Aerosol delivery device providing flavor control - Patent Application 20070122997

Abstract

To provide a cartridge capable of adding one or more flavor additives to an aerosol precursor composition as desired by a user.SOLUTION: A flavor delivery article includes a hollow elongate unit formed of a substantially continuous wall extending between a first end and a second end and defining an interior storage volume, the substantially continuous wall being formed of a porous material having a graded porosity across a thickness of the substantially continuous wall. The flavor delivery article further includes a flavor liquid contained with the interior storage volume of the hollow elongate unit. The flavor delivery article may be positioned anywhere within an aerosol delivery device 100 (or a mouthpiece 165 or cartridge 104 of the aerosol delivery device) where the flavor liquid may pass through the substantially continuous wall so as to be entrained in an air stream and / or vapor stream and / or aerosol stream passing through the aerosol delivery device.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol delivery device, and more particularly to an aerosol delivery device that includes a reservoir and a vaporization assembly that can utilize electrical power to heat an aerosol precursor composition to generate an aerosol. The aerosol precursor composition, which may incorporate materials and / or components made from or derived from tobacco, or may otherwise incorporate tobacco, is heated by the vaporization assembly to generate an inhalable substance for human consumption. [Background technology]

[0002] Many smoking articles have been proposed over the years as an improvement or replacement for smoking products based on tobacco combustion.Exemplary replacements include devices in which solid or liquid fuel is burned to transfer heat to tobacco, or chemical reactions are used to provide such a heat source.Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

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

[0004] Representative products that mimic many of the characteristics of traditional cigarettes, cigars or pipes include ACCORD® from Philip Morris Incorporated, ALPHA™, JOYE 510™ and M4™ from InnoVapor LLC, CIRRUS™ and FLING™ from White Cloud Cigarettes, BLU™ from Lorillard Technologies, Inc., COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™ and SENSE™ from EPUFFER® International Inc., DUOPRO™, STORM™ and VAPORKING® from Electronic Cigarettes, Inc., EGAR™ from Egar Australia, eGo-C™ and eGo-T™ from Joyetech, ELUSION™ from Elusion UK Ltd, and Eonsmoke. EONSMOKE® by FIN Branding Group, LLC, FIN™ by FIN Branding Group, LLC, SMOKE® by Green Smoke Inc. USA, GREENARETTE™ by Greenarette LLC, HALLIGAN™, HENDU™, JET™, MAXXQ™, PINK™ and PITBULL™ by SMOKE STIK®, HEATBAR™ by Philip Morris International, Inc., HYDRO IMPERIAL™ and LXE™ by Crown7, LOGIC™ and THE CUBAN™ by LOGIC Technology, LUCI® by Luciano Smokes Inc., METRO® by Nicotek, LLC, NJOY® and ONEJOY™ by Sottera, Inc., NO.7™ by SS Choice LLC, PREMIUM ELECTRONIC by PremiumEstore LLC. CIGARETTE(TM), Ruyan America, Inc.These products are commercially available as RAPP E-MYSTICK™ from Red Dragon Products, LLC, RED DRAGON™ from Red Dragon Products, LLC, RUYAN® from Ruyan Group (Holdings) Ltd., SF® from Smoker Friendly International, LLC, GREEN SMART SMOKER® from The Smart Smoking Electronic Cigarette Company Ltd., SMOKE ASSIST® from Coastline Products LLC, SMOKING EVERYWHERE® from Smoking Everywhere, Inc., V2CIGS™ from VMR Products LLC, VAPOR NINE™ from VaporNine LLC, VAPOR4LIFE® from Vapor 4 Life, Inc., VEPPO™ from E-CigaretteDirect, LLC, VUSE® from RJ Reynolds Vapor Company, Mistic Menthol products from Mistic Ecigs, and Vype products from CN Creative Ltd. Still other electrical aerosol delivery devices, particularly those characterized as so-called electronic cigarettes, are commercially available under the trade names COOLER VISIONS™, DIRECT E-CIG™, DRAGONFLY™, EMIST™, EVERSMOKE™, GAMUCCI®, HYBRID FLAME™, KNIGHT STICKS™, ROYAL BLUES™, SMOKETIP®, and SOUTH BEACH SMOKE™. [Prior art documents] [Patent documents]

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

[0006] Some existing embodiments of aerosol delivery devices include a control body (i.e., a power supply assembly) and a cartridge (i.e., a reservoir housing). A power source (e.g., a battery) may be disposed within the control body, and the aerosol precursor composition may be held and / or stored within the cartridge. It is desirable to provide a cartridge that allows a user to add one or more flavor additives to the aerosol precursor composition as desired. [Means for solving the problem]

[0007] In various embodiments, the present disclosure provides a flavor delivery article that can be included in or combined with an aerosol delivery device. The flavor delivery article can incorporate a defined porosity gradient that allows flavor liquid stored therein to migrate outward from the flavor delivery article to the outer surface of the flavor delivery article and be entrained in the gas stream. Thus, the flavor delivery article is configured to be included within or attached to the aerosol delivery device at any location along which the flowing gas stream may pass.

[0008] The present disclosure may provide a variety of articles, each adapted or configured to provide a flavor. In some embodiments, the present disclosure may relate to a flavor delivery article that may be adapted or configured to be combined with additional articles, such as a cartridge of an aerosol delivery device and / or a mouthpiece attachable to the cartridge of an aerosol delivery device. In further embodiments, the present disclosure may relate to a flavor delivery mouthpiece that includes the flavor delivery article and is adapted or configured to be attached to the cartridge of an aerosol delivery device. In other embodiments, the present disclosure may relate to a cartridge of an aerosol delivery device. Such a cartridge may include a flavor delivery article that may be included directly in the cartridge housing and / or in a mouthpiece attached to the cartridge housing. In still further embodiments, the present disclosure may relate to an aerosol delivery device that includes a power unit and a cartridge. The power unit and cartridge may be provided in a single housing or in separate housings. The aerosol delivery device may, among other things, include a flavor delivery article combined therewith, e.g., included in the cartridge and / or included in a mouthpiece attached to the cartridge.

[0009] In an exemplary embodiment, a flavor delivery article according to the present disclosure may comprise: a hollow elongated unit formed from a substantially continuous wall extending between a first end and a second end and defining an interior storage volume, the substantially continuous wall being formed from a porous material having a porosity that varies gradually across a thickness of the substantially continuous wall; and a flavor liquid contained by the interior storage volume of the hollow elongated unit. In further embodiments, the flavor delivery article may be further defined by any one or more of the following statements, which may be combined in any order and number:

[0010] The porous material forming the substantially continuous wall of the hollow elongate unit may be a polymeric material.

[0011] The polymeric material may be selected from the group consisting of polyethersulfone, polypropylene, polyethylene, polyester, nylon, cellulose nitrate, regenerated cellulose, cellulose acetate, and combinations thereof.

[0012] The porous material forming the substantially continuous wall of the hollow elongate unit may be a ceramic material.

[0013] The graduated porosity may be configured such that the average size of the pores within the substantially continuous wall of the hollow elongated unit increases across the substantially continuous thickness of the wall from the inner surface to the outer surface of the outer wall.

[0014] The pores in the substantially continuous wall of the hollow elongated units may have a first average size of about 10 nm to about 3 μm on one of the interior and exterior surfaces.

[0015] The pores within the substantially continuous wall of the hollow elongated unit may have a second average size of about 0.5 μm to about 30 μm on the other of the inner and outer surfaces.

[0016] One or both of the first and second ends of the hollow elongate unit may be open.

[0017] The flavor delivery article may further include an end unit that engages one or both of the first end and second end of the hollow elongated unit.

[0018] The end unit may be a lattice structure containing a plurality of airflow passages therethrough.

[0019] The flavor delivery article may further comprise an outer casing.

[0020] In an exemplary embodiment, the present disclosure may provide a flavor delivery mouthpiece comprising a flavor delivery article as otherwise described herein disposed within a mouthpiece shell including a first end and an opposing second end, wherein the second end includes one or more openings configured to allow air to pass therethrough, and wherein the flavor delivery article disposed within the mouthpiece shell is spaced from an inner surface of the mouthpiece shell to allow air to pass through the mouthpiece shell between the flavor delivery article and the inner surface of the mouthpiece shell. In further embodiments, the flavor delivery mouthpiece may be further defined in connection with any one or more of the following statements, which may be combined in any order and number:

[0021] The mouthpiece shell may include one or more protrusions extending inwardly from the inner surface of the mouthpiece shell.

[0022] The one or more protrusions can be configured to contact the flavor delivery article and substantially maintain the lateral position of the flavor delivery article within the mouthpiece shell.

[0023] The flavor delivery mouthpiece may further include a mandrel disposed within the mouthpiece shell proximate its second end, the mandrel configured to engage with one of the first end and second end of the hollow elongated unit of the flavor delivery article.

[0024] The flavor delivery mouthpiece may further comprise a removably replaceable cover configured to engage the second end of the mouthpiece shell.

[0025] In an exemplary embodiment, the present disclosure may provide a cartridge for an aerosol delivery device, the cartridge comprising: a cartridge housing having a mouth end; a reservoir containing an aerosol precursor composition; a heater configured to vaporize the aerosol precursor composition; and a flavor delivery mouthpiece, as otherwise described herein, engaged with the cartridge such that a first end of the mouthpiece shell is attached to the mouth end of the cartridge housing. In further embodiments, the cartridge may be further defined by any one or more of the following statements, which may be combined in any order and number:

[0026] The cartridge may further comprise a liquid transport element configured to transport the aerosol precursor composition between the reservoir and the heater.

[0027] The reservoir may include a fibrous material.

[0028] The reservoir may be a tank.

[0029] In an exemplary embodiment, the present disclosure can provide an aerosol delivery device comprising a power supply unit housing containing a power supply and a controller, and a cartridge as otherwise described herein.

[0030] In an exemplary embodiment, the present disclosure may provide a cartridge for an aerosol delivery device, the cartridge comprising: a cartridge housing having a mouth end; a reservoir containing an aerosol precursor composition; a heater configured to vaporize the aerosol precursor composition; and a flavor delivery article, wherein the flavor delivery article comprises a hollow elongated unit extending between a first end and a second end and formed from a substantially continuous wall defining an interior storage volume, the substantially continuous wall being formed from a porous material having a porosity that varies gradually across a thickness of the substantially continuous wall; and a flavor liquid contained by the interior storage volume of the hollow elongated unit. In further embodiments, the cartridge may be further defined in relation to any one or more of the following statements, which may be combined in any order and number:

[0031] The cartridge may further include an air inlet and an airflow passageway through the cartridge.

[0032] Both the heater and the flavor delivery article can be disposed substantially within the airflow passage.

[0033] A flavor delivery article can be positioned in the airflow path upstream of the heater.

[0034] A flavor delivery article can be positioned in the airflow path downstream of the heater.

[0035] The flavor delivery article can be disposed in a mouthpiece attached to the mouth end of the cartridge housing.

[0036] The present disclosure includes, but is not limited to, the following embodiments.

[0037] Embodiment 1: A flavor delivery article comprising: a hollow elongated unit formed from a substantially continuous wall extending between a first end and a second end and defining an interior storage volume, the substantially continuous wall being formed from a porous material having a porosity that varies gradually across a thickness of the substantially continuous wall; and a flavor liquid contained by the interior storage volume of the hollow elongated unit.

[0038] Embodiment 2: The flavor delivery article of claim 1, wherein the porous material forming the substantially continuous wall of the hollow elongated unit is a polymeric material.

[0039] Embodiment 3: The flavor delivery article of any one of claims 1-2, wherein the polymeric material is selected from the group consisting of polyethersulfone, polypropylene, polyethylene, polyester, nylon, cellulose nitrate, regenerated cellulose, cellulose acetate, and combinations thereof.

[0040] Embodiment 4: A flavor delivery article according to any one of claims 1 to 3, wherein the porous material forming the substantially continuous wall of the hollow elongated unit is a ceramic material.

[0041] Embodiment 5: A flavor delivery article as described in any one of claims 1 to 4, wherein the porosity is configured to be graded such that the average size of the pores within the substantially continuous wall of the hollow elongated unit increases across the thickness of the substantially continuous wall from the inner surface to the outer surface of the outer wall.

[0042] Embodiment 6: A flavor delivery article described in any one of claims 1 to 5, wherein the pores in the substantially continuous wall of the hollow elongated unit have a first average size of about 10 nm to about 3 μm on one of the inner and outer surfaces.

[0043] Embodiment 7: A flavor delivery article described in any one of claims 1 to 6, wherein the pores in the substantially continuous wall of the hollow elongated unit have a second average size of about 0.5 μm to about 30 μm on the other of the inner and outer surfaces.

[0044] Embodiment 8: A flavor delivery article according to any one of claims 1 to 7, wherein one or both of the first end and second end of the hollow elongated unit are open.

[0045] Embodiment 9: A flavor delivery article as described in any one of claims 1 to 8, further comprising an end unit that engages with one or both of the first end and second end of the hollow elongated unit.

[0046] Embodiment 10: The flavor delivery article of any one of claims 1 to 9, wherein the end unit is a lattice structure with multiple airflow passages therethrough.

[0047] Embodiment 11: The flavor delivery article of any one of claims 1 to 10, further comprising an outer casing.

[0048] Embodiment 12: A flavor delivery mouthpiece comprising a flavor delivery article according to any one of claims 1 to 11 disposed within a mouthpiece shell having a first end and an opposing second end, wherein the second end includes one or more openings configured to allow air to pass therethrough, and wherein the flavor delivery article disposed within the mouthpiece shell is spaced from the inner surface of the mouthpiece shell so as to allow air to pass through the mouthpiece shell between the flavor delivery article and the inner surface of the mouthpiece shell.

[0049] Embodiment 13: The flavor delivery mouthpiece of claim 12, wherein the mouthpiece shell comprises one or more protrusions extending inward from the inner surface of the mouthpiece shell.

[0050] Embodiment 14: A flavor delivery mouthpiece described in any one of claims 12 to 13, wherein one or more protrusions are configured to contact the flavor delivery article and substantially maintain the lateral position of the flavor delivery article within the mouthpiece shell.

[0051] Embodiment 15: A flavor delivery mouthpiece as described in any one of claims 12 to 14, further comprising a mandrel disposed within the mouthpiece shell adjacent its second end, wherein the mandrel is configured to engage with one of the first end and the second end of the hollow elongated unit of the flavor delivery article.

[0052] Embodiment 16: A flavor delivery mouthpiece according to any one of claims 12 to 15, further comprising a removably replaceable cover configured to engage with the second end of the mouthpiece shell.

[0053] Embodiment 17: A cartridge for an aerosol delivery device, comprising: a cartridge housing having a mouth end; a reservoir containing an aerosol precursor composition; a heater configured to vaporize the aerosol precursor composition; and a flavor delivery mouthpiece according to any one of claims 12 to 16 engaged with the cartridge such that a first end of the mouthpiece shell is attached to the mouth end of the cartridge housing.

[0054] Embodiment 18: The cartridge of claim 17, further comprising a liquid transport element configured to transport the aerosol precursor composition between the reservoir and the heater.

[0055] Embodiment 19: A cartridge according to any one of claims 17 to 18, wherein the reservoir comprises a fibrous material.

[0056] Embodiment 20: A cartridge according to any one of claims 17 to 19, wherein the reservoir is a tank.

[0057] Embodiment 21: An aerosol delivery device comprising a power supply unit housing containing a power supply and a controller, and a cartridge described in any one of claims 17 to 20.

[0058] Embodiment 22: A cartridge for an aerosol delivery device, comprising: a cartridge housing having a mouth end; a reservoir containing an aerosol precursor composition; a heater configured to vaporize the aerosol precursor composition; and a flavor delivery article, wherein the flavor delivery article comprises a hollow elongated unit extending between a first end and a second end and formed from a substantially continuous wall defining an internal storage volume, the substantially continuous wall being formed from a porous material having a porosity that varies gradually across a thickness of the substantially continuous wall; and a flavor liquid contained by the internal storage volume of the hollow elongated unit.

[0059] Embodiment 23: The cartridge of claim 22, further comprising an air inlet and an airflow passage through the cartridge.

[0060] Embodiment 24: A cartridge according to any one of claims 22-23, wherein both the heater and the flavor delivery article are disposed substantially within the airflow passage.

[0061] Embodiment 25: A cartridge according to any one of claims 22 to 24, wherein the flavor delivery article is positioned in the airflow passage upstream of the heater.

[0062] Embodiment 26: A cartridge according to any one of claims 22 to 25, wherein the flavor delivery article is positioned in the airflow passage downstream of the heater.

[0063] Embodiment 27: The cartridge of any one of claims 22 to 26, wherein the flavor delivery article is disposed in a mouthpiece attached to the mouth end of the cartridge housing.

[0064] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, as well as combinations of any two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, appear as intended to be combinable, unless the context clearly dictates otherwise.

[0065] To aid in understanding aspects of the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale and in which like reference numerals refer to like elements, and which are illustrative only and should not be construed as limiting the present disclosure. [Brief explanation of the drawings]

[0066] [Figure 1] 1 shows a partial cross-sectional view of an exemplary embodiment of an aerosol delivery device according to embodiments of the present disclosure. [Figure 2] 1 shows a perspective view of an exemplary embodiment of a hollow elongated unit of a flavor delivery article according to the present disclosure. [Figure 3A] 1 shows a partial cross-sectional view of an exemplary embodiment of a hollow elongated unit of a flavor delivery article according to the present disclosure. [Figure 3B] 1 shows a partial cross-sectional view of a portion of an exemplary embodiment of a wall of a hollow elongated unit of a flavor delivery article according to the present disclosure. [Figure 4] 1 illustrates an exploded view of an exemplary embodiment of a flavor delivery article according to the present disclosure. [Figure 5] 1 shows a perspective view of an exemplary embodiment of a flavor delivery article according to the present disclosure. [Figure 6] 1 shows a perspective view of an exemplary embodiment of a flavor delivery article according to the present disclosure. [Figure 7]1 shows a perspective view of an exemplary embodiment of a flavor delivery article present within the mouthpiece of an aerosol delivery device according to the present disclosure. [Figure 8] 1 shows an exploded view of an exemplary embodiment of a flavor delivery article and a mouthpiece for an aerosol delivery device according to the present disclosure. [Figure 9] 1 shows an exploded view of an exemplary embodiment of a flavor delivery article and mouthpiece according to the present disclosure. [Figure 10] FIG. 1 illustrates a perspective view of a mouthpiece shell according to an exemplary embodiment of the present disclosure. [Figure 11] 1 shows an exploded view of an exemplary embodiment of a flavor delivery article and mouthpiece according to the present disclosure. [Figure 12] FIG. 1 illustrates a perspective view of a mouthpiece shell according to an exemplary embodiment of the present disclosure. [Figure 13] 1 shows a partial cross-sectional view of a mouthpiece including a flavor delivery article according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0067] The present disclosure will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, this 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 variations unless the context clearly dictates otherwise.

[0068] This disclosure provides a description of an aerosol delivery device. The aerosol delivery device may use electrical energy to heat a material to form an inhalable substance. Such an article may be small enough to be considered a "handheld" device. The aerosol delivery device may provide some or all of the sensations of smoking a cigarette, cigar, or pipe (e.g., the inhalation and exhalation format, the type of taste or flavor, the sensory stimulating effect, the physical feel, the mode of use, the visual stimulation such as that provided by a visible aerosol, etc.) without substantially burning any components of the article or device. The aerosol delivery device may not produce smoke in the sense of an aerosol resulting from the by-products of tobacco combustion or thermal decomposition; rather, the article or device may produce vapor (which may be considered to be described as smoky, including vapor within an aerosol that may be considered a visible aerosol) due to the volatilization or vaporization of certain components of the article or device, although in other implementations, the aerosol may be invisible. In some implementations, the aerosol delivery device may incorporate tobacco and / or tobacco-derived components. As such, the aerosol delivery device can be characterized as an electronic smoking article, such as an electronic cigarette ("e-cigarette").

[0069] Although the systems are generally described herein with respect to implementations related to aerosol delivery devices, such as so-called "electronic cigarettes," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of items. For example, the descriptions provided herein may be used in combination with implementations of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and related packaging for any of the products disclosed herein. Accordingly, it should be understood that the descriptions of the features, components, features, and methods disclosed herein are discussed by way of example only with respect to embodiments related to aerosol delivery devices, and may be embodied in and used in a variety of other products and methods.

[0070] The aerosol delivery device of the present disclosure can also be characterized as a vapor product or drug delivery article. Accordingly, such an article or device can be configured to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance can be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not they are visible and whether or not they are in a form that can be considered smoky.

[0071] In use, the aerosol delivery device of the present disclosure can undergo many of the physical actions used by an individual when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe used by lighting tobacco and inhaling.) For example, a user of the aerosol delivery device of the present disclosure can hold the article like a traditional type of smoking article, draw on one end of the article to inhale the aerosol produced by the article, take puffs at selected time intervals, etc.

[0072] The aerosol delivery devices of the present disclosure generally include a number of components disposed within an outer shell or body. The overall design of the outer shell or body can vary, and the type or configuration of the outer body can vary, which can define the overall dimensions and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, integral shell, or the elongated body can be formed from two or more separable parts. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and can resemble the shape of a traditional cigarette or cigar. However, in other embodiments, various other shapes and configurations can be used (e.g., rectangular or fob-shaped). Thus, the aerosol delivery devices described herein can have any desired configuration.

[0073] In one implementation, all components of the aerosol delivery device are housed within a single outer body, which may be defined as a housing or shell. Alternatively, the aerosol delivery device may include two or more shells that are joined and separable. For example, the aerosol delivery device may include a control body or power supply unit including a shell housing one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the item) and may include a removably attached shell configured as a disposable portion (e.g., a disposable flavor-containing cartridge). More specific formats, configurations, and arrangements of components within a single-shell type unit or a multi-part separable-shell type unit will become apparent in light of the further disclosure provided herein. Furthermore, the design and component arrangements of various aerosol delivery devices can be understood in light of commercially available electronic aerosol delivery devices.

[0074] The aerosol delivery device of the present disclosure may comprise any combination of a power source (i.e., a power source), at least one control component (e.g., a means for activating, controlling, regulating, and / or terminating power for heat generation, such as by controlling the flow of current from the power source to other components of the aerosol delivery device), a heater or heat-generating member (e.g., an electrical resistance or induction heating element or component commonly referred to as part of an "atomizer"), and an aerosol precursor composition (e.g., a liquid that can generally generate an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouth end region or tip that allows the aerosol delivery device to be drawn upon for aerosol inhalation (e.g., a defined air flow path through the article so that the generated aerosol can be drawn therefrom by suction).

[0075] The arrangement of components within the aerosol delivery device of the present disclosure can vary. In certain implementations, the aerosol precursor composition can be positioned near an end of the aerosol delivery device that can be configured to be positioned proximate the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heating element can be positioned sufficiently close to the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (which itself may contain one or more flavorings, medicinal agents, or other additives) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be interpreted to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, inhalable substances are released in the form of vapors or aerosols or mixtures thereof, and such terms are used interchangeably herein unless otherwise specified.

[0076] As described above, the aerosol delivery device may incorporate a battery and / or other power source (e.g., a capacitor) to provide sufficient current to provide various functions for the aerosol delivery device, such as powering a heater, powering a control system, powering indicators, etc. The power source can take various implementation forms. In one example, the power source can provide sufficient power to rapidly heat a heating element to form an aerosol and power the aerosol delivery device throughout use for a desired duration. The power source may be sized to be conveniently configured within the aerosol delivery device so that the aerosol delivery device can be easily handled. Furthermore, in one embodiment, the power source is lightweight enough so as not to detract from the desired smoking experience.

[0077] More specific forms, configurations, and arrangements of components within the aerosol delivery device of the present disclosure will become apparent in light of the further disclosure provided below. Furthermore, the selection of various aerosol delivery device components can be understood by considering commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device can be understood by considering commercially available electronic aerosol delivery devices. Examples of commercially available products whose components, methods of operation, materials contained therein, and / or other characteristics may be included in the device of the present disclosure, as well as manufacturers, designers, and / or assignees of components and related technology that may be used in the aerosol delivery device of the present disclosure, are described in U.S. Patent Application No. 15 / 222,615, filed July 28, 2016, to Watson et al., which is incorporated herein by reference in its entirety.

[0078] An exemplary embodiment of an aerosol delivery device 100, illustrating components that may be utilized in an aerosol delivery device according to the present disclosure, is shown in FIG. 1. The aerosol delivery device 100 may include a power unit 102 and a cartridge 104, which may be permanently or removably aligned in a functional relationship, as seen in the cutaway view shown therein. Engagement between the power unit 102 and the cartridge 104 may be press-fit (as shown), threaded, interference fit, magnetic, or the like. Specifically, connection components as further described herein may be used. For example, the power unit may include a coupler configured to engage with a connector on the cartridge.

[0079] In certain embodiments, one or both of the power unit 102 and cartridge 104 may be referred to as disposable or reusable. For example, the power unit 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, connection to an automobile charger (i.e., cigarette lighter socket), and connection to a computer via a Universal Serial Bus (USB) cable or the like. For example, an adapter including a USB connector on one end and a power unit connector on the opposite end is disclosed in U.S. Patent Application 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 disposable cartridge such as that disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0080] As shown in FIG. 1 , the power unit 102 can be formed from a power unit shell 101 that can include control components 106 (e.g., a printed circuit board (PCB), integrated circuits, memory components, a microcontroller, etc.), a flow sensor 108, a battery 110, and an LED 112, which can be variably aligned. In addition to or as an alternative to the LED, additional indicators (e.g., tactile feedback components, audio feedback components, etc.) can be included. Additional representative types of components or indicators that provide visual cues, such as light-emitting diode (LED) components, and their construction and use, are described in U.S. Pat. No. 5,154,192 to Sprinkel et al., U.S. Pat. No. 8,499,766 to Newton, U.S. Pat. No. 8,539,959 to Scatterday, U.S. Pat. App. No. 2015 / 0020825 to Galloway et al., and U.S. Pat. App. No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference.

[0081] The cartridge 104 can be formed from a cartridge shell 103 enclosing a reservoir 144 in fluid communication with a liquid transport element 136 configured to wick or otherwise transport the aerosol precursor composition stored in the reservoir housing to the heater 134. The liquid transport element can be formed from one or more materials configured to transport liquid, such as by capillary action. The liquid transport element can be formed from, for example, fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose cloth, glass fiber), porous ceramic, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillaries, etc. Thus, the liquid transport element can be any material that includes an open pore network (i.e., multiple pores interconnected such that fluid can flow from one pore to another in multiple directions through the element).

[0082] Various embodiments of materials configured to generate heat upon application of an electric current may be used to form the resistive heating element 134. Examples of 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)), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), and ceramics (e.g., positive or negative temperature coefficient ceramics). Various other implementations of the heating element may be used as well. For example, a metal mesh may be disposed around a cylindrical wick, or a ribbon-shaped metal mesh may be disposed on a ribbon-shaped or sheet-shaped wick. For example, as described in U.S. Patent Application Publication No. 2017 / 0020193, filed December 3, 2015, the contents of which are incorporated herein by reference, the heating element may be configured to heat an aerosol precursor composition disposed within a liquid transport element via radiant heating. In another implementation, the heating element may be configured to heat the aerosol precursor composition via induction heating, as described in U.S. Patent Application Publication No. 2017 / 0127722, filed November 6, 2015, the contents of which are incorporated herein by reference. A variety of heater components may be used in the aerosol delivery devices of the present disclosure. In various implementations, one or more microheaters or similar solid-state heaters may be used. Microheaters suitable for use in the devices of the present disclosure, as well as nebulizers incorporating microheaters, are described in U.S. Patent No. 8,881,737 to Collett et al., which is incorporated herein by reference.

[0083] An opening 128 may be present in the cartridge shell 103 (e.g., at the mouth end) to allow the formed aerosol to be released 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 this disclosure.

[0084] Cartridge 104 may also include one or more electronic components 150, which may include integrated circuits, memory components, sensors, etc. Electronic components 150 may be configured to communicate with control component 106 and / or external devices by wired or wireless means. Electronic components 150 may be located anywhere within cartridge 104 or its base 140.

[0085] 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 mass airflow sensor directly mounted thereto. Furthermore, the electronic circuit board may be positioned horizontally relative to the view of FIG. 1 in that the electronic circuit board may be longitudinally parallel to the central axis of the power unit. In some embodiments, the mass airflow sensor may include its own circuit board or other base element to which it may be mounted. 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.

[0086] The power unit 102 and cartridge 104 may include components configured to facilitate fluid engagement therebetween. As shown in FIG. 1 , the power unit 102 may include a coupler 124 having a cavity 125 therein. The cartridge 104 may include a base 140 configured to engage with the coupler 124 and may include a protrusion 141 configured to fit within the cavity 125. Such engagement may facilitate a stable connection between the power unit 102 and the cartridge 104 as well as establish an electrical connection between the battery 110 and control components 106 in the power unit and the heater 134 in the cartridge. Additionally, the power unit shell 101 may include an air inlet 118, which may be a notch in the shell that connects to the coupler 124, allowing ambient air around the coupler to pass into the shell, then through the cavity 125 of the coupler, and into the cartridge via the protrusion 141.

[0087] Useful couplers and bases according to the present disclosure are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. For example, as seen in FIG. 1 , the coupler 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 that is 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. However, various other embodiments of structures, shapes, and components may be used to couple the base to the coupler. In some embodiments, the connection between the base 140 of the cartridge 104 and the coupler 124 of the power unit 102 may be substantially permanent, while in other embodiments, the connection therebetween may be releasable, for example, so that the power unit may be reused with one or more additional cartridges, which may be disposable and / or refillable.

[0088] In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped, or substantially tubular-shaped, or substantially cylindrical-shaped. Other embodiments encompass additional shapes and dimensions, such as rectangular or triangular cross-sections, polyhedral shapes, etc. Specifically, the power unit 102 may not be rod-shaped, but rather may be substantially rectangular, circular, or have some additional shape. Similarly, the power unit 102 may be substantially larger than a power unit that would be expected to be substantially the size of a conventional cigarette.

[0089] The reservoir 144 shown in FIG. 1 can be a container (e.g., formed from walls substantially impermeable to the aerosol precursor composition) or a fibrous reservoir. The container walls can be flexible or collapsible. Alternatively, the container walls can be substantially rigid. The container reservoir can be referred to as a tank. Also, at least a portion of the container can be provided with a fibrous material. In an exemplary embodiment, the reservoir 144 can comprise one or more layers of nonwoven fibers substantially formed in the shape of a tube that surrounds the interior of the cartridge shell 103. The reservoir 144 can hold the aerosol precursor composition. For example, a liquid component can be sorptively held by the reservoir 144 (i.e., if the reservoir 144 includes a fibrous material). The reservoir 144 can be fluidly connected to the liquid transport element 136. In this embodiment, the liquid transport element 136 can transport the aerosol precursor composition stored in the reservoir 144 via capillary action to the heating element 134, which is in the form of a metal wire coil. Thus, the heating element 134 is in a heating configuration with the liquid transport element 136 .

[0090] In 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. When drawing on the mouth end of article 100, ambient air enters air inlet 118 and passes through cavity 125 in coupler 124 and a central opening in protrusion 141 of base 140. In cartridge 104, the drawn-in air combines with the formed vapor to form an aerosol. The aerosol is blown, inhaled, or otherwise drawn through heating element 134 and exits through mouth opening 128 in the mouth end of article 100.

[0091] In one or more embodiments, a mouthpiece 165 is provided in accordance with the present disclosure, and the mouthpiece can be adapted or configured to connect to the mouth end of the cartridge 104. As described further below, a flavor delivery article 290 can be included in the cartridge 104, such as proximate the mouth end of the cartridge. The flavor delivery article 290 can be disposed directly within the interior of the cartridge 104 so as to be at least partially surrounded by the cartridge shell 103. Alternatively or additionally, the flavor delivery article 290 can be disposed within the mouthpiece 165. Further, in various embodiments, the mouthpiece 165 can be associated with, attached to, or otherwise connected to the mouth end of the cartridge 104. For example, the mouthpiece 165 can be adapted or configured to be removably attached to the mouth end of the cartridge 104, such as via a threaded connection, a magnetic connection, a press-fit (or friction-fit) connection, or the like. Further, the mouthpiece 165 can be adapted or configured to be disposed on at least a portion of the exterior of the cartridge shell 103. Alternatively, the mouthpiece 165 may be adapted or configured to be inserted into an opening formed in the mouth end of the cartridge shell 103 .

[0092] An input device may be included in the aerosol delivery device. The input may be included to allow a user to control the device's functions and / or output information to the user. Any component or combination of components may be utilized as an input for controlling the device's functions. For example, one or more push buttons may be used, as described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touch screen may be used, as described in U.S. Patent Application No. 14 / 643,626 to Sears et al., filed March 10, 2015, which is incorporated herein by reference. As a further example, a component adapted for gesture recognition based on specific movements of the aerosol delivery device may be used as an input. See U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference.

[0093] In some embodiments, the input may include a computer or computing device such as a smartphone or tablet. Specifically, the aerosol delivery device may be wired to a computer or other device, such as via a USB cord or similar protocol. The aerosol delivery device may also communicate with the computer or other device acting as the input via wireless communication. See, for example, U.S. Patent Application Publication No. 2016 / 0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference. In such embodiments, an application or other computer program may be used in conjunction with a computer or other computing device to input control instructions to the aerosol delivery device, including, for example, the ability to form an aerosol of a specific composition by selecting the nicotine content and / or the content of additional flavors to be included.

[0094] 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 in accordance with the present disclosure is described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0095] The aerosol delivery device can incorporate a sensor or detector for controlling the supply of power to the heating element when aerosol generation is desired (e.g., when inhaled during use). Thus, for example, a manner or method is provided for turning off the power supply to the heating element when the aerosol delivery device is not being inhaled during use, and turning on the power supply to activate or cause the heating element to generate heat during inhalation. Additional representative types of sensing or detection mechanisms, their structure and configuration, their components, and their general operating methods 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.

[0096] Most preferably, the aerosol delivery device 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 features, 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. Pat. App. Pub. No. 2009 / 0230117 to Fernando et al., U.S. Pat. App. Pub. No. 2014 / 0060554 to Collet et al., and U.S. Pat. App. Pub. No. 2014 / 0270727 to Ampolini et al., and U.S. Pat. App. Pub. No. 2015 / 0257445 to Henry et al., which are incorporated herein by reference.

[0097] Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014 / 0261487 to Chapman et al. and 2014 / 0059780 to Davis et al., and U.S. Patent Application Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference. Additionally, various wicking materials and the configuration and operation of those wicking materials within particular types of electronic cigarettes are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference.

[0098] In aerosol delivery systems characterized as electronic cigarettes, the aerosol precursor composition most preferably incorporates tobacco or tobacco-derived components. In one respect, tobacco may be provided as tobacco parts or pieces, such as finely ground, crushed, or powdered tobacco flakes. In another respect, 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 a relatively high-concentration nicotine-containing extract that also incorporates small amounts of other extracted components derived from tobacco. In another respect, 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).

[0099] Aerosol precursor compositions, also referred to as vapor precursor compositions, may contain a variety of ingredients, including, for example, polyhydric alcohols (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorings. Representative types of aerosol precursor ingredients and formulations are also described and characterized in U.S. Pat. No. 7,217,320 to Robinson et al., U.S. Patent Application Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Application Publication No. 2013 / 0213417 to Chong et al., U.S. Patent Application Publication No. 2014 / 0060554 to Collett et al., U.S. Patent Application Publication No. 2015 / 0020823 to Lipowicz et al., and U.S. Patent Application Publication No. 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those incorporated into RJ Reynolds Vapor Company's VUSE® products, Lorillard Technologies' BLU™ products, Mistic Ecigs' MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. Also desirable are so-called "smoke juices" for e-cigarettes available from Johnson Creek Enterprises LLC.

[0100] 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 generate a visible mainstream aerosol that resembles in many respects the appearance of cigarette smoke. The amount of aerosol precursor in the aerosol-generating system may depend on factors such as the desired number of puffs per aerosol-generating component. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system, 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.

[0101] Still other features, controls or components that can be incorporated into the aerosol delivery systems of the present disclosure are described in U.S. Pat. No. 5,967,148 to Harris et al., U.S. Pat. No. 5,934,289 to Watkins et al., U.S. Pat. No. 5,954,979 to Counts et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 8,365,742 to Hon, U.S. Pat. No. 8,402,976 to Fernando et al. ... U.S. Patent Application Publication No. 2010 / 0163063, U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent Application Publication No. 2013 / 0298905 to Leven et al., U.S. Patent Application Publication No. 2013 / 0180553 to Kim et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., and U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al.

[0102] The above description of the use of the article can be applied to the various embodiments described herein through minor modifications that may be apparent to one of ordinary skill 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 necessary disclosure requirements of the present disclosure. Any of the elements shown in FIG. 1 or otherwise shown in the article described above may be included in an aerosol delivery device according to the present disclosure.

[0103] In one or more embodiments of the present disclosure, an aerosol delivery device may include a flavor delivery article. However, it is understood that the flavor delivery article is a “standalone” element that can be provided in a variety of devices in which it is desirable to incorporate particles or droplets of a flavor liquid into a gas stream passing therethrough. For example, nebulizers, aerosol generators, drug delivery devices, heated-not-burn (HNB) smoking articles, carbon tobacco heated products (CTHPs), electric tobacco heated products (ETHPs), and the like can all benefit from the incorporation of a flavor delivery article described herein. Therefore, it is understood that the description of a flavor delivery article in combination with an aerosol delivery device is merely intended to provide an example for a complete disclosure of the present invention, and that the use of the flavor delivery article should be considered limited to combination with an aerosol delivery device.

[0104] The flavor delivery articles 290 described herein can include a storage unit for holding or otherwise containing a flavor liquid. An example of such a storage unit is shown in FIG. 2. As seen therein, the storage unit is shown as a hollow elongated unit 205 formed from a substantially continuous wall 207 extending between a first end 211 and a second end 213. The hollow elongated unit 205 can define an interior storage volume within a hollow space 216.

[0105] Although hollow elongated unit 205 is shown as being substantially in the form of a tube or hollow cylinder, it can take on a variety of shapes. For example, hollow elongated unit 205 can have a cross-sectional shape such as a square, rectangle, oval, triangular polygon, etc. Although hollow elongated unit 205 is shown as having a substantially continuous diameter throughout its length, in some embodiments, the diameter can vary along its length. For example, the diameter may increase from first end 211 to second end 213 such that the diameter at the second end is about 25% to about 500%, about 50% to about 400%, or about 75% to about 250% larger than the diameter at the first end. Alternatively, the diameter may decrease from first end 211 to second end 213 such that the diameter at the first end is about 25% to about 500%, about 50% to about 400%, or about 75% to about 250% larger than the diameter at the second end. Thus, the hollow elongated unit 205 may be substantially conical or frustoconical in shape.

[0106] The size of the hollow elongated unit 205 can vary depending on the size of the additional device in which it will be contained and the desired volume of flavor liquid to be stored therein. For example, the hollow elongated unit 205 can have a length of about 0.5 cm to about 5 cm, about 0.5 cm to about 3 cm, about 0.5 cm to about 2.5 cm, or about 0.5 cm to about 2 cm. The length of the hollow elongated unit 205 can be measured along its longitudinal axis. The hollow elongated unit 205 can also have an average diameter or other dimension (e.g., width) measurable transversely to the longitudinal axis, and such other dimension can be about 0.2 cm to about 2 cm, about 0.3 cm to about 1.8 cm, or about 0.5 cm to about 1.5 cm. The thickness of the substantially continuous wall 207 of the hollow elongated unit 205 can vary along the longitudinal axis of the unit. In some embodiments, the thickness of the substantially continuous wall 207 is preferably substantially uniform along the longitudinal axis of the unit. The substantially continuous wall 207 can have an average thickness of, for example, about 0.05 mm to about 5 mm, about 0.1 mm to about 4 mm, or about 0.25 mm to about 3 mm. The interior storage volume of the hollow space 216 defined within the hollow elongated unit 205 is about 2 cm. 3 ~about 500cm 3 , about 10cm 3 ~about 250cm 3 , about 25cm 3 ~about 200cm 3 or about 50 cm 3 ~Approx. 100cm 3 It can be said that:

[0107] The substantially continuous wall 207 of the hollow elongated unit 205 can be formed from a porous material configured to allow flavor liquid stored within the hollow space 216 to diffuse or wick through interconnected pores. In this manner, the flavor liquid contacts the inner surface 221 of the substantially continuous wall 207 and passes through the interconnected pores to reach the outer surface 223 of the substantially continuous wall. Accordingly, the substantially continuous wall 207 may be formed from nanoporous, microporous, and / or macroporous materials. In some embodiments, the substantially continuous wall 207 may be at least partially formed from one or more polymeric materials, such as polyethersulfone, polypropylene, polyethylene, polyester, nylon, cellulose nitrate, regenerated cellulose, cellulose acetate, and combinations thereof. For example, the substantially continuous wall 207 may be at least partially formed from fibers formed from any of the aforementioned materials, alone or in combination. Similarly, any one or more of the aforementioned materials may be explicitly excluded from use in one or more embodiments of the present disclosure.

[0108] In some embodiments, the substantially continuous wall 207 may be at least partially formed from a ceramic material such as alumina, silica, zirconia, or the like. Combinations of materials may be utilized if desired. Furthermore, the substantially continuous wall 207 of the hollow elongated unit 205 may be formed from one or more layers (e.g., one, two, three, four, or more layers), with separate layers being formed from different materials. When multiple layers are used, the layers may be prepared using coextrusion or other techniques known in the art. Thus, the substantially continuous wall 207 may be configured to absorb a flavor liquid stored within the hollow space 216 and transport the liquid flavor material via capillary action through the thickness of the substantially continuous wall. When the liquid flavor material reaches the outer surface of the substantially continuous wall 207, particles or droplets of the liquid flavor material may be entrained by a gas stream passing along the outer surface.

[0109] In some embodiments, the substantially continuous wall 207 (or one or more of its layers) can be formed from a porous material having a graded porosity across the substantially continuous wall thickness. As used herein, a graded or functionally graded material is understood to be a material whose composition, microstructure, or both vary locally such that a specific change in local material properties is achieved. Functionally graded materials are particularly useful for forming the substantially continuous walls described herein in that they can be structurally designed to allow for discrete or continuous changes in the molecular modeling of the wall. This allows for the preparation of coatings with varying capillary action across the wall thickness. A substantially continuous wall can be defined as functionally graded, particularly in that the average pore size can vary across the wall thickness. In some embodiments, the material forming the substantially continuous wall is functionally graded such that the average pore size increases from the inner layer or portion of the wall to the outer layer or portion of the wall. Thus, the wall can be functionally graded in average pore size from the inner or inner portion of the wall to the outer or outer portion of the wall, such that the average pore size in the inner or inner portion of the wall is smaller than the average pore size in the outer or outer portion of the wall. In a further embodiment, the material forming the substantially continuous wall is functionally graded in average pore size, such that the average pore size decreases from the inner or inner portion of the wall to the outer or outer portion of the wall. Thus, the wall can be functionally graded in average pore size from the inner or inner portion of the wall to the outer or outer portion of the wall, such that the average pore size in the inner or inner portion of the wall is larger than the average pore size in the outer or outer portion of the wall.

[0110] An exemplary embodiment of a hollow elongated unit 205 having a substantially continuous wall 207 that is functionally graded across its thickness is shown in FIG. 3A. As can be seen therein, the substantially continuous wall 207 is formed from a first or inner layer 231 and a second or outer layer 233. The inner layer 231 is formed from a porous material having a first average pore size, and the outer layer 233 is formed from a porous material having a second average pore size. Relatively speaking, in some embodiments, the first average pore size can be smaller than the second average pore size, and the second average pore size can be larger than the first average pore size. In other embodiments, the first average pore size can be larger than the second average pore size, and the second average pore size can be smaller than the first average pore size. If desired, one or more intermediate layers may be included between the first (inner) layer 231 and the second (outer) layer 233, and the one or more intermediate layers may exhibit an average pore size that falls between the average pore size of the first (inner) layer and the average pore size of the second (outer) layer. Thus, the substantially continuous wall 207 is functionally graduated in that the average pore size varies across the thickness of the wall. While the inner layer 231 and the outer layer 233 are shown as having substantially the same thickness, the relative thicknesses of the layers can be varied as desired to modify vapor liquid migration across the entire thickness of the substantially continuous wall 207. For example, the outer layer 233 may have a greater thickness than the inner layer 231 to increase the amount of flavor liquid present on the outer surface 223 of the substantially continuous wall 207 or to increase the flow rate of flavor liquid through the wall. Thus, the ratio of the thickness of the inner layer 231 to the outer layer can be from about 0.1 to about 1, from about 0.2 to about 1, from about 0.5 to about 1, or from about 0.75 to about 1. In other embodiments, the ratio of the thickness of the inner layer 231 to the outer layer can be from about 1 to about 10, from about 1 to about 8, or from about 1 to about 5.

[0111] FIG. 3B provides a further exemplary embodiment of a substantially continuous wall 207, showing an enlarged view of a partial cross-section of the wall. In the embodiment of FIG. 3B, the substantially continuous wall 207 is substantially or completely formed from a single layer of material, although the single layer of material has a graduated transition across its thickness. The substantially continuous wall 207 includes a plurality of pores 227. As shown, the substantially continuous wall 207 has relatively small pores 227a at or near the inner surface 221 of the wall and relatively large pores 227b at or near the outer surface 223 of the wall. However, in alternative embodiments, the relatively small pores may be at or near the outer surface 223 of the wall, and the relatively large pores may be at or near the inner surface 221 of the wall. In some embodiments, the phrase "inner surface" may refer to a volume adjacent to the inner surface and extending outward a distance of about 5% to about 45%, about 5% to about 35%, or about 5% to about 25% of the total thickness of the substantially continuous wall 207. Preferably, the defined volume extends around substantially the entire inner surface of the wall. Similarly, in some embodiments, the phrase "outwardly" can refer to a volume adjacent to the outer surface and that can extend inwardly a distance of about 5% to about 45%, about 5% to about 35%, or about 5% to about 25% of the total thickness of the substantially continuous wall 207. Preferably, the defined volume extends around substantially the entire outer surface of the wall.

[0112] The relatively small pores can have a first average size, and the relatively large pores can have a second average size. In further embodiments, pores can also be present having an intermediate average size between the first and second average sizes. The intermediate average size can be referred to as a third average size. In one or more embodiments, the first average size of the relatively small pores can be about 10 nm to about 3 μm, about 100 nm to about 3 μm, about 250 μm to about 2.5 μm, or about 500 nm to about 2 μm. In further embodiments, the second average size of the relatively large pores can be about 0.5 μm to about 30 μm, about 1 μm to about 30 μm, about 2 μm to about 25 μm, or about 3 μm to about 20 μm. In some embodiments, the pores in approximately the inner half of the thickness of the substantially continuous wall 207 can have a first average pore size, and the pores in approximately the outer half of the thickness of the substantially continuous wall can have a second average pore size.

[0113] The extent of the gradation in average pore size can be varied to determine how quickly flavor liquid from the hollow space 216 wicks up through the thickness of the substantially continuous wall 207 to replenish liquid displaced from its outer surface 223. This can be varied based on the nature of the flavor liquid present in the hollow space 216 and the total amount of flavor liquid desired to be available for uptake at a given time. Thus, the volume of the substantially continuous wall 207 containing pores 227 having the second pore size can be decreased or increased as desired to decrease or increase, respectively, the amount of flavor liquid made available. For example, the pores 227 having the second average pore size can be present in about the outer 65%, about the outer 45%, about the outer 35%, about the outer 25%, about the outer 15%, or about the outer 5% of the total thickness of the substantially continuous wall 207. Alternatively, the pores 227 having the first average pore size can be present in about the outer 65%, about the outer 45%, about the outer 35%, about the outer 25%, about the outer 15%, or about the outer 5% of the total thickness of the substantially continuous wall 207.

[0114] In some embodiments, the pore morphology may be graduated across the thickness of the substantially continuous wall 207 so that the wicking characteristics of a liquid through the substantially continuous wall may be varied. For example, the pore morphology near the inner surface 221 of the substantially continuous wall 207 may be such that relatively rapid wicking occurs, and the pore morphology may change moving outward from the inner surface so that the wicking rate decreases. Thus, the pore morphology near the outer surface 223 of the substantially continuous wall 207 may be such that relatively slow wicking occurs for the portion of the substantially continuous wall near the inner surface 221.

[0115] As mentioned above, a flavor liquid can be contained by the internal storage volume (i.e., hollow space 216) of hollow elongated unit 205. Thus, in some embodiments, the aerosol precursor composition held within reservoir 144 (see FIG. 1 ) may comprise an unflavored aerosol precursor composition, although flavored aerosol precursor compositions (i.e., aerosol precursor compositions comprising one or more flavorings) are also contemplated. The flavor liquid, in turn, can comprise one or more flavorings, which may themselves be provided in the form of a composition comprising aerosol precursor components. As used herein, reference to a “flavoring” is intended to refer to a compound or ingredient that can be present in a flavor liquid, can be aerosolized and delivered to a user, and that imparts a sensory experience in terms of taste and / or aroma. Exemplary flavorings include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rosehip, yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monniera, ginkgo, ashwagandha, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Also, syrups such as high fructose corn syrup can be used. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one skilled in the art of tobacco and tobacco-related or tobacco-derived products.See, for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the entire disclosures of which are incorporated herein by reference. For other examples of perfume materials that may be suitable for the disclosed products, see, for example, U.S. Patent Application Publication No. 2002 / 0162562 to Williams, U.S. Patent Application Publication No. 2002 / 0162563 to Williams, U.S. Patent Application Publication No. 2003 / 0070687 to Atchley et al., U.S. Patent Application Publication No. 2004 / 0020503 to Williams, U.S. Patent Application Publication No. 2005 / 0178398 to Breslin et al., U.S. Patent Application Publication No. 2006 / 0191548 to Strickland et al., U.S. Patent Application Publication No. 2006 / 0191548 to Holton, Jr. et al., each of which is incorporated herein by reference. See U.S. Patent Application Publication No. 2007 / 0062549, U.S. Patent Application Publication No. 2007 / 0186941 to Holton, Jr. et al., U.S. Patent Application Publication No. 2007 / 0186942 to Strickland et al., U.S. Patent Application Publication No. 2008 / 0029110 to Dube et al., U.S. Patent Application Publication No. 2008 / 0029116 to Robinson et al., U.S. Patent Application Publication No. 2008 / 0029117 to Mua et al., U.S. Patent Application Publication No. 2008 / 0173317 to Robinson et al., and U.S. Patent Application Publication No. 2008 / 0209586 to Neilsen et al. It should be noted that reference to flavorings should not be limited to any single flavoring such as those listed above, and may, in fact, represent a combination of one or more flavorings.

[0116] The hollow elongated unit 205 can be configured such that one or both of the first end 211 and the second end 213 are substantially open. This can facilitate filling the hollow space 216 with flavor liquid. However, the open ends can also be configured to engage one or more portions of one or more end units, which can be useful for positioning the flavor delivery device within a piece of additional equipment, such as an aerosol delivery device. In particular, the flavor delivery article 290 can further include end units disposed on one or both of the first end 211 and the second end 213 of the hollow elongated unit 205. The end units can be substantially plugs or caps (see, for example, element 371 in FIG. 9 ) or can be substantially in the form of frames. As shown in FIG. 4 , the first end frame 245 is positioned to engage the first end 211 of the hollow elongated unit 205, and the second end frame 246 is positioned to engage the second end 213 of the hollow elongated unit. In the illustrated exemplary embodiment, the first end frame 245 and the second end frame are substantially identical. However, each end frame may have a different structure. In the exemplary embodiment, both end frames (245, 246) have a hub and spoke configuration. In particular, the first end frame 245 includes a central hub 245a from which extend a plurality of arms 245b (e.g., configured as spokes having a substantially circular cross-section or as vanes having a substantially elongated cross-section) and connect to an outer frame wall 245c. In the exemplary embodiment of FIG. 4, the frames (245, 246) are substantially circular, although it is understood that other shapes are also encompassed. Additionally, a fewer or greater number of arms 245b may be used, and the dimensions of each element of the frames (245, 246) may be independently varied. Similarly, the second end frame 246 includes a central hub 246a from which extend a plurality of arms 246b (e.g., configured as spokes having a substantially circular cross-section or as vanes having a substantially elongated cross-section) and connect to an outer frame wall 246c.The second frame 246 further includes a shaft 246e extending from the hub 246a and configured to be inserted into the hollow space 216 of the second end 213 of the hollow elongated unit 205. However, other mechanisms for engaging the frames (245, 246) with the first end 211 and second end 213 of the hollow elongated unit 205 are also encompassed. As shown, the engagement between the shaft 246 and the second end 213 of the hollow elongated unit 205 is preferably a sealing engagement so that flavor liquid stored in the hollow space 216 does not leak around the shaft. Figure 5 shows various elements of a flavor delivery article 290 combined with two end frames (245, 246) engaging with the respective first end 211 and second end 213 of the hollow elongated unit 205.

[0117] The central hub (245a, 246a), arms (245b, 246b), and frame walls (245c, 246c) forming each frame define a plurality of openings (245d, 246d) therebetween, the openings being suitable for gas flow to pass through. The arrangement of the hubs, arms, and frame walls can thus define a lattice structure with a plurality of airflow passages therethrough. The lattice structure can be a wheel-type design, as shown in the exemplary embodiment of FIG. 4, although other lattice structures including a plurality of interconnected sections to form end frames are also encompassed.

[0118] The end frames (245, 246) can be formed from any suitable material that does not react with the flavor liquid. In some embodiments, the end frames (245, 246) can be substantially non-porous or have very low nanoporosity, so that substantially no flavor liquid migrates therethrough. By way of non-limiting example, the end frames (245, 246) can be made from an inert material such as a polymer and / or ceramic.

[0119] The flavor delivery article 290 can be provided substantially as shown in FIG. 5 (including being filled with flavor liquid). However, in some embodiments, it may be desirable for the flavor delivery article 290 to further include an outer casing 260, as shown in FIG. 6. The outer casing 260 can extend from the first end frame 245 to the second end frame 246 and can be useful for providing the flavor delivery article 290 as a unit suitable for insertion into various devices. In certain embodiments, the outer casing 260 can be useful for reducing or preventing loss of flavor liquid due to evaporation over the outer surface 223 of the substantially continuous wall 207 when the flavor delivery device (or the device into which the flavor delivery device is inserted) is not in use. Similarly, the outer casing 260 can be useful for containing any possible leakage from additional components of the flavor delivery unit. By way of non-limiting example, the outer casing 260 can be formed from any suitable material, such as a polymer, including, but not limited to, polycarbonate, polyester, polypropylene, polyethylene, etc. As a further example, silicone or similar materials may be used.

[0120] The flavor delivery article 290 is beneficially useful for imparting a desired flavoring effect to a gas stream. Thus, the flavor delivery article 290 can be combined with any type of device configured to provide a gas stream flow. In an exemplary embodiment, this can include an aerosol delivery device such as that shown in FIG. 1 , or an aerosol delivery device having a different configuration of components but intended to provide the same function of acting on an aerosol precursor liquid to form a vapor that can be entrained in a passing air stream, thereby forming an aerosol. For example, returning to FIG. 1 , when the cartridge 104 is engaged with the power unit, a user inhaling through an opening 128 at the mouth end of the cartridge enters air through the air inlet 118. The air flows through and / or around the reservoir 144, entraining the vapor formed by heating the aerosol precursor composition in the liquid transport element 136 by the heater 134, thereby forming an aerosol that exits through the opening 128. Thus, there can be one or more airflow paths through the aerosol delivery device. In this manner, the heater 134 can be positioned substantially within the airflow passageway so that the vapor formed is efficiently available to be entrained in the air flowing through the cartridge 104 .

[0121] In some embodiments, the flavor delivery article 290 described herein can be disposed substantially within the airflow passage. For example, in FIG. 1 , an open space exists between the heater 134 and the opening 128 at the mouth end of the cartridge 104. Accordingly, the flavor delivery article 290 described herein may be disposed in such an open space. In such a configuration, the flavor delivery article 290 is disposed in the airflow passage downstream of the heater 134. In this manner, aerosol drawn from the heater 134 may pass through the flavor delivery article 290 to entrain particles or droplets of flavor liquid (including flavorants described herein). In further embodiments, the cartridge 104 may be configured to include additional space between the reservoir 144 and the base 140. In such embodiments, air flowing through the cartridge first passes through the flavor delivery article 290 and then through or around the heater 134 to form the aerosol. In this way, the air used to form the aerosol already contains particles or droplets of flavor liquid entrained therein as the air mixes with the vapor formed from the heater 134 to form the aerosol and is drawn through the opening 128. Thus, the flavor delivery article 290 can be positioned in the airflow path upstream of the heater 134.

[0122] In some embodiments, the present disclosure may specifically provide a mouthpiece for an aerosol delivery device. The mouthpiece may include a flavor delivery device disposed therein, and thus the flavor delivery mouthpiece so formed may be adapted or configured to be combined with another item, such as an aerosol delivery device.

[0123] An exemplary embodiment of a flavor delivery mouthpiece 265 is shown in FIG. 7. As can be seen therein, the mouthpiece 265 can be formed from a shell 266 having a first end 267 (or a connecting end configured to connect the mouthpiece to an additional device, such as the mouth end of the cartridge 104 shown in FIG. 1 ) and a second end 268 (or mouth end). The first end (or connecting end) 267 can be adapted or configured to connect to an aerosol delivery device via, for example, a threaded connection, a magnetic connection, or a press-fit connection. The first end 267 of the mouthpiece 265 can include an opening 267a that can substantially align with the opening 128 of the mouth end of the cartridge 104 or with a similar opening of an additional device to which the mouthpiece can be attached. The flavor delivery device 290 included in the mouthpiece 265 again includes a hollow elongated unit 205 formed from a substantially continuous wall 207 extending between the first end 211 and the second end 213. The hollow elongated unit 205 defines an interior storage volume for storing flavor liquid. A frame 246 is attached to the second end 213 of the hollow elongated unit 205, the frame being substantially as otherwise described herein. The first end 211 of the hollow elongated unit 205 includes a plug unit 271 including a floor member 271a, an extension 271b protruding therefrom and configured to engage the first end 211 of the hollow elongated unit 205, and one or more curtains 271c extending downward from the floor member. The one or more curtains 271c extend only partially around the circumference of the floor member 271a, separating the floor member by a distance from the opening 267a in the first end 267 of the mouthpiece 265. In this manner, aerosol entering through the opening 267a in the mouthpiece 265 impacts the bottom of the floor member 271a and spreads outward through the space around the curtains. The aerosol must then pass longitudinally through the mouthpiece 265 and past the outer surface 223 of the substantially continuous wall 207 of the hollow elongated unit 205, where particles or droplets of the flavor liquid become entrained in the aerosol.The aerosol, entrained with particles or droplets of flavor liquid, then passes through opening 246d between arms 246b of second frame 246 and exits mouthpiece 265 through its second end 268. The combination of components is further illustrated in the exploded view of an exemplary embodiment of a mouthpiece and flavor delivery article combination provided in FIG.

[0124] A further exemplary embodiment of a flavor delivery mouthpiece 365 for combination with an aerosol delivery device or similar device is shown in Figure 9. As seen therein, mouthpiece 365 can be formed from a shell 366 having a first end 367 (or a connecting end configured to connect the mouthpiece to an additional device, e.g., the mouth end of cartridge 104 shown in Figure 1) and a second end 368 (or mouth end). First end (or connecting end) 367 can be adapted or configured to connect to an aerosol delivery device, for example, via any suitable connection as otherwise mentioned herein.

[0125] The flavor delivery device 290 included in the mouthpiece 365 again includes a hollow elongated unit 205 formed from a substantially continuous wall 207 extending between a first end 211 and a second end 213. The hollow elongated unit 205 defines an interior storage volume for storing flavor liquid. A plug unit 371 is provided at the first end 211 of the hollow elongated unit 205 and is adapted or configured to engage the first end 211 of the hollow elongated unit 205 and substantially prevent leakage of the flavor liquid therefrom. In this manner, aerosol entering the first end 367 of the mouthpiece 365 impacts the plug unit 371 and expands outward to pass around the hollow elongated unit 205. The aerosol then must pass longitudinally through the mouthpiece 365 and past the outer surface 223 of the substantially continuous wall 207 of the hollow elongated unit 205, where particles or droplets of the flavor liquid become entrained in the aerosol. A second end 368 of the shell 366 of the mouthpiece 365 includes an end wall 369 that includes a plurality of aerosol openings 369a for passing an aerosol that has entrained particles or droplets of flavor liquid therethrough.

[0126] The shell 366 of the mouthpiece 365 is further shown in FIG. 10 to reveal its internal components. As can be seen, the shell 366 is formed from a wall 366a having an inner surface 366b and an outer surface 366c. The inner surface 366c includes a plurality of protrusions 372 extending inward a fixed distance from the inner surface of the shell 366. The number of protrusions 372 can be varied as needed and adapted or configured to maintain the lateral position of the hollow elongate unit 205 within the shell 366. In an exemplary embodiment, the protrusions 372 can be adapted or configured to maintain a substantially centered positioning of the hollow elongate unit 205 within the shell 366. The protrusions 372 are discontinuously spaced around the circumference of the inner surface 366b so as not to substantially impede aerosol flow through the interior of the shell 366 of the mouthpiece 365. As illustrated, the protrusions are positioned proximate the first end 367 of the shell such that they are closer to the first end 367 of the shell than to the second end 368 of the shell. Preferably, in this embodiment, the protrusion may be located between approximately the midpoint of the longitudinal length of the shell 366 and the first end 367 of the shell.

[0127] The end wall 369 of the well 366 further includes a mandrel 369b (or other element providing a similar function) that protrudes inward into the interior of the shell and is sized and shaped to engage with the opening at the second end 213 of the hollow elongated unit 205. Thus, the mandrel 369b and the protrusion 372 cooperate to substantially stabilize the positioning of the flavor delivery device 290 within the shell 366 of the mouthpiece 365. The mandrel 369b is preferably substantially centrally located on the end wall 369 of the shell 366. The shell 366 of the mouthpiece 365 can be sized to, for example, substantially slide around the outer surface of the mouth end of the aerosol delivery device such that the inner surface 366b of the wall 366a of the shell 366 establishes a friction fit with the outer surface of the aerosol delivery device. Thus, by way of non-limiting example, the mouthpiece 365 may be removably connected to an aerosol delivery device or a similar device.

[0128] Another exemplary embodiment of a flavor delivery mouthpiece 465 for combination with an aerosol delivery device or similar device is shown in FIG. 11 . As seen therein, the mouthpiece 465 can be formed from a shell 466 having a first end 467 (or a connecting end configured to connect the mouthpiece to an additional device, e.g., the mouth end of the cartridge 104 shown in FIG. 1 ) and a second end 468 (or mouth end). The first end (or connecting end) 467 can be adapted or configured to connect to an aerosol delivery device via any suitable connection, for example, as otherwise mentioned herein. As shown, the first end 467 of the mouthpiece 465 extends a certain distance toward the second end 468 before flare-out at a flange 475. Thus, the region between the flange 475 and the first end 467 can be formed into an insert 476 adapted or configured to be inserted into an opening in the mouth end of the cartridge. Thus, by way of non-limiting example, the mouthpiece 465 can be removably connected to an aerosol delivery device or similar device.

[0129] The flavor delivery device 290 included in the mouthpiece 465 again includes a hollow elongated unit 205 formed from a substantially continuous wall 207 extending between a first end 211 and a second end 213. The hollow elongated unit 205 defines an interior storage volume for storing flavor liquid. A plug unit 471 is provided at the first end 211 of the hollow elongated unit 205 and is adapted or configured to engage the first end 211 of the hollow elongated unit 205 and substantially prevent leakage of the flavor liquid therefrom. In this manner, aerosol entering the first end 467 of the mouthpiece 465 impacts the plug unit 471 and expands outward to pass around the hollow elongated unit 205. The aerosol then must pass longitudinally through the mouthpiece 465 and past the outer surface 223 of the substantially continuous wall 207 of the hollow elongated unit 205, where particles or droplets of the flavor liquid become entrained in the aerosol. A second end 468 of the shell 466 of the mouthpiece 465 includes an opening 469a for passing an aerosol containing entrained particles or droplets of flavor liquid.

[0130] Shell 466 of mouthpiece 465 is further shown in FIG. 12 to reveal its internal components. As can be seen, shell 466 is formed from wall 466a having inner surface 466b and outer surface 466c. Shell 466 further includes a mandrel 469b (or other element providing a similar function) that protrudes inwardly into the interior of the shell and is sized and shaped to engage an opening in second end 213 of hollow elongate unit 205. Mandrel 369b is attached to inner surface 466b of shell 466 by a plurality of spacers 479 that maintain mandrel 469b in a substantially centered position and also provide a gap therebetween to allow aerosol passing around substantially continuous wall 297 of hollow elongate unit 205 to exit shell 366 through opening 469a in second end 468 of shell 466.

[0131] Because flavor liquid stored in a flavor delivery device is susceptible to being entrained in the passing airflow (and / or aerosol flow), a certain content of flavor liquid may naturally volatilize into the surrounding ambient air. While this may represent a negligible amount of flavor liquid present within the flavor delivery device, it may be desirable to provide the flavor delivery device and / or mouthpiece with components adapted or configured to substantially prevent loss of flavor liquid. More specifically, this can substantially prevent or reduce the undesired leakage of aroma or odor from the mouthpiece or another device containing the flavor delivery device. Similarly, this can substantially prevent or reduce loss of flavor liquid when the device is not in use, which may undesirably shorten the useful life of the flavor delivery device.

[0132] In one or more embodiments, a mouthpiece (265, 365, 465) according to the present disclosure can include one or more components adapted or configured to substantially prevent volatilized flavor liquid (or non-volatile liquid that may otherwise seep or otherwise leak from the flavor delivery device) from exiting the mouthpiece. In one exemplary embodiment, as seen in FIG. 11 , a removably replaceable cover 480 can be provided. The removably replaceable cover 480 can include at least one cap 481 that can be sized and dimensioned to cover at least a portion of the second end 468 of the mouthpiece shell 466. In other embodiments, the cap 481 can be adapted or configured to be at least partially inserted into an opening 469 a in the second end 468 of the mouthpiece shell 466. The cap can thus provide the functional aspects described above and may also provide a hygienic function of substantially preventing contamination of the second end 468 of the mouthpiece shell 466 when the device is not in use. As shown, to help prevent loss of cap 481, removably replaceable cover 480 may optionally include a stem 482 connected at one end to the cap and at an opposite end to a loop 483 that may be sized to slide around insert 476 of mouthpiece shell 466. However, other configurations for attaching cap 481 to shell 466 of mouthpiece 465 are also encompassed. Removably replaceable cover 480 may be formed from silicone or a flexible polymer material.

[0133] In some embodiments, one or more valves may be utilized to substantially prevent volatilized flavor liquid from exiting the mouthpiece. As shown in FIG. 13 , mouthpiece 565 includes a shell 566 having a first end (or attachment end) 567 and a second end (or mouth end) 568. Inside shell 566, a spacer 579 is utilized to attach a mandrel 569b to the shell, and a hollow elongated unit 205, as otherwise described herein, is attached to the mandrel. Mouthpiece 565 is shown in a closed position but includes a valve 585 (e.g., a one-way valve or check valve) adapted or configured to open when air flows through the mouthpiece from first end 567 of shell 566 to second end 568 of the shell. Valve 568 can be biased to the closed position by a suitable biasing mechanism, such as a spring, which can be included in the valve or a separate element. 13, the mouthpiece 565 may include one or more protrusions 586 disposed proximate the first end 567 of the shell 566 to help provide a friction fit of the mouthpiece over the mouth end of the aerosol delivery device. The protrusions may be adapted or configured to prevent the mouthpiece from being forced too far into the end of the aerosol delivery device, which could result in damage to the hollow elongated unit 205 or substantially prevent an insufficient amount of air and / or aerosol from flowing through the mouthpiece from the mouth end of the aerosol delivery device.

[0134] In another aspect, the present disclosure may be directed to a kit providing various components described herein. For example, the kit may include a control body having one or more cartridges. The kit may further include a control body having one or more charging components. The kit may further include a control body having one or more batteries. The kit may further include a control body having one or more cartridges and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple cartridges. The kit may further include multiple cartridges and one or more batteries and / or one or more charging components. The kit may further include a case (or other packaging, transport, or storage component) for housing one or more of the additional kit components. The case may be a reusable hard or soft container. Furthermore, the case may simply be a box or other packaging structure. In still further embodiments, the disclosed kit may include a mouthpiece described herein and one or more flavor delivery articles described herein. Furthermore, the kit may include multiple mouthpieces packaged together for disposable use with an aerosol delivery device. Still further, the kit may include one or more mouthpieces and one or more flavor delivery articles and / or one or more cartridges described herein.

[0135] The above description of the use of the device can be applied to the various implementations described herein through minor modifications that may be apparent to those skilled in the art in light of the further disclosure provided herein, however, the above description of use is not intended to limit the use of the article but is provided to comply with all necessary disclosure requirements of the present disclosure.

[0136] Many modifications and other implementations of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A cartridge for an aerosol delivery device, the cartridge comprising: a cartridge housing having a mouth end; a reservoir containing an aerosol precursor composition; a heater configured to vaporize the aerosol precursor composition; a hollow elongated unit formed from a substantially continuous wall extending between a first end and a second end and defining an interior storage volume, and a flavor delivery article comprising a flavor liquid contained by the interior storage volume of the hollow elongated unit; A cartridge in which the substantially continuous wall is formed from a porous material.

2. A cartridge as described in claim 1, further comprising a mouthpiece attached to the mouth end of the cartridge housing.

3. A cartridge as described in claim 2, wherein the flavor delivery article is disposed in a mouthpiece attached to the mouth end of the cartridge housing.

4. A cartridge according to any one of claims 1 to 3, wherein the cartridge further comprises an air inlet and an air flow passage through the cartridge.

5. A cartridge according to any one of claims 1 to 4, wherein the flavour liquid stored in the flavour delivery article volatilizes and becomes entrained in the surrounding air.

6. A cartridge according to any preceding claim, wherein the aerosol precursor composition is an unflavored aerosol precursor composition.

7. The cartridge of any one of claims 1 to 6, wherein the flavour delivery article further comprises an outer casing.

8. 8. The cartridge of claim 7, wherein the outer casing is formed from a material selected from polycarbonate, polyester, polypropylene, polyethylene, and silicone.

9. A cartridge as described in claim 7 or 8, wherein the flavor delivery article has a first end frame and a second end frame, and the outer casing extends from the first end frame to the second end frame of the flavor delivery article.

10. A cartridge according to any one of claims 1 to 9, wherein the porous material is a polymeric material.

11. 11. The cartridge of claim 10, wherein the polymeric material is selected from the group consisting of polyethersulfone, polypropylene, polyethylene, polyester, nylon, cellulose nitrate, regenerated cellulose, cellulose acetate, and combinations thereof.

12. The cartridge of any one of claims 1 to 11, wherein the cartridge further comprises one or more valves.

13. 13. The cartridge of claim 12, wherein the one or more valves are selected from the group consisting of one-way valves or check valves.

14. A cartridge according to any one of claims 1 to 13, wherein the flavoured liquid comprises one or more flavourings.

15. 15. The cartridge of claim 14, wherein the one or more flavorings are selected from the group consisting of vanillin, ethyl vanillin, cream, tea, coffee, fruit (preferably fruit is apple, cherry, strawberry, peach, and citrus including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hips, yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monniera, ginkgo, ashwagandha, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and tobacco extract.

16. An aerosol delivery device comprising a power unit and a cartridge according to any one of claims 1 to 15.

17. 17. The aerosol delivery device of claim 16, wherein the aerosol delivery device further comprises one or more airflow passages through the aerosol delivery device.

18. 18. The aerosol delivery device of claim 16 or 17, wherein the mouthpiece is removably connected to the aerosol delivery device.

Images