prongs may extend any portion of the length of the receiving chamber 536, including up to about 25%, up to about 50%, up to about 75%, and up to nearly the entire length of the receiving chamber. In still other embodiments, the heating assembly 528 may have other configurations. Examples of other heater configurations that may be adapted for use in the present disclosure in accordance with the discussion provided above are described in U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al., U.S. Pat. No. 5,224,498 to Deevi et al., U.S. Pat. No. 5,224,498 to Sprinkel et al., and U.S. Pat. No. 5,311,623 to Counts et al., and U.S. Pat. No. 5,311,623 to Counts et al., and U.S. Pat. No. 5,311,623 to Deevi et al., and U.S. Pat. No. 5,311,623 to Sprinkel ... No. 5,228,460 to Jr. et al., U.S. Pat. No. 5,322,075 to Deevi et al., U.S. Pat. No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al., U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S. Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 to Hajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, and U.S. Pat. No. 5,573,692 to Das et al., and U.S. Pat. No. 5,591,368 to Fleischhauer et al., which are incorporated herein by reference.

[0103] In various embodiments, the control body 302 may include an air intake 538 (e.g., one or more openings or apertures) therein to allow ambient air to enter the interior of the receiving chamber 536. In such a manner, in some embodiments, the receiving base 534 may also include an air intake. Thus, in some embodiments, when a consumer inhales on the mouth-end of the aerosol source member 304, air may be drawn into the receiving chamber through the air intakes of the control body and receiving base, proceed into the aerosol source member, and be drawn through the aerosol precursor composition 410 of the aerosol source member for inhalation by the consumer. In some embodiments, the drawn air carries the inhalable substance through the optional filter 414 and out the opening at the mouth-end 408 of the aerosol source member. With the heating element 532 positioned within the aerosol precursor composition, the heater prongs may be activated to heat the aerosol precursor composition and cause the release of the inhalable substance through the aerosol source member.

[0104] As discussed above, particularly with reference to FIGS. 5 and 6, various embodiments of the present disclosure use an electrically conductive heater to heat the aerosol precursor composition 410. Also as indicated above, various other embodiments use an inductive heater to heat the aerosol precursor composition. In some of these embodiments, the heating assembly 528 may be configured as an inductive heater comprising a transformer with an inductive transmitter and an inductive receiver. In embodiments in which the heating assembly is configured as an inductive heater, the outer barrel 530 may be configured as an inductive transmitter and the heating element 532 (e.g., multiple heater prongs) extending from the receiving base 534 may be configured as an inductive receiver. In various embodiments, one or both of the inductive transmitter and the inductive receiver may be disposed in the control body 302 and / or the aerosol source member 304.

[0105] In various embodiments, the outer barrel 530 and the heating element 532 as the inductive transmitter and receiver may be constructed from one or more conductive materials, and in further embodiments, the inductive receiver may be constructed from a ferromagnetic material, including but not limited to cobalt, iron, nickel, and combinations thereof. In one exemplary embodiment, the foil material is constructed from a conductive material and the heater prongs are constructed from a ferromagnetic material. In various embodiments, the receiving base may be constructed from a non-conductive and / or insulating material.

[0106] The outer cylinder 530 as an induction transmitter may include a laminate with a foil material surrounding a support cylinder. In some embodiments, the foil material may include electrical traces printed thereon, such as, for example, one or more electrical traces that may form a helical coil pattern when the foil material is positioned around the heating element 532 as an induction receiver in some embodiments. The foil material and the support cylinder may each define a tubular configuration. The support cylinder may be configured to support the foil material such that the foil material does not move into contact with the heater prongs and thereby short out with the heater prongs. In such a manner, the support cylinder may include a non-conductive material, which may be substantially transparent to the oscillating magnetic field generated by the foil material. In various embodiments, the foil material may be embedded in or otherwise coupled to the support cylinder. In the illustrated embodiment, the foil material is engaged with an outer surface of the support cylinder; however, in other embodiments, the foil material may be positioned on an inner surface of the support cylinder or may be fully embedded in the support cylinder.

[0107] The foil material of the outer barrel 530 may be configured to create an oscillating magnetic field (e.g., a magnetic field that changes periodically with time) when an alternating current is directed therethrough. The heater prongs of the heating element 532 are at least partially disposed or received within the outer barrel and may include an electrically conductive material. By directing an alternating current through the foil material, eddy currents may be generated in the heater prongs via induction. The eddy currents flowing through the resistance of the material defining the heater prongs may heat the heater prongs by Joule heating (i.e., through the Joule effect). The heater prongs may be wirelessly heated to form an aerosol from an aerosol precursor composition 410 positioned near the heater prongs.

[0108] Other embodiments of aerosol delivery devices, control bodies, and aerosol source members are described in the above-cited U.S. patent application Ser. No. 15 / 916,834 to Sur et al., U.S. patent application Ser. No. 15 / 916,696 to Sur, and U.S. patent application Ser. No. 15 / 836,086 to Sur.

[0109] As mentioned above, the aerosol delivery device of the exemplary embodiment may include various electronic components in the context of either an e-cigarette or a non-combustion heating device, or even in the case of a device including both functions. FIG. 7 illustrates a circuit diagram of an aerosol delivery device 700, which may be either or both of the aerosol delivery devices 100, 300, or may incorporate the functions thereof, according to various exemplary embodiments of the present disclosure. As shown in FIG. 7, the aerosol delivery device 700 includes a control body 702 including a power source 704 and a control component 706, which may correspond to or include the functions of the power source 212, 524, the control components 208, 522, and the control body 102, 302, respectively. The aerosol delivery device also includes a heating element 716, which may correspond to or include the functions of the heating element 220, 532. In some embodiments, the aerosol delivery device 700, particularly the control body 702, includes a terminal 714 configured to connect the power source 704 to the aerosol delivery device, or particularly to the control body. The control body may include a heating element or a second terminal 718 configured to connect a heating element to the control body.

[0110] In some embodiments, the control component 706 includes a boost converter 708, an inverter 710, and at least one non-inverting amplifier circuit 712. The boost converter is configured to step up the voltage from the power source 704 to a higher voltage. In some embodiments where the power source is or includes a single lithium ion battery (LiB), the boost converter is configured to step up the voltage from the single LiB to the higher voltage.

[0111] The inverter 710 is configured to convert the higher voltage from the boost converter 708 to a complementary negative voltage. In some embodiments, the inverter includes a logic gate configured to invert the higher voltage to the complementary negative voltage.

[0112] The non-inverting amplifier circuit 712 may include an operational amplifier (OP-AMP shown in FIG. 7) and two resistors R1 and R2 arranged in a non-inverting configuration. In the non-inverting configuration, the operational amplifier may receive a voltage from the power supply 704 as the non-inverting input (+) of the operational amplifier, and the inverting input (-) of the operational amplifier may be connected to feedback from the output of the operational amplifier through resistor R1 and to ground through resistor R2. In some examples, the gain of the operational amplifier in this configuration is

number

[0113] The non-inverting amplifier circuit 712 is coupled to a heating element 716, or a second terminal 718 configured to connect the heating element to the control body 702. In some embodiments, the non-inverting amplifier circuit, particularly the operational amplifier, is configured to receive a voltage from the power supply 704 as an input voltage, such as at its non-inverting (+) input, as described above. The non-inverting amplifier circuit 712, particularly the operational amplifier, is also configured to receive a higher voltage from the boost converter 708 and a complementary negative voltage from the inverter 710 as supply voltages. For example, the operational amplifier can receive the higher voltage and the complementary negative voltage as a positive supply voltage and a negative supply voltage, respectively.

[0114] In another example, the non-inverting amplifier circuit 712, particularly the operational amplifier, may be configured to receive the higher voltage from the boost converter 708 as a single supply voltage. In this example, the higher voltage from the boost converter may be provided as a positive supply voltage for the operational amplifier. The higher voltage from the boost converter may be 8V or 16V in some examples. Also, the negative supply voltage for the operational amplifier may be connected to ground. Thus, in this example, the control component 706 may not include an inverter 710 to convert the higher voltage from the boost converter 708 to a complementary negative voltage.

[0115] The non-inverting amplifier circuit 712 is configured to amplify the input voltage (i.e., the voltage from the power supply 704) to an output voltage and provide a continuous output current from which the heating element 716 is powered. That is, the heating element is powered by the continuous output current. In some embodiments, the continuous output current is at least about 9 amps (A) when the heating element is at 0.3 ohms. In these embodiments, the continuous output current can include a margin of error or manufacturing tolerance, for example, the continuous output current may be 8.9 amps to account for the margin of error or manufacturing tolerance. In some embodiments, the continuous output current may include momentary fluctuations above or below a certain continuous output target.

[0116] In some embodiments, the non-inverting amplifier circuit 712 includes multiple operational amplifiers, each of which is configured to receive a voltage from the power supply 704 as an input voltage, a higher voltage from the boost converter 708, and a complementary negative voltage from the inverter 710 as supply voltages, similar to that described above. The multiple operational amplifiers are configured to amplify the input voltages to respective output voltages and provide respective continuous output currents from which the heating element 716 is powered.

[0117] In some embodiments, the multiple operational amplifiers are configured to provide a sum of their respective continuous output currents to the heating element 716. For example, the sum of their respective continuous output currents can be 27 A. In some embodiments, the multiple operational amplifiers are configured to provide a sum of their respective output voltages to the heating element. For example, the sum of their respective output voltages can be 27 volts (V). A non-inverting amplifier circuit including multiple operational amplifiers is described in more detail with reference to FIG. 9 below.

[0118] 8 illustrates a circuit diagram of components of an aerosol delivery device including a power supply 704, a non-inverting amplifier circuit 800, and a load resistor 801, which may correspond to the non-inverting amplifier circuit 712 and the heating element 716, respectively, according to an exemplary embodiment of the present disclosure. As shown, in some embodiments, the non-inverting amplifier circuit 800 includes an operational amplifier 802. One example of a suitable operational amplifier is model OPA549T manufactured by Texas Instruments. The operational amplifier may receive a voltage of 4V from the power supply as the non-inverting input (+) of the operational amplifier. The inverting input (-) of the operational amplifier may be connected to feedback from the output of the operational amplifier via resistor R1 and to ground via resistor R2.

[0119] In one example, the positive supply voltage of the operational amplifier 802 may be V2=8V, as indicated by arrow 803. The boost converter 708 (not shown in FIG. 8) may step up a voltage of 4V from the power supply 704 to generate a positive supply voltage V2 having 8V. In this example, the negative supply voltage of the operational amplifier may be a complementary negative voltage V1=-8V, as indicated by arrow 804. The inverter 710 (not shown in FIG. 8) may convert V2 having 8V from the boost converter to generate a complementary negative voltage V1 having -8V. Based on the circuit described in FIG. 8, the operational amplifier may provide a continuous output current, such as at least 9A, to the load resistor 801. It should be noted that the values ​​(e.g., voltage, current, frequency, and resistance) shown in FIG. 8 are merely for illustrative purposes, and unless otherwise specified, the values ​​should not be construed as limiting the present disclosure.

[0120] 9 shows a circuit diagram of components of an aerosol delivery device including a power source 704 and multiple non-inverting amplifier circuits 901, 902, and 903 (e.g., three are shown) according to another exemplary embodiment of the present disclosure. As shown, each of the non-inverting amplifier circuits may correspond to the non-inverting amplifier circuits 712 or 800 described above. Each of the non-inverting amplifier circuits includes a respective operational amplifier 911, 912, and 913, which may correspond to an OP-AMP as shown in FIG. 7, or operational amplifier 801 as shown in FIG.

[0121] 9, in a non-inverting configuration, each of the operational amplifiers 911, 912 and 913 may receive a voltage from the power supply 704 as an input voltage, such as a non-inverting input (+). The inverting input (-) of each of the operational amplifiers may be connected to a feedback from the output of the operational amplifier via a respective resistor R2, R6 or R10, and connected to ground via a respective resistor R1, R5 or R4.

[0122] As also shown in FIG. 9, the positive supply voltage of the operational amplifier 911 can be V1 and the negative supply voltage of the operational amplifier 911 can be V2. The boost converter 708 (not shown in FIG. 9) can step up a voltage (e.g., 4V) from the power supply 704 to generate a positive supply voltage V1 (e.g., 8V). The inverter 710 (not shown in FIG. 9) can invert V1 from the boost converter to generate a complementary negative voltage V2 (e.g., −8V). Similarly, the positive supply voltage of the operational amplifier 912 can be V3 and the negative supply voltage of the operational amplifier 912 can be V4. The positive supply voltage of the operational amplifier 913 can be V5 and the negative supply voltage of the operational amplifier 913 can be V6. As above, the positive supply voltages V3 and V5 can be generated by the boost converter and the negative supply voltages V4 and V6 can be generated by the inverter.

[0123] In one example, based on the circuit described in FIG. 9, the multiple operational amplifiers can amplify the input voltage to a respective output voltage and provide a respective continuous output current. The heating element 716 can be powered by the respective continuous output current. For example, each of the three operational amplifiers 911, 912, and 913 can provide a respective continuous output current of at least 9 A. Thus, with the three operational amplifiers configured as in FIG. 9, the sum of the respective continuous output currents (e.g., at least 9+9+9=27 A) can be provided to the heating element. In another example, each of the three operational amplifiers can provide a respective output voltage of at least 9 V. Thus, with the three operational amplifiers arranged as in FIG. 9, the sum of the respective output voltages (e.g., at least 9+9+9=27 V) can be provided to the heating element.

[0124] 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 therefore to be understood that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol delivery device comprising: a terminal configured to connect a power source to the aerosol delivery device; a boost converter configured to step up a voltage from a power supply to a higher voltage; an inverter configured to convert the higher voltage from the boost converter to a complementary negative voltage; at least one non-inverting amplifier circuit including an operational amplifier configured to receive a voltage from the power source as an input voltage, a higher voltage from the boost converter and a complementary negative voltage from the inverter as supply voltages to the operational amplifier, the at least one non-inverting amplifier circuit configured to amplify the input voltage from the power source to an output voltage and provide a continuous output current from which an aerosol delivery device is powered to generate an aerosol from the aerosol precursor composition; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the power source comprises a single battery or a single battery cell.

3. 3. The aerosol delivery device of claim 1 or 2, wherein the power source is or includes a single lithium ion battery (LiB) and the boost converter is configured to step up the voltage from the single LiB to a higher voltage.

4. 4. The aerosol delivery device of claim 1, wherein the continuous output current is at least about 9 amps.

5. 5. The aerosol delivery device of claim 1, wherein the at least one non-inverting amplifier circuit includes a plurality of operational amplifiers, each configured to receive a voltage from a power source as an input voltage and a higher voltage and a complementary negative voltage as supply voltages, the plurality of operational amplifiers configured to amplify the input voltages to respective output voltages and provide respective continuous output currents from which the aerosol delivery device is powered to generate an aerosol from the aerosol precursor composition.

6. 6. The aerosol delivery device of claim 5, wherein the plurality of operational amplifiers are configured such that a sum of their respective continuous output currents is provided to power the aerosol delivery device to generate an aerosol from the aerosol precursor composition.

7. 7. The aerosol delivery device of claim 5 or 6, wherein the multiple operational amplifiers are configured such that a sum of their respective output voltages is provided to power the aerosol delivery device to generate an aerosol from the aerosol precursor composition.

8. 8. The aerosol delivery device of claim 1, wherein the aerosol precursor composition comprises a liquid, a solid, or a semi-solid.

9. 9. The aerosol delivery device of claim 1, wherein the inverter comprises a logic gate configured to invert the higher voltage to a complementary negative voltage.

10. A control body of an aerosol delivery device, comprising: a terminal configured to connect a power source to the control body; a boost converter configured to step up a voltage from a power supply to a higher voltage; an inverter configured to convert the higher voltage from the boost converter to a complementary negative voltage; at least one non-inverting amplifier circuit including an operational amplifier configured to receive a voltage from the power source as an input voltage, a higher voltage from the boost converter and a complementary negative voltage from the inverter as supply voltages to the operational amplifier, the at least one non-inverting amplifier circuit configured to amplify the input voltage from the power source to an output voltage and provide a continuous output current from which an aerosol delivery device is powered to generate an aerosol from the aerosol precursor composition; A control body of an aerosol delivery device comprising:

11. The control body of claim 10, wherein the power source comprises a single battery or a single battery cell.

12. 12. The control body of claim 10 or 11, wherein the power source is or includes a single lithium ion battery (LiB), and the boost converter is configured to step up the voltage from the single LiB to a higher voltage.

13. 13. A control body according to any one of claims 10 to 12, wherein the continuous output current is at least about 9 amps.

14. A control body as described in any one of claims 10 to 13, wherein at least one non-inverting amplifier circuit includes a plurality of operational amplifiers each configured to receive a voltage from a power source as an input voltage and a higher voltage and a complementary negative voltage as supply voltages, the plurality of operational amplifiers configured to amplify the input voltages to respective output voltages and provide respective continuous output currents from which an aerosol delivery device is powered to generate an aerosol from an aerosol precursor composition.

15. The control body of claim 14 , wherein the plurality of operational amplifiers are configured such that a sum of their respective continuous output currents is provided to power an aerosol delivery device to generate an aerosol from the aerosol precursor composition.

16. 16. The control body of claim 14 or 15, wherein the multiple operational amplifiers are configured such that the sum of their respective output voltages is provided to power an aerosol delivery device to generate an aerosol from the aerosol precursor composition.

17. 17. The control body of any one of claims 10 to 16, wherein the aerosol precursor composition comprises a liquid, a solid, or a semi-solid.

18. 18. A control body as claimed in any one of claims 10 to 17, wherein the inverter comprises a logic gate configured to invert the higher voltage to a complementary negative voltage.

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