Aerosol delivery device having a replaceable wick and heater assembly

Abstract

To provide a reservoir that may be included in an aerosol delivery device, and / or a method of combining the aerosol delivery device with the reservoir.SOLUTION: An aerosol delivery device includes a housing 100, and a reservoir 200 having an open end and an opposite closed end. The reservoir includes an aerosol precursor composition therein. The aerosol delivery device also includes an electrical contact in or on the housing. The device further includes a vaporizing unit 300. The vaporizing unit includes a liquid transport element 306, a heating element, and an electrical connector. The vaporizing unit is configured to removably engage the open end of the reservoir such that the liquid transport element is in arrangement with the reservoir to transfer the aerosol precursor composition from the reservoir to the heating element, and configured to engage the electrical contact in or on the housing.SELECTED DRAWING: Figure 2

Description

[Technical Field]

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

[0002] Many smoking devices have been proposed over the years as an improvement or replacement for smoking products that require tobacco combustion for use.Many of these devices are designed to provide the sensation associated with smoking cigarettes, cigars, or pipes, but are said to not deliver significant amounts of incomplete combustion and pyrolysis products resulting from tobacco combustion.For this purpose, many smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials, or to provide the sensation of smoking cigarettes, cigars, or pipes without significantly burning tobacco.See, for example, the various alternative smoking articles, aerosol delivery devices, aerosol precursor compositions, and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, and Collett et al., U.S. Patent No. 8,881,737, both of which are incorporated herein by reference.See also, for example, the various types of smoking articles, aerosol delivery devices, and electric heat sources referenced by trade name and commercial source described in Bless et al., U.S. Patent Application Publication No. 2015 / 0216232, both of which are incorporated herein by reference. Additionally, various types of electrical aerosol and vapor delivery devices have also been proposed in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., U.S. Patent Application Publication No. 2014 / 0283859 to Minskoff et al., U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al., U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., U.S. Patent Application Publication No. 2016 / 0007651 to Ampolini et al., and U.S. Patent Application Publication No. 2016 / 0050975 to Worm et al., all of which are incorporated herein by reference.

[0003] Some existing embodiments of aerosol delivery devices include a control body (i.e., a power supply assembly) and a cartridge (i.e., a reservoir housing). A power source (e.g., a battery) may be disposed within the control body, and the aerosol precursor composition may be held and / or stored within the cartridge. The cartridge and control body may engage with one another to define an elongated tubular configuration. However, other specific form factors for the aerosol delivery device and other aerosol precursor composition storage configurations may be desirable. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 2] U.S. Patent No. 8,881,737 [Patent Document 3] US Patent Application Publication No. 2015 / 0216232 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2014 / 0283859 [Patent Document 6] US Patent Application Publication No. 2015 / 0335070 [Patent Document 7] US Patent Application Publication No. 2015 / 0335071 [Patent Document 8] US Patent Application Publication No. 2016 / 0007651 [Patent Document 9] US Patent Application Publication No. 2016 / 0050975 Summary of the Invention [Problem to be solved by the invention]

[0005] The present disclosure relates to materials and combinations thereof useful in aerosol delivery devices (e.g., electronic smoking articles) and similar personal devices. In particular, the present disclosure relates to reservoirs that may be included in aerosol delivery devices and / or methods of combining aerosol delivery devices with reservoirs. [Means for solving the problem]

[0006] In various aspects, the present disclosure provides an aerosol delivery device including a housing and a reservoir having an open end and an opposite closed end. The reservoir is configured to hold an aerosol precursor composition therein. The aerosol delivery device further includes electrical contacts within or on the housing. The aerosol delivery device includes a vaporization unit including a liquid transport element, a heating element, and an electrical connector. The vaporization unit is configured to removably engage the open end of the reservoir such that the liquid transport element is positioned relative to the reservoir to transfer the aerosol precursor composition from the reservoir to the heating element. The vaporization unit is further configured to engage with the electrical contacts within or on the housing.

[0007] According to some aspects, the aerosol delivery device may include a power source disposed within the housing. The power source may be configured to provide electrical current to the heating element when the vaporization unit is engaged with the open end of the reservoir and placed in an operative position. The aerosol delivery device may further include a mouthpiece in operably engagement with the vaporization unit.

[0008] In some aspects, the mouthpiece may be configured to receive electrical current from the power source when the mouthpiece is in operable engagement with the vaporization unit such that the vaporization unit engages the open end of the reservoir. The power source may be configured to provide electrical current to the heating element when the mouthpiece is in operable engagement with the vaporization unit in the operative position.

[0009] According to some embodiments, the vaporization unit may include an outer shell. The outer shell may define an opening proximate a first end of the outer shell and an annular channel proximate an opposite second end of the outer shell. Additionally, a heating element and a liquid transport element may be disposed within the outer shell. In some embodiments, the housing may further include an engagement element configured to operably engage with the annular channel when the vaporization unit is disposed in an operating position. The engagement element may include electrical contacts. In some embodiments, a mouthpiece connectably engaged with the vaporization unit may be configured to receive electrical current from a power source when an electrical connector of the vaporization unit engages with an electrical contact in or on the housing.

[0010] In some aspects, the aerosol delivery device includes a sealing element disposed proximate the open end of the reservoir. The vaporization unit may sealably engage with the sealing element when the vaporization unit is disposed in an operative position. According to some aspects, the sealing element may be configured to retain the aerosol precursor composition within the reservoir when the vaporization unit is removably disengaged from the open end of the reservoir. Furthermore, the sealing element may be configured to remove excess aerosol precursor composition from the vaporization unit when the vaporization unit traverses the sealing element and is removably disengaged from the open end of the reservoir.

[0011] According to some embodiments, the housing may define a fill orifice in fluid communication with the open end of the reservoir. The aerosol delivery device may further include a fill orifice engaging element configured to removably and sealably engage a container for filling the reservoir with the aerosol precursor composition.

[0012] The present disclosure may also provide an aerosol delivery device including a housing having a reservoir configured to hold an aerosol precursor composition therein. The aerosol delivery device further includes a removable vaporizer unit configured to engage the reservoir and a mouthpiece connectably engaging the vaporizer unit. Furthermore, the housing, vaporizer unit, and mouthpiece collectively form an electrical circuit.

[0013] According to some embodiments, the aerosol delivery device may further include at least one electrical contact within or on the housing. In some embodiments, the electrical contact is electrically connected to the circuit. Additionally or alternatively, the mouthpiece may be configured to coupleably engage with the vaporization unit to form an electrical circuit. According to one embodiment, the mouthpiece may be configured to couple with the at least one electrical contact to form an electrical circuit. In some embodiments, the aerosol delivery device may further include a power source, and the vaporization unit may include a liquid transport element and a heating element. The power source may be configured to supply current to the heating element through the electrical circuit when the housing, the vaporization unit, and the mouthpiece are coupleably engaged with each other.

[0014] The present disclosure may also provide an aerosol delivery device including a housing and a reservoir disposed within or on the housing. The reservoir includes an open end and an opposite closed end and is configured to hold an aerosol precursor composition therein. The aerosol delivery device further includes electrical contacts within or on the housing and a power source disposed within the housing. The power source is electrically connected to the electrical contacts. The aerosol delivery device further includes a controller disposed within the housing. The controller is configured to control the current supplied by the power source to the electrical contacts.

[0015] The aerosol delivery device may further include a vaporization unit configured to removably engage an open end of the reservoir such that, when the vaporization unit is placed in an operating position, a liquid transport element of the vaporization unit is positioned relative to the reservoir to transfer the aerosol precursor composition from the reservoir to a heating element within the vaporization unit. The aerosol delivery device may further include a mouthpiece connectably engaged with the vaporization unit.

[0016] According to some aspects, the power source is configured to provide current to the heating element and be in electrical communication with the mouthpiece when the mouthpiece is connectably engaged with the vaporization unit and the vaporization unit is placed in the operative position. The aerosol delivery device may further include an engagement element within the housing. The engagement element may be configured to operably engage with the annular channel defined by the outer shell of the vaporization unit when the vaporization unit is placed in the operative position. In some aspects, the engagement element may include electrical contacts within or on the housing.

[0017] In one or more embodiments, the aerosol delivery device can be configured such that the reservoir removably engages with the housing. For example, the reservoir can be a self-contained unit that can be inserted into or attached to the housing. In some embodiments, the reservoir can be disposed adjacent to the outer wall of the housing. For example, the housing can be configured such that the outer wall of the housing includes a horizontal portion and a connected vertical portion, e.g., the horizontal and vertical portions can be at a substantially 90-degree angle with each other. In this manner, the reservoir can include a bottom wall and a side wall, and the bottom wall of the reservoir can be configured to engage with the horizontal portion of the housing wall, and the side wall of the reservoir can be configured to engage with the vertical portion of the housing wall. In some embodiments, the outer wall of the housing (e.g., the horizontal and / or vertical portions described above) can include a light source configured to illuminate the reservoir.

[0018] The present invention includes, but is not limited to, the following embodiments.

[0019] Embodiment 1: An aerosol delivery device comprising: a housing; a reservoir having an open end and an opposite closed end, the reservoir configured to hold an aerosol precursor composition therein; electrical contacts in or on the housing; and a vaporization unit comprising a liquid transport element, a heating element, and an electrical connector, the vaporization unit configured to removably engage the open end of the reservoir and to engage the electrical contacts in or on the housing such that the liquid transport element is positioned relative to the reservoir to transfer the aerosol precursor composition from the reservoir to the heating element.

[0020] Embodiment 2: The aerosol delivery device of any preceding or subsequent embodiment, further comprising: a power source disposed within the housing, the power source configured to supply current to the heating element when the vaporization unit engages the open end of the reservoir and is positioned in an operative position; and a mouthpiece connectably engaged with the vaporization unit.

[0021] Embodiment 3: The aerosol delivery device of any preceding or subsequent embodiment, further configured such that when the mouthpiece is connectably engaged with the vaporization unit and the vaporization unit engages with the open end of the reservoir, the mouthpiece is electrically connected to the power source, and when the mouthpiece is connectably engaged with the vaporization unit disposed in the operative position, the power source supplies current to the heating element.

[0022] Embodiment 4: The aerosol delivery device of any preceding or subsequent embodiment, wherein the vaporization unit includes an outer shell, the outer shell defining an opening proximate a first end of the outer shell and an annular channel proximate an opposite second end of the outer shell, and the heating element and liquid transport element are disposed within the outer shell.

[0023] Embodiment 5: The aerosol delivery device of any preceding or subsequent embodiment, wherein the housing further includes an engagement element, and the engagement element is configured to operably engage with the annular channel when the vaporization unit is placed in the operating position.

[0024] Embodiment 6: The aerosol delivery device of any preceding or subsequent embodiment, wherein the engaging element comprises an electrical contact.

[0025] Embodiment 7: The aerosol delivery device of any preceding or subsequent embodiment, wherein a mouthpiece connectably engaged with the vaporization unit electrically connects to a power source when the electrical connector of the vaporization unit engages with electrical contacts in or on the housing.

[0026] Embodiment 8: The aerosol delivery device of any preceding or subsequent embodiment, further comprising a sealing element disposed proximate to the open end of the reservoir, wherein the sealing element is configured to sealably engage the vaporizing unit when the vaporizing unit is disposed in an operative position, and to retain the aerosol precursor composition within the reservoir when the vaporizing unit is removably disengaged from the open end of the reservoir.

[0027] Embodiment 9: The aerosol delivery device of any preceding or subsequent embodiment, wherein the sealing element is configured to remove excess aerosol precursor composition from the vaporization unit when the vaporization unit is releasably disengaged from the open end of the reservoir across the sealing element.

[0028] Embodiment 10: The aerosol delivery device of any preceding or subsequent embodiment, wherein the housing defines a fill orifice in fluid communication with the open end of the reservoir.

[0029] Embodiment 11: The aerosol delivery device of any preceding or subsequent embodiment, wherein the fill orifice comprises a fill engagement element configured to removably and sealably engage a container for filling the reservoir with the aerosol precursor composition.

[0030] Embodiment 12: An aerosol delivery device comprising: a housing including a reservoir configured to hold an aerosol precursor composition therein; a removable vaporization unit configured to engage the reservoir; and a mouthpiece connectably engaged with the vaporization unit, wherein the housing, vaporization unit, and mouthpiece collectively form an electrical circuit.

[0031] Embodiment 13: The aerosol delivery device of any preceding or subsequent embodiment, further comprising at least one electrical contact within or on the housing, the electrical contact being in electrical communication with the electrical circuit.

[0032] Embodiment 14: The aerosol delivery device of any preceding or subsequent embodiment, wherein the mouthpiece is configured to coupleably engage with the vaporization unit to form an electrical circuit.

[0033] Embodiment 15: The aerosol delivery device of any preceding or subsequent embodiment, wherein the mouthpiece is configured to engage with at least one electrical contact to form an electrical circuit.

[0034] Embodiment 16: The aerosol delivery device of any preceding or subsequent embodiment, further comprising a power source, wherein the vaporization unit further comprises a liquid transport element and a heating element, and wherein the power source is configured to supply current to the heating element through an electrical circuit when the housing, the vaporization unit and the mouthpiece are connectably engaged with each other.

[0035] Embodiment 17: An aerosol delivery device comprising: a housing; a reservoir disposed within or on the housing, the reservoir having an open end and an opposite closed end, the reservoir defining an orifice proximate to an opening configured to receive a removable vaporization unit such that the vaporization unit is in fluid communication with the reservoir and in electrical communication with the electrical contacts, the reservoir configured to hold an aerosol precursor composition therein; electrical contacts within or on the housing; a power source disposed within the housing and in electrical communication with the electrical contacts; and a controller disposed within the housing and configured to control the current supplied to the electrical contacts by the power source.

[0036] Embodiment 18: The aerosol delivery device of any preceding or subsequent embodiment, further comprising a vaporization unit configured to removably engage the open end of the reservoir such that, when the vaporization unit is placed in an operating position, a liquid transport element of the vaporization unit is positioned relative to the reservoir to transfer the aerosol precursor composition from the reservoir to a heating element within the vaporization unit.

[0037] Embodiment 19: The aerosol delivery device of any preceding or subsequent embodiment, further comprising a mouthpiece in connectable engagement with one or both of the reservoir and the vaporization unit.

[0038] Embodiment 20: The aerosol delivery device of any preceding or subsequent embodiment, wherein the power source is configured to supply current to the heating element and to be in electrical communication with the mouthpiece when the mouthpiece is connectably engaged with the vaporization unit and the vaporization unit is placed in an operating position.

[0039] Embodiment 21: The aerosol delivery device of any preceding or subsequent embodiment, further comprising an engagement element within the housing, the engagement element configured to operably engage an annular channel defined by the outer shell of the vaporization unit when the vaporization unit is placed in an operating position.

[0040] Embodiment 22: The aerosol delivery device of any preceding or subsequent embodiment, wherein the engagement element comprises an electrical contact in or on the housing.

[0041] Embodiment 23: The aerosol delivery device of any preceding or subsequent embodiment, wherein the reservoir removably engages the housing.

[0042] Embodiment 24: The aerosol delivery device of any preceding or subsequent embodiment, wherein the reservoir is disposed adjacent to an outer wall of the housing.

[0043] Embodiment 25: The aerosol delivery device of any preceding or subsequent embodiment, wherein the exterior wall of the housing includes a light source configured to illuminate the reservoir.

[0044] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, as well as combinations of any two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, appear as intended to be combinable, unless the context clearly dictates otherwise.

[0045] The present disclosure having been described in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0046] [Figure 1] 1 illustrates an aerosol delivery device according to one embodiment of the present disclosure. [Figure 2] 2 shows an exploded view of selected components of the aerosol delivery device of FIG. 1 according to one embodiment of the present disclosure. [Figure 3A] FIG. 1 shows a top view of an aerosol delivery device according to one embodiment of the present disclosure. [Figure 3B] FIG. 1 shows a top view of an aerosol delivery device according to another embodiment of the present disclosure. [Figure 4A] 1 shows a schematic diagram of a vaporization unit of an aerosol delivery device according to one embodiment of the present disclosure. [Figure 4B] 1 shows a schematic diagram of a vaporization unit of an aerosol delivery device according to one embodiment of the present disclosure. [Figure 5A] 4B shows a schematic diagram of an aerosol delivery device including the vaporization unit of FIG. 4A according to one embodiment of the present disclosure. [Figure 5B] FIG. 4C shows a schematic diagram of an aerosol delivery device including the vaporization unit of FIG. 4B, according to one embodiment of the present disclosure. [Figure 6] 1 shows an exploded view of a vaporization unit of an aerosol delivery device according to one embodiment of the present disclosure. [Figure 7A] 1 shows a perspective view of a vaporization unit of an aerosol delivery device according to one embodiment of the present disclosure. [Figure 7B] 1 shows a cross-sectional view of a vaporization unit of an aerosol delivery device according to one embodiment of the present disclosure. [Figure 8] 1 shows an exploded view of a reservoir assembly of an aerosol delivery device according to one aspect of the present disclosure. [Figure 9] 1 illustrates a reservoir assembly of an aerosol delivery device according to one aspect of the present disclosure. [Figure 10] FIG. 2 shows an embodiment incorporating a removable reservoir 200. [Figure 11]FIG. 2 shows an embodiment incorporating a removable reservoir 200. [Figure 12] FIG. 10 includes a tongue formed on the wall of the reservoir. DETAILED DESCRIPTION OF THE INVENTION

[0047] The present disclosure will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, this disclosure may be expressed in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0048] As described below, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat a material (preferably without significantly burning and / or significantly chemically altering the material) to form an inhalable substance, and components of such systems most preferably have the form of an item small enough to be considered a handheld device. That is, the use of preferred aerosol delivery system components does not produce smoke (i.e., from by-products of tobacco combustion or pyrolysis); rather, the use of these preferred systems produces a vapor / aerosol resulting from the volatilization or vaporization of certain components, such as, for example, an aerosol precursor composition incorporated therein. In preferred embodiments, the aerosol delivery system components may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver the tobacco-derived components in aerosol form.

[0049] The aerosol-generating components and / or components of certain preferred aerosol delivery systems may provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, sensory stimulating effects, physical sensations, modes of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe that is used by lighting and burning tobacco (and thus by inhaling tobacco smoke) without substantially burning any of its components. For example, a user of an aerosol-generating component of the present disclosure can hold and use the component in the same way as a smoker would use a conventional type of smoking article (e.g., a cigarette, cigar, or pipe that is used by lighting it with a flame and subsequently inhaling the charred and / or burned tobacco), draw on one end of the component to inhale the aerosol generated by the component, take puffs or puffs at selected time intervals, etc. However, the devices described herein are not limited to devices that are substantially shaped and sized like a conventional cigarette. Rather, the devices of the present disclosure may have any shape and can be substantially larger than a conventional cigarette. In certain preferred embodiments, the device may be small enough to be considered a "handheld" device.

[0050] The aerosol delivery device of the present disclosure can also be characterized as a vapor product or drug delivery article. Accordingly, such articles or devices can be configured to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance can be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not they are visible and whether or not they are in a form that can be considered smoky.

[0051] According to aspects of the present disclosure, the aerosol precursor composition can vary. Most preferably, the aerosol precursor composition is comprised of a combination or mixture of various raw materials or components. The selection of specific aerosol precursor components and the relative amounts of those components used may be varied to control the overall chemical composition of the mainstream aerosol generated by the aerosol generating device. Of particular interest are aerosol precursor compositions that can be characterized as generally liquid in nature. For example, a typical generally liquid aerosol precursor composition may have the form of a solution, a viscous gel, a mixture of miscible components, or a liquid incorporating suspended or dispersed components. Typical aerosol precursor compositions can vaporize upon exposure to heat under conditions experienced during use of the aerosol generating device featured in the present disclosure, thereby producing an inhalable vapor and aerosol.

[0052] According to some embodiments, the aerosol delivery device may contain or incorporate tobacco, tobacco components, or tobacco-derived materials (i.e., materials naturally found in tobacco, which may be isolated directly from tobacco or synthetically prepared). For example, the aerosol delivery device may contain a quantity of flavorful, aromatic tobacco in cut filler form. In some embodiments, the aerosol precursor composition may contain tobacco, tobacco components, or tobacco-derived materials that have been processed to provide desired qualities, such as those processed according to the methods described in U.S. Patent No. 9,066,538 to Chen et al., U.S. Patent No. 9,155,334 to Moldoveanu et al., U.S. Patent Application Publication No. 2016 / 0015078 to Moldoveanu et al., or U.S. Patent Application No. 15 / 043,177 to Marshall et al., filed February 12, 2016, the disclosures of which are incorporated herein by reference in their entireties.

[0053] Additionally or alternatively, highly purified tobacco-derived nicotine (e.g., pharmaceutical-grade nicotine having a purity of greater than 98% or greater than 99%) or a derivative thereof can be incorporated into the aerosol precursor composition. Representative nicotine-containing extracts can be provided using the techniques described in U.S. Pat. No. 5,159,942 to Brinkley et al., incorporated herein by reference. In certain embodiments, the products of the present invention can include any form of nicotine obtained from any source, whether tobacco-derived or synthetic. The nicotine compound used in the products of the present invention can include nicotine in free base form, salt form, complex, or solvate form. See, for example, the description of nicotine in free base form described in U.S. Pat. No. 8,741,348 to Hansson et al., incorporated herein by reference in its entirety. At least a portion of the nicotine compound can be used in the form of a nicotine resin complex, such as nicotine polacrilex, in which nicotine is bound in an ion-exchange resin. See, for example, U.S. Patent No. 3,901,248 to Lichtneckert et al., which is incorporated herein by reference in its entirety. At least a portion of the nicotine can be used in the form of a salt. Nicotine salts can be provided using the types of ingredients and techniques described in U.S. Patent No. 2,033,909 to Cox et al., U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al., U.S. Patent Application No. 15 / 951,939 to Dull et al., filed November 25, 2015, and Perfetti, Beitrage Tabakforschung Int., 12, 43-54 (1983), the disclosures of which are incorporated herein by reference in their entirety. Furthermore, nicotine salts are available from suppliers such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc.Exemplary pharmaceutically acceptable salts of nicotine include tartrates (e.g., nicotine tartrate and nicotine bitartrate), chloride compounds (e.g., nicotine hydrochloride and nicotine dihydrochloride), sulfates, perchlorates, ascorbates, fumarates, citrates, malates, lactates, aspartates, salicylates, tosylates, succinates, pyruvates, and the like, nicotine salt hydrates (e.g., nicotine zinc chloride monohydrate), etc. In certain embodiments, at least a portion of the nicotine compounds are in the form of salts with organic acid moieties, including, but not limited to, levulinic acid, as described in U.S. Patent Application Publication No. 2011 / 0268809 to Brinkley et al., which is incorporated herein by reference in its entirety.

[0054] In another embodiment, the aerosol precursor composition may include tobacco, tobacco components, or tobacco-derived materials that may be treated, manufactured, produced, and / or processed to incorporate an aerosol-forming material (e.g., a humectant such as propylene glycol, glycerin, or the like). Additionally or alternatively, the aerosol precursor composition may include at least one flavoring agent. Additional components that may be included in the aerosol precursor composition are described in U.S. Patent No. 7,726,320 to Robinson et al., which is incorporated herein by reference. Various modes and methods for incorporating tobacco and other materials into aerosol generating devices are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,290,549 to Banerjee et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al. and U.S. Patent Application Publication No. 2016 / 0073695 to Sears et al., the disclosures of which are incorporated herein by reference in their entireties.

[0055] The aerosol delivery device of the present disclosure generally includes many components disposed within an outer body or shell, which may be referred to as a housing. The overall design of the outer body or shell can vary, and the type or configuration of the outer body can vary, which can define the overall dimensions and shape of the aerosol delivery device. In exemplary embodiments, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, integral housing, or the elongated housing can be formed from two or more separable bodies. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and resembling the shape of a traditional cigarette or cigar. In one aspect, all components of the aerosol delivery device are contained within a single housing. Alternatively, the aerosol delivery device can include two or more joined, separable housings.

[0056] The aerosol delivery devices of the present disclosure may be formed from an outer housing or shell that is not substantially tubular in shape, but may be formed to substantially larger dimensions, i.e., substantially "palm-sized," for being held in the palm of a user's hand. The housing or shell may be configured to include a mouthpiece and / or may be configured to house a separate shell (e.g., a cartridge) that can contain consumable elements such as a liquid aerosol precursor composition. In some embodiments, the housing or shell may be configured to house a separate shell that can contain a vaporizer or atomizer.

[0057] The aerosol delivery device of the present disclosure most preferably includes some combination of a power source (i.e., a source of electrical power), at least one control component (e.g., a means (e.g., a microcontroller or microprocessor) for activating, controlling, regulating, and terminating electrical power for heat generation, such as by controlling the flow of electrical current from the power source to other components of the article), a heater or heat-generating member (e.g., an electrical resistance heating element or other component that, alone or in combination with one or more additional elements, may commonly be referred to as an "atomizer"), an aerosol precursor composition (e.g., a liquid that can generally generate an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece and mouth area that allows the aerosol delivery device to be drawn on for aerosol inhalation (e.g., a defined air flow path through the article so that the generated aerosol may be drawn therefrom by inhalation).

[0058] More specific forms, configurations, and arrangements of components within the aerosol delivery systems of the present disclosure will become apparent in light of the further disclosure provided below. Furthermore, the selection and arrangement of various aerosol delivery system components can be understood in light of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure. One exemplary embodiment of an aerosol delivery device 10 according to the present disclosure is provided in FIG. 1. The aerosol delivery device 10 includes a housing 100, a reservoir 200, and a vaporization unit 300.

[0059] In various embodiments, the present disclosure is particularly beneficial in that the use of a replaceable vaporization unit 300 and reservoir 200 in the aerosol delivery device 10 can facilitate filling the reservoir 200 with an aerosol precursor composition. Many conventional aerosol delivery devices (e.g., electronic cigarettes) utilize a combination of components to form an aerosol from an aerosol precursor composition stored in the reservoir. For example, some conventional aerosol delivery devices include a heater or heating element (e.g., an electrical resistance heating element or component commonly referred to as an "atomizer") within the same housing that defines the reservoir. The atomizers incorporated within these conventional aerosol delivery devices are typically not replaceable and are therefore discarded when the atomizer components malfunction and / or fail. Furthermore, while some conventional aerosol delivery devices may include replaceable components, such as a heater or heating element and / or wick, they may include numerous parts that are difficult and / or complex to operate. For example, some conventional aerosol delivery devices may include a replaceable nebulizer disposed within a reservoir body, which may require draining the remaining aerosol precursor composition from the reservoir before replacing the nebulizer. Furthermore, some conventional aerosol delivery devices may include a reservoir configured to receive a vaporizer through one open end and aerosol precursor composition from a second open end on the opposite side. Such devices suffer from various disadvantages, such as difficulty for users in assembling and operating the aerosol delivery device (e.g., disassembling the nebulizer to fill the reservoir with the aerosol precursor composition, draining the aerosol precursor composition from the reservoir to replace the heating element and / or liquid transport element, etc.).

[0060] Aerosol delivery device 10 according to embodiments of the present disclosure can facilitate use during operation (e.g., filling the reservoir with an aerosol precursor composition, replacing heating elements and / or liquid transport elements, etc.) For example, the ability to replace vaporization unit 300 without having to drain the aerosol precursor composition from reservoir 200 can provide an improved user experience.

[0061] As shown in FIGS. 1, 2, 3A, and 3B, the housing 100 includes a top surface 102 and a bottom surface 104. The top surface 102 defines at least one orifice (e.g., a vaporization orifice 108). In some embodiments, the top surface 102 of the housing 100 defines both the vaporization orifice 108 and the fill orifice 110. The vaporization orifice 108 may be in fluid communication with a reservoir 200. For example, the reservoir 200 includes an open end 202 and an opposite closed end 204. The open end 202 of the reservoir 200 may be in fluid communication with the vaporization orifice 108. Additionally, the open end 202 of the reservoir 200 may be in fluid communication with the fill orifice 110. Thus, it will be understood that the open end 202 of the reservoir 200 is construed as being "open" in that the vaporization unit 300 may be removably inserted into the open end 202 of the reservoir 200.

[0062] Referring to FIG. 1 , reservoir 200 may be disposed within or attached to housing 100. That is, in some embodiments, reservoir 200 may be configured to be integrally formed within housing 100 and securely retained therein, or reservoir 200 may be integrally secured to housing 100 such that at least a portion of reservoir 200 forms at least a portion of the exterior surface of aerosol delivery device 10. Alternatively, reservoir 200 may be configured to removably engage housing 100 (e.g., removably insertable within or removably attachable to the housing). Reservoir 200 is illustrated as being substantially cylindrical in shape, but may be any suitable shape including an open end 202 and an opposite closed end 204. In some embodiments, reservoir 200 may be shaped to retain a desired amount of aerosol precursor composition therein. For example, reservoir 200 may be configured to retain the aerosol precursor composition therein, and reservoir 200 may be formed from a material that is impermeable to the aerosol precursor composition. In some embodiments, reservoir 200 can be formed from a metallic material, a ceramic material, a glass material, a polymeric material, or a combination thereof. Reservoir 200 may be shaped to hold a limited amount of an aerosol precursor composition therein to provide a number of sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, organoleptic effects, etc.) of smoking a particular amount of a traditional type of smoking article (e.g., a cigarette, a cigar, a pipe, etc.).

[0063] An embodiment incorporating a removable reservoir 200 is particularly shown with reference to Figures 9, 10, and 11. The removable reservoir 200 can be defined by an outer wall 205 having an open top 206 and a closed bottom 207. A lower portion of the reservoir wall 205 can be telescoping and reduced in size relative to the remainder of the reservoir wall 205. A cover 209 for the reservoir 200 can be formed from a lower gasket housing 210, an upper gasket housing 215, and an intervening gasket 220 including a resealable membrane 221 through which the vaporization unit 300 can be inserted. The lower gasket housing 210 includes a bottom insert wall 212 that engages the open top 206 of the outer wall 205 of the reservoir 200, and a top rim wall 211 that rests on the wall 205 of the reservoir 200. Interposer gasket 220 is placed on base 213 of lower gasket housing 210, and upper gasket housing 215 is placed thereon such that upper gasket housing 2105 and lower gasket housing 210 are interconnected. When properly aligned, gasket extension 110a, upper gasket housing extension perimeter 110b, and lower gasket housing gasket port 110c are aligned to form fill orifice 110. A reservoir cap 230 can be attached to the top of the reservoir during storage.

[0064] The housing 100 can include a cutout 115 configured to receive a removable reservoir 200, and the cutout 115 can define a cutout wall 116 and a cutout floor 117 that can be recessed relative to a cutout rim 118. The reservoir 200 can be aligned within the cutout 115 such that the back surface 205a of the reservoir wall 205 is positioned against the cutout wall 116 and the closed bottom 207 of the reservoir wall 207 is positioned against the cutout floor 117. The cutout rim 118 can be configured to secure the reservoir 200 in place when the reservoir 200 is aligned within the cutout 115. The cutout rim 118 can include a groove 119 that can be aligned with, for example, a tongue 219 formed on the wall 205 of the reservoir 200 (see FIG. 12 ). If desired, a locking mechanism can be included to further secure the reservoir 200 within the cutout 115 of the housing 100. The back surface 205a of the reservoir wall 205 can be textured, include a surface treatment, or incorporate other elements useful for configuring the back surface 205a to improve the transmission and / or diffusion of light from the LEDs 190 disposed on the cutout wall 116 of the housing 100. In this manner, the reservoir housing 200 can define a light pipe. In some embodiments, a sensor 195 may also be present on the cutout wall 116 and / or the cutout floor 117. The sensor 195 can be configured to detect a properly inserted reservoir 200, read a corresponding signal on the reservoir 200 to confirm that a genuine and compatible reservoir is being used, detect the amount of aerosol precursor composition in the reservoir 200, etc.

[0065] Referring to FIG. 2, the aerosol delivery device 10 further includes a vaporization unit 300 configured to removably engage the open end 202 of the reservoir 200. The vaporization unit 300 includes a liquid transport element 306 and a heating element 308 (shown in FIGS. 4A and 4B ) and may include an outer shell 301. In some embodiments, the liquid transport element 306 and the heating element 308 are disposed within the outer shell 301. The outer shell 301 may include a first end 302 and an opposite second end 304. Additionally, the outer shell 301 may define an opening 303 proximate the first end 302 of the outer shell 301. As shown in FIG. 2, the vaporization unit 300 may include first and second portions arranged in series extending between the first end 302 and the opposite second end 304. In some embodiments, the first portion may taper toward the first end 302, and the second portion may be substantially cylindrical in shape. In some aspects, the first and second portions may be separated by a gasket 312 or similar element. Accordingly, the outer shell 301 may be formed from a single housing or multiple interconnected sub-housings in some embodiments. As shown in FIG. 2 , a first sub-housing 301a may be interconnected with a second sub-housing 301b to collectively form the outer shell 301. Additionally, an additional outer sub-housing 301c may be included. As described further herein, such a third sub-housing 301c may function to direct intake air into the vaporizer 300. The vaporization unit 300 is configured to removably engage the open end 202 of the reservoir 200 by extending therethrough. For example, the open end 202 of the reservoir 200 may define an orifice configured to receive the vaporization unit 300. That is, removably engaging the vaporization unit 300 with the reservoir 200 may include inserting the first end 302 of the vaporization unit 300, and thus the opening 303 located proximate to the first end 302, through an orifice defined by the open end 202 of the reservoir.In some embodiments, the reservoir orifice configured to receive the vaporization unit 300 may be shaped and / or sized to sealably engage the vaporization unit 300 (i.e., the diameter of the reservoir orifice may be substantially equal to the maximum diameter of the vaporization unit 300). With reference to Figures 5A and 5B, when the vaporization unit 300 removably engages with the open end 202 of the reservoir 200, an opening 303 defined proximate the first end 302 of the outer shell 301 may be in fluid communication with the reservoir 200. Additionally, a liquid transport element 306 may be disposed within the outer shell 301 and in fluid communication with the opening 303, such that when the vaporization unit 300 is removably engaged with the open end 202 of the reservoir 200, the liquid transport element 306 may be in fluid communication with the reservoir 200 and may be positioned relative to the reservoir 200 to transport the aerosol precursor composition from the reservoir 200 to the heating element 308. That is, when the vaporization unit 300 is placed in an operating position, the liquid transport element 306 may be in fluid communication with the reservoir 200 to transport a desired amount of the aerosol precursor composition from the reservoir 200 to the heating element 308. In some embodiments, as shown in FIGS. 4A and 4B , the liquid transport element 306 may be positioned parallel to the longitudinal axis Y of the outer shell 301 of the vaporization unit.

[0066] The liquid transport element 306 may comprise a material configured to facilitate the transfer of the aerosol precursor composition from the reservoir 200 to the heating element 308. That is, the liquid transport element 306 can be absorbent, adsorbent, or otherwise configured to retain the aerosol precursor composition. In this manner, the aerosol precursor composition can be characterized as being coated on, adsorbed by, or absorbed by the porous medium. According to some embodiments, the liquid transport element 306 may comprise a flexible material, such as, for example, fibers and / or fibrous materials (e.g., woven or nonwoven). Additionally or alternatively, the liquid transport element 306 may comprise a braided material, such as that described in U.S. Pat. No. 8,910,640 to Sears et al. Non-limiting examples may further include natural and synthetic fibers, such as cotton, cellulose, polyester, polyamide, polylactic acid, fiberglass, and combinations thereof. According to some embodiments, the liquid transport element 306 may comprise a non-flexible material, such as, for example, metal, ceramic, and the like. Other exemplary materials that can be used for the liquid transport element 306 to transport the aerosol precursor composition from the reservoir 200 to the heating element 308 can include carbonized filaments (e.g., materials formed from carbonaceous materials that have been calcined to remove non-carbon components of the material) and foams, such as carbon foam. Examples of materials suitable for use as liquid transport elements are described in U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al., U.S. Patent Application Publication No. 2014 / 0261487 to Chapman et al., U.S. Patent Application Publication No. 2013 / 0255702, and U.S. Patent Application No. 14 / 988,109, filed January 5, 2016, the disclosures of which are incorporated herein by reference.

[0067] 4A and 4B, the vaporization unit 300 may further include a gasket 312 configured to substantially seal a portion of the vaporization unit 300 from the aerosol precursor composition when the vaporization unit 300 is removably engaged with the open end 202 of the reservoir 200 and / or disposed in an operating position. That is, the gasket 312 may be configured to substantially seal a portion of the vaporization unit 300 and substantially prevent an excess amount of the aerosol precursor composition from entering the sealed portion (e.g., the vapor formation chamber 314) when the vaporization unit 300 is in fluid communication with the reservoir 200. Furthermore, the gasket 312 may define a liquid transport element opening configured to receive a liquid transport element 306, such that the liquid transport element 306 may transport the aerosol precursor composition from the reservoir 200 to a heating element 308, which may be disposed within the vapor formation chamber 314 of the vaporization unit 300.

[0068] As shown in FIGS. 2, 4A, and 4B, outer shell 301 may further define an annular channel 305 proximate a second end 304 opposite outer shell 301 of vaporization unit 300. With reference to FIGS. 5A and 5B, aerosol delivery device 10 may include an engagement element 120 configured to operably engage with vaporization unit 300 when vaporization unit 300 is engaged with reservoir 200 and / or when placed in an operating position. For example, engagement element 120 may be configured to operably engage with annular channel 305 when vaporization unit 300 is placed in an operating position. As shown in FIGS. 4A-5B, vaporization unit 300 may include at least one electrical connector 310. In some embodiments, as shown in FIGS. 4B and 5B, the vaporization unit 300 may include a first electrical connector 310a and a second electrical connector 310b configured to engage with respective first and second electrical contacts 122a, 122b disposed within or on the housing 100.

[0069] 4A and 5A, the annular channel 305 may include an electrical connector 310 configured to engage with electrical contacts 122 disposed in or on the housing 100 of the aerosol delivery device 10. In some embodiments, the electrical connector 310 may be configured to coupleably engage with an engaging element 120, which may include the electrical contacts 122, when the vaporization unit 300 is placed in the operating position. For example, the engaging element 120 may include a biasing element configured to bias the electrical contacts 122 toward the electrical connector 310 in the annular channel 305 such that the biasing element engages the electrical contacts 122 with the electrical connector 310 of the vaporization unit 300 when the vaporization unit 300 is placed in the operating position. According to some embodiments, the engaging element may include a channel in the housing configured to coupleably engage with a reciprocating-shaped member of the vaporization unit, including the electrical connector.

[0070] The heating element 308 may be in a heating configuration with the liquid transport element 306. In particular, the heating element 308 may extend at least partially around a portion of the liquid transport element 306, and more particularly, at least partially around the liquid transport element 306 at a position between a first end and an opposite second end of the liquid transport element 306. In some embodiments, the heating element 308 may be configured to heat an aerosol precursor composition coated on, adsorbed by, or absorbed by a portion of the liquid transport element 306 proximate to the heating element 308 to generate an aerosol for inhalation by a user. In particular, the heating element 308 may be formed from a material that provides resistive heating when an electric current is applied. According to some embodiments, the heating element 308 may include a carbon heater. As mentioned above, the liquid transport element 306 may include a carbon wick, and the outer shell 301 of the vaporization unit 300 may include a carbon material. Such materials advantageously allow the vaporization unit 300 to be disposed of in an environmentally friendly manner.

[0071] 4A and 4B, the heating element 308 may include a wire defining multiple coils wound around a portion of the liquid transport element 306. The heating element 308 may include a wire material that provides resistive heating and may extend between a first electrical terminal (i.e., the electrical connector 310) and a second electrical terminal 320. For example, in some embodiments, the wire material may include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)), ceramic (e.g., a positive temperature coefficient ceramic), titanium, gold, silver, and / or related alloys, although in other embodiments, various other materials may be used. In some embodiments, the heating element 308 may be formed by winding a wire around the liquid transport element 306, as described in U.S. Pat. No. 9,210,738 to Ward et al., which is incorporated herein by reference in its entirety. However, various other embodiments of methods may be used to form the heating element 308. For example, the heating element 308 may be configured to heat the aerosol precursor composition disposed within the liquid transport element 306 via radiant heating, as described in U.S. Patent Application Nos. 14 / 808,405, filed July 24, 2015, and 14 / 958,651, filed December 3, 2015, the contents of which are incorporated herein by reference in their entireties. According to some embodiments, the heating element 308 may be configured to heat the aerosol precursor composition via inductive heating, as described in U.S. Patent Application Nos. 14 / 934,763, filed November 6, 2015, and 15 / 002,056, filed January 20, 2016, the disclosures of which are incorporated herein by reference. Additionally or alternatively, the heating element 308 may be configured to heat the aerosol precursor composition absorbed by the liquid transport element 306 via electrical current heating.In some embodiments, microheaters can be used, as described in U.S. Pat. No. 8,881,737 to Collett et al., U.S. Pat. Appl. Pub. No. 2015 / 0117841 to Brammer et al., U.S. Pat. Appl. Pub. No. 2015 / 0117842 to Brammer et al., and U.S. Pat. Appl. Pub. No. 2015 / 0114409 to Brammer et al., the disclosures of which are incorporated herein by reference.

[0072] According to some embodiments, the housing 100, the vaporization unit 300, and the mouthpiece 400 may collectively form an electrical circuit 132. For example, as shown in FIGS. 5A and 5B , when the vaporization unit 300 is removably engaged with the open end 202 of the reservoir 200 contained in the housing 100 and placed in an operating position, the electrical connector (e.g., first electrical terminal 310) may engage with electrical contacts 122 in or on the housing 100. The electrical contacts 122 may be electrically connected to and / or included in the electrical circuit 132.

[0073] In some embodiments, the vaporization unit 300 may include a second electrical terminal 320. The first and second electrical terminals 310, 320 may be configured to supply electrical current to the heating element 308 when the vaporization unit 300, the housing 100, and the mouthpiece 400 collectively form an electrical circuit 132. For example, the power source 130 disposed within the housing 100 may be configured to supply electrical current to the heating element 308 (e.g., a resistive heating element) through a completed electrical circuit 132 that includes the first and second electrical terminals 310, 320 of the vaporization unit 300. In some embodiments, as shown in FIGS. 4B and 5B , the vaporization unit 300 may include third and fourth electrical terminals 330, 340. The third electrical terminal 330 may be electrically connected to the fourth electrical terminal 340.

[0074] 5A, electrical circuit 132 may be formed when vaporization unit 300 engages open end 202 of reservoir 200 and mouthpiece 400 is connectably engaged with vaporization unit 300 and housing 100 simultaneously. Alternatively, as shown in FIG. 5B, electrical circuit 132 may be formed when vaporization unit 300 engages open end 202 of reservoir 200 and mouthpiece 400 is connectably engaged with vaporization unit 300 only. That is, first and second electrical terminals 310, 320 may be configured to supply electrical current to heating element 308 when mouthpiece 400 is connectably engaged with vaporization unit 300 and / or when vaporization unit 300 is connectably engaged with housing 100 simultaneously.

[0075] In some embodiments, the mouthpiece 400 may include a first electrical terminal 402a and a second electrical terminal 402b electrically connected to each other and each configured to engage a respective electrical terminal (e.g., the second electrical terminal 320 of the vaporization unit 300, an electrical contact 122 disposed in or on the housing 10, etc.). For example, as shown in FIG. 5A, when the mouthpiece 400 is simultaneously connectably engaged with the vaporization unit 300 and the housing 100, the first electrical terminal 402a may engage and electrically connect with the second electrical contact 124 disposed in or on the housing 100 to form the electrical circuit 132. Additionally, the second electrical terminal 402b of the mouthpiece 400 may engage and electrically connect with the corresponding second electrical terminal 320 of the vaporization unit 300 to form the electrical circuit 132. In this manner, the mouthpiece 400, which simultaneously engages the housing 100 and the vaporization unit 300 when the vaporization unit 300 is engaged with the housing 100, may form an electrical circuit 132 configured to transmit electrical current from the power source 130 within the housing 100 to the heating element 308.

[0076] According to another embodiment, the mouthpiece 400 may be configured to solely engage with the vaporization unit 300 when the vaporization unit 300 engages with the housing 100 to form the electrical circuit 132. As shown in FIG. 5B , when the mouthpiece 400 is connectably engaged with the vaporization unit 300, the first electrical terminal 402a of the mouthpiece 400 may be electrically connected to the fourth electrical terminal 340 of the vaporization unit 300, and the second electrical terminal 402b of the mouthpiece 400 may be electrically connected to the second electrical terminal 320 of the vaporization unit 300. Furthermore, when the vaporization unit 300 is removably engaged with the open end 202 of the reservoir 200 and placed in the operative position, the third electrical terminal 330 of the vaporization unit may be configured to engage and electrically connect with the second electrical contact 124 disposed in or on the housing 100 to form the electrical circuit 132. That is, as shown in Figures 5A and 5B, when an electrical circuit 132 is collectively formed by the housing 100, the vaporization unit 300, and the mouthpiece 400, the power source 130 located within the housing 100 may supply current to the heating element 308 through the completed electrical circuit 132.

[0077] An exploded view of an exemplary embodiment of a vaporization unit 300 according to the present disclosure is shown in Figure 6. It should be understood that such an embodiment is merely one example of a vaporization unit 300 suitable for use according to the present disclosure, and that the apparatus 10 described herein is not limited to only this single embodiment. As shown, the vaporization unit 300 includes a first sub-housing 301a, a gasket 312, an outer coil contact 327, a center coil contact 325, a liquid transport element 306, a heating element 308, a flow tube 322, a flow tube gasket 316, a second sub-housing 301b, a third sub-housing 301c, a vaporization unit cap 318, and an O-ring 319.

[0078] The structure of the vaporization unit 300 according to this embodiment is further illustrated in Figures 7A and 7B. In particular, the first sub-housing 301a is sealed at its end 302 but includes an opening 303 or openings formed in the wall of the first sub-housing 301a, allowing the first sub-housing 301a to function as a capillary surrounding a portion of the liquid transport element 306 to meter the aerosol precursor composition from the reservoir 200. The first sub-housing 301a is interconnected with the second sub-housing 301b adjacent to a gasket 312 effective to separate the vapor formation chamber 314 from the aerosol precursor composition inlet in the first sub-housing 301a. The third sub-housing 301c is sheathed around at least a portion of the second sub-housing 301b, and the space between the inner surface of the third sub-housing 301c and the outer surface of the second sub-housing 301b defines an intake channel 345. The air intake channel 345 may comprise an annular space completely surrounding the second sub-housing 301b, or it may comprise one or more individual channels. The second sub-housing 301b is formed with one or more vapor formation chamber air inlets 313 for directing air passing through the air intake channel 345 into the vapor formation chamber 314. Inside the vapor formation chamber 314, a heater 308 is wrapped around the liquid transport element 306. The liquid transport element 306 is adjacent to the end of a flow tube 322, which includes aerosol outlet ports 323a, 323b, and 323c (although the exact number of aerosol outlet ports may vary, at least above the aerosol outlet ports present in the flow tube 322). The aerosol outlet ports 323a, 323b, and 323c open into an aerosol outlet channel 324, which opens at an end that engages with the vaporization unit cap 318. Conduit 322 specifically passes through a channel through vaporizer unit cap 318. Conduit gasket 316 surrounds conduit 322 and prevents the passage of air or vapor between conduit 322 and vaporizer unit cap 318. Vaporizer unit cap 318 includes intake ports 317a and 317b in fluid communication with intake channel 345. O-ring 319 forms a seal against the interior of mouthpiece 400.

[0079] 7A and 7B, in use, the aerosol precursor composition travels through liquid transport element 306 into vapor formation chamber 314, where it is vaporized by heater 308. When a user draws on mouthpiece 400 (see FIGS. 1 and 2), which is in fluid communication with open end 304 of vaporization unit 300, air enters intake ports 317a and 317b, passes through intake channel 345, and passes through vapor formation chamber air inlet 313 to mix with the formed vapor in vapor formation chamber 314. The air mixed with the vapor forms an aerosol, which is drawn through aerosol outlet ports 323a, 323b, and 323c into aerosol outlet channel 324, where it passes through mouthpiece 400.

[0080] 8, the aerosol delivery device 10 provides a secure electrical connection that prevents activation of the heater 308 in the spray unit 300 unless the device is fully assembled and the mouthpiece 400 is in place. More specifically, with reference to FIGS. 5A, 7B, and 8, when the spray unit 300 is fully inserted into the reservoir 200, the engagement element 120 (e.g., a spring-loaded detent) engages the annular channel 305 and forms an electrical connection through the second and third sub-housings 301b and 301c to the outer coil contact 327. The outer coil contact 327 connects to one end of the heater 308, and the second end of the heater 308 connects to the central coil contact 325, which provides an electrical connection with the flow tube 322. When the mouthpiece 400 is placed on the device 10, the electrical contact spring 412a electrically connects to the flow tube 322, and the mouthpiece contact 412b electrically connects to the electrical contact 124 on the housing. The electrical contacts 124 and engaging element 120 electrically connect with the battery 130, thus completing the circuit. In this manner, when the mouthpiece is removed, the electrical connection is severed, preventing accidental heating of the vaporization unit 300 during removal and replacement.

[0081] The mouthpiece 400 may also include one or more air openings 417 for admitting air as described above. The air openings 417 may be adjustable to control the amount of air entering the device 10.

[0082] According to some embodiments, the power source 130 may include a battery disposed within the housing 100. In some embodiments, the power source within the housing 100 may be referred to as disposable or reusable. For example, the power source may include a replaceable power source, such as a replaceable battery. In other embodiments, the power source may include a rechargeable battery and, therefore, may be combined with any type of charging technology, including connection to a typical electrical outlet, connection to an automobile charger (e.g., a cigarette lighter socket), and / or connection to a computer via a Universal Serial Bus (USB) cable or the like. For example, an adapter including a USB connector on one end and a control body connector on the opposite end is disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. Examples of useful rechargeable power sources include lithium-ion batteries, and more particularly, lithium polymer batteries. Additional examples of batteries that can be used in accordance with the present disclosure are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0083] In some embodiments, the aerosol delivery device 10 may include multiple power sources within the housing 100. For example, the aerosol delivery device 10 may include two batteries having different charges. According to one embodiment, the aerosol delivery device may include a first battery having approximately half the charge of a second battery within the housing 100. One advantage of incorporating two separate batteries having two different charges within the aerosol delivery device 10 is to maximize the energy density of the aerosol delivery device 10 and / or provide more efficient power management during operation of the aerosol delivery device 10. Examples of batteries that can be used in accordance with the present disclosure are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0084] The aerosol delivery device 10 may further include signs and / or other indicators (e.g., light-emitting diodes (LEDs)) that can be variably positioned within and / or on the housing 100 to provide an output to the user. In addition to or as an alternative to LED indicators, additional indicators (e.g., tactile feedback components, audio feedback components, LCD screens, etc.) can be included. Additional representative types of components or indicators that provide visual cues, such as LED components, and their configurations and uses, are described in U.S. Pat. No. 5,154,192 to Sprinkel et al., U.S. Pat. No. 8,499,766 to Newton, and U.S. Pat. No. 8,539,959 to Scatterday, and U.S. Patent Application Publication No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference. In some embodiments, for example, an LED 190 can be present on the housing 100. In particular, an LED can be positioned on the housing 100 behind the reservoir 200. Such positioning may be useful for illumination of reservoir 200 for aesthetic purposes and / or to improve the ability to visualize the amount of aerosol precursor composition remaining in reservoir 200. Control component 150 may be configured to illuminate the LED under defined conditions and for defined periods of time. For example, device 10 may be configured such that when mouthpiece 400 is removed and the user is filling reservoir 200, engaging push button switch 160 causes the LED to illuminate reservoir 200, making filling easier, especially in low light.

[0085] In one embodiment, the aerosol delivery device 10 may include a display unit 140 configured to display information regarding the operational status of the aerosol delivery device. For example, as shown in Figures 3A and 3B, the display unit 140 may be configured to display indicators corresponding to the settings of the aerosol delivery device. For example, as shown in the focus diagram, the display unit 140 is configured to provide visual indicators in the form of a heating element temperature setting indicator 142, a power level indicator 144, and an operability indicator 146 (e.g., a temperature unlocked for use in Figure 3A and a temperature locked in Figure 3B).

[0086] 5A and 5B, the aerosol delivery device 10 may further include a control component 150 (e.g., a microcontroller) and / or an actuation component (e.g., a push button switch 160) within and / or on the housing 100. For example, as shown in FIGS. 1, 3A, and 3B, the aerosol delivery device 10 may include a membrane potentiometer 162 configured to control functions of the device. In another embodiment, the aerosol delivery device 10 may include a push button switch 160 configured to control various functions of the device (e.g., powering the device on and off, etc.). In some embodiments, the aerosol delivery device 10 may include a touch screen, which may be configured to allow a user to control functions of the device and output visual cues or indicators to the user. Additionally or alternatively, a component suitable for gesture recognition based on specific movements of the aerosol delivery device (e.g., an accelerometer, a gyroscope, etc.) may be used as an actuation component to allow a user to provide input to the aerosol delivery device 10. See U.S. Patent Application No. 14 / 565,137 to Henry et al., filed December 9, 2014, which is incorporated by reference in its entirety.

[0087] The presence of potentiometer 162 can be useful for providing easy, real-time temperature adjustment of the heater by the user. For example, potentiometer 162 can be configured to operate in conjunction with control component 150 to increase the heater temperature (e.g., by sliding a finger upward on potentiometer 162) or decrease the heater temperature (e.g., by sliding a finger downward on potentiometer 162) as desired during use of device 10. Similarly, predetermined positions on potentiometer 162 can be configured to correspond to predetermined operating temperatures of the heater, and the heater temperature can be simply adjusted by touching a position on the potentiometer (e.g., higher for a higher temperature or lower for a lower temperature). The control component can be configured to return the heater to a predetermined temperature setpoint after a certain period of time. However, device 10 can be configured to allow the user to select a temperature as described above and then lock that temperature (e.g., by pressing pushbutton switch 160). During use, as the user adjusts the temperature, the effective temperature range can be visualized via the heating element temperature setting indicators 142 on the display unit 140 .

[0088] In some embodiments, the input device may include a computer or computing device such as a smartphone or tablet. Specifically, the aerosol delivery device may be hardwired to a computer or other device, such as via a USB cord or similar protocol. The aerosol delivery device may also be configured to communicate wirelessly with a computer or computing device. See, for example, U.S. Patent Application No. 14 / 327,776 to Ampolini et al., filed July 10, 2014, the disclosure of which is incorporated herein by reference in its entirety, for a system and method for controlling a device via a readout request. In such embodiments, an application or other computer program product may be used in conjunction with a computer or other computing device to input control instructions to the aerosol delivery device, including, for example, the ability to form an aerosol of a specific composition by selecting the nicotine content and / or the content of additional flavors to be included.

[0089] 5A and 5B, the aerosol delivery device 10 may further include a sealing element 170 disposed proximate the open end 202 of the reservoir 200. In some embodiments, the sealing element 170 may be disposed within the reservoir 200. Furthermore, the sealing element 170 may be disposed proximate the vaporization orifice 108 defined by the housing 100. The sealing element 170 may be configured to sealingly engage with the vaporization unit 300 when the vaporization unit 300 is disposed in an operative position and / or when the vaporization unit 300 is connectably engaged with the open end 202 of the reservoir 200. That is, the sealing element 170 may be configured to prevent a substantial amount of the aerosol precursor composition from exiting the reservoir through the open end 202 of the reservoir 200 and / or through the vaporization orifice 108 defined by the housing 100 when the vaporization unit 300 is connectably engaged with the open end 202 of the reservoir 200. Additionally, sealing element 170 may be configured to seal, protect, and / or otherwise substantially prevent the aerosol precursor composition from leaking from reservoir 200 through open end 202 when vaporization unit 300 is disengaged from open end 202 of reservoir 200. In this manner, open end 202 of reservoir 200 may be construed as “open” in that the sealing element allows free insertion and removal of vaporization unit 300 even though the open end 202 is substantially prevented from liquid escape. For example, sealing element 170 may include a one-way valve configured to removably engage vaporization unit 300. That is, the one-way valve may be configured to retain the aerosol precursor composition within reservoir 200 when vaporization unit 300 is disengaged. In some embodiments, sealing element 170 may include a membrane comprising a flexible material configured to retain the aerosol precursor composition within reservoir 200 when vaporization unit 300 is removably disengaged from sealing element 170.

[0090] According to one embodiment of the present disclosure, the sealing element 170 may be further configured to engage with the liquid transport element 306 and / or the outer shell 301. For example, the sealing element 170 may be configured to remove excess aerosol precursor composition from a portion of the liquid transport element 306 and / or the outer shell 301 of the vaporization unit 300 when the portion of the vaporization unit 300 passes over the sealing element 170. As the portion of the vaporization unit 300 passes over the sealing element 170, the sealing element 170 removes excess aerosol precursor composition therefrom. In some embodiments, the sealing element 170 may include a membrane comprising a flexible material (e.g., silicone) that removes excess aerosol precursor composition from the liquid transport element 306 and / or the outer shell 301 of the vaporization unit 300 when they pass over the membrane. Additionally or alternatively, the sealing element 170 may include a polymeric material extending across the vaporization orifice 108. In some embodiments, when the vaporization unit 300 engages the open end 202 of the reservoir 200, the vaporization unit 300 pierces the membrane as it extends into the reservoir 200. The polymeric material included in the sealing element 170 may be configured to reseal the opening created by the vaporization unit 300 piercing the membrane when the vaporization unit 300 is removably disengaged from the open end 202 of the reservoir 200.

[0091] 3A and 3B, aerosol delivery device 10 may further include fill engaging elements (180a and 180b) configured to removably and sealably engage a container for filling reservoir 200 with an aerosol precursor composition. In some embodiments, as shown in FIGS. 2 and 3A, fill engaging element 180a may be positioned proximate fill orifice 110 and may be configured to accept aerosol precursor compositions from various fill containers. Additionally, fill engaging element 180b (see FIG. 3B) may include structure arranged to reciprocally engage a particular fill container to ensure that reservoir 200 is filled with the appropriate aerosol precursor composition using an approved aerosol precursor composition stored in the approved fill container. See, for example, systems and methods for filling an aerosol delivery device, such as those described in U.S. Patent Application No. 14 / 802,667, filed July 17, 2015, to O'Brien et al., the disclosure of which is incorporated herein by reference in its entirety. Additionally or alternatively, fill engagement elements (180a and 180b) may be configured, like sealing element 170, to prevent aerosol precursor composition stored in reservoir 200 from crossing fill orifice 110. According to some embodiments, the aerosol delivery device may include a single orifice (i.e., vaporization orifice 108) configured to engage with vaporization unit 300 to generate vapor for ingestion, and may be further configured to receive additional aerosol precursor composition from a fill container to provide the aerosol precursor composition to reservoir 200.

[0092] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol delivery device comprising: Housing and a reservoir disposed within or on the housing, the reservoir having an open end and an opposite closed end, the reservoir configured to hold an aerosol precursor composition therein; a liquid transport element; a heating element in a heating configuration with a liquid transport element; an electrical connector configured to supply electrical current to the heating element; a flow conduit extending at least partially through the reservoir and including at least one aerosol outlet; An aerosol delivery device, wherein a liquid transport element and a heating element are positioned relative to the reservoir such that the liquid transport element transfers an aerosol precursor composition from the reservoir to the heating element.

2. The aerosol delivery device of claim 1, further comprising a mouthpiece.

3. 3. The aerosol delivery device of claim 2, wherein the housing and mouthpiece collectively form an electrical circuit.

4. 10. The aerosol delivery device of claim 1, further comprising a power source disposed within the housing.

5. 10. The aerosol delivery device of claim 1, wherein the housing defines a fill orifice in fluid communication with the open end of the reservoir.

6. 10. The aerosol delivery device of claim 1, wherein the reservoir removably engages the housing.

7. 7. The aerosol delivery device of claim 6, wherein the reservoir is disposed adjacent to an outer wall of the housing.

8. 8. The aerosol delivery device of claim 7, wherein the exterior wall of the housing includes a light source configured to illuminate the reservoir.

9. 8. The aerosol delivery device of claim 7, wherein the outer wall of the housing includes a horizontal portion and a connected vertical portion, the reservoir includes a bottom wall and a side wall, the bottom wall of the reservoir configured to engage with the horizontal portion of the outer wall of the housing, and the side wall of the reservoir configured to engage with the vertical portion of the outer wall of the housing.

10. 7. The aerosol delivery device of claim 6, wherein the housing includes a cutout configured to receive the removable reservoir.

11. 11. The aerosol delivery device of claim 10, wherein the notch is configured to lock the reservoir in place when aligned with the notch.

12. The notch includes a notch wall, a notch floor, and a sensor, the sensor comprising: Detects a properly inserted reservoir or Verify that a genuine, compatible reservoir is inserted by reading the corresponding signal on the reservoir, or detecting the level of the aerosol precursor composition held in the reservoir; 12. The aerosol delivery device of claim 11, configured to:

13. 10. The aerosol delivery device of claim 1, further comprising electrical contacts in or on the housing.

14. The aerosol delivery device of claim 1, wherein the housing comprises a first sub-housing.

15. An aerosol delivery device as described in claim 14, wherein the first sub-housing surrounds a portion of the liquid transport element.

16. An aerosol delivery device as described in claim 15, wherein the heating element is wrapped around the liquid transport element.

17. An aerosol delivery device as described in claim 14, wherein the liquid transport element is adjacent to the end of the flow path tube.

18. An aerosol delivery device as described in claim 14, wherein the first sub-housing has electrical contacts.

19. The aerosol delivery device of claim 14, wherein the housing further comprises a second sub-housing and a third sub-housing.

20. The aerosol delivery device further comprising an engagement element; 20. The aerosol delivery device of claim 19, wherein the second sub-housing and the third sub-housing are configured to engage with electrical contacts of the first sub-housing via engaging elements to form an electrical circuit.

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