Temperature control circuit for an aerosol delivery device

Abstract

An aerosol delivery device is provided. The aerosol delivery device includes a power source, a heating element having a resistance that is variable and proportional to the temperature of the heating element, and a power switch coupled to the power source and the heating element and located between the power source and the heating element. The aerosol delivery device also includes a processing circuit and a low-side current sensing circuit coupled to the heating element and located between the heating element and the processing circuit. The low-side current sensing circuit generates an output voltage equal to or proportional to an output heater voltage at the heating element. The processing circuit measures the output voltage, determines the resistance of the heating element, determines the temperature of the heating element from the resistance, and adjusts a signal to the power switch when the temperature deviates from a predetermined set point.

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 electronic cigarettes) that can utilize electrically generated heat for aerosol generation. The smoking article may be configured to heat an aerosol precursor, which can incorporate materials that can be made from or extracted from tobacco, or otherwise incorporate tobacco, and the precursor can form an inhalable substance for human consumption.

Background Art

[0002] Over the years, many smoking articles have been proposed as improved or alternative smoking products by burning tobacco for use. Some exemplary alternatives include devices where a solid fuel or a liquid fuel is burned to transfer heat to the tobacco or where a chemical reaction is used to provide such a heat source. Additional exemplary alternatives 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 points of improved or alternative products for smoking articles typically involve providing the sensations associated with cigarette, cigar, or pipe smoking without delivering significant amounts of incomplete combustion and pyrolysis products. For this purpose, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile substances, or to provide the sensations of cigarette, cigar, or pipe smoking without burning the tobacco to a significant extent. Reference is made to the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art as set forth in, for example, 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., the disclosures of which are incorporated herein by reference. Also, reference is made to the various types of smoking articles, aerosol delivery devices, and electric heat sources as referenced by trademark name and commercial source in, for example, U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., the disclosure of which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electric heat sources referenced by trademark name and commercial provider are listed in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., the disclosure of which is also incorporated herein by reference.has been described, and in some examples, other representative cigarette or smoking articles that are commercially available include those described in U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patents Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,249,586 to Morgan et al.; U.S. Patent No. 5,388,594 to Counts et al.; U.S. Patent 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. 7,513,253 to Kobayashi; 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 Publications Nos. 2006 / 0196518, 2009 / 0126745, and 2009 / 0188490 to Hon; U.S. Patent Publication No. 2009 / 0272379 to Thorens et al.; U.S. Patent Publications Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al.; U.S. Patent Publications Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al.; U.S. Patent Publication No. 2010 / 0307518 to Wang; and those described in WO2010 / 091593 to Hon, and these patents are incorporated herein by reference.

[0004] Many representative products that resemble many attributes of traditional types of cigarettes, cigars or pipes are 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 B.V.; 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(TM) by FIN Branding Group, LLC; SMOKE(R) by Green Smoke Inc.; GREENARETTE(TM) by Greenarette LLC, HALLIGAN(TM), HENDU(TM), JET(TM), MAXXQ(TM), PINK(TM) and PITBULL(TM) by SMOKE STIK(R); 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 LLC7(TM); PREMIUM ELECTRONIC CIGARETTE(TM) by PremiumEstore LLC; RAPP E-MYSTICK(TM) by Ruyan America; 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 R.J. Reynolds Vapor Company; MISTIC MENTHOL products by Mistic Ecigs; the VYPE products by CN Creative Ltd; IQOS(TM) by Philip Morris International; GLO(TM) by British American Tobacco; MARK TEN products by Nu Mark LLC; and JUUL products by Juul Labs, Inc. are commercially available. Additionally, other electric aerosol delivery devices, and in particular, those devices characterized as so-called electronic cigarettes, are also commercially available under trade names such as COOLER VISIONS(TM); DIRECT E-CIG(TM); DRAGONFLY(TM); EMIST(TM); EVERSMOKE(TM); GAMUCCI(R); HYBRID FLAME(TM); KNIGHT STICKS(TM); ROYAL BLUES(TM); SMOKETIP(R); and SOUTH BEACH SMOKE(TM).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

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SUMMARY OF THE INVENTION

PROBLEMS TO BE SOLVED BY THE INVENTION

[0006] However, it may be desirable to provide an aerosol delivery device with an improved electronic device that can extend the usefulness of the device.

MEANS FOR SOLVING THE PROBLEMS

[0007] The present disclosure relates to an aerosol delivery device configured to generate an aerosol, which may be referred to as an electronic cigarette or a non-combustion heated cigarette in some embodiments. The present disclosure includes, without limitation, examples of the following exemplary embodiments.

[0008] Exemplary Embodiment 1: An aerosol delivery device comprising: a power source configured to provide a voltage; a heating element powered to vaporize components of an aerosol precursor composition, the heating element being variable and having a resistance proportional to the temperature of the heating element; a power switch coupled between the power source and the heating element; a processing circuit coupled to the power switch and configured to output a signal during a heating period to switchably connect and disconnect a voltage provided by the power source to the power switch to supply power to the heating element, and to measure an input heater voltage in the heating element equal to or proportional to the voltage provided by the power source; A low-side current sensing circuit coupled to a heating element and a processing circuit and located between the heating element and the processing circuit, the low-side current sensing circuit being configured to generate an output voltage equal to or proportional to the output heater voltage in the heating element, and the processing circuit being further configured to measure the output voltage, determine the resistance of the heating element from the input heater voltage and the output voltage, determine the temperature of the heating element from the resistance, and adjust a signal when the temperature deviates from a predetermined set point, an aerosol delivery device.

[0009] Exemplary embodiment 2: The power source includes one or more batteries or battery cells, an aerosol delivery device of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments.

[0010] Exemplary embodiment 3: The processing circuit is configured to output a pulse width modulation (PWM) signal and adjust the duty cycle of the PWM signal, an aerosol delivery device of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments.

[0011] Exemplary embodiment 4: The heating element is formed from an element including platinum (Pt), titanium (Ti), copper (Cu), nickel (Ni), or at least one alloy thereof, an aerosol delivery device of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments.

[0012] Exemplary embodiment 5: The aerosol precursor composition includes one or more of a liquid, a solid, or a semi-solid, an aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments.

[0013] Exemplary embodiment 6: The input heater voltage in the heating element is equal to the voltage provided by the power source, an aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments.

[0014] Exemplary embodiment 7: The aerosol delivery device is an aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, further comprising a switching regulator including a power switch. The switching regulator steps down the voltage provided by the power supply to an input heater voltage, which is configured to be proportional to the voltage provided by the power supply.

[0015] Exemplary embodiment 8: The low-side current sensing circuit is an aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, coupled between the output of the heating element and ground and including a shunt resistor between the output of the heating element and ground. The output voltage generated by the low-side current sensing circuit is equal to the output heater voltage, the output heater voltage is equal to the input resistor voltage across the shunt resistor, and the processing circuit is further configured to determine the resistance of the heating element from the resistance value of the shunt resistor.

[0016] Exemplary embodiment 9: The low-side current sensing circuit is an aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, including a non-inverting operational amplifier circuit and a shunt resistor, both of which are coupled to the output of the heating element, and the processing circuit is further configured to determine the resistance of the heating element from the gain of the non-inverting operational amplifier circuit and the resistance value of the shunt resistor.

[0017] Exemplary embodiment 10: The aerosol delivery device is an aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, wherein the resistance value of the shunt resistor is the reciprocal of the gain of the non-inverting operational amplifier circuit.

[0018] Exemplary Embodiment 11: The aerosol delivery device of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, wherein the low-side current sensing circuit further includes two decoupling capacitors coupled to the non-inverting operational amplifier and configured to cancel the noise gain of the non-inverting operational amplifier.

[0019] Exemplary Embodiment 12: A control body for an aerosol delivery device, comprising: A power supply configured to provide a voltage; A heating element or a terminal configured to connect the heating element to the control body, wherein the heating element is powered to vaporize a component of the aerosol precursor composition and has a variable resistance proportional to the temperature of the heating element, the heating element or the terminal; A power switch coupled between the power supply and the heating element; A processing circuit coupled to the power switch and configured to output a signal during a heating period to switchably connect and disconnect the power switch to the voltage provided by the power supply to supply power to the heating element, and to measure an input heater voltage at the heating element equal to or proportional to the voltage provided by the power supply; A low-side current sensing circuit coupled between the heating element and the processing circuit and configured to generate an output voltage equal to or proportional to the output heater voltage at the heating element, wherein the processing circuit measures the output voltage, determines the resistance of the heating element from the input heater voltage and the output voltage, determines the temperature of the heating element from the resistance, and is further configured to adjust a signal when the temperature deviates from a predetermined set point, the control body for an aerosol delivery device.

[0020] Exemplary Embodiment 13: The control body of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, wherein the power supply includes one or more batteries or battery cells.

[0021] Exemplary Embodiment 14: The control body of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments, wherein the processing circuit is configured to output a pulse width modulation (PWM) signal and adjust the duty cycle of the PWM signal.

[0022] Exemplary Embodiment 15: The control body of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments, wherein the heating element is formed from an element comprising platinum (Pt), titanium (Ti), copper (Cu), nickel (Ni), or at least one alloy thereof.

[0023] Exemplary Embodiment 16: The control body of any of the foregoing exemplary embodiments, or any combination of any of the foregoing exemplary embodiments, wherein the aerosol precursor composition comprises one or more of a liquid, a solid, or a semi-solid.

[0024] Exemplary Embodiment 17: The control body of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments, wherein the input heater voltage in the heating element is equal to the voltage provided by the power source.

[0025] Exemplary Embodiment 18: The control body of any of the foregoing exemplary embodiments, and any combination of any of the foregoing exemplary embodiments, wherein the aerosol delivery device further comprises a switching regulator including a power switch. The switching regulator steps down the voltage provided by the power source to the input heater voltage, and the input heater voltage is configured to be proportional to the voltage provided by the power source.

[0026] Exemplary Embodiment 19: The low-side current sensing circuit is coupled to the output of the heating element and ground, and includes a shunt resistor between the output of the heating element and ground, and is a control body of any of the foregoing exemplary embodiments and any combination of any of the foregoing exemplary embodiments. The output voltage generated by the low-side current sensing circuit is equal to the output heater voltage, the output heater voltage is equal to the input resistor voltage across the shunt resistor, and the processing circuit is further configured to determine the resistance of the heating element from the resistance value of the shunt resistor.

[0027] Exemplary Embodiment 20: The low-side current sensing circuit includes a non-inverting operational amplifier circuit and a shunt resistor, both of which are coupled to the output of the heating element, and the processing circuit is further configured to determine the resistance of the heating element from the gain of the non-inverting operational amplifier circuit and the resistance value of the shunt resistor, and is a control body of any of the foregoing exemplary embodiments and any combination of any of the foregoing exemplary embodiments.

[0028] Exemplary Embodiment 21: The resistance value of the shunt resistor is the reciprocal of the gain of the non-inverting operational amplifier circuit, and is a control body of any of the foregoing exemplary embodiments and any combination of any of the foregoing exemplary embodiments.

[0029] Exemplary Embodiment 22: The low-side current sensing circuit further includes two decoupling capacitors coupled to the non-inverting operational amplifier and configured to cancel the noise gain of the non-inverting operational amplifier, and is a control body of any of the foregoing exemplary embodiments and any combination of any of the foregoing exemplary embodiments.

[0030] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description when read 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 herein, whether or not such features or elements are explicitly combined or otherwise recited in the specific exemplary embodiments described herein. The present disclosure is intended to be read as a whole such that, unless the context of its disclosure clearly indicates otherwise, any separable feature or element of the present disclosure may be combined in any of its aspects and exemplary embodiments.

[0031] Accordingly, it is to be understood that this brief summary is provided for the sole purpose of providing a basic understanding of some aspects of the present disclosure by summarizing some exemplary embodiments and is not intended to limit the scope or spirit of the present disclosure in any way. Thus, it is to be understood that the above exemplary embodiments are merely examples and should in no way be construed as limiting the scope or spirit of the present disclosure. Other exemplary embodiments, aspects, and advantages will become apparent from the following detailed description when read in conjunction with the accompanying drawings, which illustrate the principles of some of the described exemplary embodiments by way of example.

[0032] Having thus described aspects of the present disclosure in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale.

Brief Description of the Drawings

[0033]

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DETAILED DESCRIPTION OF THE INVENTION

[0034] The present disclosure will be described more fully hereinafter with reference to its exemplary embodiments. These exemplary embodiments are described so that the present disclosure will be thorough and complete and will fully convey the scope of the present disclosure to those skilled in the art. In fact, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will meet applicable legal requirements. As used in the specification and the appended claims, the singular forms "a," "an," "the," etc. include plural referents unless the context clearly dictates otherwise. Also, although quantitative measures, values, geometric relationships, etc. may be referred to herein, unless otherwise specified, all or any one or more of these are absolute or may be approximate to account for possible variations, such as technical tolerances.

[0035] As described below, exemplary embodiments of the present disclosure relate to aerosol delivery devices. An aerosol delivery device according to the present disclosure uses electrical energy to heat a material (preferably without significantly burning the material) to form an inhalable substance, and the components of such a system 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 a preferred aerosol delivery device does not result in the generation of smoke in the sense that the aerosol mainly results from the by-products of tobacco combustion or pyrolysis. Rather, the use of such a preferred system results in the generation of vapor resulting from the volatilization or vaporization of the specific components incorporated therein. In some exemplary embodiments, the components of the aerosol delivery device may be characterized as electronic cigarettes, and these electronic cigarettes most preferably incorporate tobacco and / or tobacco-derived components, and thus deliver tobacco-derived components in aerosol form.

[0036] The aerosol-generating components of certain preferred aerosol delivery devices can provide many of the sensations (e.g., inhalation and exhalation actions, types of taste or flavor, sensory effects, physical sensations, usage behaviors, visual cues such as those provided by the visible aerosol) used by smoking a cigarette, cigar, or pipe by igniting and burning tobacco (and thus inhaling tobacco smoke) without causing any substantial degree of combustion of any of its components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the components in the same manner as a smoker uses a traditional type of smoking article, inhaling one end of the components for inhalation of the aerosol generated by the components, and exhaling at selected time intervals, etc.

[0037] This system is generally described herein in terms of embodiments related to aerosol delivery devices such as so-called "electronic cigarettes," "tobacco heating products," etc., but it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and may be associated with a variety of articles. For example, the descriptions provided herein may be used in connection with embodiments of related packaging for any of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustible heated cigarettes, and the products disclosed herein. Accordingly, it should be understood that the descriptions of the mechanisms, 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.

[0038] The aerosol delivery devices of the present disclosure may also be characterized as vapor generating articles or drug delivery articles. Accordingly, such articles or devices can be adapted to provide one or more substances in an inhalable form or state (e.g., flavorants and / or pharmaceutically active ingredients). For example, the inhalable substance can be substantially in the form of vapor (i.e., a substance in the gas phase at a temperature below the critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For simplicity, the term "aerosol" as used herein means to include vapors, gases, and aerosols in a form or type suitable for human inhalation, whether visible or not, and whether or not it can be regarded as resembling smoke.

[0039] In use, the aerosol delivery device of the present disclosure may be subject to many physical acts that an individual takes when using traditional types of smoking articles (e.g., cigarettes, cigars, or pipes that are used by lighting tobacco and inhaling the tobacco). For example, a user of the aerosol delivery device of the present disclosure can hold the article in a manner very similar to traditional types of smoking articles, suck on one end of the article for inhalation of the aerosol generated by the article, and puff at selected time intervals, among other things.

[0040] The aerosol delivery devices of the present disclosure generally include several components provided within an outer housing, which may sometimes be referred to as a body or shell. The overall design of the housing can vary, and the form or configuration of the housing that defines the overall size and shape of the aerosol delivery device can change. Typically, an elongated body resembling the shape of a cigarette or cigar can be formed from a single integral housing, or the elongated housing may sometimes be formed of two or more separable bodies. For example, the aerosol delivery device may be substantially tubular in shape and thus can comprise an elongated housing that may resemble the shape of a conventional cigarette or cigar. In one example, all components of the aerosol delivery device are contained within one housing. Alternatively, the aerosol delivery device may comprise two or more housings that are joined and separable. For example, the aerosol delivery device can have a control body at one end with a housing containing one or more reusable components (e.g., a rechargeable battery, a rechargeable supercapacitor, a solid state battery (SSB), a thin film SSB, an accumulator such as a lithium ion or hybrid lithium ion supercapacitor, as well as various electronic devices for controlling the operation of the article), and at the other end, an outer body or shell containing a disposable portion (e.g., a disposable cartridge containing flavor) that can be removably coupled thereto. The more specific forms, configurations, and arrangements of the components within a single housing type unit or within a separable housing type unit consisting of multiple parts will be apparent in light of the further disclosure provided herein. Further, considering commercially available electronic aerosol delivery devices, the designs and component configurations of various aerosol delivery devices can be understood.Alternative non-tubular housings may also be used, including device housings having a shape and size generally similar to those of packs and form factors of cigarette tobacco, such as those used in GLO(TM) by British American Tobacco and IQOS(TM) by Philip Morris International, Inc.

[0041] As will be discussed in more detail below, the aerosol delivery device of the present disclosure includes a power source (i.e., an electrical power source), at least one control component (e.g., means for actuating, controlling, regulating, and stopping the power for 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 components and / or an induction coil or other related components 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 providing an aerosol when sufficient heat is applied, and a mouth end region or tip (e.g., an air flow path defined through the article so that the generated aerosol can be drawn therefrom when inhaled) that enables inhalation of the aerosol with the aerosol delivery device. In some embodiments, the power source includes one or more batteries or battery cells.

[0042] The alignment of components within the aerosol delivery device of the present disclosure can vary. In certain embodiments, the aerosol precursor composition may be disposed near an end of the aerosol delivery device configured to be positioned near the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heating element may be positioned sufficiently close to the aerosol precursor composition such that heat from the heating element can volatilize the aerosol precursor (as well as any one or more flavorants, medicaments, etc. that 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, with respect to references to emitting, emitted, emits, or has emitted, are meant to be interchangeable with forming, or generating, forming, or generating, forming, or generating, and formed, or generated, such that, specifically, the inhalable substance is emitted in the form of a vapor or aerosol or a mixture thereof, and such terms are also used interchangeably herein with each other unless otherwise specified.

[0043] As pointed out above, the aerosol delivery device may incorporate a battery, supercapacitor, SSB, or other power source to provide a flow of current sufficient to provide various functionalities to the aerosol delivery device, such as powering the heating element, powering the control system, powering the indicator, etc. The power source can take various 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 the desired period of use. The power source is preferably sized to fit conveniently within the aerosol delivery device such that the aerosol delivery device can be easily handled. Further, a preferred power source is sufficiently lightweight so as not to detract from the desired smoking experience.

[0044] The more specific forms, configurations, and arrangements of the components within the aerosol delivery device of the present disclosure will be apparent in light of the further disclosure provided below. Further, the selection of components for various aerosol delivery devices can be understood in view of commercially available electronic aerosol delivery devices. Further, the configuration of the components within the aerosol delivery device can also be understood in view of commercially available electronic aerosol delivery devices.

[0045] 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 (which may also be referred to as an inhalable substance medium) to generate an aerosol (an 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 what is commonly referred to as an electronic cigarette. In other embodiments, the aerosol delivery device may include a non-combustion heating device.

[0046] The liquid aerosol precursor composition, also referred to as a vapor precursor composition or "e-liquid", may include various components including, by way of example, polyhydric alcohols (e.g., glycerin, propylene glycol or mixtures thereof), nicotine, tobacco, tobacco extracts and / or flavorants. In some examples, the aerosol precursor composition includes glycerin and nicotine.

[0047] Some liquid aerosol precursor compositions that can be used in combination with various embodiments can include one or more acids such as levulinic acid, succinic acid, lactic acid, pyruvic acid, benzoic acid, fumaric acid, combinations thereof, etc. By including an acid(s) in a liquid aerosol precursor composition containing nicotine, a protonated liquid aerosol precursor composition containing nicotine in salt form can be provided. 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., and 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 can be used include aerosol precursors incorporated into any of some of the representative products identified above. Also desirable are so-called "smoke juices" for electronic cigarettes available from Johnson Creek Enterprises LLC. Yet another example of an aerosol precursor composition is sold under the brand names of 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 foaming material can be used with aerosol precursors, as described, for example, in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which patent is incorporated herein by reference. Further, the use of foaming materials is described, for example, in U.S. Patent No. 4,639,368 to Niazi et al., U.S. Patent No. 5,178,878 to Wehling et al., U.S. Patent No. 5,223,264 to Wehling et al., U.S. Patent No. 6,974,590 to Pather et al., U.S. Patent No. 7,381,667 to Bergquist et al., U.S. Patent No. 8,424,541 to Crawford et al., U.S. Patent No. 8,627,828 to Strickland et al., and U.S. Patent No. 9,307,787 to Sun et al., as well as U.S. Patent Application Publication No. 2010 / 0018539 to Brinkley et al., and International Patent Application Publication No. 97 / 06786 to Johnson et al., all of these patents being incorporated herein by reference.

[0048] Representative types of substrates, reservoirs or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication 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 these patents being incorporated herein by reference. Further, various wicking materials, and the construction 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 patent is incorporated herein by reference.

[0049] 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-filled tobacco paste). The aerosol precursor composition may include beads containing tobacco, tobacco flakes, tobacco pieces, reconstituted tobacco material, or combinations thereof, and / or ground tobacco, tobacco extracts, spray-dried tobacco extracts, or optional inorganic materials (such as calcium carbonate), optional flavorants, and other tobacco forms mixed with an aerosol-forming material that forms 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 arrangements include those found in the NEOSTIKS(TM) consumable aerosol source member of the GLO(TM) product by British American Tobacco and the HEETS(TM) consumable aerosol source member of the IQOS(TM) product by Philip Morris International, Inc.

[0050] In various embodiments, the inhalable substance can specifically be a tobacco component or a tobacco-derived material (i.e., a material found in nature in tobacco that can be isolated directly from tobacco or prepared synthetically). For example, the aerosol precursor composition can include a tobacco extract or a portion thereof combined with an inert substrate. The aerosol precursor composition can further include unburned tobacco or a composition containing unburned tobacco that releases an inhalable substance when heated to a temperature lower than its combustion temperature. In some embodiments, the aerosol precursor composition can include a tobacco condensate or a portion thereof (i.e., a condensed component of the smoke produced by the combustion of tobacco that leaves behind flavor and perhaps nicotine).

[0051] Tobacco materials useful in the present disclosure can vary and may include, for example, yellow tobacco, burley tobacco, oriental tobacco or Maryland tobacco, dark tobacco, dark-fired tobacco and rusticata tobacco, as well as other rare or special tobaccos, or blends thereof. Tobacco materials can also include so-called "blended" forms and processed forms, such as processed tobacco stems (e.g., cut roll or cut puff stems), expanded tobacco (preferably in the form of cut filler, such as expanded tobacco like dry ice expanded tobacco (DIET)), reconstituted tobacco (e.g., reconstituted tobacco manufactured using a papermaking type or cast sheet type process), and the like. Various representative tobacco types, processed tobacco types, and types of tobacco blends are described in U.S. Patent No. 4,836,224 to Lawson et al., U.S. Patent No. 4,924,888 to Perfetti et al., U.S. Patent No. 5,056,537 to Brown et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,220,930 to Gentry, U.S. Patent No. 5,360,023 to Blakley et al., U.S. Patent No. 6,701,936 to Shafer et al., U.S. Patent 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. 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, p. 11-17 (1997) by Bombick et al., which are hereby incorporated by reference herein. 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 patent is hereby incorporated by reference herein.

[0052] Furthermore, the aerosol precursor composition can include an inert substrate having an inhalable substance or a precursor thereof incorporated therein or otherwise deposited thereon. For example, upon application of heat, a liquid containing the inhalable substance is coated onto, absorbed by, or adsorbed onto the inert substrate such that the inhalable substance is released in a form that can be drawn from the article of the invention through the application of positive or negative pressure. In some embodiments, the aerosol precursor composition can include a more tobacco-like blend of flavorful scents in cut filler form. In another embodiment, the aerosol precursor composition can include a reconstituted tobacco material as described in U.S. Patent No. 4,807,809 to Pryor et al., U.S. Patent No. 4,889,143 to Pryor et al., and U.S. Patent No. 5,025,814 to Raker, the disclosures of which are incorporated herein by reference. For further information regarding suitable aerosol precursor compositions, reference is made to U.S. Patent Application No. 15 / 916,834 to Sur et al., filed on March 9, 2018, which is incorporated herein by reference.

[0053] Regardless of the type of aerosol precursor composition to be 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 varies periodically with time) when an alternating current is passed through it. The induction receiver may be at least partially disposed within or received within the induction transmitter and may include a conductive material (a ferromagnetic material or an aluminum-coated material). By passing an alternating current through the induction transmitter, eddy currents can be generated within 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 heated wirelessly to form an aerosol from an aerosol precursor composition positioned proximate to the induction receiver. Various embodiments of aerosol delivery devices with induction heaters 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 on November 15, 2016, U.S. Patent Application No. 15 / 799,365 to Sebastian et al. filed on October 31, 2017, and U.S. Patent Application No. 15 / 836,086 to Sur, all of which patents are hereby incorporated by reference herein.

[0054] 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 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 current therethrough. Such resistive heaters can be positioned near the aerosol precursor composition to heat the aerosol precursor composition to generate an aerosol. Various conductive substrates that may be used in conjunction with the present disclosure are described in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al.

[0055] In some embodiments, the aerosol delivery device may include a control body and a cartridge, as in the case of a so-called electronic cigarette, or a control body and an aerosol source member, as in the case of a non-combustion heating device. In either 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 to be disposable. The cartridge / aerosol source member may include an aerosol precursor composition. To heat the aerosol precursor composition, the heating element may be positioned in contact with or in proximity to the aerosol precursor composition, such as across the control body and the cartridge or within the control body where the aerosol source member may be positioned. The control body may include a power source that may be rechargeable or replaceable, whereby the control body may be reused with a number of cartridges / aerosol source members.

[0056] The control body may also include means for activating an aerosol delivery device such as push buttons, touch-sensitive surfaces, etc. for manually controlling the device. Additionally or alternatively, the control body may include a flow sensor for detecting when the user inhales with the cartridge / aerosol source member, thereby activating the aerosol delivery device.

[0057] In various embodiments, the aerosol delivery devices according to the present disclosure may have various overall shapes, including but not limited to overall shapes that may be defined as being substantially rod-shaped, substantially tubular-shaped, or substantially cylindrical-shaped. In the embodiments shown and described with reference to the accompanying drawings, the aerosol delivery device has a substantially circular cross-section; however, other cross-sectional shapes (e.g., regular polygons such as elliptical, square, rectangular, triangular, or irregular polygons, outer shapes including combinations of one or more substantially straight sides and one or more curved sides, etc.) are also encompassed by the present disclosure. Such language describing the physical shape of the 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 on another handheld shape, such as a small box shape.

[0058] 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 battery or a rechargeable battery, an SSB, a thin-film SSB, a rechargeable supercapacitor, a lithium-ion or hybrid lithium-ion supercapacitor. An example of a power source is a rechargeable lithium-ion battery of TKI-1550 manufactured by Tadiran Batteries GmbH of Germany. In another embodiment, a useful power source may be an N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Co., Ltd. of Japan. In other embodiments, for example, a plurality of such batteries each providing 1.2 volts may be connected in series.

[0059] In some examples, the power source is then connected to any type of recharge technology and may thereby be combined with the recharge technology. Examples of suitable chargers include chargers that simply supply a constant current or pulsed direct current (DC) power to the power source, fast chargers that add a control circuit, three-stage chargers, inductively powered chargers, smart chargers, motion-powered chargers, pulse chargers, solar chargers, USB-based chargers, and the like. In some examples, the charger includes a power adapter and any suitable charging circuit. In other examples, the charger includes a power adapter and the control body is equipped with a charging circuit. In these other examples, the charger may sometimes simply be referred to as a power adapter.

[0060] The control body may include any of several different terminals, electrical connectors, etc. for connecting to a suitable charger and, in some examples, for connecting to other peripheral devices for communication. More specific suitable examples include cylindrical connectors, cigarette lighter connectors, and DC connectors such as USB 1.x (e.g., Type A, Type B), USB 2.0, and its updated versions 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 device, or the two may also be connected via a suitable cable having appropriate connectors. In an example where the two are connected by a cable, the control body and the charger or other peripheral device may have the same or different types of connectors, and the cable may have one type of connector or both types of connectors.

[0061] In examples involving induction-powered charging, the aerosol delivery device may be equipped with induction wireless charging technology, include an induction transmitter, and include an induction receiver for connection to a wireless charger, charging pad, etc. that uses induction wireless charging (including, for example, wireless charging compliant with 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 induction wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is hereby incorporated by reference in its entirety. Further, in some exemplary embodiments in the case of an electronic cigarette, the cartridge may include a single-use cartridge as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is hereby incorporated by reference.

[0062] One or more connections may be used to connect the power source to a recharging technology, some of which may involve a charging case, cradle, dock, sleeve, etc. More specifically, for example, the control body may be configured to engage with a cradle that includes a USB connector for connection to a power supply source. Alternatively, in another example, the control body may be configured to fit within and engage with a sleeve that includes a USB connector for connection to a power supply source. In these and similar examples, the USB connector may be directly connected to the power source or the USB connector may be connected to the power source via a suitable power adapter.

[0063] 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 Oct. 21, 2015, the disclosures of which are incorporated herein by reference. With regard 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., all of U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., U.S. Patent No. 8,205,622 to Pan, U.S. Patent Application Publication No. 8,881,737 to Collet et al., U.S. Patent No. 9,423,152 to Ampolini et al., U.S. Patent No. 9,439,454 to Fernando et al., and U.S. Patent Application No. 2015 / 0257445 to Henry et al., the entireties of these patents being incorporated herein by reference.

[0064] The input elements may be included with the aerosol delivery device (and may replace or supplement the flow sensor). The input may be included to enable the user to control the functionality of the device and / or for output of information to the user. Any component or combination of components may be utilized as an input for controlling the functionality of the device. For example, as described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., one or more push buttons may be used, which patent 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 on March 10, 2015, which patent is incorporated herein by reference. As a further example, a component adapted for gesture recognition based on a particular movement of the aerosol delivery device may be used as an input. Reference is made to U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which patent is incorporated herein by reference. As yet another example, a capacitance sensor may be implemented in the aerosol delivery device such that the user can provide an input, such as by touching the surface of the device in which the capacitance sensor is implemented. In another example, a sensor capable of detecting movement associated with the device (e.g., an accelerometer, gyroscope, photoelectric proximity sensor, etc.) may be implemented in the aerosol delivery device to enable the user to provide an 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.

[0065] As indicated above, the aerosol delivery device can include various electronic devices such as at least one control component. Suitable control components may include several electronic components and, in some examples, may be formed on 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 at least one processor core, a microprocessor, a coprocessor, a controller, a microcontroller, or various other computing devices or processing devices such as one or more integrated circuits including, for example, ASIC (application specific integrated circuit), FPGA (field programmable gate array), or some combination thereof, embodied in various forms. In some examples, the processing circuit can include memory coupled or integrated with the processor, and the memory can store data, computer program instructions executable by the processor, some combination thereof, and the like.

[0066] In some examples, the control component may include one or more input / output peripherals that can be coupled or integrated with the processing circuitry. More specifically, the control component may include a communication interface to enable wireless communication with one or more networks, computing devices, or other suitably enabled devices. Examples of suitable communication interfaces are disclosed in U.S. Patent Application Publication No. 2016 / 0261020 to Marion et al., the content of which is 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 can be configured to communicate wirelessly 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 these patents being incorporated herein by reference.

[0067] Yet another component can be utilized in the aerosol delivery device of the present disclosure. An example of a suitable component is an indicator such as a light-emitting diode (LED), a 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 these patents being incorporated herein by reference.

[0068] Other indices of operation are also encompassed by the present disclosure. For example, visual indicators of operation also include changes in the color or intensity of light to indicate the progression of the smoking experience. Tactile (haptic) indicators of operation and audible (audio) indicators of operation are likewise included in the present disclosure. Further, combinations of such operation indicators are also suitable for use in a single smoking article. According to another aspect, an aerosol delivery device may include one or more indicators or indices, such as a display, configured to provide information corresponding to the operation of the smoking article, such as, for example, the remaining battery power of the power source, the progression of the smoking experience, an indication corresponding to activating the heat source.

[0069] Still other components are contemplated. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device to detect the user's lip activity associated with inhalation and then trigger heating of a 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 heating load array in response to a pressure drop through a mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device that includes an identifier for detecting non-uniformity in the infrared transmittance of an inserted component and a controller for executing a detection routine when the component is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with a number of differential phases; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic optronic component; U.S. Patent No. 5,954,979 to Counts et al. discloses means for varying the draw resistance through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a particular battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses computer interfacing means for a smoking device to facilitate charging and enable computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; International Patent Application Publication No. 2010 / 003480 by Flick discloses a fluid flow sensing system for indicating puffs within an aerosol generating system; all of the foregoing disclosures are hereby incorporated by reference in their entirety.

[0070] Examples of additional components related to electronic aerosol delivery articles and materials or components that may be used herein are disclosed in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent No. 5,249,586 to Morgan et al., U.S. Patent 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. 7,513,253 to Kobayashi, U.S. Patent No. 7,896,006 to Hamano, U.S. Patent No. 6,772,756 to Shayan, U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon, U.S. Patent No. 8,794,231 to Thorens et al., U.S. Patent No. 8,851,083 to Oglesby et al., U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Patent No. 9,220,302 to DePiano et al., U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon, U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, International Patent Application Publication No. 2010 / 091593 to Hon, and International Patent Application Publication No. 2013 / 089551 to Foo, each of these patents being incorporated herein by reference. Further, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al. discloses capsules that may be included in an aerosol delivery device and a fob-shaped configuration of an aerosol delivery device, and this patent is incorporated herein by reference. The various materials disclosed by the foregoing documents can be incorporated into the device in various embodiments, and all of the foregoing disclosures are incorporated herein by reference.

[0071] Other features, controls or components that can be incorporated into the aerosol delivery device of the present disclosure are described in U.S. Patent No. 5,967,148 to Harris et al., U.S. Patent No. 5,934,289 to Watkins et al., U.S. Patent No. 5,954,979 to Counts et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,402,976 to Fernando et al., U.S. Patent Application Publication No. 2005 / 0016550 to Katase, U.S. Patent No. 8,689,804 to Fernando et al., U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent 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 hereby incorporated by reference into this specification.

[0072] Figures 1 and 2 illustrate embodiments of an aerosol delivery device that includes a control body and a cartridge in the case of an electronic cigarette. More specifically, Figures 1 and 2 show an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. As shown, the aerosol delivery device can include a control body 102 and a cartridge 104. The control body and the cartridge can be aligned permanently or removably in a functional relationship. In this regard, Figure 1 shows a perspective view of the aerosol delivery device in an assembled configuration, while Figure 2 shows a partially cut-away side view of the aerosol delivery device in a separated configuration. The aerosol delivery device can be, in some exemplary embodiments, for example, substantially rod-shaped, substantially tube-shaped or substantially cylindrical when the control body and the cartridge are in an assembled configuration.

[0073] The control body 102 and the cartridge 104 can be configured to engage with each other by various connections such as press-fit (or interference fit) connection, screw connection, magnetic connection, etc. Thus, the control body may 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 may be reversible. As an example, either the first engagement element or the second engagement element may be a male screw, and the other may be a female screw. As a further example, either the first engagement element or the second engagement element may be a magnet, and the other may be a metal or a mating magnet. In certain embodiments, the engagement elements may be directly defined by existing components of the control body and the cartridge. For example, the housing of the control body may define a cavity at its end, and the cavity may be 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, with the mouthpiece of the cartridge remaining exposed outside the cavity of the control body, the storage tank of the cartridge may be at least partially received within the cavity of the control body. The cartridge may be held within the cavity formed by the control body housing by interference fit (e.g., through the use of a detent and / or other features creating an interference engagement between the outer surface of the cartridge and the inner surface of the 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 techniques.

[0074] As can be seen in the cutaway view shown in FIG. 2, the control body 102 and the cartridge 104 each include several respective components. The components shown in FIG. 2 are representative of the components that may be present within the control body and the cartridge, and are not intended to limit the scope of the components encompassed by the present disclosure. As shown, for example, the control body can be formed by a housing 206 (which may also be referred to as a control body shell) that includes a control component 208 (such as a processing circuit, etc.), a flow sensor 210, a power source 212 (such as a battery, supercapacitor), and an indicator 214 (such as an LED, quantum dot-based LED), and such components can be variably aligned. The power source can be rechargeable and configured to provide a voltage.

[0075] The cartridge 104 can be formed by a housing 216 (which may also be referred to as a cartridge shell) that surrounds a reservoir 218 configured to hold an aerosol precursor composition and includes a heating element 220 (which may also be referred to as a heater). In various configurations, such a structure may sometimes be referred to as a tank, and thus the terms "cartridge," "tank," etc. may be used interchangeably to refer to a shell or other housing that surrounds a reservoir for an aerosol precursor composition and includes a heating element.

[0076] 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 aerosol precursor composition passed or delivered from the reservoir to the heating element.

[0077] Various exemplary materials configured to generate heat when an electric current is applied may be used to form the heating element 220. The heating elements in these examples can be resistive heating elements such as wire coils, micro heaters, etc. Examples of materials from which the heating element can be formed include Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tin oxide, tungsten, molybdenum disilicide (MoSi 2 2 )), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si, Al))), titanium, platinum, silver, palladium, an alloy 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 element may be a resistive heating element or a heating element configured to generate heat through induction. The heating element may be coated with a thermally conductive ceramic such as aluminum nitride, silicon carbide, beryllium oxide, alumina, silicon nitride, or a composite material thereof. Exemplary embodiments of heating elements useful in the aerosol delivery device according to the present disclosure are further described below and can be incorporated into devices as described herein.

[0078] An opening 224 may be present in the housing 216 (e.g., at the mouth end) to allow for the discharge of the formed aerosol from the cartridge 104.

[0079] The cartridge 104 may also include one or more electronic components 226 that can 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 an external device by wired or wireless means. The electronic components may be positioned anywhere within the cartridge or its base 228.

[0080] Although the control component 208 and the flow sensor 210 are shown separately, it is understood that various electronic components including the control component and the flow sensor may be combined on a circuit board (e.g., a PCB) that supports and electrically connects these components. Further, the circuit board may be positioned horizontally with respect to the figure of FIG. 1 in that it may be parallel in the longitudinal direction with respect to the central axis of the control body. In some examples, the airflow sensor may comprise its own circuit board or other base element to which it can be attached. In some examples, a flexible circuit board may be utilized. The flexible circuit board may be configured in various 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.

[0081] 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 the coupler and may include a protrusion 234 adapted to fit within the cavity. Such engagement facilitates a stable connection between the control body and the cartridge and can establish an electrical connection between the power source 212 and the control component 208 within the control body and the heating element 220 within the cartridge. Further, the housing 206 may include an air intake 236, which may be a notch in the housing, in which case it is connected to the coupler and allows ambient air to pass around the coupler and into the housing, after which the air passes through the cavity 232 of the coupler and through the protrusion 234 and into the cartridge.

[0082] Couplers and bases useful in accordance with 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, a coupler 230, as seen in FIG. 2, may define an outer perimeter 238 configured to fit within an inner perimeter 240 of a base 228. In one example, the inner perimeter of the base may define a radius that is substantially equal to, or slightly larger than, the radius of the outer perimeter of the coupler. Further, the coupler may define one or more protrusions 242 on the outer perimeter configured to engage one or more recesses 244 defined in the inner perimeter 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 between them may be releasable such that, for example, the control body is reusable with one or more additional cartridges that may be disposable and / or refillable.

[0083] The reservoir 218 shown in FIG. 2 may be a container or, in some cases, a fibrous reservoir as presently described. For example, in this instance, the reservoir may include one or more layers of non-woven fibers substantially formed in a tube shape surrounding the interior of the housing 216. An aerosol precursor composition can be retained within the reservoir. For example, the liquid component can be retained by the reservoir in an adsorptive manner. The reservoir can be in fluid connection with a liquid transport element 222. The liquid transport element can transport the aerosol precursor composition stored in the reservoir to a heating element 220, in this example in the form of a metal wire coil, via capillary action or via a micropump. Thus, the heating element is in a heating configuration with the liquid transport element.

[0084] In some examples, the 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 system (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 can be incorporated into devices as described herein. Specifically, certain combinations of heating members and transport elements as further described herein may be incorporated into devices such as those described herein.

[0085] In use, when a user inhales with the aerosol delivery device 100, an air flow 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. Inside the cartridge 104, the inhaled air combines with the formed vapor to form an aerosol. The aerosol is removed from, drawn through, or otherwise withdrawn from the heating element and exits through the opening 224 at the mouth end of the aerosol delivery device.

[0086] For further details regarding embodiments of aerosol delivery devices including a control body and a cartridge in the case of an electronic cigarette, reference is made to U.S. Patent Application No. 15 / 836,086 to Sur et al., U.S. Patent Application No. 15 / 916,834 to Sur et al., and U.S. Patent Application No. 15 / 916,696 to Sur filed on March 9, 2018, which patents are also incorporated herein by reference.

[0087] Figures 3 through 6 illustrate embodiments of an aerosol delivery device that includes a control body and an aerosol source member in the case of a non-combustion heating device. 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 aligned permanently or removably in a functional relationship. In this regard, FIG. 3 shows an aerosol delivery device in an assembled configuration, while FIG. 4 shows an aerosol delivery device in a separated configuration. Various mechanisms can result in screw engagement, press-fit engagement, interference fit, slip fit, magnetic engagement, etc. by connecting the aerosol source member to the control body.

[0088] As shown in FIG. 4, in various embodiments of the present disclosure, the aerosol source member 304 may include a heated end 406 configured to be inserted into the control body 302 and a mouth end 408 that a user inhales to create an aerosol. In various embodiments, at least a portion of the heated end may include an aerosol precursor composition 410.

[0089] In various embodiments, the aerosol source member 304 or a portion thereof may be wrapped with an outer overlap material 412 formed of any material useful for providing additional structure and / or support to the aerosol source member. In various embodiments, the outer overlap material can include a material that resists heat transfer, which can include other fibrous materials such as paper or cellulose materials. The outer overlap material may also include at least one filler material embedded within or dispersed throughout the fibrous material. In various embodiments, the filler material may be in the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the outer overlap may be formed of multiple layers, such as an underlying bulk layer and an overlying layer such as a typical wrapper in a cigarette. Such materials may include lightweight "waste fibers" such as linen, hemp, sisal, rice straw, and / or esparto. The outer overlap may also include materials commonly used in conventional cigarette filter elements, such as cellulose acetate. Further, an excessive length of the overlap at the mouth end 408 of the aerosol source member may function to simply separate the aerosol precursor composition 410 from the consumer's mouth, or may function to provide space for positioning filter materials as described below, or may function to affect inhalation in the article, or to affect the flow characteristics of the vapor or aerosol exiting the device during inhalation. Further discussion regarding the configuration of the overlap material that can be used in the present disclosure can be found in the above-mentioned U.S. Patent No. 9,078,473 to Worm et al.

[0090] In various embodiments, other components may be present between the aerosol precursor composition 410 and the mouth end 408 of the aerosol source member 304, and in this case, the mouth end may include, for example, a filter 414 that may be made from a cellulose acetate or polypropylene material. The filter may additionally or alternatively include strands of tobacco-containing material as described in U.S. Patent No. 5,025,814 to Raker et al., which patent is hereby incorporated by reference in its entirety. In various embodiments, the filter can increase the structural integrity of the mouth end of the aerosol source member and / or provide filtration capabilities as needed and / or provide resistance to inhalation. In some embodiments, one or any combination of the following may be positioned between the aerosol precursor composition and the mouth end: a void; a phase change material for cooling air; a flavor release medium; ion exchange fibers capable of selective chemisorption; aerogel particles as a filter medium; and other suitable materials.

[0091] In various embodiments of the present disclosure, one or more conductive heating elements are used to heat the aerosol precursor composition 410 of the aerosol source member 304. In various embodiments, the heating element can 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 the electrical resistance associated with passing an electric current therethrough. Such resistive heating elements may be positioned in direct contact with, or in proximity to, the aerosol source member, particularly the aerosol precursor composition of the aerosol source member 304. The heating element may be disposed within the control body and / or the aerosol source member. In various embodiments, the aerosol precursor composition may include a substrate portion that functions as a heating assembly or facilitates the function of the heating assembly, or alternatively may include components (i.e., thermally conductive components) that are part of the substrate portion. Some examples of various heating members and elements are described in U.S. Patent No. 9,078,473 to Worm et al.

[0092] 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 outside 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). In some examples, the aerosol precursor composition can include structures in contact with the aerosol precursor composition, beads or particles embedded in the aerosol precursor composition, or alternatively that are part of the aerosol precursor composition, that function as a heating element or can facilitate the function of the heating element.

[0093] FIG. 5 shows a front view of an aerosol delivery device 300 according to an exemplary embodiment of the present disclosure, and FIG. 6 shows a cross-sectional view through the aerosol delivery device of FIG. 5. In particular, the control body 302 of the illustrated embodiment may comprise an end cap including a housing 516 having an opening 518 defined at its engagement end, a flow sensor 520 (e.g., a puff sensor or a pressure switch), control components 522 (e.g., a processing circuit, etc.), a power source 524 (e.g., a battery, a supercapacitor), and an indicator 526 (e.g., an LED). The power source may be rechargeable and configured to provide a voltage.

[0094] In one embodiment, the indicator 526 may include one or more LEDs, quantum dot-based LEDs, etc. The indicator is in communication with the control components 522 and may be illuminated, for example, when detected by the flow sensor 520 when the user inhales with the aerosol source member 304 when coupled to the control body 302.

[0095] The control body 302 of the illustrated embodiment includes one or more heating assemblies 528 (collectively or individually referred to as heating assemblies) configured to heat the aerosol precursor composition 410 of the aerosol source member 304. Although the heating assemblies of various embodiments of the present disclosure can take various forms, in the particular embodiments shown in FIGS. 5 and 6, the heating assembly includes an outer cylinder 530 and a heating element 532, and the heating element 532 includes a plurality of heater prongs (in various configurations, the heating assembly, or more specifically the heater prongs, may be referred to as heaters) extending from the receiving base 534 in this embodiment. In the illustrated embodiment, the outer cylinder includes a double-walled vacuum tube constructed of stainless steel so as to maintain the heat generated by the heater prongs within the outer cylinder, and more specifically, to maintain the heat generated by the heater prongs within the aerosol precursor composition. In various embodiments, the heater prongs can 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.

[0096] As shown, the heating assembly 528 may extend near the engaging 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 that contains 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 outer cylinder 530 so as to create a receiving chamber 536. In such a manner, in various embodiments, the outer cylinder can 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.

[0097] In some embodiments, one or more portions or components of the heating assembly 528 may be 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 contain one or more conductive materials mixed therein. In some of these embodiments, when the aerosol source member is inserted into the receiving chamber of the control body, the contacts may be directly connected to the aerosol precursor composition such that 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 the contacts form an electrical connection with the aerosol precursor composition when the aerosol source member is inserted into the receiving chamber of the control body. The presence of the conductive material in the aerosol precursor composition allows for the application of power from the electrical energy source to the aerosol precursor composition, thereby enabling current flow and thus generating heat from the conductive material. Accordingly, in some embodiments, the heating element may be described as being integral with the aerosol precursor composition. By way of non-limiting example, graphite or other suitable conductive material may be mixed with, embedded within, or otherwise directly present on or within the material forming the aerosol precursor composition to create a heating element integral with the medium.

[0098] As noted above, in the exemplary embodiments, the outer cylinder 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 outer cylinder of the heating assembly 528 may engage the inner surface of the housing to align the heating assembly with respect to the housing. Thereby, as a result of the fixed connection 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 opening 518 of the housing to the receiving base 534 to create the receiving chamber 536.

[0099] 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 internal volume of the receiving chamber. For example, in the illustrated embodiment, the outer cylinder 530 defines an inner surface that defines the internal volume of the receiving chamber. In the illustrated embodiment, the inner diameter of the outer cylinder is sized to be slightly larger than or approximately equal to the outer diameter of the corresponding aerosol source member (e.g., to create a slip fit) such that the outer cylinder is configured to guide the aerosol source member to an appropriate position (e.g., a lateral position) relative to the control body. Thus, the maximum outer diameter of the aerosol source member (or other dimension according to the particular cross-sectional shape of this embodiment) 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 respective diameters may be small enough such that the aerosol source member fits snugly in the receiving chamber and frictional forces prevent the aerosol source member from moving without an applied force. On the other hand, such a difference may be sufficient to allow the aerosol source member to slide into and out of the receiving chamber without requiring excessive force.

[0100] In the illustrated embodiment, when the aerosol source member 304 is inserted into the control body 302, the heating element 532 (e.g., a heater prong) is configured to be disposed at approximately the radial center of 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 combination with a solid or semi-solid aerosol precursor composition, the heater prong can be in direct contact with the aerosol precursor composition. In other embodiments, the heater prong may be disposed inside a cavity defined by the inner surface of an extruded aerosol precursor composition that defines a tube structure, such as when used in combination with an extruded aerosol precursor composition, and may not contact the inner surface of the extruded tube structure.

[0101] During use, the consumer begins heating the heating assembly 528, particularly the heating element 532 adjacent the aerosol precursor composition 410 (or a particular layer thereof). Heating the aerosol precursor composition to produce an inhalable substance releases the inhalable substance into the aerosol source member 304. 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 begin heating, the 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 supplied for a predetermined time or may be manually controlled.

[0102] In some embodiments, the flow of electrical energy does not substantially occur between puffs at device 300 (although the flow of energy may occur to maintain a baseline temperature higher than the ambient temperature - for example, a temperature that facilitates rapid heating to an active heating temperature). However, in the illustrated embodiment, heating is initiated by the act of the consumer taking a puff through the use of one or more sensors such as flow sensor 520. When the puffing ceases, the heating stops or is 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 be equivalent to a typical smoking experience), the aerosol source member 304 may be removed 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 No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference.

[0103] In various embodiments, the aerosol source member 304 is suitable for forming and maintaining a suitable conformation, such as a tubular shape, and may be formed of any material suitable for holding 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 heat resistant (natural or synthetic) to maintain its structural integrity—e.g., not degrade—at least at the temperature provided by the electrical heating element, as further discussed herein. In some embodiments, a heat resistant polymer may be used, but in other embodiments, the aerosol source member may be formed from paper, such as substantially straw-shaped paper. As further discussed herein, the aerosol source member may have one or more associated layers 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 prevent heat from being unduly dissipated from the aerosol precursor composition. Further exemplary types of components and materials that may be used to provide the above functions or may be used as alternatives to the above materials and components may be of the types described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., and U.S. Patent Application Publication No. 2011 / 0041861 to Sebastian et al., which patents are incorporated herein by reference.

[0104] 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 (which may be connected to additional components as further described herein) connected to a power source 524 by a conductive wire (not shown). In various embodiments, the processing circuit may control how and when the heating assembly 528, particularly the heater prong, receives electrical energy to heat the aerosol precursor composition 410 for the release of an inhalable substance for consumer inhalation. In some embodiments, such control may be activated by a flow sensor 520 as described in more detail above.

[0105] As can be seen in FIGS. 5 and 6, the heating assembly 528 of the illustrated embodiment includes an outer cylinder 530 and a heating element 532 (e.g., a plurality of heater prongs) extending from a receiving base 534. In some embodiments, such as where the aerosol precursor composition 410 includes a tube structure, the heater prongs may be configured to extend into a cavity defined by the inner surface of the aerosol precursor composition. In other embodiments, such as the illustrated embodiment where the aerosol precursor composition includes a solid or semi-solid, when the aerosol source member is inserted into the control body 302, the plurality of heater prongs are configured to penetrate the aerosol precursor composition included in the heated end 406 of the aerosol source member 304. 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 anti-stick 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 a non-stick coating, such as a polytetrafluoroethylene (PTFE) coating, such as Teflon(R), or an anti-stick enamel coating, or other coatings, such as a ceramic coating, such as Greblon(R) or Thermolon(TM), or a ceramic coating, such as Greblon(R) or Thermolon(TM).

[0106] In addition, in the illustrated embodiment, there are a number of heater prongs 532 that are substantially equally distributed around the receiving base 534, but it should be noted that in other embodiments, any other suitable spatial configuration may be used, with any number of heater prongs, including only one. Further, in various embodiments, the length of the heater prongs can vary. For example, in some embodiments, the heater prongs may comprise small protrusions, but in other embodiments, the heater prongs may extend to any portion of the length of the receiving chamber 536, including up to about 25%, up to about 50%, up to about 75%, and substantially the entire length of the receiving chamber. Further still, in other embodiments, the heating assembly 528 may take other configurations. Examples of other heater configurations that can be adapted for use in the present disclosure in accordance with the discussion provided above can be found in U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 to Deevi et al., U.S. Patent No. 5,228,460 to Sprinkel Jr. et al., U.S. Patent No. 5,322,075 to Deevi et al., U.S. Patent No. 5,353,813 to Deevi et al., U.S. Patent No. 5,468,936 to Deevi et al., U.S. Patent No. 5,498,850 to Das, U.S. Patent No. 5,659,656 to Das, U.S. Patent No. 5,498,855 to Deevi et al., U.S. Patent No. 5,530,225 to Hajaligol, U.S. Patent No. 5,665,262 to Hajaligol, U.S. Patent No. 5,573,692 to Das et al., and U.S. Patent No. 5,591,368 to Fleischhauer et al., and these patents are incorporated herein by reference.

[0107] 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 at the mouth end of the aerosol source member 304, air is drawn into the receiving chamber through the air intakes of the control body and the receiving base, proceeds into the aerosol source member, and can be drawn through the aerosol precursor composition 410 of the aerosol source member for inhalation by the consumer. In some embodiments, the inhaled air carries the inhalable substance through an optional filter 414 and out of the opening at the mouth end 408 of the aerosol source member. With the heating element 532 positioned inside the aerosol precursor composition, the heater prong can be activated to heat the aerosol precursor composition and cause the release of the inhalable substance through the aerosol source member.

[0108] As described above with particular reference to FIGS. 5 and 6, various embodiments of the present disclosure heat the aerosol precursor composition 410 using a conductive heater. Also as shown above, various other embodiments use an induction heater to heat the aerosol precursor composition. In some of these embodiments, the heating assembly 528 may be configured as an induction heater comprising a transformer with an induction transmitter and an induction receiver. In embodiments where the heating assembly is configured as an induction heater, the outer cylinder 530 may be configured as the induction transmitter, and the heating element 532 (e.g., a plurality of heater prongs) extending from the receiving base 534 may be configured as the induction receiver. In various embodiments, one or both of the induction transmitter and the induction receiver may be disposed within the control body 302 and / or the aerosol source member 304.

[0109] In various embodiments, the outer cylinder 530 and the heating element 532 as the inductive transmitter and the inductive receiver may be constructed from one or more conductive materials. 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 prong is constructed from a ferromagnetic material. In various embodiments, the receiving base may be constructed from a non-conductive and / or insulating material.

[0110] The outer cylinder 530 as the inductive 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 one or more electrical traces that may form a helical coil pattern when the foil material is positioned around the heating element 532 as the inductive 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 moves into contact with the heater prong and thereby does not short circuit with the heater prong. In such a manner, the support cylinder may include a non-conductive material that 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 the outer surface of the support cylinder; however, in other embodiments, the foil material may be positioned on the inner surface of the support cylinder or fully embedded in the support cylinder.

[0111] The foil material of the outer cylinder 530 may be configured to create an oscillating magnetic field (e.g., a magnetic field that varies periodically with time) when an alternating current is conducted through it. The heater prong of the heating element 532 may be at least partially disposed within or received within the outer cylinder and may include a conductive material. By conducting an alternating current through the foil material, eddy currents may be generated within the heater prong via induction. The eddy currents flowing through the resistance of the material defining the heater prong may heat the heater prong by Joule heating (i.e., through the Joule effect). The heater prong, being heated wirelessly, can form an aerosol from the aerosol precursor composition 410 positioned near the heater prong.

[0112] Other embodiments of the aerosol delivery device, the control body, and the aerosol source member are described in U.S. Patent Application No. 15 / 916,834 to Sur et al., U.S. Patent Application No. 15 / 916,696 to Sur, and U.S. Patent Application No. 15 / 836,086 to Sur, which are incorporated by reference above.

[0113] As described above, the aerosol delivery device of the exemplary embodiment may include various electronic components in the context of either an electronic cigarette or a non-combustion heating device, or even in the case of a device that includes both functions. FIG. 7 illustrates a circuit diagram of an aerosol delivery device 100, 300, or both, according to various exemplary embodiments of the present disclosure, or an aerosol delivery device 700 that may incorporate its functions.

[0114] As shown in FIG. 7, the aerosol delivery device 700 includes a control body 702 having a power source 704 and a control component 706 that can correspond to or include the functions of the power sources 212, 524 and the control components 208, 522, and the control bodies 102, 302, respectively. The aerosol delivery device also includes a heating element 716 that can correspond to or include the function of the heating elements 220, 532. In some embodiments, the heating element is powered to vaporize components of the aerosol precursor composition and has a variable resistance proportional to the temperature of the heating element. In these embodiments, the heating element is formed from an element including platinum (Pt), titanium (Ti), copper (Cu), nickel (Ni), or an alloy of at least one of them. In some embodiments, the aerosol delivery device 700, particularly the control body 702, includes a heating element or a terminal 718 configured to connect the heating element to the control body.

[0115] In some embodiments, the control component 706 is coupled to the power source 704 and the heating element 716 and includes a power switch 708 between the power source 704 and the heating element 716, and also includes a processing circuit 710 coupled to the power switch. In some embodiments, as shown by arrow 720, the processing circuit is configured to output a signal during the heating period to switchably connect and disconnect the voltage provided by the power source to the power switch to supply power to the heating element. In these embodiments, the processing circuit is also configured to measure the input heater voltage in the heating element that is equal to or proportional to the voltage provided by the power source, as shown by arrow 722. The processing circuit can use a sensor, such as an analog voltage sensor, to measure the input heater voltage in the heating element. In some embodiments, the input heater voltage in the heating element is equal to the voltage provided by the power source.

[0116] Optionally, in some embodiments, the control component 706 includes a switching regulator 712 that includes a power switch 708. The switching regulator steps down the voltage provided by the power supply 704 to an input heater voltage at the heating element 716, and the input heater voltage is thereby configured to be proportional to the voltage provided by the power supply. In these embodiments, the input heater voltage at the heating element may be higher or lower than the voltage provided by the power supply. An example of a suitable switching regulator is model MAX 15053 of Maxim Integrated Company.

[0117] In some embodiments, the control component 706 also includes a low-side current sensing circuit 714 coupled between the heating element 716 and the processing circuit 710. For example, the low-side current sensing circuit may be coupled to the heating element 716 via a terminal 718. In these embodiments, the low-side current sensing circuit is configured to generate an output voltage equal to, or proportional to, the output heater voltage at the heating element, as indicated by arrow 724. In these embodiments, the processing circuit is configured to measure the output voltage from the low-side current sensing circuit and determine the resistance of the heating element from the input heater voltage at the heating element and this output voltage. In these embodiments, the processing circuit is also configured to determine the temperature of the heating element from the resistance and adjust a signal to the power switch 708 when the temperature deviates from a predetermined set point.

[0118] In some embodiments, the processing circuit 710 is configured to output a pulse-width modulation (PWM) signal during the heating period to switchably connect and disconnect the power switch 708 to and from the voltage provided by the power supply 704 to supply power to the heating element 716. Further, the processing circuit is configured to adjust the duty cycle of the PWM signal when the temperature of the heating element deviates from a predetermined set point. In one example, when the temperature of the heating element is higher than the predetermined set point, the processing circuit can adjust the signal to open the power switch over that period such that the voltage from the power supply for supplying power to the heating element is disconnected for a predetermined period. Thereby, the temperature of the heating element can be reduced to the predetermined set point.

[0119] In some embodiments, the low-side current sensing circuit 714 is coupled between the output of the heating element and ground and includes a shunt resistor therebetween. In these embodiments, the output voltage generated by the low-side current sensing circuit is equal to the output heater voltage, and the output heater voltage is equal to the input resistor voltage across the shunt resistor. In these embodiments, the processing circuit 710 is further configured to determine the resistance of the heating element 716 from the resistance value of the shunt resistor. The low-side current sensing circuit including the shunt resistor will be described in more detail with reference to FIG. 8 below.

[0120] In other embodiments, the low-side current sensing circuit 714 includes a non-inverting operational amplifier circuit and a shunt resistor. Both the non-inverting operational amplifier circuit and the shunt resistor are coupled to the output of the heating element 716. In these embodiments, the processing circuit 710 is further configured to determine the resistance of the heating element from the gain of the non-inverting operational amplifier circuit and the resistance value of the shunt resistor. In some embodiments, the resistance value of the shunt resistor is the reciprocal of the gain of the non-inverting operational amplifier circuit. In some embodiments, the low-side current sensing circuit further includes two decoupling capacitors coupled to the non-inverting operational amplifier. The two decoupling capacitors are configured to cancel out the noise gain of the non-inverting operational amplifier. The low-side current sensing circuit including the non-inverting operational amplifier circuit will be described in more detail with reference to FIG. 9 below.

[0121] FIG. 8 shows a circuit diagram of the components of an aerosol delivery device including a power source 704, a processing circuit 800 and a low-side current sensing circuit 802 that may respectively correspond to the processing circuit 710 and the low-side current sensing circuit 714 according to an exemplary embodiment of the present disclosure. An example of a suitable processing circuit is an MSP430™ microcontroller manufactured by Texas Instruments.

[0122] In one example, the low-side current sensing circuit 802 is coupled between the output of the heating element 716 and ground and includes a shunt resistor 804 therebetween. In this example, the output voltage

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[0123] In the example shown in FIG. 8, the resistance of the heating element 716

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[0124] The current flowing through the heating element 716

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[0126] The resistance of the heating element 716

Number

[0127] FIG. 9 shows a circuit diagram of components of an aerosol delivery device including a power source 704 and a processing circuit 900 and a low-side current sensing circuit 902 that may respectively correspond to the processing circuit 710 and the low-side current sensing circuit 714 according to another exemplary embodiment of the present disclosure.

[0128] In one example, the low-side current sensing circuit 902 includes a non-inverting operational amplifier circuit 906 and a shunt resistor 904. Both the non-inverting operational amplifier circuit and the shunt resistor are coupled to the output of the heating element 716. In this example, the processing circuit 900 can determine the resistance of the heating element from the input heater voltage

Number

Number

[0129] In the example shown in FIG. 9, the resistance

Number

Number

Number

[0130] In the above example,

Number

Number

Number

Number

Number

[0131] Based on Equation (5), Equation (4) is:

Number

[0132] Therefore, the processing circuit 900 can

Number

Number

[0133] In one example, the resistance value of the shunt resistor 904 is the reciprocal of the gain of the non-inverting operational amplifier circuit 906, i.e., [Number] is. In this example, the above Equation (6) is: [Number] can be expressed as follows.

[0134] In one example, the gain of the non-inverting operational amplifier circuit 906 can be adjusted based on the resistance value of the shunt resistor 904.

[0135] In one example, the gain of the non-inverting operational amplifier circuit 906 includes a signal gain and a noise gain. In this example, the low-side current sensing circuit 902 can include two decoupling capacitors 908 and 910 coupled to the non-inverting operational amplifier. The two decoupling capacitors can cancel out the noise gain of the non-inverting operational amplifier. The two decoupling capacitors can be, for example, 0.1 uF and 0.01 uF respectively. For a high-frequency power supply or battery, the decoupling capacitors can be, for example, in the range of 0.01 uF to 0.1 uF. For a low-frequency power supply, the decoupling capacitors can be, for example, in the range of 1 uF to 10 uF.

[0136] The foregoing description of the use of the smoking article(s) can be applied to the various exemplary embodiments described herein through minor modifications that may be apparent to those skilled in the art in light of the further disclosure provided herein. However, the foregoing description of the use is not intended to limit the use of the article, but is provided to meet all of the necessary requirements of the disclosure of the present disclosure. Some of the elements shown in the smoking article(s) illustrated in FIGS. 1 to 9 or otherwise described above may be included in the aerosol delivery device according to the present disclosure.

[0137] Those skilled in the art to which the present disclosure pertains, having the benefit of the teachings presented in the foregoing description and the associated drawings, will envision many modifications and other embodiments of the present disclosure. Accordingly, it is to be understood that the present disclosure is not to be 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

Claim 1 An aerosol delivery device comprising a power source configured to provide a voltage, a heating element powered to vaporize components of an aerosol precursor composition, the heating element having a variable resistance proportional to the temperature of the heating element, a power switch coupled between the power source and the heating element, a processing circuit coupled to the power switch, the processing circuit configured to output a signal during a heating period to selectively connect and disconnect the voltage provided by the power source to the heating element to supply power to the heating element, and configured to measure an input heater voltage at the heating element equal to or proportional to the voltage provided by the power source, a low-side current sensing circuit coupled between the heating element and the processing circuit, the low-side current sensing circuit including a non-inverting operational amplifier circuit and a shunt resistor, both the non-inverting operational amplifier circuit and the shunt resistor being coupled to an output of the heating element and configured to generate an output voltage equal to or proportional to an output heater voltage at the heating element, and the processing circuit is further configured to measure the output voltage, determine the resistance of the heating element from the input heater voltage and the output voltage, and further from the gain of the non-inverting operational amplifier circuit and the resistance value of the shunt resistor, determine the temperature of the heating element from the resistance, and adjust the signal when the temperature deviates from a predetermined set point. An aerosol delivery device. Claim 2 The aerosol delivery device according to claim 1, wherein the power source includes one or more batteries or battery cells. Claim 3 The aerosol delivery device according to claim 1, wherein the processing circuit being configured to output a signal includes being configured to output a pulse width modulation (PWM) signal, and the processing circuit being configured to adjust the signal includes being configured to adjust the duty cycle of the PWM signal. Claim 4 The aerosol delivery device according to claim 1, wherein the heating element is formed from an element including platinum (Pt), titanium (Ti), copper (Cu), nickel (Ni), or at least one alloy thereof. Claim 5 The aerosol delivery device according to claim 1, wherein the aerosol precursor composition includes one or more of a liquid, a solid, or a semi-solid. Claim 6 The aerosol delivery device according to claim 1, wherein the input heater voltage in the heating element is equal to the voltage provided by the power supply. **Claim 7** The aerosol delivery device according to claim 1, further comprising a switching regulator including a power switch, the switching regulator stepping down the voltage provided by the power supply to the input heater voltage, and the input heater voltage being configured to be proportional to the voltage provided by the power supply. **Claim 8** The aerosol delivery device according to claim 1, wherein the resistance value of the shunt resistor is the reciprocal of the gain of the non-inverting operational amplifier circuit. **Claim 9** The aerosol delivery device according to claim 1, wherein the low-side current sensing circuit is coupled to the non-inverting operational amplifier circuit and further includes two decoupling capacitors configured to cancel the noise gain of the non-inverting operational amplifier circuit. **Claim 10** A control body of the aerosol delivery device, the control body comprising: a power supply configured to provide a voltage; a heating element or a terminal configured to connect the heating element to the control body, the heating element being capable of being powered to vaporize a component of the aerosol precursor composition and having a variable resistance proportional to the temperature of the heating element; a power switch coupled between the power supply and the heating element; a processing circuit coupled to the power switch, the processing circuit configured to output a signal during a heating period to switchably connect and disconnect the power switch to the voltage provided by the power supply for supplying power to the heating element and configured to measure an input heater voltage in the heating element that is equal to or proportional to the voltage provided by the power supply; a low-side current sensing circuit coupled between the heating element and the processing circuit, the low-side current sensing circuit including a non-inverting operational amplifier circuit and a shunt resistor, both the non-inverting operational amplifier circuit and the shunt resistor being coupled to the output of the heating element and configured to generate an output voltage equal to or proportional to the output heater voltage in the heating element; and comprising. The processing circuit measures the output voltage, determines the resistance of the heating element from the input heater voltage and the output voltage, and further from the gain of the non-inverting operational amplifier circuit and the resistance value of the shunt resistor, determines the temperature of the heating element from the resistance, and is further configured to adjust a signal when the temperature deviates from a predetermined set point, the control body of the aerosol delivery device.

11. The power supply includes one or more batteries or battery cells, the control body according to claim 10.

12. The processing circuit being configured to output a signal includes being configured to output a pulse width modulation (PWM) signal, and the processing circuit being configured to adjust a signal includes being configured to adjust the duty cycle of the PWM signal, the control body according to claim 10.

13. The heating element is formed from an element including platinum (Pt), titanium (Ti), copper (Cu), nickel (Ni), or at least one alloy thereof, the control body according to claim 10.

14. The aerosol precursor composition includes one or more of liquid, solid, or semi-solid, the control body according to claim 10.

15. The input heater voltage in the heating element is equal to the voltage provided by the power supply, the control body according to claim 10.

16. Further comprising a switching regulator including a power switch, the switching regulator stepping down the voltage provided by the power supply to the input heater voltage, and the input heater voltage is configured to be proportional to the voltage provided by the power supply, the control body according to claim 10.

17. The resistance value of the shunt resistor is the reciprocal of the gain of the non-inverting operational amplifier circuit, the control body according to claim 10.

18. The low-side current sensing circuit is coupled to the non-inverting operational amplifier circuit and further includes two decoupling capacitors configured to cancel the noise gain of the non-inverting operational amplifier circuit, the control body according to claim 10.

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