Aerosol delivery devices and methods of forming same

Abstract

To provide an aerosol delivery device produced utilizing a reservoir.SOLUTION: The present disclosure relates to an aerosol delivery device including a shell 4201 that is divided into a first half 4201a and a second half 4201b along a longitudinal axis thereof. One or more batteries 410 may be positioned within the shell 4201 along with a battery lead 433 that provides an electrical connection to battery terminals 410a, b. A base unit 424 may be included and may have electrical contacts for matching with a battery terminal 410a, b and the battery lead 433. The base unit 424 can include one or both of a printed circuit board and a pressure sensor. The shell 4201 can attach to a cartridge which houses: a reservoir for an aerosol-forming composition; a heater; a liquid transport element configured for transport of the aerosol forming composition between the reservoir and the heater; and heater terminals. Such construct can provide simplified assembly of the device.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices (e.g., smoking articles commonly referred to as e-cigarettes) that can utilize electrically generated heat to generate an aerosol. The smoking article can be configured to heat an aerosol precursor, which can be made from tobacco, or can incorporate a material that can be derived from tobacco or that can otherwise incorporate tobacco, that can be vaporized to form an inhalable substance for human consumption, the precursor can be vaporized to 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 the burning of tobacco. Many of these devices are purportedly designed to provide the sensation associated with cigarette, cigar, or pipe smoking without delivering significant amounts of incomplete combustion and pyrolysis products resulting from the burning of tobacco. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensation of cigarette, cigar, or pipe smoking without significant tobacco combustion. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0255702 to Griffith Jr. et al., and U.S. Patent Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference in their entireties. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heat sources referenced by trade name and vendor in U.S. Patent Application No. 14 / 170,838 to Bless et al., filed February 3, 2014, which is incorporated herein by reference in its entirety.

[0003] It would be desirable to provide a reservoir for an aerosol precursor composition for use in an aerosol delivery device, the reservoir being provided to improve the formation of the aerosol delivery device. It would also be desirable to provide an aerosol delivery device made utilizing such a reservoir. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0096781 Summary of the Invention

[0005] The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure relates to a power supply unit for an aerosol delivery device configured to provide ease of manufacture and / or ease of recycling of some or all of the elements used to form the power supply unit. The power supply unit may also provide lower capital expenditures, thus enabling the formation of lower-cost aerosol delivery devices suitable for disposal in their entirety after use. Thus, the aerosol delivery device incorporating such a power supply unit may be referred to as a low-cost disposable device. The aerosol delivery device may be configured so that disposal can be accomplished by recycling its various elements. For example, the connection of the power supply unit to a cartridge may be configured for easy disassembly. The housing of the power supply unit may also be configured for easy disassembly to remove the elements contained therein. Various advantages of power supply units and aerosol delivery devices incorporating such a power supply unit are further disclosed in the description of various embodiments provided herein.

[0006] In some embodiments, the present disclosure specifically provides a power supply unit for an aerosol delivery device. The power supply unit may include an elongated shell having a proximal end and an opposing distal end, the elongated shell being divided into two separate halves along its longitudinal axis. A power supply unit according to the present disclosure may be further described with reference to one or more of the following features, which may be combined in any number without limitation:

[0007] The two halves of the elongate shell may be separably joined together.

[0008] The two halves of the elongated shell may be permanently joined together.

[0009] The two halves of the elongated shell may be welded together.

[0010] The power supply unit may include at least one elongated battery positioned within the elongated shell, the at least one elongated battery extending from a distal end of the elongated shell toward a proximal end of the elongated shell.

[0011] The power supply unit may include a battery lead including a protrusion configured for electrical connection with a terminal of the at least one battery and including an arm extending from the protrusion along the length of the at least one battery.

[0012] The power supply unit may include a base unit attached at the proximal end of the elongated shell.

[0013] The base unit may be attached to at least one battery.

[0014] The base unit may include one or both of a printed circuit board (PCB) and a pressure sensor.

[0015] The base unit may include a first contact configured for electrical connection with a terminal of the at least one battery and may include a second contact configured for electrical connection with an opposing terminal of the at least one battery.

[0016] The battery lead protrusion may be configured for electrical connection with a negative terminal of at least one battery, and the battery lead arm may be configured for electrical connection with one of the first contact and the second contact of the base unit.

[0017] The electrical connections within the power supply unit do not have to be fused.

[0018] In some embodiments, the present disclosure may specifically provide a base unit configured to interconnect a power supply unit and a cartridge to form an aerosol delivery device. The base unit may be configured to facilitate assembly of the aerosol delivery device by providing "drop-in" connectivity between the power supply unit and the cartridge associated with the electrical connections required therein. Specifically, the present disclosure may provide a base unit for an aerosol delivery device, the base unit may include a first section configured for engagement with the power supply unit and a second section configured for engagement with the cartridge, the base unit including a cavity extending at least partially therethrough. Base units according to the present disclosure may be further described with reference to one or more of the following features, which may be combined in any number without limitation.

[0019] The first section of the base unit may have a first diameter and the second section of the base unit may have a second diameter that is less than the first diameter.

[0020] The first section of the base unit may be defined by a wall and a skirt extending longitudinally from the wall.

[0021] The skirt of the first section of the base unit may include at least one opening that may be characterized as an air intake.

[0022] The wall of the first section of the base unit may include a plurality of openings, which may be characterized as heater terminal openings in that terminals extending from a heater within the cartridge may pass therethrough.

[0023] The second section of the base unit may be defined by a longitudinal wall extending from the wall of the first section of the base unit.

[0024] The cavity in the base unit may extend completely from the free end of the second section of the base unit and at least partially into the first section of the base unit a distance sufficient to provide an air passage from the air intake on the skirt of the first section, through at least a portion of the first section of the base unit, and through the second section of the base unit.

[0025] The second section of the base unit may be sized and shaped to engage a flow tube in the cartridge.

[0026] The base unit may have a PCB positioned therein.

[0027] The base unit may have one or more contacts configured for electrical connection to one or more of the battery terminals, battery leads, and heater terminals.

[0028] One or more of the contacts may be located on a PCB.

[0029] One or more of the contacts may be positioned on the skirt of the first section of the base unit.

[0030] The base unit may include one or more clips configured to attach the base unit to a battery in the power supply unit.

[0031] The first section of the base unit may include a support plate positioned therein.

[0032] The support plate may be positioned between the air intake and the distal end of the first section of the base unit.

[0033] The PCB may be attached to a support plate.

[0034] The support plate may provide a liquid impermeable barrier.

[0035] In addition to the foregoing, the present disclosure may also provide an aerosol delivery device including one or both of the power supply unit and base unit described above and throughout this disclosure. In some embodiments, the aerosol delivery device may include a first elongated outer shell configured to contain an aerosol-forming composition and having a mouthpiece and opposing mating ends, and a second elongated outer shell having a proximal end configured for connection with the mating end of the first elongated outer shell and having opposing distal ends, the second elongated outer shell being split into two separate halves along its longitudinal axis. The aerosol delivery device according to the present disclosure may be further described with reference to one or more of the following features, which may be combined in any number without limitation.

[0036] The two halves of the second elongate shell may be separably joined together.

[0037] The two halves of the second elongated shell may be permanently joined together.

[0038] The two halves of the second elongated shell may be welded together.

[0039] The second elongated shell may include at least one elongated battery positioned therein, the at least one elongated battery extending from a distal end of the second elongated shell toward a proximal end of the second elongated shell.

[0040] The aerosol delivery device may include a base unit configured for connection with the first elongated outer shell and the second elongated outer shell, which may be defined separably or in combination according to any embodiment described herein.

[0041] The base unit may include one or both of a printed circuit board (PCB) and a pressure sensor.

[0042] The base unit may include a first contact configured for electrical connection with a terminal of the at least one battery and may include a second contact configured for electrical connection with an opposing terminal of the at least one battery.

[0043] The aerosol delivery device may include a battery lead including a protrusion configured for electrical connection with an opposing terminal of the at least one battery and including an arm extending from the protrusion along the length of the at least one battery to electrically connect with a second contact of the base unit.

[0044] The electrical connections within the aerosol delivery device may not be fused.

[0045] may include an elongated flow tube positioned at least partially within the first elongated shell, the elongated flow tube including a central airflow passage therethrough.

[0046] The elongated flow tube may be configured for one or both of physical and electrical connection with the base unit.

[0047] The elongated flow tube may include a plurality of heater terminals configured for electrical connection with the base unit.

[0048] The aerosol delivery device may include a heater positioned within the first elongated shell.

[0049] The aerosol delivery device may include a reservoir positioned within the first shell and configured to store an aerosol-forming composition.

[0050] The aerosol delivery device may include a liquid transport element configured for transfer of the aerosol-forming composition from the reservoir to the heater.

[0051] The aerosol delivery device may include a mouthpiece attached to the mouthpiece of the first elongate shell.

[0052] In some embodiments, the aerosol delivery device may include a first elongated shell having a mouthpiece and opposing mating ends, the first elongated shell housing a reservoir for an aerosol-forming composition, a heater, a liquid transport element configured for transporting the aerosol-forming composition between the reservoir and the heater, and heater terminals. The aerosol delivery device may further include a second elongated shell having a proximal end configured for connection with the mating end of the first elongated shell and an opposing distal end, the second elongated shell being split into two separate halves along its longitudinal axis, a base unit including at least one battery, one or both of a printed circuit board (PCB), and a pressure sensor positioned within the second elongated shell, a first contact configured for electrical connection with a terminal of the at least one battery, and a second contact configured for electrical connection with an opposing terminal of the at least one battery. The base unit may specifically be electrically connected to the heater terminals. Aerosol delivery devices according to the present disclosure may be further described with reference to one or more of the following features, which may be combined in any number without limitation.

[0053] The aerosol delivery device may include a battery lead including a protrusion configured for electrical connection with an opposing terminal of the at least one battery and including an arm extending from the protrusion along the length of the at least one battery to electrically connect with a second contact of the base unit.

[0054] The aerosol delivery device may include an elongated flow tube positioned at least partially within a first elongated shell, the elongated flow tube including a central airflow passage therethrough.

[0055] The heater terminals may pass through the flow tube, specifically through a flange portion of the flow tube.

[0056] The flow tube may be attached to the base unit.

[0057] The mating end of the first elongated shell may be connected to at least a portion of the base unit.

[0058] A proximal end of the second elongate shell may be connected to at least a portion of the base unit.

[0059] In some embodiments, the present disclosure may further provide a method for forming an aerosol delivery device. As described herein, the method may be characterized in terms of the ease of combining multiple elements of the aerosol delivery device and the ability to simply disassemble the device to recycle one or more of its components. In some embodiments, the method for forming an aerosol delivery device includes providing a first longitudinal half-shell configured for attachment to a second longitudinal half-shell to form an elongated clamshell divided into a first half and a second half along its longitudinal axis; placing battery leads and at least one battery within the first longitudinal half-shell such that protrusions of the battery leads electrically connect with a first terminal of the at least one battery and such that arms of the battery leads extend from the protrusions along the length of the at least one battery; attaching a first contact configured for electrical connection with a second terminal of the at least one battery, the first contact comprising one or both of a printed circuit board (PCB) and a pressure sensor, and the battery providing a base unit further comprising a second contact configured for electrical connection with an arm of the lead; providing a cartridge comprising a shell housing a reservoir for the aerosol-forming composition, a heater, a liquid transport element configured for transporting the aerosol-forming composition between the reservoir and the heater, and a heater terminal; combining the cartridge, the base unit, and a first longitudinal half-shell such that the heater terminal is electrically connected to the base unit, the first contact of the base unit is electrically connected to a second terminal of the at least one battery, and the second contact of the base unit is electrically connected to an arm of the battery lead; and pairing the second longitudinal half-shell with the first longitudinal half-shell. Methods of forming an aerosol delivery device according to the present disclosure may be further described with reference to one or more of the following features, which may be combined in any number without limitation.

[0060] The method may include first adding a base unit to the first longitudinal half-shell and then attaching the cartridge to the base unit.

[0061] The method may include first attaching the cartridge to a base unit and then adding the base unit to the first longitudinal half-shell.

[0062] The method may include one or more of crimping, welding (eg, laser welding or ultrasonic welding), and gluing the clamshell to one or both of the base unit and cartridge shell.

[0063] The method may include adding a label to the aerosol delivery device. For example, a suitably sized sheet of paper or similar material commonly used to form wrapping paper or labels may be positioned around the aerosol delivery device. The label may completely or partially surround the aerosol delivery device circumferentially. The label may completely or partially cover the bond (or connection point) between the base unit and the cartridge and may extend substantially from the distal end of the base unit to the mouthpiece of the cartridge. The label may be adhered to one or both of the base unit and the cartridge. The presence of the label and its attachment to the base unit and the cartridge may function to secure the cartridge to the base unit. The presence of the label may replace or complement one or more additional methods described herein for attaching the base unit and the cartridge.

[0064] The present invention includes, but is not limited to, the following embodiments.

[0065] Embodiment 1: An aerosol delivery device comprising: a first elongated shell configured to contain an aerosol-forming composition, the first elongated shell having a mouthpiece and opposing mating ends; and a second elongated shell having a proximal end configured for connection with the mating end of the first elongated shell and having opposing distal ends, the second elongated shell being split into two separate halves along its longitudinal axis.

[0066] Embodiment 2: An aerosol delivery device according to any of embodiments 1-39, wherein the two halves of the second elongated shell are detachably joined together.

[0067] Embodiment 3: An aerosol delivery device according to any of embodiments 1 to 39, wherein the two halves of the second elongated shell are permanently joined together.

[0068] Embodiment 4: An aerosol delivery device according to any of embodiments 1 to 39, wherein the two halves of the second elongated shell are welded together.

[0069] Embodiment 5: An aerosol delivery device according to any of embodiments 1-39, wherein the second elongated outer shell comprises at least one elongated battery positioned therein, the at least one elongated battery extending from the distal end of the second elongated outer shell towards the proximal end of the second elongated outer shell.

[0070] Embodiment 6: The aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a base unit configured for connection with the first elongated outer shell and the second elongated outer shell.

[0071] Embodiment 7: An aerosol delivery device according to any of embodiments 1 to 39, wherein the base unit comprises one or both of a printed circuit board (PCB) and a pressure sensor.

[0072] Embodiment 8: An aerosol delivery device according to any of embodiments 1 to 39, wherein the base unit comprises a first contact configured for electrical connection with a terminal of the at least one battery and a second contact configured for electrical connection with an opposing terminal of the at least one battery.

[0073] Embodiment 9: An aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a battery lead including a protrusion configured for electrical connection with the opposing terminal of the at least one battery, and including an arm extending from the protrusion along the length of the at least one battery to electrically connect with the second contact of the base unit.

[0074] Embodiment 10: An aerosol delivery device according to any of embodiments 1 to 39, wherein the electrical connections are not fused.

[0075] Embodiment 11: An aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises an elongated flow tube positioned at least partially within the first elongated outer shell, the elongated flow tube comprising a central airflow passage therethrough.

[0076] Embodiment 12: An aerosol delivery device according to any of embodiments 1 to 39, wherein the elongate flow tube is configured for one or both of physical and electrical connection with the base unit.

[0077] Embodiment 13: An aerosol delivery device according to any of embodiments 1 to 39, wherein the elongated flow tube comprises a plurality of heater terminals configured for electrical connection with the base unit.

[0078] Embodiment 14: The aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a heater positioned within the first elongated shell.

[0079] Embodiment 15: The aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a reservoir positioned within the first shell and configured to store the aerosol-forming composition.

[0080] Embodiment 16: The aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a liquid transport element configured for transfer of the aerosol-forming composition from the reservoir to the heater.

[0081] Embodiment 17: An aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a mouthpiece attached to the mouthpiece of the first elongate shell.

[0082] Embodiment 18: An aerosol delivery device comprising: a first elongated outer shell having a mouthpiece and opposing mating ends, the first elongated outer shell housing a reservoir for an aerosol-forming composition, a heater, a liquid transport element configured for transporting the aerosol-forming composition between the reservoir and the heater, and heater terminals; a second elongated outer shell having a proximal end configured for connection with the mating end of the first elongated outer shell and an opposing distal end, the second elongated outer shell being divided into two separate halves along its longitudinal axis; and a base unit comprising one or both of at least one battery, a printed circuit board (PCB), and a pressure sensor positioned within the second elongated outer shell, the base unit further comprising a first contact configured for electrical connection with a terminal of the at least one battery and a second contact configured for electrical connection with an opposing terminal of the at least one battery, the base unit being in electrical connection with the heater terminals.

[0083] Embodiment 19: An aerosol delivery device according to any of embodiments 1 to 39, wherein the aerosol delivery device comprises a battery lead including a protrusion configured for electrical connection with the opposing terminal of the at least one battery and including an arm extending from the protrusion along the length of the at least one battery to electrically connect with the second contact of the base unit.

[0084] Embodiment 20: An aerosol delivery device according to any of embodiments 1 to 39, further comprising an elongated flow tube positioned at least partially within said first elongated shell, said elongated flow tube comprising a central airflow passage therethrough.

[0085] Embodiment 21: The aerosol delivery device according to any of embodiments 1 to 39, wherein the heater terminal passes through the flow tube.

[0086] Embodiment 22: An aerosol delivery device according to any of embodiments 1 to 39, wherein the flow tube is attached to the base unit.

[0087] Embodiment 23: An aerosol delivery device according to any of embodiments 1 to 39, wherein the joining end of the first elongated shell is connected to at least a portion of the base unit.

[0088] Embodiment 24: An aerosol delivery device according to any of embodiments 1 to 39, wherein the proximal end of the second elongated shell is connected to at least a portion of the base unit.

[0089] Embodiment 25: A method for forming an aerosol delivery device, comprising: providing a first longitudinal half-shell configured for attachment to a second longitudinal half-shell to form an elongated clamshell divided into a first half and a second half along its longitudinal axis; placing a battery lead and at least one battery within the first longitudinal half-shell such that a protrusion of the battery lead electrically connects with a first terminal of the at least one battery and such that an arm of the battery lead extends from the protrusion along a length of the at least one battery; and attaching a first contact portion of the battery lead to the second half-shell, the first contact portion comprising one or both of a printed circuit board (PCB) and a pressure sensor, the first contact portion configured for electrical connection with a second terminal of the at least one battery, and the arm of the battery lead to the second half-shell. providing a cartridge comprising a shell containing a reservoir for an aerosol-forming composition, a heater, a liquid transport element configured for transporting the aerosol-forming composition between the reservoir and the heater, and a heater terminal; assembling the cartridge, the base unit, and the first longitudinal half-shell so that the heater terminal is electrically connected to the base unit, the first contact of the base unit is electrically connected to the second terminal of the at least one battery, and the second contact of the base unit is electrically connected to the arm of the battery lead; and mating the second longitudinal half-shell with the first longitudinal half-shell.

[0090] Embodiment 26: A method according to any of embodiments 1 to 39, comprising first adding the base unit to the first longitudinal half-shell and then attaching the cartridge to the base unit.

[0091] Embodiment 27: A method according to any of embodiments 1 to 39, comprising first attaching the cartridge to the base unit and then adding the base unit to the first longitudinal half-shell.

[0092] Embodiment 28: A method according to any of embodiments 1 to 39, comprising one or more of crimping, welding, and gluing the clamshell to one or both of the base unit and the cartridge shell.

[0093] Embodiment 29: A power supply unit for an aerosol delivery device, comprising an elongated outer shell having a proximal end and an opposing distal end, the elongated outer shell being split along its longitudinal axis into two separate halves.

[0094] Embodiment 30: A power supply unit according to any of embodiments 1 to 39, wherein the two halves of the elongated shell are detachably joined together.

[0095] Embodiment 31: A power supply unit according to any of embodiments 1 to 39, wherein the two halves of the elongated shell are permanently joined together.

[0096] Embodiment 32: A power supply unit according to any of embodiments 1 to 39, wherein the two halves of the elongated shell are welded together.

[0097] Embodiment 33: A power supply unit according to any of embodiments 1 to 39, comprising at least one elongated battery positioned within the elongated outer shell, the at least one elongated battery extending from the distal end of the elongated outer shell towards the proximal end of the elongated outer shell.

[0098] Embodiment 34: A power supply unit according to any of embodiments 1 to 39, comprising a battery lead including a protrusion configured for electrical connection with a terminal of the at least one battery, and including an arm extending from the protrusion along the length of the at least one battery.

[0099] Embodiment 35: A power supply unit according to any of embodiments 1 to 39, comprising a base unit attached at the proximal end of the elongated shell.

[0100] Embodiment 36: A power supply unit according to any of embodiments 1 to 39, wherein the base unit comprises one or both of a printed circuit board (PCB) and a pressure sensor.

[0101] Embodiment 37: A power supply unit according to any of embodiments 1 to 39, wherein the base unit includes a first contact portion configured for electrical connection with the terminal of the at least one battery, and a second contact portion configured for electrical connection with an opposing terminal of the at least one battery.

[0102] Embodiment 38: A power supply unit according to any of embodiments 1 to 39, wherein the battery lead protrusion is configured for electrical connection with the negative terminal of the at least one battery, and the battery lead arm is configured for electrical connection with one of the first contact portion and the second contact portion of the base unit.

[0103] Embodiment 39: The power supply unit according to any of embodiments 1 to 39, wherein the electrical connections are not melted.

[0104] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, and any combination of two, three, four, or more features or elements described in this disclosure, whether or not such features or elements are expressly combined in the description of a particular embodiment herein. It is intended that, when read as a whole, the present disclosure should be considered to be intended as any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, being combinable unless the context clearly dictates otherwise.

[0105] Having thus described the present disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0106] [Figure 1] FIG. 1 is a partial cutaway view of an aerosol delivery device comprising a cartridge and a regulator that includes various elements that may be utilized in an aerosol delivery device according to various embodiments of the present disclosure. [Figure 2] 1 is a cross-section of a power supply unit according to an exemplary embodiment of the present disclosure illustrating the relationship of the battery and battery leads to the two halves of the clamshell with the clamshell halves assembled; [Figure 3] 1 is a cross-section of a power supply unit according to an exemplary embodiment of the present disclosure illustrating the relationship of the battery and battery leads to the two halves of the clamshell with the clamshell in an open configuration. [Figure 4] FIG. 1 is an exploded view of a power supply unit according to an exemplary embodiment of the present disclosure, the power supply unit including an associated base unit according to an exemplary embodiment of the present disclosure. [Figure 5a] FIG. 10 is a plan view of a distal end of a base unit according to an exemplary embodiment of the present disclosure. [Figure 5b] FIG. 10 is a plan view of the proximal end of the base unit, according to an exemplary embodiment of the present disclosure. [Figure 6] 1 is an exploded view of a cartridge useful in combination with a power unit and / or base unit according to an exemplary embodiment of the present disclosure. FIG. [Figure 7a] FIG. 10 is an exploded view of a partial flow tube, base unit, and insulator cap illustrating the functional relationship therebetween according to an exemplary embodiment of the present disclosure. [Figure 7b] 10 is a cross section of a partial flow tube, base unit, and insulator cap illustrating their substantially permanent engagement according to an exemplary embodiment of the present disclosure. [Figure 8a] FIG. 10 is an exploded view of a partial flow tube, a base unit, and an intermediate housing illustrating the functional relationship therebetween according to an exemplary embodiment of the present disclosure. [Figure 8b]10 is a cross-section of a partial flow tube, base unit, and intermediate housing illustrating their removable engagement according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0107] The present disclosure will now be described more fully hereinafter 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, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0108] As described below, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat materials (preferably without significant combustion and / or significant chemical alteration of the materials) to form inhalable substances, and the components of such systems have the form of articles that are most preferably small enough to be considered handheld devices. That is, use of the components of preferred aerosol delivery systems does not result in the production of smoke (i.e., from by-products of tobacco combustion or pyrolysis); rather, use of these preferred systems results in the production of vapor due to the volatilization or vaporization of certain components incorporated therein. In preferred embodiments, the components of the aerosol delivery systems may be characterized as electronic cigarettes, and these electronic cigarettes most preferably incorporate tobacco and / or tobacco-derived components to deliver the tobacco-derived components in aerosol form.

[0109] The aerosol-generating components of certain preferred aerosol delivery systems can provide many of the sensations (e.g., inhalation and exhalation habits, taste or flavor types, organoleptic effects, physical sensations, usage habits, visual cues such as those provided by visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used with tobacco lighting and burning (and the resulting inhalation of tobacco smoke) without burning any of their components to any significant extent. For example, a user of an aerosol-generating component of the present disclosure can hold and use the component, draw on one end of the component to inhale the aerosol generated by the component, take puffs or draws at selected intervals, etc., much in the same way as a smoker uses a traditional type of smoking article.

[0110] The aerosol delivery device of the present disclosure may also be characterized as a vapor product or drug delivery article. Thus, such an article or device may be adapted to provide one or more substances (e.g., flavors and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension of solid particles or liquid droplets in a gas). For purposes of brevity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible and whether or not in a form that can be considered smoke-like.

[0111] The aerosol delivery system of the present disclosure generally includes multiple components provided within an outer body or shell, which may be referred to as a housing. The overall design of the outer body or shell may vary, and the format or configuration of the outer body may vary, which may define the overall size and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar may be formed from a single, integral housing, or the elongated housing may be formed from two or more separable bodies. For example, the aerosol delivery device may include an elongated outer shell or body that is substantially tubular in shape and may therefore resemble the shape of a traditional cigarette or cigar. In one embodiment, all of the components of the present aerosol delivery device are contained within a single housing. Alternatively, the aerosol delivery device may include two or more housings that are joined and separable. For example, the aerosol delivery device may have at one end a control body with a housing containing one or more power and / or control components (e.g., a battery and various electronics for controlling the operation of the item), and at the other end an outer body or shell removably attached thereto containing the aerosol-forming components (e.g., a heater and a reservoir for storing the aerosol precursor composition).

[0112] The aerosol delivery systems of the present disclosure most preferably comprise some combination of a power source (i.e., a source of electrical power), at least one control component (e.g., a means for activating, controlling, regulating, and terminating electrical power for heat generation, such as by controlling electrical current that power source to other components of the article, e.g., a microcontroller or microprocessor), a heater or heat-generating member (e.g., an electrical resistance heating element or other component, which alone or in combination with one or more additional elements may be commonly referred to as an "atomizer"), an aerosol precursor composition (e.g., a liquid that can generate an aerosol when sufficient heat is applied, such as components commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece region or tip that allows the aerosol delivery device to be drawn upon for aerosol inhalation (e.g., a defined airflow path through the article so that, when drawn upon, the generated aerosol can be drawn therethrough).

[0113] 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.

[0114] In various embodiments, the aerosol delivery device can include a reservoir configured to hold an aerosol precursor composition, which can also be referred to as an aerosol-forming composition. The reservoir can be specifically formed of a porous material (e.g., a fibrous material) and thus can be referred to as a porous substrate (e.g., a fibrous substrate).

[0115] Fibrous substrates useful as reservoirs in aerosol delivery devices can be woven or nonwoven materials formed from a plurality of fibers or filaments, and can be formed from one or both of natural and synthetic fibers. For example, the fibrous substrate can include continuous glass fiber material or polyethylene terephthalate. In certain embodiments, cellulose acetate material can be used. In other exemplary embodiments, carbon material can be used. The reservoir can be substantially in the form of a container and can include the fibrous material therein.

[0116] One exemplary embodiment of an aerosol delivery device 100 according to the present disclosure is provided in FIG. 1. As seen in the cutaway view illustrated in FIG. 1, the aerosol delivery device 100 can include a control body 102 and a cartridge 104, which can be permanently or removably aligned in a functional relationship. The engagement between the control body 102 and the cartridge 104 can be a snap fit (as shown), threaded, interference fit, magnetic, or the like. Specifically, connecting components such as those described further herein can be used. For example, the control body can include a coupler adapted to engage a connector on the cartridge.

[0117] In certain embodiments, one or both of the controller 102 and cartridge 104 may be referred to as disposable or reusable. For example, the controller may have a replaceable or rechargeable battery and, therefore, may be combined with any type of recharging technology, including connection to a typical electrical outlet, a car charger (i.e., cigarette lighter receptacle), and a computer via a Universal Serial Bus (USB) cable or the like. For example, an adapter including a USB connector on one end and a controller connector on the opposite end is disclosed in U.S. Patent Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety. Furthermore, in some embodiments, the cartridge may comprise a single-use cartridge, such as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0118] As shown in FIG. 1 , the controller 102 may be formed with a controller shell 101 that may include a control component 106 (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, or a microcontroller), a flow sensor 108, a battery 110, and an LED 112, which may be variably aligned. Additional indicators (e.g., tactile or audio feedback components) may be included in addition to or as an alternative to the LED. For example, additional exemplary types of components that produce visual cues or indicators, such as light-emitting diode (LED) components, and their construction and use, are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al., 8,499,766 to Newton, and 8,539,959 to Scatterday, and U.S. Patent Application No. 14 / 173,266 to Sears et al., filed February 5, 2014, which are incorporated herein by reference.

[0119] The cartridge 104 may be formed from a cartridge shell 103 enclosing a reservoir 144 in fluid communication with a liquid transport element 136 adapted to wick or otherwise transport the aerosol precursor composition stored in the reservoir housing to the heater 134. Various embodiments of materials configured to generate heat upon application of an electric current through the material may be used to form the resistive heating element 134. Exemplary materials from which the wire coil may be formed include Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)), graphite and graphite-based materials (e.g., carbon-based foams and yarns), and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0120] An opening 128 may be present in the cartridge shell 103 (e.g., at the mouthpiece) to allow the formed aerosol to escape from the cartridge 104. Such components are representative of components that may be present in a cartridge and are not intended to limit the scope of cartridge components encompassed by the present disclosure.

[0121] The cartridge 104 may also include one or more electronic components 150, which may include integrated circuits, memory components, sensors, or the like. The electronic components 150 may be adapted to communicate with the control component 106 and / or external devices by wired or wireless means. The electronic components 150 may be located anywhere within the cartridge 104 or its base 140.

[0122] Although the control component 106 and the flow sensor 108 are illustrated separately, it is understood that the control component and the flow sensor may be combined as an electronic circuit board with the airflow sensor directly attached. Furthermore, the electronic circuit board may be positioned horizontally relative to the illustration of FIG. 1 in that the electronic circuit board may be longitudinally parallel to the central axis of the control body. In some embodiments, the airflow sensor may comprise its own circuit board or other base element to which it may be attached. In some embodiments, a flexible circuit board may be utilized. The flexible circuit board may be configured in a variety of shapes, including a substantially tubular shape.

[0123] The regulator 102 and cartridge 104 may include components adapted to facilitate fluid engagement therebetween. As shown in FIG. 1 , the regulator 102 may include a coupler 124 having a cavity 125 therein. The cartridge 104 may include a base 140 adapted to engage the coupler 124 and may include a protrusion 141 adapted to fit within the cavity 125. Such engagement may facilitate a stable connection between the regulator 102 and cartridge 104 as well as establish an electrical connection between the battery 110 and control components 106 in the regulator and the heater 134 in the cartridge. Additionally, the regulator shell 101 may include an air inlet 118, which may be an indentation in the shell that connects to the coupler 124, allowing ambient air to pass around the coupler and into the shell, then through the cavity 125 of the coupler and through the protrusion 141 into the cartridge.

[0124] Useful couplers and bases according to the present disclosure are described in U.S. Patent Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. For example, the coupler seen in FIG. 1 may define an outer periphery 126 configured to mate with an inner periphery 142 of a base 140. In one embodiment, the inner periphery of the base may define a radius substantially equal to or slightly greater than the radius of the outer periphery of the coupler. Additionally, the coupler 124 may define one or more protrusions 129 on the outer periphery 126 configured to engage with one or more recesses 178 defined in the inner periphery of the base. Such protrusions and recesses may interact to function substantially as an anti-rotation mechanism so that the control body 102 and cartridge 104 remain positionally aligned. However, various other embodiment structures, shapes, and components may be used to couple a base to a coupler. In some embodiments, the connection between the base 140 of the cartridge 104 and the coupler 124 of the control body 102 may be substantially permanent, while in other embodiments, the connection therebetween may be releasable, so that, for example, the control body may be reused with one or more additional cartridges, which may be disposable and / or refillable.

[0125] The aerosol delivery device 100 may, in some embodiments, be substantially rod-shaped, or substantially tubular-shaped, or substantially cylindrical-shaped, while other embodiments encompass additional shapes and dimensions, such as rectangular or triangular cross-sections, multi-sided shapes, and the like.

[0126] The reservoir 144 depicted in FIG. 1 may be a container or may be a fibrous reservoir as currently described. For example, the reservoir 144, in this embodiment, may comprise one or more layers of nonwoven fibers formed in the shape of a tube that substantially surrounds the inside of the cartridge shell 103. The aerosol precursor composition may be held within the reservoir 144. For example, the liquid components may be adsorptively held by the reservoir 144. The reservoir 144 may be in fluid communication with the liquid transport element 136. The liquid transport element 136 may transport the aerosol precursor composition stored within the reservoir 144 by capillary action to the heating element 134, which in this embodiment is in the form of a metal wire coil. Thus, the heating element 134 is in a heating arrangement with the liquid transport element 136.

[0127] During use, when a user draws on article 100, airflow is detected by sensor 108, activating heating element 134, which vaporizes the components of the aerosol precursor composition. Drawing on the mouthpiece of article 100 causes ambient air to enter inlet 118 and pass through cavity 125 in coupler 124 and a central opening in protrusion 141 of base 140. Within cartridge 104, the drawn-in air combines with the formed vapor to form an aerosol. The aerosol is quickly displaced, sucked, or otherwise drawn away from heating element 134 and exits through mouth opening 128 within the mouthpiece of article 100.

[0128] An input device element may be included with the aerosol delivery device. The input device may be included to allow a user to control device functions and / or to output information to the user. Any component or combination of components may be utilized as an input device for controlling device functions. For example, one or more push buttons may be used, as described in U.S. patent application Ser. No. 14 / 193,961 to Worm et al., filed February 28, 2014, which is incorporated herein by reference. Similarly, a touchscreen may be used, as described in U.S. patent application Ser. No. 14 / 643,626 to Sears et al., filed March 10, 2015, which is incorporated herein by reference. As a further example, a component adapted for gesture recognition based on specific movements of the aerosol delivery device may be used as an input device. See U.S. patent application Ser. No. 14 / 565,137 to Henry et al., filed December 9, 2014, which is incorporated herein by reference.

[0129] In some embodiments, the input device may include a computer or a computing device such as a smartphone or tablet. Specifically, the aerosol delivery device may be wired to a computer or other device, for example, via a USB cord or similar protocol. The aerosol delivery device may also communicate with a computer or other device serving as an input device via wireless communication. See, for example, the system and method for controlling a device via a read request, as described in 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 such embodiments, an APP or other computer program may be used in connection with the computer or other computing device to input control instructions into the aerosol delivery device, such as 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.

[0130] The various components of the aerosol delivery device according to the present disclosure can be selected from those described in the art and commercially available. An example of a battery that can be used according to the present disclosure is described in U.S. Patent Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference.

[0131] The aerosol delivery device may incorporate a sensor or detector for controlling the supply of power to the heating element when aerosol generation is desired (e.g., during inhalation during use). Thus, for example, a manner or method is provided for turning off power to the heating element when the aerosol delivery device is not being inhaled during use, and for turning on power to activate or induce heat generation by the heating element during inhalation. Further exemplary types of sensing or detection mechanisms, their structure and configuration, their components, and their general methods of operation are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr., U.S. Patent No. 5,372,148 to McCafferty et al., and PCT Publication No. WO 2010 / 003480 to Flick, which are incorporated herein by reference.

[0132] The aerosol delivery device preferably incorporates a control mechanism for controlling the amount of power to the heating element during inhalation. Representative types of electronic components, their structure and configuration, their characteristics, and their general methods of operation are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, U.S. Patent Publication Nos. 2009 / 0230117 to Fernando et al., 2014 / 0060554 to Collet et al., and 2014 / 0270727 to Ampolini et al., and U.S. Patent Application No. 14 / 209,191 to Henry et al., filed March 13, 2014, which are incorporated herein by reference.

[0133] 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 Publication Nos. 2014 / 0261487 to Chapman et al., and 2014 / 0059780 to Davis et al., and U.S. Patent Application No. 14 / 170,838 to Bless et al., filed February 3, 2014, which are incorporated herein by reference. Additionally, various wicking materials, as well as their construction and operation within certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference.

[0134] In an aerosol delivery system characterized as an electronic cigarette, it is most preferred that the aerosol precursor composition incorporate tobacco or tobacco-derived components. In one respect, the tobacco may be provided as tobacco parts or pieces, such as finely ground, milled, or powdered tobacco leaf pieces. In another respect, the tobacco may be provided in the form of an extract, such as a spray-dried extract, that incorporates many of the water-soluble components of tobacco. Alternatively, the tobacco extract may have the form of an extract with a relatively high nicotine content, which also incorporates small amounts of other extracted components derived from tobacco. In another respect, the tobacco-derived components may be provided in a relatively pure form, such as certain flavoring agents derived from tobacco. In one respect, a component derived from tobacco that may be used in a highly purified or essentially pure form is nicotine (e.g., pharmaceutical-grade nicotine).

[0135] The aerosol precursor composition, also referred to as a vapor precursor composition, may include a variety of components, including, for example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extract, and / or flavoring materials. Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Patent No. 7,217,320 to Robinson et al., and U.S. Patent Publication Nos. 2013 / 0008457 to Zheng et al., 2013 / 0213417 to Chong et al., 2014 / 0060554 to Collett et al., 2015 / 0020823 to Lipowicz et al., and 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those incorporated into VUSE® products by RJ Reynolds Vapor Company, BLU™ products by Lorillard Technologies, MISTIC MENTHOL products by Mistic Ecigs, and VYPE products by CN Creative Ltd. Also desirable are so-called "smoke juices" for e-cigarettes, available from Johnson Creek Enterprises LLC.

[0136] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating component provides acceptable sensation and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material (e.g., glycerin and / or propylene glycol) be used to provide for the production of a visible mainstream aerosol that resembles in many respects the appearance of tobacco smoke. The amount of aerosol precursor in the aerosol generating system can depend on factors such as the number of puffs desired per aerosol generating component. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system, and particularly the aerosol generating component, is less than about 2 g, generally less than about 1.5 g, often less than about 1 g, and frequently less than about 0.5 g.

[0137] Still other features, controls, or components that may be incorporated into the aerosol delivery systems of the present disclosure are disclosed in U.S. Pat. No. 5,967,148 to Harris et al., U.S. Pat. No. 5,934,289 to Watkins et al., U.S. Pat. No. 5,954,979 to Counts et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 8,365,742 to Hon, U.S. Pat. No. 8,402,976 to Fernando et al. ... and DePiano et al., which are incorporated herein by reference.

[0138] The foregoing description of the use of the article may be applied to the various embodiments described herein with minor modifications, which may be apparent to those skilled in the art in light of the further disclosure provided herein. However, the above description of use is not intended to limit the use of the article, but is provided to comply with all of the requirements of the disclosure of the present disclosure. Any of the elements shown in the article illustrated in FIG. 1 or otherwise described above may be included in an aerosol delivery device according to the present disclosure.

[0139] In some embodiments, the present disclosure relates to a power supply unit suitable for use in an aerosol delivery device. The power supply unit may include an elongated outer shell, which may be substantially tubular so as to define a cavity therein. The outer shell may have a proximal end and an opposing distal end.

[0140] An elongated outer shell may be characterized specifically with respect to its separable nature. More specifically, the outer shell may be divided into two separate halves along its longitudinal axis. In other words, the outer shell may be substantially partitioned through an axis extending from the proximal end to the distal end. The separable portions of the outer shell may be referred to as "halves" throughout this disclosure, with it being understood that such references are not intended to limit the relative size of the separable portions. In some embodiments, the separable halves (or separable portions) of the outer shell may be substantially equal in distance around the outer (or inner) surface of the outer shell. For example, FIG. 2 illustrates an embodiment in which the halves are substantially equal in dimension, such that each separable half (or separable portion) of the outer shell may form approximately 50% of the circumference of the outer shell. As can be seen here, the outer shell 201 is separated substantially through the middle of its cross section, such that when the halves are combined, they form a first half (portion) 2201a and a second half (portion) 2201b, each of which is approximately 50% of the circumference of the outer shell. Also visible in cross section, as explained further below, is a battery 210 and battery leads 233. While the two halves may usefully be substantially equal in size, other embodiments are encompassed in which the outer shell 201 is separated through its cross section at a portion other than the middle. The relative dimensions may be such that either half (portion) of the outer shell may be the larger portion.

[0141] In some embodiments, a structure in which the outer shell is divided into separable portions may be referred to as a clamshell structure. Thus, the two separate halves of the outer shell may be substantially hinged together along at least a portion of the length of the outer shell. As illustrated in FIG. 3 , for example, outer shell 301 may be formed from a first half 301a hingedly attached to a second half 301b using connecting member 315. Connecting member 315 may be formed from the same material as outer shell 301 or may be a thinned or slit portion of the outer shell. In other embodiments, the two separate halves of the outer shell may be completely separate from one another but configured to be attached to one another to form a completed power supply unit. In some embodiments, the seam formed where the two halves connect may be sealed, for example, through the use of a sealant or by processing the outer shell (e.g., welding the seam). As described further below, battery 310 and battery leads 333 are also seen in cross section.

[0142] In some embodiments, the two halves of the elongated shell used to form the power unit can be separably joined together. Thus, the halves can be configured for repeated attachment and detachment without any anticipated damage to the shell. For example, the two halves can include elements suitable for forming a snap fit between the halves.

[0143] In a further embodiment, the two halves of the elongate shell may be substantially permanently joined together. This means that the two halves of the shell that are combined to form the completed shell do not have to be physically separated by a non-destructive action. For example, the two halves of the shell may be welded together, glued together, etc.

[0144] The structure of the outer shell (i.e., provided as separate halves) can facilitate ease of assembly of the completed power unit. In conventional aerosol-forming articles utilizing a substantially tubular outer shell, the outer shell is pre-formed to its completed state, and the internal components (e.g., battery, electronics, electrical connections, etc.) are inserted into the completed outer shell from either end of the outer shell. Therefore, the internal components must be substantially fully connected prior to insertion. In other words, wires, etc. used to form electrical connections between the battery and PCB, sensor, and / or connector elements must be soldered to the respective elements prior to inserting the elements into the outer shell.

[0145] Thus, a power supply unit according to the present disclosure may solve the problem of ease of manufacturing the power supply unit, including ease of automating the manufacturing of the power supply unit. As described further below, half (or portions) of a housing may be provided, and various internal elements of the power supply unit may be placed within the partial housing. This may, in some embodiments, eliminate the need to solder elements, as otherwise described herein. After the desired elements are placed within the partial housing, the remaining portion of the housing may be attached to form a completed housing with the power supply unit elements installed therein.

[0146] In a similar manner, the present structure can also facilitate ease of recycling of the various components of the power supply unit. In conventional power supply units for aerosol-forming devices, the entire unit must be disposed of as a single component after use of the device. While it would be desirable to recycle the various components of the power supply unit separately, the nature of the structure of conventional devices (e.g., all components soldered together and inserted end-on into an inseparable outer shell) can prevent or significantly increase the difficulty of such recycling.

[0147] However, in accordance with the present disclosure, a used power supply unit can be easily disassembled by simply separating the two halves of the shell. While such separation requires cutting at least a portion of the shell to free the two halves from one another, particularly in embodiments described herein where elements can be combined without the need for fusing (e.g., soldering), once one of the halves is removed, the individual elements within the shell can be easily removed for recycling.

[0148] Shells according to the present disclosure may be formed from a variety of materials. In some embodiments, plastic materials such as, for example, high density polyethylene terephthalate (HDPE), polypropylene, or polycarbonate may be used. In further embodiments, metallic materials such as, for example, aluminum or steel may be used. In certain embodiments, the shell may be substantially a plastic clamshell.

[0149] Many of the elements included in the power supply unit described herein may be present in previously known power supply units, however, as will be seen below, various elements may be provided in different forms for ease of manufacturing the device.

[0150] In some embodiments, the power supply unit may include at least one elongated battery positioned within the elongated outer shell. The at least one battery may extend from the distal end of the second elongated outer shell toward the proximal end of the elongated outer shell. In other words, the at least one battery may be positioned closer to (specifically adjacent to) the distal end of the outer shell than to the proximal end of the outer shell. In certain embodiments, a single battery may be used, or two batteries may be used. The total number of batteries utilized may depend on the rated power output of the batteries used (e.g., the rated voltage of the batteries).

[0151] 4, in which the power supply unit 401 is formed from a first shell half 4201a and a second shell half 4201b, which when combined form the completed shell 4201, enclosing a battery 410 and battery leads 433. The battery 410 includes a positive terminal 410a and a negative terminal 410b. For example, in embodiments in which two batteries may be utilized, the batteries may be arranged electrically in series such that the negative terminal of the first battery is substantially adjacent the distal end 4301b of the power supply unit shell 4201, and the positive terminal of the second battery is substantially adjacent the proximal end 4301a of the power supply unit shell 4201.

[0152] The power supply unit 401 further includes a battery lead 433 configured to form an electrical connection between various components of the aerosol delivery device and the battery 410. As shown, the battery lead 433 includes a protrusion 433b configured for electrical connection with an end stop of the battery 410. In the illustrated embodiment, the protrusion 433b is configured for electrical connection with the negative terminal 410b. The protrusion is illustrated as being substantially rounded; however, other configurations are also encompassed. A biasing member 445 may be included to bias the protrusion 433b toward the terminal 410b of the battery 410. In the illustrated embodiment, the biasing member 445 is a spring; however, additional embodiments are also encompassed. The biasing member 445 may specifically be configured for contact with the end cap 411 of the power supply unit 401. The end cap 411 may be attached to one or both of the first and second outer shell halves 4201a, 4201b, for example, by crimping, welding, or gluing, and the end cap may be made of any material, including metal and plastic. The end cap 411 may be transparent or translucent, as desired, to allow external visibility of, for example, a light source that may be included within the power supply unit 401. See, for example, element 112 in FIG. 1. In such an embodiment, the deflector 445 may be attached to one or both of the first and second outer shell halves 4201a, 4201b, for example. In some embodiments, the end cap 411 may be substantially captured between the clamshell hinges 4201a, 4201b.

[0153] The battery lead 433 further includes an arm 433a extending from the protrusion 433b along the length of the battery 410. The arm 433a may be configured to provide an electrical connection with one or more additional elements of the power supply unit 401 or with additional components of the aerosol delivery device. The battery lead 433 may be formed from any electrically conductive material, particularly a metal such as copper. Beneficially, the battery lead 433 may be configured to form an electrical connection with the battery and one or more additional elements of the aerosol delivery device without requiring soldering or other means for fusing an electrical connection.

[0154] Power supply unit 401, in some embodiments, may further comprise a base unit 424 attached at proximal end 4301a of shell 4201. As will become apparent from further disclosure provided herein, base unit 424 may be an element of the completed power supply unit 401, may be an element of the completed cartridge (see element 104 in FIG. 1 ), or may be a separate element of the aerosol delivery device (see 100 in FIG. 1 ), which may, for example, interconnect the power supply unit to the cartridge.

[0155] The base unit 424 may include a first base section 424a having a first diameter and a second base section 424b having a second diameter that is less than the first diameter. The first diameter may be substantially similar to the diameter of the outer shell 4201 of the power supply unit 401. Specifically, the first diameter of the first base section 424a may be substantially the same as the inner diameter of the outer shell 4201 such that the outer shell may be attached to the first base section. The first base section 424a may include a first heater terminal opening 427a and a second heater terminal opening 427b, which provide access for heater terminals to enter the base unit 424 for connection to control and / or power members, as described further below. The first and second heater terminal openings are positioned within a wall 4424a that defines the first section of the base unit, as shown. The first base section 424a may further include an air inlet 418 through which air may be drawn during use of the completed aerosol delivery device. The air inlet 418 is positioned within a skirt 4424a' extending longitudinally from the wall to further define the first section 424a of the base unit 424, as shown. The wall 4424a and skirt 4424a' of the first section 424a of the base unit 424 may intersect at a substantially right angle (although other angular arrangements are also encompassed). The base unit 424 may include a cavity 425 extending at least partially therethrough. For example, the cavity 425 may extend from at least the air inlet 418 through the open end of the second base section 424b. As described further herein, the second base section 424b may connect with a portion of the cartridge such that air drawn through the inlet 418 passes through the inlet, through the cavity 425, through the second base section 424b, and into the cartridge to combine with the formed vapor. The second base section 424b may be formed from a longitudinal wall 4424b extending from the wall 4424a of the first base section 424a and may be substantially parallel to the skirt 4424a' of the first base section. The skirt may include an anti-rotation element (see FIG. 1).

[0156] As previously mentioned, the aerosol delivery device may include one or both of a control component and a pressure sensor. In some embodiments, the base unit may include one or both of a control component and a pressure sensor. For example, a PCB may be attached to (or otherwise associated with) the base unit. In some embodiments, the PCB may be at least partially inside the base unit.

[0157] One embodiment of the base unit 524 is illustrated in FIG. 5a, which shows the distal end 5524a of the base unit. The PCB 5106 may be positioned at the distal end 5524a of the base unit 524 and may include circuitry necessary to provide control functions to the aerosol delivery device in which it is incorporated. The PCB 5106 may specifically be inside the skirt 5424a′ of the first base section 524a. The PCB 5106 may include a sensor 5108. As shown, the sensor 5108 is positioned on the opposite side of the PCB 5106 so as to be proximate the air inlet 418. In some embodiments, a support plate 537 may be present and may substantially or completely separate the PCB 5106 from the cavity 525 of the base unit 524. The support plate 537 may form a liquid-tight or airtight relationship with the base unit 524 so that liquid from the cartridge cannot pass therethrough into the power unit and / or air cannot pass through or from the power unit before being drawn into the cartridge. The sensor 5108 may pass through the support plate 537 so as to be positioned at least partially within the cavity 525 of the base unit 524.

[0158] The PCB 5106 may include a plurality of electrical contacts. Because the PCB 5106 may be combined with the base unit 524, in some embodiments, the base unit may be characterized as including a plurality of electrical contacts. In the example of FIG. 5a, the PCB 5106 includes a first battery contact 5106c that may be configured for electrical connection with the positive terminal 410a of the battery 410. The first battery contact 5106c may protrude from the PCB 5106 a distance sufficient to bridge any open space between the base unit 524 and the battery 410. The PCB 5106 further includes a first heater contact 5106a and a second heater contact 5106b configured for electrical connection with first and second heater terminals, respectively, that may pass through first and second heater terminal openings 527a and 527b in the base unit 524.

[0159] The base unit 524 may further include a second battery contact 531 that may be positioned on the base unit to contact a corresponding corresponding contact on the PCB 5106. Alternatively, the second battery contact 531 may be positioned on the PCB 5106, which is itself attached to the base unit 524. As shown in FIG. 5a, the second battery contact 531 is connected to the first base section 524a of the base unit 524, and the PCB 5106 is in electrical communication therewith. The second battery contact 531 may be configured for electrical connection with the negative terminal 410b of the battery 410. The electrical connection between the second battery contact 531 and the negative terminal 410b of the battery 410 may be via a battery lead 433. The second battery contact 531 may be sufficiently sized to ensure contact with the battery lead 433 through various locations. In some embodiments, the second battery contact 531 may be shaped to receive a portion of the battery lead 433. For example, the second battery contact 531 may be substantially tubular, and the battery lead 433 may slide within the tubular portion of the second battery contact to maintain electrical connection. Alternatively, a clip may be used to interconnect the second battery contact 531 and the battery lead 433. Such a configuration may allow the electrical connection between the second battery contact 531 and the battery lead 433 to be non-fused—i.e., no soldering is required to form or secure the connection.

[0160] The proximal end 5524b of the base unit 524 is visible in Figure 5b. As can be seen here, the cavity 525 extends through the second base section 524b, such that the support plate 537 is visible. Similarly, the first heater contact 5106a and the second heater contact 5106b are visible through the first heater terminal opening 527a and the second heater terminal opening 527b, respectively, in the wall 5424a of the first base section 524a.

[0161] The power supply unit, either separately or in combination with the base unit, can be utilized to form an aerosol delivery device. Specifically, the power supply unit can be combined with a cartridge that includes a nebulizer and is configured to receive and store an aerosol-forming composition. Even more specifically, the cartridge can be configured for attachment to the proximal end of the base unit such that the power supply unit, base unit, and cartridge together form the aerosol delivery device. Cartridges that can be configured for combination with the power supply units and / or base units described herein are described in U.S. Patent Application No. 14 / 286,552, filed May 23, 2014, to Brinkley et al., the disclosure of which is incorporated herein by reference.

[0162] An exemplary embodiment of a cartridge 604 configured for combination with a power supply unit is shown in FIG. 6 . As shown here, the cartridge 604 comprises an elongated shell 603 having a reservoir 644 therein. The reservoir 644 may be, for example, a fibrous mat (e.g., cellulose acetate), although other types of reservoirs (e.g., containers) are also encompassed. A liquid transport element 636 may be combined with a heater 634 to form a sprayer. In the illustrated embodiment, the liquid transport element 636 may specifically extend at least partially through the reservoir 644. The heater 634 may be positioned near the midpoint of the liquid transport element 636. For example, the heater 634 may be a resistive heating wire wrapped around the liquid transport element 636. The heater-wrapped portion of the liquid transport element 636 may extend out from one end of the reservoir 644, specifically, the end of the reservoir near the proximal end 603 a of the cartridge shell 603. The mouthpiece 647 may be coupled to the cartridge shell 603 at its proximal end 603a. The proximal end 603a of the cartridge shell 603 may be characterized as a mouthpiece, and the distal end 603b of the cartridge shell may be characterized as a mating end of the shell. The mating end and the proximal end 4301a of the cartridge shell may be configured for connection together.

[0163] The base unit 524 may be configured for connection with the power supply unit enclosure 4201. The base unit 524 may be configured for connection with the cartridge enclosure 603. The base unit 524 may be configured for connection with both the power supply unit enclosure 4201 and the cartridge enclosure 603.

[0164] The cartridge 604 may further include an elongated flow tube 648 that may be configured to direct airflow through the cartridge. Specifically, the flow tube 648 may include a central airflow passage 648a extending therethrough. The flow tube 648 may be further configured for physical connection with the base unit 524, electrical connection with the base unit, or both physical and electrical connection with the base unit.

[0165] In some embodiments, the proximal end 5524b of the second base section 524b can be configured to engage the flow tube 648, such as through at least partial insertion into the central airflow passage 648a. Such a physical connection allows air to enter the air inlet 418 of the base unit 424, pass through the cavity 425, enter the central airflow passage 648a of the flow tube 648, traverse the heater 634 in combination with the liquid transport element 636, and exit the mouthpiece when drawing on the mouthpiece 647 of the cartridge 604.

[0166] The flow tube 648 includes a first heater terminal 649a and a second heater terminal 649b, which may be configured to establish an electrical connection between the cartridge and the base unit 524. For example, the ends of the heater terminals extending from the end of the flow tube 648 near the distal end 603b of the cartridge shell 603 may be configured for insertion into the first heater terminal 527a and the second heater terminal 527b to create an electrical connection with the first heater contact 5106a and the second heater contact 5106b of the PCB 5106. The heater terminals may therefore be configured for electrical connection with the base unit 524. The heater terminals (527a, 527b) may be characterized as extending through the flow tube 648. In the illustrated embodiment, the heater terminals (527a, 527b) are integral with the flow tube 648 and extend through a flange 675 of the flow tube.

[0167] Forming the aerosol delivery device may include attaching a base unit to one of the power unit shell and the cartridge shell, and then attaching the other of the power unit shell and the cartridge shell thereto. In some embodiments, the base unit may be attached to a flow tube of the cartridge, and this combination may be combined with the power unit before connecting the first and second halves of the power unit shell. In this manner, the second battery contacts on the base unit may be positioned in electrical connection with the battery leads. The two halves of the power unit shell may then be interconnected. Such connection may provide a substantially tight fit with the cartridge shell so that no additional retention means are required. A label may be placed around the aerosol delivery device, and the presence of the label may further maintain the interconnection of the power unit shell and the cartridge shell. In some embodiments, gluing, welding, crimping, or the like may be used to interconnect the power unit shell and the cartridge shell.

[0168] In some embodiments, a method for forming an aerosol delivery device can include providing a first shell half of a power unit shell. As described above, the first shell half can be configured for attachment to a second shell half to form an elongated clamshell that is the power unit shell. Thus, the power unit clamshell can be characterized as being divided into a first half and a second half along its longitudinal axis. The assembly method can further include placing a battery lead and a battery (or batteries) within the first shell half. This placement can be such that a protruding portion of the battery lead electrically connects with a first terminal of the battery, and an arm of the battery lead extends from the protruding portion along the length of the battery. Specifically, the battery lead protruding portion can be configured to electrically connect with a negative terminal of the battery, and the arm of the battery lead can be configured to electrically connect with a positive terminal of the battery (including using one or more interconnecting elements, such as battery contacts on a base unit). The assembly method can further include providing a base unit, which can include the various elements described above. For example, the base unit may include a PCB, a pressure sensor, a first battery contact configured for electrical connection with the positive terminal of the battery, and a second battery contact configured for electrical connection with an arm of the battery lead. The first battery contact may be part of the PCB, and the second battery contact may be attached to the base unit, the PCB, or both the base unit and the PCB. The assembly method may further include providing a cartridge as described herein. For example, the cartridge may include an outer shell housing a reservoir for the aerosol-forming composition, a heater, a liquid transport element configured for transporting the aerosol-forming composition between the reservoir and the heater, and a heater terminal. The assembly method may further include combining the cartridge, base unit, and first outer shell half so that the heater terminal is in electrical communication with the base unit, the first battery contact of the base unit is in electrical communication with the second terminal of the battery (in this example, the positive terminal), and the second battery contact of the base unit is in electrical communication with the arm of the battery lead (which ultimately provides an electrical connection with the negative terminal of the battery).The assembly method may further include mating the second shell half with the first shell half. Connecting the power supply unit shell, cartridge shell, and base unit may include one or more of crimping, laser welding, and gluing the clamshell to one or both of the base unit and cartridge shell.

[0169] In addition to the foregoing, the present disclosure encompasses alternative configurations by which electrical connection may be provided between the heater and the power supply unit. Such configurations may include, for example, modifications to one or both of the flow tube and base unit as otherwise described herein. The configurations may particularly relate to removable attachment of the cartridge and regulator. Accordingly, the regulator may be reusable (i.e., includes a rechargeable battery and charging element). The configurations may also particularly relate to securing non-removable attachment of the cartridge and regulator.

[0170] 7a and 7b, heater terminals 749a and 749b may be configured for laterally sliding arrangement with base unit 724 to combine with the power supply unit housing to provide a substantially permanent engagement therebetween. Base unit 724 may include PCB 7106 having sensor 7108, first battery contact 7106c, and second battery contact 731. Base unit 724 may be configured to engage flow tube 748 of cartridge unit (see FIG. 6), which flow tube may include first heater terminal 749a and second heater terminal 749b that are substantially L-shaped (i.e., include an extension substantially parallel to the longitudinal axis of the flow tube and a protrusion substantially perpendicular to the longitudinal axis of the flow tube), although other similar structures are also encompassed. In assembly, the first and second heater terminals (749a and 749b) slide around the base unit 724 such that the protrusions on the heater terminals are positioned below the base unit and the extensions of the heater terminals run along the sides of the base unit. In this manner, the base unit is substantially supported by the flow tube 748 and heater terminals (749a and 749b), and the flow tube cannot be disengaged from the base unit via longitudinal movement. Once the combined flow tube 748 and base unit 724 are positioned within the power supply unit enclosure (see element 4201 in FIG. 4), the sliding relationship is no longer possible, and a substantially permanent attachment is provided. As configured, the first heater terminal 749a is electrically connected to the first heater contact 7106a of the PCB 7106, and the second heater terminal 749b is electrically connected to the second heater contact 7106b of the PCB. The construction may further include an insulator cap 781 that substantially covers the sensor 7108 to prevent electrical shorting. The insulator cap 781 may include an opening 788 to provide fluid access to the sensor.

[0171] In the embodiment illustrated in FIGS. 8a and 8b, heater terminals 849a and 849b may be configured to longitudinally engage heater contacts 8106a and 8106b of the base unit 824 to provide a substantially removable engagement therebetween. Specifically, the base unit 824 may include a PCB 8106 having a sensor 8108, a first battery contact 8106c, and a second battery contact 831. The base unit 824 may be configured to engage a flow tube 848 of the cartridge unit (see FIG. 6), which flow tube may include a first heater terminal 849a and a second heater terminal 849b extending therefrom. In assembly, the first and second heater terminals (849a and 849b) create a “wiping” connection with the first and second heater contacts (8106a and 8106b) extending upward from the base unit 824. The first and second heater terminals (849a and 849b) and / or the first and second heater contacts (8106a and 8106b) may be flexible (i.e., exhibit spring characteristics) so that the heater terminals and heater contacts are deflected together when creating a wiping connection. As shown, the heater terminals and heater contacts include shaped sections to better facilitate connection therebetween in making an electrical connection. In this manner, the base unit 824 and the flow tube 848 may exhibit a substantial longitudinal press-fit, whereby engagement of the heater terminals and heater contacts contributes to a structural connection therebetween. To enclose the space between the flow tube 848 and the base unit 824 where the heater terminals and heater contacts create the wiping connection, an intermediate housing 880 may be included and may be formed from an outer wall 881 and an inner plate 882 (as seen in the partial cross-section of the intermediate housing illustrated in FIG. 8a). With such a configuration, the annular gap 883 provides space for a wiping connection to occur, and the intermediate housing may function to substantially prevent electrical shorts. The intermediate housing 880 may be permanently or removably connected to one of the base unit 824 and the flow conduit 848 to prevent loss of components when the flow conduit and base unit are not connected.In certain embodiments where the power unit including base unit 824 is a reusable component and the cartridge including flow tube 848 is a disposable component, intermediate housing 880 may specifically be permanently engaged with the base unit. In other embodiments, intermediate housing 880 may be permanently or removably engaged with the power unit housing or the cartridge housing.

[0172] While the foregoing disclosure may describe embodiments of an aerosol delivery device (or its power unit) in relation to the use of a clamshell structure, it is understood that additional components of the device may be utilized with an integrated shell (i.e., a tube that is not longitudinally separable). Accordingly, in some embodiments, the present disclosure relates to a "drop-in" construction in which a tube may be provided as the power unit shell (i.e., in place of first and second shell halves 4201a and 4201b of FIG. 4). Specifically, a one-piece shell may be provided (including end caps), and the deflectable member 445, battery leads 433, and battery 410 may be sequentially loaded into the shell. The base unit 424 may then be added. Optionally, the base unit may be connected to a cartridge (e.g., to a flow tube, as described above in connection with FIGS. 8a and 8b) before being added to the power unit shell. Any of the embodiments described above may be utilized with an integrated tube in this manner.

[0173] Many modifications and other embodiments of the present disclosure will come to mind for one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. It is 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: an outer housing configured for connection to a further component of the aerosol delivery device, the outer housing having a distal end and an opposing proximal end; at least one battery located within the outer housing; an end cap connected to a distal end of the outer housing; a biasing member in contact with the end cap; The outer housing of the aerosol delivery device has at least one battery that is removable from the outer housing and replaceable with at least one replaceable battery. Aerosol delivery devices.

2. 10. The aerosol delivery device of claim 1, wherein at least one battery is a rechargeable battery.

3. 3. The aerosol delivery device of claim 2, wherein the aerosol delivery device further comprises a component configured for recharging at least one battery.

4. 10. The aerosol delivery device of claim 1, wherein the at least one battery is not soldered or fused to any further component of the aerosol delivery device.

5. 10. The aerosol delivery device of claim 1, further comprising a battery lead extending from a first terminal of the at least one battery to an opposing second terminal of the at least one battery.

6. 6. The aerosol delivery device of claim 5, wherein the first terminal of the battery lead includes a protrusion configured for electrical connection with the terminal of the at least one battery.

7. 7. The aerosol delivery device of claim 6, wherein the battery lead defines an arm extending from the protrusion along the length of the at least one battery so as to be configured to provide an electrical connection with a further component of the aerosol delivery device.

8. The aerosol delivery device of claim 1 , wherein the biasing member is a spring.

9. 6. The aerosol delivery device of claim 5, wherein the battery leads are not soldered or fused to the at least one battery.

10. 10. The aerosol delivery device of claim 1, comprising two or more batteries located within the outer housing.

11. 11. The aerosol delivery device of claim 10, wherein the two or more batteries are electrically arranged in series.

12. The aerosol delivery device of claim 1 , wherein the outer housing is configured to be at least partially disassembled to at least remove the at least one battery.

13. 10. The aerosol delivery device of claim 1, wherein the outer housing is divided into two separate halves along its longitudinal axis, the two halves being separably joined together.

14. 10. The aerosol delivery device of claim 1, further comprising one or both of a printed circuit board (PCB) and a pressure sensor.

15. The aerosol delivery device of claim 14, wherein one or both of the PCB and the pressure sensor are located within a base unit configured for electrical or mechanical connection with the outer housing or a component thereof.

16. 16. The aerosol delivery device of claim 15, wherein the PCB includes a first contact and a second contact configured for electrical connection with terminals of the at least one battery.

17. 17. The aerosol delivery device of claim 16, wherein the electrical connections are not fused.

18. 10. The aerosol delivery device of claim 1, further comprising a cartridge connectable to the outer housing, the cartridge including an outer shell having at least a reservoir therein for storing a liquid for vaporization.

19. 20. The aerosol delivery device of claim 18, wherein the cartridge further comprises a heater configured to heat the liquid for vaporization and a liquid transport element for transporting the liquid from the reservoir to the heater.

20. 20. The aerosol delivery device of claim 18, further comprising a mouthpiece disposed on the outer shell to provide a passageway for vaporized liquid.

21. 14. The aerosol delivery device of claim 13, wherein the end cap is attached to one of the separate halves of the outer housing.

22. 22. The aerosol delivery device of claim 21, wherein the deflection member is attached to one or both of the separate halves of the outer housing.

23. The aerosol delivery device of claim 1, wherein the end cap is connected to the distal end of the outer housing by crimping, welding, or gluing.

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