Aerosol Delivery Device

Abstract

To provide an aerosol delivery device comprising a control device that is connectable with a cartridge and that can include one or more additional elements for improving one or both of visible indications of use to a user and resistance to infiltration of liquid into the control device.SOLUTION: A control device 100 may include a light guide configured for transmitting to a window 135 from a light source that is off-set from the window, and a controller configured to direct a varying level of light from the light source. The control device may include one or more elements that are configured to limit infiltration of liquids into the control device and thus may be considered to be water-resistant or water-proof.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62 / 769,296, filed November 19, 2018, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices (e.g., smoking articles commonly referred to as e-cigarettes) that may utilize electrically generated heat for the generation of an aerosol. The smoking article may be configured to heat an aerosol precursor, which may be made from tobacco, derived from tobacco, or may otherwise incorporate materials that may incorporate tobacco, and the precursor can form an inhalable substance for human consumption. [Background technology]

[0003] Many smoking devices have been proposed for many years as an improvement or replacement for the smoking product that requires tobacco to be burned for use.Many of these devices are allegedly designed to provide the sensation associated with smoking cigarettes, cigars or pipes, but do not deliver a significant amount of incomplete combustion and pyrolysis products resulting from tobacco combustion.For this purpose, many smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials, or to provide the smoking of cigarettes, cigars or pipes without significant tobacco combustion.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, Griffith Jr. et al., U.S. Patent Publication No. 2013 / 0255702 and Sears et al., U.S. Patent Publication No. 2014 / 0096781, all of 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 trade name and commercial source in U.S. Patent Application No. 14 / 170,838 to Bless et al., filed February 3, 2014, which is incorporated herein by reference in its entirety. It would be desirable to provide an aerosol delivery device with advantageous ease-of-use features. [Prior art documents] [Patent documents]

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

[0005] The present disclosure relates to aerosol delivery devices, methods for forming such devices, and elements of such devices. In particular, the present disclosure relates to various elements and combinations thereof that are effective in providing one or more more favorable user experiences and improved resistance of the device to liquid intrusion. For example, in some embodiments, the present disclosure provides an aerosol delivery device that can provide visible illumination to the exterior of the device (e.g., through an aperture or a series of microapertures in the device). Similarly, in some embodiments, the present disclosure can provide a device that includes one or more features (e.g., a sealing member or a microaperture) that can improve the water resistance of the device.

[0006]

[0010] Thus, in one or more embodiments, the present disclosure may provide an aerosol delivery device including: at least one wall defining an outer housing; a window in the at least one wall extending between a first end and a second end; a light source disposed within the outer housing proximate the window but offset from the window beyond one of the first end and the second end of the window, the light source connectable to a power source; a light guide disposed within the outer housing proximate the window, the light guide being sized to substantially fill the window and at least partially overlapping the light source; and a control component configured to direct a variable level of power from the power source to the light source such that light emitted from the light source transmits through the light guide and fills an amount of the window, the amount corresponding to the variable level of power delivered to the light source. In further embodiments, the aerosol delivery device may be defined in conjunction with one or more of the following statements, which may be combined in any number and order:

[0007] The position of the light source and the position of the light guide may be effective to achieve that light emitted from the light source and transmitted through the light guide increases in a direction from one of the first end of the window and the second end of the window to the other of the first end of the window and the second end of the window as power delivered to the light source from the power source increases, and decreases in the opposite direction as power delivered to the light source from the power source decreases.

[0008] The aerosol delivery device may further include a pressure sensor configured to detect changes in pressure within the outer housing over a continuous range of pressure intensities and provide a signal corresponding to the pressure intensity to the controller.

[0009] The control component may be configured to adjust the variable level of power delivered from the power source to the light source in response to signaling received from the pressure sensor.

[0010] Power and control components may be configured for connection with the atomizer.

[0011] The control component may be configured to direct variable levels of power from the power source to the atomizer in response to signaling received from the pressure sensor.

[0012] The aerosol delivery device may further include a printed circuit board disposed within the outer housing, the light source being disposed on the printed circuit board.

[0013] The control components may be located on the same printed circuit board as the light sources.

[0014] The aerosol delivery device may further include a sealing member disposed between the light guide and at least one wall defining the outer housing.

[0015] The sealing member may be integral with the light guide.

[0016] The light guide may be formed from a translucent elastomeric material.

[0017] The aerosol delivery device can further include a liquid-resistant membrane disposed within the outer housing, the liquid-resistant membrane covering a window in the at least one wall.

[0018] The liquid-resistant membrane may be adhered to the interior surface of at least one wall.

[0019] In some embodiments, an aerosol delivery device may be provided that includes at least one wall defining an outer housing extending between a proximal end and a distal end, an inner frame disposed within the outer housing at its proximal end and defining a chamber configured to receive a cartridge, an end cap disposed at the distal end of the outer housing, and at least one sealing member in contact with the inner frame or the end cap, the at least one sealing member configured to substantially prevent passage of liquid around the at least one sealing member. In further embodiments, the aerosol delivery device may be defined in association with one or more of the following statements, which may be combined in any number and order:

[0020] The at least one sealing member may include an O-ring.

[0021] An O-ring may be disposed between the inner frame and at least one wall defining the outer housing.

[0022] The inner frame may include a groove formed around an outer surface thereof, with the O-ring engaging the groove.

[0023] An O-ring may be disposed between the end cap and at least one wall defining the outer housing.

[0024] The end cap may include a groove formed around its outer surface, with the O-ring engaging the groove.

[0025] The at least one sealing member can include a contact seal configured to form a seal between the inner frame and one or more electrical connectors extending through the inner frame.

[0026] The at least one sealing member can include a pin seal configured to form a seal between the end cap and one or more external connection elements extending through the end cap.

[0027] The at least one sealing member may include a sensor seal that substantially surrounds a pressure sensor mounted on the printed circuit board.

[0028] The sensor seal can include a flexible member configured to deform upon application of a pressure differential.

[0029] The sensor seal may be configured to define an enclosed volume around the pressure sensor and to transmit a pressure differential to the pressure sensor.

[0030] In some embodiments, an aerosol delivery device may be provided that includes at least one wall defining an outer housing and a light source disposed within the housing, wherein at least a portion of the at least one wall includes a series of microperforations, and the light source is positioned relative to the series of microperforations such that light from the light source is visible through the series of microperforations. In further embodiments, the aerosol delivery device may be defined by one or more of the following statements, which may be combined in any number and order:

[0031] The light source may be offset from the series of perforations, and the aerosol delivery device may further include a light guide disposed within the outer housing, the light guide being adjacent to the series of micro-perforations and at least partially overlapping the light source.

[0032] At least one wall defining the outer housing can extend between a proximal end and a distal end, and the aerosol delivery device can further include an inner frame disposed within the outer housing at its proximal end and defining a chamber configured to receive the cartridge, an end cap disposed at the distal end of the outer housing, and at least one sealing member in contact with the inner frame or the end cap, the at least one sealing member configured to substantially prevent passage of liquid around the at least one sealing member.

[0033] The present disclosure includes, but is not limited to, the following embodiments.

[0034] Embodiment 1: An aerosol delivery device comprising: at least one wall defining an outer housing; a window in the at least one wall, the window extending between a first end and a second end; a light source disposed within the outer housing and offset from the window beyond one of the first end of the window and the second end of the window, the light source connectable to a power source; a light guide disposed within the outer housing and proximate to the window, the light guide being sized to substantially block the window and at least partially overlapping the light source; and a control component configured to direct a variable level of power from the power source to the light source such that light emitted from the light source transmits through the light guide and fills an amount of the window, the amount corresponding to the variable level of power delivered to the light source.

[0035] Embodiment 2: The aerosol delivery device of any preceding embodiment, wherein the position of the light source and the position of the light guide are effective to achieve that light emitted from the light source and transmitted through the light guide increases in a direction from one of the first end of the window and the second end of the window to the other of the first end of the window and the second end of the window as power delivered to the light source from the power source increases, and decreases in the reverse direction as power delivered to the light source from the power source decreases.

[0036] Embodiment 3: The aerosol delivery device of any preceding embodiment, further comprising a pressure sensor configured to detect changes in pressure within the outer housing over a continuous range of pressure intensities and provide signaling corresponding to the pressure intensity to the controller.

[0037] Embodiment 4: The aerosol delivery device of any preceding embodiment, wherein the control component is configured to regulate the variable level of power delivered from the power source to the light source in response to signaling received from the pressure sensor.

[0038] Embodiment 5: The aerosol delivery device of any preceding embodiment, wherein the power and control components are configured for connection with a nebulizer.

[0039] Embodiment 6: The aerosol delivery device of any preceding embodiment, wherein the control component is configured to direct variable levels of power from the power source to the nebulizer in response to signaling received from the pressure sensor.

[0040] Embodiment 7: The aerosol delivery device of any preceding embodiment, further comprising a printed circuit board disposed within the outer housing, wherein the light source is disposed on the printed circuit board.

[0041] Embodiment 8: The aerosol delivery device of any preceding embodiment, wherein the control components are located on the same printed circuit board as the light source.

[0042] Embodiment 9: The aerosol delivery device of any preceding embodiment, further comprising a sealing member disposed between the light guide and at least one wall defining the outer housing.

[0043] Embodiment 10: The aerosol delivery device of any preceding embodiment, wherein the sealing member is integral with the light guide.

[0044] Embodiment 11: The aerosol delivery device of any preceding embodiment, wherein the light guide is formed from a translucent elastomeric material.

[0045] Embodiment 12: The aerosol delivery device of any preceding embodiment, further comprising a liquid-resistant membrane disposed inside the outer housing, the liquid-resistant membrane covering the window in at least one wall.

[0046] Embodiment 13: The aerosol delivery device of any preceding embodiment, wherein the liquid-resistant membrane is adhered to the inner surface of at least one wall.

[0047] Embodiment 14: An aerosol delivery device comprising: at least one wall defining an outer housing extending between a proximal end and a distal end; an inner frame disposed within the outer housing at its proximal end and defining a chamber configured to receive a cartridge; an end cap disposed at the distal end of the outer housing; and at least one sealing member in contact with the inner frame or the end cap, the at least one sealing member configured to substantially prevent passage of liquid around the at least one sealing member.

[0048] Embodiment 15: The aerosol delivery device of any preceding embodiment, wherein at least one sealing member comprises an O-ring.

[0049] Embodiment 16: The aerosol delivery device of any preceding embodiment, wherein an O-ring is disposed between the inner frame and at least one wall defining the outer housing.

[0050] Embodiment 17: The aerosol delivery device of any preceding embodiment, wherein the inner frame includes a groove formed around its outer surface, the O-ring engaging the groove.

[0051] Embodiment 18: The aerosol delivery device of any preceding embodiment, wherein an O-ring is disposed between the end cap and at least one wall defining the outer housing.

[0052] Embodiment 19: The aerosol delivery device of any preceding embodiment, wherein the end cap includes a groove formed around its outer surface, the O-ring engaging the groove.

[0053] Embodiment 20: The aerosol delivery device of any preceding embodiment, wherein at least one sealing member includes a contact seal configured to form a seal between the inner frame and one or more electrical connectors extending through the inner frame.

[0054] Embodiment 21: The aerosol delivery device of any preceding embodiment, wherein the at least one sealing member includes a pin seal configured to form a seal between the end cap and one or more external connection elements extending through the end cap.

[0055] Embodiment 22: The aerosol delivery device of any preceding embodiment, wherein the at least one sealing member includes a sensor seal that substantially surrounds a pressure sensor mounted on the printed circuit board.

[0056] Embodiment 23: The aerosol delivery device of any preceding embodiment, wherein the sensor seal comprises a flexible member configured to deform upon application of a pressure differential.

[0057] Embodiment 24: The aerosol delivery device of any preceding embodiment, wherein the sensor seal defines an enclosed volume around the pressure sensor and is configured to transmit a pressure differential to the pressure sensor.

[0058] Embodiment 25: An aerosol delivery device comprising at least one wall defining an outer housing and a light source disposed within the housing, wherein at least a portion of the at least one wall comprises a series of microscopic perforations, and the light source is positioned relative to the series of microscopic perforations such that light from the light source is visible through the series of microscopic perforations.

[0059] Embodiment 26: The aerosol delivery device of any preceding embodiment, wherein the light source is offset from the series of through holes, and the aerosol delivery device further includes a light guide disposed within the outer housing, the light guide being adjacent to the series of micro-through holes and at least partially overlapping the light source.

[0060] Embodiment 27: The aerosol delivery device of any preceding embodiment, wherein at least one wall defining the outer housing extends between a proximal end and a distal end, the aerosol delivery device further comprising: an inner frame disposed within the outer housing at its proximal end and defining a chamber configured to receive a cartridge; an end cap disposed at the distal end of the outer housing; and at least one sealing member in contact with the inner frame or the end cap, the at least one sealing member configured to substantially prevent passage of liquid around the at least one sealing member.

[0061] 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.

[0062] The present disclosure having been described in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0063] [Figure 1]FIG. 1 is a perspective view of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 2] 10 is a partial cross-sectional view of a portion of a control device showing an embodiment of a light guide proximate an optical window according to an exemplary embodiment of the present disclosure. [Figure 3A] 10 illustrates a light effect that increases as light from a light source gradually fills the light window, according to an exemplary embodiment of the present disclosure. [Figure 3B] 10 illustrates a light effect that increases as light from a light source gradually fills the light window, according to an exemplary embodiment of the present disclosure. [Figure 3C] 10 illustrates a light effect that increases as light from a light source gradually fills the light window, according to an exemplary embodiment of the present disclosure. [Figure 3D] 10 illustrates a light effect that increases as light from a light source gradually fills the light window, according to an exemplary embodiment of the present disclosure. [Figure 4] FIG. 1 is a partial cross-sectional view of an aerosol delivery device including a control device and a cartridge according to an exemplary embodiment of the present disclosure. [Figure 5] FIG. 1 is an exploded view of a control device including elements useful for providing resistance to liquid intrusion. [Figure 6] 10 is a partial cross-sectional view of a portion of a control device showing an embodiment of a light guide proximate an optical window according to an exemplary embodiment of the present disclosure. [Figure 7] 10 is a partial cross-sectional view of a portion of a control device showing the implementation of a light guide and sealing member proximate an optical window according to an exemplary embodiment of the present disclosure. [Figure 8] 10 is a partial cross-sectional view of a portion of a control device illustrating the implementation of a light guide proximate a portion of a wall of the control device that includes micro-perforations, according to an exemplary embodiment of the present disclosure. [Figure 9] 10 is a partial cross-sectional view of a control device illustrating the implementation of a sensor seal around a pressure sensor according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0064] The present disclosure will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0065] As described below, embodiments of the present disclosure relate to aerosol delivery devices or vaporization devices, and the terms are used interchangeably herein. Aerosol delivery devices according to the present disclosure use electrical energy to vaporize and / or aerosolize materials to form inhalable substances; components of such devices most preferably have the form of items small enough to be considered handheld devices. In some embodiments, the aerosol delivery devices may be configured to heat materials to form inhalable substances (preferably without significantly burning and / or significantly chemically altering the materials). The use of preferred aerosol delivery device components preferably does not produce smoke, i.e., from by-products of tobacco combustion or pyrolysis; rather, the use of these preferred systems produces vapors resulting from the volatilization or vaporization of certain components incorporated therein. In preferred embodiments, the aerosol delivery device components may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver the tobacco-derived components in aerosol form.

[0066] The aerosol delivery device may provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, sensory stimulating effects, physical sensations, modes of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of the aerosol generating device of the present disclosure can hold and use its components, draw on one end of the component to inhale the aerosol generated by the component, puff at selected time intervals, etc., in the same way as a smoker uses a conventional type of smoking article.

[0067] The aerosol delivery device of the present disclosure may also be characterized as a vapor product or drug delivery article. Accordingly, such articles or devices may be adapted 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 may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension of 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, regardless of whether they are visible or in a form that can be considered smoky.

[0068] The aerosol delivery device of the present disclosure most preferably includes some combination of a power source (i.e., a source of electrical power), at least one control component (e.g., a means (e.g., a microcontroller or microprocessor) for activating, controlling, regulating, and terminating electrical power for heat generation, such as by controlling the flow of electrical current from the power source to other components of the article), a heater or heat-generating member (e.g., an electrical resistance heating element or other component, which, alone or in combination with one or more additional elements, may commonly be referred to as an "atomizer"), a liquid composition (e.g., an aerosol precursor composition liquid that can generally result in an aerosol upon application of sufficient heat, such as components commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece and mouth area that allows drawing on the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the article so that the generated aerosol may be drawn therethrough upon inhalation).

[0069] In some embodiments, the subject matter of the present disclosure may be used in connection with various aerosol and / or vapor generating devices, including, but not limited to, devices commonly known as electronic cigarettes, heat-not-burn (HNB) devices, carbon tobacco heated products (cTHPs), and electric tobacco heated products (eTHPs). Non-limiting examples of such devices, into which any portion or all of the present disclosure may be incorporated, are described in U.S. Patent Nos. 9,839,238, 9,913,493, and 10,085,485.

[0070] More specific forms, configurations, and arrangements of components within the aerosol delivery devices of the present disclosure will become apparent in light of the further disclosure provided below. Additionally, the selection and configuration of various aerosol delivery device components can be understood in light of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure.

[0071] An exemplary embodiment of an aerosol delivery device 10 of the present disclosure is shown in FIG. 1. As shown, the aerosol delivery device 10 can include a control device 100 and a removable cartridge 200. As further described elsewhere herein, the control device 100 can be adapted or configured to receive a portion of the cartridge 200, with the combination of the cartridge and control device 100 forming a functional device. The control device 100 can include an aperture 135 (e.g., a cutout, opening, or notch) that allows viewing of the cartridge 100 when inserted into the control device; however, the window 135 may be explicitly excluded. The control device 100 can further include an optical window 160, which can be adapted or configured to provide external visibility of variable intensity light provided therethrough. Electronic circuitry present within the aerosol delivery device 10 can be configured to control transmission of illumination through the optical window 160 to provide one or more effects visible to a user of the device. For example, the illumination can provide feedback to the user regarding variable puff intensity and corresponding power level indication. In particular, this can be achieved using one or more light emitting diodes (LEDs) to create a variable illumination intensity window.

[0072] In some embodiments, an aerosol delivery device 10 according to the present disclosure may be configured substantially as shown in FIG. 2 , which provides a partial cross-sectional view of a portion of a control device 100 including an outer housing 102 defined at least in part by a control device outer wall 104. In the illustrated embodiment, an optical window 160 is defined in the outer wall 104 and extends along a direction parallel to the longitudinal axis of the control device 100 between a first window end 164 and a second window end 166. The optical window 160 of the illustrated embodiment similarly extends along a direction perpendicular to the longitudinal axis of the control device 100 between a first side 165 and a second side 167. The optical window 160 may essentially be a notch or aperture present in the outer wall 104. More specifically, the optical window 160 may include a slot, notch, cutout, or any other method for exposing an opening to internal components. However, in some embodiments, the optical window 160 may be at least partially or completely blocked by a transparent or translucent member 162 (as shown in FIG. 2 by the partially removed element shown in dashed lines). The transparent or translucent member 162 may be formed, for example, from glass, plastic, or a similar material. In some embodiments, the length of the optical window 160 is longer in a direction between the first end 164 and the second end 166 than in a direction between the first side 165 and the second side 167. The ratio of the end-to-end length to the side-to-side length may be, for example, about 1.5 to about 15, about 2 to about 12, or about 3 to about 10. In some embodiments, the optical window 160 may encompass a defined area of ​​the control device outer housing 102, the defined area being at least 5 mm 2 , at least 10 mm 2 , or at least 20 mm 2 (For example, about 5 mm 2 Approximately 50 mm from 2 , about 5mm 2 Approximately 40 mm from 2 , or about 5 mm 2 Approximately 25 mm from 2 It can be an area encompassing (within the range of

[0073] As further seen in Figure 2, light source 139 is disposed within outer housing 102. As shown, light source 139 is disposed proximate optical window 160. Any element configured to emit light may be used as light source 139, and in some embodiments, the light source may be, among other things, a light emitting diode (LED). While only a single element, such as an LED, may be used, multiple light elements configured to emit light of the same or different colors may also be used.

[0074] In the illustrated embodiment, the light source 139 is positioned so as to be offset from the optical window 160, i.e., beyond one of the first end 164 and second end 166 of the optical window. While the light source 139 is shown as being offset beyond the second end 166 of the optical window 160, it will be understood that the light source may also be offset beyond the first end 164 of the optical window. In either case, the light source 139 in such embodiments is not positioned within the actual boundaries of the optical window 160 and therefore is not positioned so as to provide significant light distribution through the optical window. More specifically, the offset positioning of the light source 139 may be configured so that the light source is positioned such that its location is not directly aimed at the optical window 160.

[0075] However, the offset positioning of the light source 139 positions the light source to provide varying light intensities through the light window 160 through the use of the light guide 175. More specifically, the light guide 175 is disposed within the outer housing 102 and is positioned proximate to the light window 160 and is sized sufficiently to substantially fill the light window and at least partially overlap the light source 139. As shown, the light guide 175 extends from beyond the second end 166 of the light window 160 to beyond the first end 164 of the light window. Preferably, the light guide 175 is similarly sized with respect to the side-to-side dimension of the light window 160. The light guide 175 can be any light-conductive material adapted or configured to guide light from the light source 139 to partially fill the light window 160 in some embodiments, and to completely fill the light window in some embodiments. For example, the light guide 175 can include a light pipe, silicon, plastic, or any other semi-transparent material that allows for the conduction of light. As a non-limiting exemplary embodiment, a suitable light guide 175 may be at least partially formed from a transparent or translucent material to enhance the desired enhancement effect. The transparent or translucent material may include one or more additives adapted or configured to aid in the desired diffusion, refraction, reflection, and / or attenuation of light as it passes longitudinally through the material. Non-limiting examples include the inclusion of glass and / or pigments or other solid particles in a polymer. These particles may be used to enhance the diffusion of light traveling substantially longitudinally down the light pipe, reflecting or refracting a portion of the light in a different direction, thereby allowing a portion of the light to exit the housing opening. The remaining amount of light continuing longitudinally down the light pipe is successively attenuated by the amount absorbed or reflected / refracted / diffused in the direction of exiting the housing opening, thereby creating the effect of the light pipe emitting less light in the direction of exiting the housing opening at the end of the opening farthest from the light source, and allowing relatively more light to exit the opening at the end closest to the light source.

[0076] In some embodiments, the light guide 175 may utilize features such as included angled surfaces and selectively applied gloss and / or matte finishes to help change the direction of light in a desired manner to create a gain effect in the light window 160. It is the intentional attenuation of light as it travels longitudinally down the light guide 175 and the gradient in intensity as light is emitted at a given light intensity level from the end near or far from the light source that can be particularly useful in providing a gain effect in the light window 160.

[0077] In the embodiment shown in FIG. 2 , the light source 139 is positioned proximate the optical window 160; however, it is understood that the light source may be positioned further away from the optical window. In such an embodiment, the light guide 175 may simply be enlarged to at least partially overlap the light source 139 and extend a suitable distance to cover the optical window 160, as described above. In other embodiments, multiple separate light guides 175 may be utilized. For example, the first light guide may be substantially as shown in FIG. 2 , extending from the light source 139 toward the optical window 160 but not covering the optical window, and the second light guide may be substantially as shown in FIG. 5 , partially or completely covering the optical window and extending toward the first light guide. The first and second light guides (i.e., the multiple light guides 175) may be in sufficient relationship such that light from the light source 139 is transmitted through the multiple light guides to the optical window 160, as described elsewhere herein.

[0078] The aerosol delivery device further includes one or more control components. As seen in FIG. 2, the control component 141 is located on the same printed circuit board (PCB) as the light source 139. However, it is understood that the control component 141 may be on a separate PCB. The control component 141 may be adapted or configured to cause the light source 139 to emit light at different light intensities, such that the light transmitted through the light guide 175 fills a portion of the optical window 160 or substantially completely fills the optical window. For example, the control component 141 may be configured to direct variable levels of power from a power source to the light source 139, such that the light emitted from the light source transmits through the light guide 175 and fills an amount of the optical window 160, the amount corresponding to the variable levels of power delivered to the light source. This variable filling of the optical window 160 with light 145 is illustrated in FIGS. 3A through 3D. The aerosol delivery device may be configured to create an increasing light effect by varying the light intensity of light 145 visible through optical window 165 as it is emitted through light guide 175, thereby providing feedback to the user regarding how hard the user is inhaling on the device as detected by pressure sensor 143 and the power level of the device as dictated by the inhalation level reading of the pressure sensor. The controller of such embodiments reads input information from the pressure sensor, and the controller outputs an appropriate power level to the heater. Thus, the controller 155 of some embodiments may output a corresponding intensity level to light source 139 based on the pressure sensor reading in one or more embodiments. The pressure sensor may be configured to detect changes in pressure within the outer housing over a continuous range of pressure intensities and provide signaling corresponding to the pressure intensity to the controller.

[0079] While variably filling the light window 160 with light 145 has been described above in connection with indicating the strength of suction on the device, it will be understood that this provides an exemplary embodiment to facilitate understanding of how the controller can control the light intensity within the light window. Variable filling of the light window 160 with light 145 may be embodied in connection with any function of the device. For example, variable filling of the light window 160 with light 145 may indicate the real-time battery level of a battery within the device, such that as the battery charge decreases, the amount of light filling the light window may decrease. As a further example, variable filling of the light 145 may indicate that the device's battery is charging. In particular, the light intensity or amount of light window 160 filled with light 145 may increase as the battery charges, such that a fully illuminated light window may indicate a fully charged battery. Similarly, the controller may be adapted or configured to directly measure and / or estimate the amount of e-liquid remaining in the device's cartridge. The controller may then control the amount of light 145 filling the light window 160 to substantially or approximately correspond to the amount of e-liquid remaining in the installed cartridge (e.g., the light window may be fully illuminated when a new cartridge is installed, and the amount of light 145 shining through the light window 160 may decrease as e-liquid is depleted through use of the device). Still other functions or states of the device may be indicated by light 145 variably filling the light window 160.

[0080] The position of the light source 139 and the position of the light guide 175 may be effective to achieve that light 145 emitted from the light source and transmitted through the light guide increases in a direction from one of the first end 164 of the window 160 and the second end 166 of the window toward the other of the first end 164 of the window and the second end 166 of the window as power delivered to the light source from the power source increases, and decreases in the opposite direction as power delivered to the light source from the power source decreases. Accordingly, the control component 155 may be configured to adjust the variable level of power delivered to the light source 139 from the power source in response to signaling received from the pressure sensor 143. The pressure sensor may include any means of detecting a pressure difference across the device as a user inhales on the device, such as a microphone, a barometric pressure sensor, or any other method capable of detecting changes in airflow across the device. Power level control may be achieved by using feedback from the pressure sensor, and a microprocessor, SOC, or another controller may adjust the power level delivered to the heater by, for example, adjusting the voltage, current, PWM, or total power.

[0081] The aerosol delivery device 10 can include various additional components as shown in Figure 4. Similar to that described above, the aerosol delivery device 10 can include a control device 100 and a cartridge 200 (or cartomizer). The cartridge 200 is engageable with, and removable from, the control device 100 to form an operating aerosol delivery device.

[0082] The control device can include an outer housing 102 defining a control device outer wall 104, a control device distal end 106, and a control device proximal end 108. The control device proximal end 108 includes an opening 110 providing access to a control device chamber 112 defined by a control device inner frame 114. In some embodiments, the control device inner frame 114 can include an aperture 115 that can be configured to transmit a pressure differential to a sensor 143 disposed within the control device 100 when air is drawn into the control device chamber 112. As shown, the sensor 143 is disposed on a printed circuit board (PCB). For example, PCB and pressure sensor configurations are described in U.S. Patent Publication No. 2015 / 0245658 to Worm et al., the disclosure of which is incorporated herein by reference. Sensor 143 may be located anywhere within control device 100 so as to be exposed to airflow and / or pressure changes that can signal suction to the device, thus causing battery 116 to deliver power to heater 219 within cartridge 200. Alternatively, in the absence of an airflow sensor, heater 219 may be activated manually, such as by a push button. Additional representative types of sensing or detection mechanisms, their construction and configuration, their components, and their general methods of operation are described in U.S. Pat. No. 5,261,424 to Sprinkel, Jr.; U.S. Pat. No. 5,372,148 to McCafferty et al.; and PCT Publication WO 2010 / 003480 to Flick, which are incorporated herein by reference.

[0083] The control device 100 may further include a battery 116 disposed within the control device outer housing 102. An example of a battery that can be used in accordance with the present disclosure is described in U.S. Patent Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference. The control device 100 may further include an external connection element 118. Preferably, the external connection element 118 is disposed at the distal end 106 of the control device outer housing 102 and may be formed from multiple electrical connectors (118a, 118b, 118c). In one or more embodiments, the control device 100 may include a light source 139, which may include, for example, one or more light-emitting diodes (LEDs) capable of providing illumination of one or more colors. The first light source 139 may be disposed directly on a printed circuit board (PCB) 141, which may include additional control components (e.g., a microcontroller and / or memory components). The LEDs utilized as the light sources described herein may be selected, for example, from a design that emits light substantially upward from the plane of the PCB. Alternatively, or additionally, suitable LEDs may include reflector elements adapted or configured to emit light in a substantially different direction, such as parallel to the plane of the PCB or at a desired angle to provide a desired result. As shown, the sensor 143 and external connection element 118 may similarly be directly mounted to the PCB 141 or otherwise electrically connected to the PCB. The control device may further include electrical pins 120 disposed in the chamber 112 to form an electrical connection with the cartridge 100 upon insertion of the cartridge into the chamber. As shown, the electrical pins 120 may be disposed proximate the bottom of the chamber 112 and, in particular, may extend through the bottom wall 114a of the inner frame 114 that defines the boundary of the chamber 112. One or more mechanical connectors 121 may also be present in the chamber 112 and, in particular, may be disposed on the inner frame 114, for example, on its bottom wall 114a. For example, the mechanical connector 121 may be a magnetic element (eg, a magnet or an element formed from a material configured to form a magnetic connection with an additional magnet).Alternatively, the mechanical connector 121 may be disposed on the side wall 114 b of the inner frame 114 and thus configured to establish a friction fit with the cartridge 200 .

[0084] The control device outer housing 102 may be formed from any suitable material, such as, for example, metal, plastic, ceramic, glass, etc. Preferably, the control device inner frame 114 is formed from the same material used to form the first device outer housing 102; however, different materials may be used. While the control device inner frame 114 is shown as a separate element from the control device outer housing 102, it will be understood that the inner frame may be defined by the inner surface of the outer housing and an additional bottom plate, if desired (e.g., the bottom plate corresponds to the illustrated inner frame bottom wall 114a, and the inner surface of the outer housing corresponds to the illustrated inner frame side wall 114b).

[0085] As can be seen from the above, the control device 100 may include several openings that provide an opportunity for liquid contaminants to enter the control device outer housing 102. Accordingly, in some embodiments, the present disclosure may provide one or a combination of components adapted or configured to reduce or prevent the opportunity for liquid contaminants to enter the control device 100. By using such components, the control device 100 may be adapted or configured to be water-resistant or waterproof. In particular, by configuring the control device to resist water ingress through openings in the outer housing (e.g., seams where end caps meet the outer housing, micro-perforations, openings accessible to electrical connectors, such as openings for LED indicators, etc.), the control device 100 may be provided with improved resistance to failure. In particular, the presence of the optical window 160 may provide a large opening in the outer wall 104 of the outer housing 102 of the control device 100 that may allow liquid contaminants to enter the control device.

[0086] An exemplary embodiment for achieving water resistance may be envisioned in connection with the configuration shown in Figure 5. In some embodiments, water resistance may be imparted by including sealing elements at various openings. For example, various means may be used to substantially prevent liquid from entering through optical window 160 formed on outer wall 104 of control device 100.

[0087] In one or more embodiments, the light guide 175 may be adapted or configured to provide a sealing engagement with the outer wall 104 of the control device outer housing 102. For example, as shown in the embodiment illustrated in FIG. 6 , a sealing member 177 may be disposed between the light guide 175 and the outer wall 104 of the control device outer housing 102. The sealing member 177 may be separate from the light guide 175 and may be, for example, a flexible gasket or similar element adapted or configured to provide a substantially liquid-tight (e.g., water-resistant) seal around substantially the entire circumference of the optical window 160 (i.e., the sealing member is present substantially completely around the entire circumference of the optical window). In some embodiments, the sealing member 177 may be integral with the light guide 175. Thus, the light guide 175 may be formed to integrally include the sealing member 177, and as described above, the sealing member may be adapted or configured to provide a substantially liquid-tight seal around substantially the entire circumference of the optical window 160. In such an embodiment, the light guide 175 may be formed from a translucent elastomeric material such as silicone rubber, which may effectively function as a seal / light diffuser, providing both a waterproof seal and a light pipe effect for the LED.

[0088] In one or more embodiments, at least one sealing member may be included in one or more locations of the device to provide a waterproof or water-resistant effect. Such sealing member may be constructed from an elastomeric material. In certain embodiments, such an elastomeric material may be combined with and / or bonded to an end cap, as further described herein. For example, such bonding may be performed using an overmolding or insert molding process. Such a process may be applied to any one or more sealing members that may be present in accordance with the present disclosure.

[0089] In some embodiments, the transparent or translucent member 162 (see FIG. 2 ) may be adapted or configured to function as a seal / light diffuser, for example, a molded elastomeric component such as silicone rubber that provides a seal for the optical window 160. Such an element may not be necessary when other elements are utilized. For example, the use of micro-perforations, as described below, may allow for the use of the transparent or translucent member 162 as a seal / light diffuser to be avoided. Similarly, in embodiments in which a selectively permeable breathable material, such as GORE-TEX®, is utilized as the liquid-resistant member 180 and is adhered to the inner surface of the outer wall 104 of the control device 100 in a location that completely covers the optical window 160, the seal / light diffuser 162 may not be utilized.

[0090] An embodiment of a liquid-resistant member 180 according to an exemplary embodiment of the present disclosure is shown in FIG. 7 , where the liquid-resistant member 180 may be in the form of a membrane, sheet, film, or the like that substantially covers the optical window 160. If desired, the liquid-resistant member 180 may be utilized in other portions of the control device 100 to improve the overall ability of the control device to withstand liquid intrusion. The liquid-resistant member 180 may be, for example, a GORE-TEX® membrane or similar material that is substantially water-resistant or waterproof while being breathable to allow gas to pass through. The liquid-resistant membrane 180 is preferably substantially permanently attached to the outer wall 104 of the control device outer housing 102 and may be, for example, glued, welded, or otherwise combined therewith. In some embodiments, the liquid-resistant membrane 180 may be provided with a pressure-sensitive adhesive on one side, with the adhesive on an outer area surrounding an adhesive-free inner area. This membrane provides both breathability and waterproofness to meet desired standards. In this case, a separate light guide may still be required in place of the water-resistant film 180. In this case, the light guide need not be an elastomeric material, but may be a rigid plastic material further optimized for light guide / diffuser function. Similarly, in such an embodiment, the light guide may also contain particulate additives or be made from a highly translucent polymer. In such cases, this may be effective in reflecting / refracting light toward the exiting optical window while attenuating the light as it travels down the length, creating a diminishing brightness effect along the length of the slot. The liquid-resistant film 180 may preferably be thin and translucent enough to allow LED light transmission. In this case, the seal / light diffuser may be adapted or configured to be only a light diffuser, allowing for the use of an optimized material for light guide / diffusion instead of an elastomer.

[0091] In some embodiments, the liquid-resistant membrane 180 may be adapted or configured to function as a breathable material, a water-resistant material, and a light-guiding material all together. For example, a translucent, selectively permeable material may be adhered to the inner surface of the control device outer shell 102 in a location that completely covers the optical window 160. The liquid-resistant membrane 180 may be provided with a pressure-sensitive adhesive on one side, as described above. In some embodiments, an expanded polytetrafluoroethylene (ePTFE) material may be used for the liquid-resistant membrane; such a material is commonly available under the trademark GORE-TEX®. In some embodiments, a microporous polyurethane material may be used for the liquid-resistant membrane; such a material is commonly available under the trademark Dermizax™. In some embodiments, the liquid-resistant membrane may include a multilayer structure including an outer layer treated with a durable water repellent (DWR), which may include, for example, a fluoropolymer, and an inner layer that may include an ePTFE material, a microporous material, or other gas-permeable and optionally water-resistant material. Preferably, in such embodiments, the membrane material exhibits optical properties tailored to appropriately diffuse the LED light for the desired "boost" effect, while maintaining other necessary physical properties. Similarly, in some embodiments, the liquid-resistant membrane 180 may be significantly thick. Instead of being adhered to the inner surface of the control device outer housing 102, the significantly thicker material may be adapted or configured to substantially form a seal against the outer wall 104 across the optical window 160 by being placed in physical contact with the outer wall. Thus, this component can provide all three properties: light diffusion, waterproofing, and breathability.

[0092] 5 , in one or more embodiments, water resistance may be achieved at least in part through the use of one or more O-rings 185, which may be used to substantially seal one or more compartments of the control device 100. The O-ring 185 may be formed from an elastomeric material, such as silicone rubber, and may be assembled, for example, within a groove 114c formed around the outer surface of the inner frame 114. The O-ring provides an airtight, watertight seal between the inner frame 114 and the outer wall 104 of the outer housing 102 of the control device 100.

[0093] In some embodiments, a sensor membrane / seal 187 may be included and may be a molded elastomeric (e.g., silicone rubber) component that provides a seal between the electrical connector 120 and the inner frame 114. The sensor membrane / seal 187 may be formed from a contact seal member 187a and, optionally, a pressure aperture seal 187b. The contact seal 187a provides sealing around the electrical connector 120 (e.g., forming a seal between the electrical connector and the inner frame 114), and the pressure aperture seal 187b provides sealing around the aperture 115 utilized to allow air flow between the interior of the control device 100 and the interior of the inner frame 114 so that a pressure drop can be read when a user aspirates a cartridge inserted into the inner frame. This seal design does not allow liquid or vapor to reach the pressure sensor and / or other interior parts of the control device 100 by passing around the electrical contact pins. As an alternative exemplary embodiment, the sensor / membrane seal may only form a seal around the pressure sensor, in which case an additional separate seal may be incorporated for the cartridge contact pin to waterproof the control device enclosure from the opening. These separate seals may be insert molded or co-molded with the inner frame components of the control device. The pressure sensor 143 may also include a sensor seal 144 that partially surrounds the pressure sensor (see FIG. 4). The sensor seal 144 may be adapted or configured to form an air seal around the pressure sensor 143 to improve sensitivity and ensure that the sensor is activated only when an actual pressure drop occurs due to use of a suction cartridge inserted into the inner frame 114. Also, as shown in FIG. 5, the device may include a haptic motor 191 that may be at least partially surrounded by a rubber boot 193.

[0094] As further shown in FIG. 9 , the sensor seal 144 may be adapted or configured to provide an isolated environment for at least the pressure sensor 143 on the PCB 141. In FIG. 9 , the PCB 141 is located above the battery 116, as opposed to being proximate the distal end 106 of the control device outer housing 102. In this exemplary embodiment, the sensor seal 144 may be adapted or configured to form a seal between the control device inner frame 114 and the PCB 141. This may be achieved by forming the sensor seal 144 from one or more seal supports 146 and a flexible member 147 (e.g., a flexible membrane, diaphragm, or similar component) that extends between the seal supports and over the pressure sensor, as shown. Preferably, the combination of elements forming the sensor seal 144 substantially completely surrounds and covers the pressure sensor 143. The seal support 146 may extend completely between the PCB 141 and the control device inner frame 114, or may terminate without contacting the inner frame. Although the flexible member 147 is disposed over the pressure sensor, such a configuration is not limiting. Rather, any one or more components of the sensor seal 144 may be formed from such a flexible member. In particular, the sensor seal 144 may include an enclosure having at least one flexible surface.

[0095] Preferably, sensor seal 144 is adapted or configured to form an enclosed volume 148 around at least pressure sensor 143 and, optionally, one or more additional elements (e.g., tactile sensors, circuitry, etc.) present on PCB 141. Formation of such enclosed volume 148 utilizing at least one flexible member can be effective to allow movement and / or deflection of the flexible member in the presence of a pressure differential across a surface. This pressure differential can be created, for example, by a user's suction of the device such that the pressure change is transmitted at least through aperture 115 to control device outer housing 102. Due to the enclosed volume 148 formed by sensor seal 144, deflection of flexible member 147 is efficiently transmitted to pressure sensor 143 enclosed therein, allowing the pressure sensor to detect the pressure differential caused by the user's suction of the device while maintaining a protective barrier against water and / or other liquids and / or aerosols and / or vapors that may be present.

[0096] At least one flexible surface of the enclosure defining the sensor seal 144 (e.g., flexible member 147) may be in the form of a substantially thin section of elastomeric material that may be integrated into the sensor seal component. Alternatively, the at least one flexible surface may comprise such a material that is separately attached to the sensor seal support 146. The at least one flexible surface (e.g., flexible member 147) may have a thickness of about 0.001 mm to about 0.3 mm, about 0.01 mm to about 0.2 mm, or about 0.05 mm to about 0.2 mm. In further embodiments, the at least one flexible surface may have a thickness of about 0.1 to about 0.3 mm. In some embodiments, the flexible member 147 or other flexible surfaces present on the sensor seal 144 may include one or more geometric features, such as corrugations and / or different areas with different thicknesses, to aid or enhance flexibility and / or increase the amount of movement or deflection of the surface in the presence of a pressure differential.

[0097] The one or more materials forming part of the sensor seal 144 may include a material adapted or configured to substantially prevent the passage of water and / or other liquids and / or aerosols and / or vapors from outside the enclosed volume 148 to the inside of the enclosed volume, thereby protecting components present within the enclosed volume from damage. In some embodiments, the one or more materials forming part of the sensor seal 144 may be formed from a selectively porous material that may be adapted or configured to allow the movement of air into and out of the enclosed volume 148 while substantially preventing the passage of water and / or other liquids.

[0098] The control device 100 may include an end cap 190 disposed at the distal end 106 of the control device outer housing 102. In some embodiments, a pin seal 192 may be included to provide a sealing arrangement between the external connection element 118 and the bottom cap 190. The pin seal 192 may be a molded elastomeric component, such as silicone rubber. As an alternative exemplary embodiment, the pin seal may be a selectively permeable flexible material instead of a waterproof elastomer. Examples include thicker versions of known selectively permeable materials made from polyolefin, polyester, or Teflon-type materials. In this case, the pin seal provides both waterproofing and breathability to the same component.

[0099] In some embodiments, bottom cap 190 may include a bottom cap O-ring 194, which may be an elastomeric material such as silicone rubber. Bottom cap O-ring 194 may be disposed in a groove 195 formed in bottom cap 190. This O-ring provides a seal between bottom cap 190 and control device outer housing 102. Optionally, the O-ring may be insert molded with bottom cap 190 or combined by a co-molded or overmolded process. This may also be done for one or both of O-ring 185 and pin seal 192, either of which may be combined with bottom cap 190 using an overmolding process, if desired.

[0100] In some embodiments, a vent membrane, as described elsewhere herein, may be inserted / adhered to the bottom cap 190, preferably its inner surface, and may be a selectively permeable material that provides air and vapor permeability but does not allow water to pass through to a desired standard. Depending on the additional materials present, such a vent membrane may not be required.

[0101] In some embodiments, an optical window may not be required to provide illumination visible through the control device outer housing 102. As shown in FIG. 8 , in some embodiments, a portion of the outer wall 104 of the outer housing 102 may be provided with a series of perforations therethrough. More specifically, the perforations in the outer wall 104 may include a series of micro-perforations 104′. The micro-perforations 104′ may be adapted or configured to provide a unique aesthetic effect through the light passing from the light source 139 through the light guide 175, and the micro-perforations may also provide inherent water resistance that meets selected criteria. In particular, the micro-perforations 104′ may be sized to substantially slow the passage of liquids such that prolonged contact with the liquid is required for the liquid to pass through the micro-perforations and enter the interior of the control device 100. In some embodiments, the micro-perforations may have an average size (e.g., diameter) of about 40 μm to about 200 μm, about 50 μm to about 180 μm, or about 60 μm to about 150 μm. The series of micro-perforations may be at least 5 mm 2 , at least 10 mm 2 , or at least 20 mm 2 (For example, about 5 mm 2 Approximately 50 mm from 2 , about 5mm 2 Approximately 40 mm from 2 , or about 5 mm 2 Approximately 25 mm from 2The micro-perforations 104' may be disposed on a defined area of ​​the control device outer housing 102, such as an area covering a portion of a surface of the control device outer housing 102 (within a range of 104'). The micro-perforations 104' may define a particular shape, such as an oval, a circle, a rectangle (or other parallelogram), or another geometric shape. In some embodiments, the micro-perforations may define a logo or other unique shape or design within the control device outer housing 102.

[0102] The foregoing disclosure encompasses numerous exemplary embodiments in which control device 100 may be substantially water-resistant or substantially waterproof. In particular, the use herein of the terms “water-resistant” and / or “waterproof” may be intended to indicate that the device is adapted or configured to meet one or more standards set forth in one or more International Protection Marking Codes, or IP Codes. In certain embodiments, the water-resistant or waterproof devices described herein may be adapted or configured to meet IP67 requirements, and the applicable IP Code requirements for being considered water-resistant or waterproof are incorporated herein by reference.

[0103] As seen in FIG. 4 , a control device 100 according to the present disclosure can be adapted or configured to be combined with a cartridge 200 to provide a functioning aerosol delivery system 10. A cartridge 200 for use in the aerosol delivery device 10 of the present disclosure can include a reservoir 201 defined by an outer reservoir wall 203 including a proximal end 205 and a distal end 207. One or more mating connectors 230 can be present at the distal end 207 of the cartridge 200 and configured to form a connection with one or more mechanical connectors 121 present in the chamber 112 of the control device 100. The mating connectors 230 can be, for example, magnetic elements (e.g., magnets or element forms of material configured to form a magnetic connection with additional magnets). Alternatively, the mating connectors 230 can be present on one or more sides of the outer reservoir wall 203 and thus configured to establish a friction fit with the chamber 112 of the control device 100.

[0104] Cartridge 200 is configured to contain a liquid composition for vaporization, i.e., an e-liquid or an aerosol precursor composition, and may be configured as described elsewhere herein. Tank 201 may include, among other things, an interior wall 202 defining a reservoir 204 in which e-liquid or the like may be held. An aerosol passage 212 may at least partially surround reservoir 204 longitudinally from distal end 207 to proximal end 205 of tank 201. However, it will be understood that in other embodiments, aerosol passage 212 may extend through at least a portion of the reservoir such that the reservoir is configured in an annular space between the aerosol passage and outer tank wall 203.

[0105] The cartridge 200 may further include a mouthpiece 209 defined by an outer mouthpiece wall 211 including a proximal end 213 having an exit portal 215 and a distal end 217 engaging the proximal end 205 of the reservoir 201. While the mouthpiece 209 is described as being a separate element from the reservoir 201, it is understood that the reservoir wall 203 may extend a greater distance to form an integrated mouthpiece. Thus, the mouthpiece may be attached to the reservoir or the mouthpiece may be integrally formed with the reservoir. The cartridge 200 may further include a heater 219 and a liquid transport element 221 defining a fluid connection between the heater and a liquid 223 contained within the reservoir 204. The heater 219 and the liquid transport element 221 may be configured as separate fluidly connected elements or as a combined element. Furthermore, the heater 219 and the liquid transport element 221 may be formed from any structure as described elsewhere herein. The cartridge 200 may also include one or more electrical contacts 225 configured to electrically connect the heater 219 with the battery 116 in the control device 100 through contact with the electrical pins 120 when the cartridge is connected to the control device.

[0106] The liquid transport element 221 may be formed from one or more materials configured for transporting liquid, such as by capillary action. Liquid transport elements may be formed, for example, from 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 may be any material that includes an open pore network (i.e., multiple interconnected pores such that fluid can flow from one pore to another in multiple directions through the element). As further described herein, some embodiments of the present disclosure may specifically relate to the use of non-fibrous transport elements. As such, fibrous transport elements may be explicitly excluded. Alternatively, a combination of fibrous and non-fibrous transport elements may be utilized. Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton; U.S. Patent Publication Nos. 2014 / 0261487 to Chapman et al. and 2014 / 0059780 to Davis et al.; and U.S. Patent Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference. Additionally, various wicking materials and the configuration and operation of wicking materials within particular types of electronic cigarettes are described in U.S. Patent No. 8,910,640 to Sears et al., which are incorporated herein by reference. In some embodiments, the liquid transport element may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Exemplary monolithic materials suitable for use with embodiments of the present disclosure are described, for example, in U.S. Patent Application Serial No. 14 / 988,109, filed January 5, 2016, and U.S. Patent Application Serial No. 2014 / 0123989 to LaMothe, the disclosures of which are incorporated herein by reference. The porous monolith can form a substantially solid core.

[0107] Various embodiments of materials configured to generate heat upon application of an electric current may be used to form the heater 219. Accordingly, the battery 116 or other power source within the control device 100 and / or control component 141 may be adapted or configured to be connected to a vaporizer that may include a heater. In particular, the control component may be adapted or configured to direct a variable level of power from the power source to the vaporizer (e.g., heater) in response to signaling received from the pressure sensor. In this manner, the control device may be adapted or configured to provide adjustable illumination from the light source 139 based on a power command received from the control component, which may directly correspond to puff intensity on the device. For example, PWM, DAC, or any other means may be used to adjust the brightness of the light source.

[0108] In some embodiments, the heater can be a wire coil. Exemplary materials from which the wire coil can be formed include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and threads). In further embodiments, the heater can be formed from conductive ink, boron-doped silica, and / or ceramic (e.g., positive or negative temperature coefficient ceramic). Other types of heaters, such as laser diodes or microheaters, can also be utilized. Laser diodes can be configured to deliver electromagnetic radiation of a specific wavelength or wavelength band that can be tuned for vaporization of the aerosol precursor composition and / or for heating a liquid transport element through which the aerosol precursor composition can be provided for vaporization. The laser diode may be specifically positioned to deliver electromagnetic radiation into the chamber, and the chamber may be configured to be radiation trapping (e.g., black body or white body). Suitable microheaters are described in U.S. Patent No. 8,881,737 to Collett et al., incorporated herein by reference. The microheater may include, for example, a substrate (e.g., quartz, silica) having thereon a heater trace (e.g., a resistive element such as Ag, Pd, Ti, Pt, Pt / Ti, boron-doped silicon, or other metal or metal alloy) that may be printed or otherwise applied to the substrate. A passivation layer (e.g., aluminum oxide or silica) may be provided on the heater trace. The heater may be specifically configured to be substantially flat. Such a heater is described in U.S. Patent Publication No. 2016 / 0345633 to DePiano et al., incorporated herein by reference.

[0109] Additional types of atomizers are also encompassed by the present disclosure. For example, in some embodiments, the atomizer may include one or more elements adapted or configured to vaporize or aerosolize an aerosol precursor liquid (or otherwise form the aerosol precursor liquid in fine particulate form) without necessarily heating the liquid. For example, in certain embodiments of the present disclosure, a piezoelectric element may be used as a vaporizer, and suitable piezoelectric elements are described, for example, in U.S. Patent Publication No. 2013 / 0319404 to Feriani et al. and U.S. Patent Publication No. 2019 / 0014819 to Sur, the disclosures of which are incorporated herein by reference.

[0110] The outer tank wall 203 may be configured to be at least partially transparent or translucent so that the liquid 223 contained therein is visible from the outside. Thus, the entire outer tank wall 203 may be transparent or translucent. Alternatively, only a single side of the outer tank wall 203 may be transparent or translucent, with the remainder of the outer tank wall being substantially opaque. In further embodiments, the outer tank wall 203 may be colored. In some embodiments, the aerosol delivery device 10 may be configured such that at least a portion of the tank 201 is visible when the cartridge 200 is engaged with the control device 100. Similarly, at least a portion of the inner wall 202 defining the reservoir 204 may be transparent or translucent. In one or more embodiments, the outer wall 104 of the control device 100 may be configured to include a window through which the outer tank wall 203, and optionally any liquid 223 present in the tank 201 (or specifically in the reservoir 204), may be visible when the cartridge 200 is engaged with the control device 100. As seen in FIG. 1 , the window 135 is configured as a cutout in the outer wall 104 of the control device 100, located near the proximal end 108 of the control device. The window 135 is preferably positioned to provide visual access to the chamber 112 of the control device 100. As shown, the cutout is substantially oval; however, it is understood that any shape is encompassed herein. In some embodiments, the window 135 may be configured as a notch extending a distance from the proximal end 108 of the outer wall 104 of the control device 100 toward the distal end 106 of the control device. In other embodiments, window 135 may be configured to have no open boundary, and thus may explicitly exclude the notch configuration as described above. In certain embodiments, window 135 may be explicitly excluded from control device 100. Furthermore, window 135 may be completely open, or it may have a transparent member (e.g., glass or plastic) disposed within the opening defined by the window or covering the window on one or both of the interior and exterior surfaces of exterior wall 104 of control device 100.

[0111] The aerosol delivery device 10 most preferably incorporates a control mechanism for controlling the amount of power to the heating element during inhalation. Representative types of electronic components, their structure and configuration, their features, and their general method 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. Publication No. 2009 / 0230117 to Fernando et al.; U.S. Pat. Publication No. 2014 / 0060554 to Collet et al. and U.S. Pat. Publication No. 2014 / 0270727 to Ampolini et al.; and U.S. Pat. Publication No. 2015 / 0257445 to Henry et al., which are incorporated herein by reference.

[0112] In use, when the cartridge 200 is inserted into the chamber 112 of the control device 100, the fit may be such that air can pass between the outer surface of the tank wall 203 and the inner surface of the inner frame 112 of the control device. Thus, when a user puffs using the mouthpiece 209, air may pass between the outer surface of the tank wall 203 and the inner surface of the inner frame 112, pass through the air inlet 220 of the cartridge 200, mix with vapor formed near the heater 219, pass through the aerosol passage 212, and finally pass through the exit portal 215. The passage of air as defined above may be effective to cause a pressure drop within the control device 100 through the aperture 115 that may be sensed by the sensor 143.

[0113] The aerosol delivery device may include an input element (which may replace or complement the airflow or pressure sensor). 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 to control the functions of the control device 100. For example, one or more push buttons may be used, as described in U.S. 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. Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference. 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 through the use of a USB cord or similar protocol. The aerosol delivery device may also communicate with a computer or other device via wireless communication, acting as an input. See, for example, the system and method for controlling a device via a read request, as described in U.S. Publication No. 2016 / 0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference.In such embodiments, an APP 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 the ability to form an aerosol of a particular composition by, for example, selecting the nicotine content and / or additional flavor content to be included, by selecting the total particulate matter (TPM) to be provided per puff, by selecting a particular heating profile to be implemented, by selecting a modifiable resistance to inhalation, etc.

[0114] In addition to or as an alternative to the LED, additional indicators (e.g., tactile feedback components, audio feedback components, etc.) can be included. Further representative types of components or indicators that provide visual cues, such as light-emitting diode (LED) components, and their configurations and uses are described in U.S. Pat. No. 5,154,192 to Sprinkel et al.; U.S. Pat. No. 8,499,766 to Newton and U.S. Pat. No. 8,539,959 to Scatterday; U.S. Pat. Publication No. 2015 / 0020825 to Galloway et al.; and U.S. Pat. Publication No. 2015 / 0216233 to Sears et al., which are incorporated herein by reference. It is understood that not all of the illustrated elements are required. For example, the LED may be absent or replaced with a different indicator, such as a vibration indicator. Similarly, the flow sensor may be replaced with a manual actuator, such as a push button.

[0115] In one or more embodiments, the present disclosure may be directed to a kit providing the various components described herein. For example, the kit may include a control device having one or more cartridges. The kit may further include a control device having one or more charging components. The kit may further include a control device having one or more batteries. The kit may further include a control device 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. In the above embodiments, the cartridges or control devices may include a heating element included therein. The kits of the present invention may further include a case (or other packaging, carrying, or storage component) for housing one or more of the additional kit components. The case may be a reusable hard or soft container. Additionally, the case may simply be a box or other packaging structure.

[0116] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol delivery device comprising: an outer housing including at least one wall extending between a proximal end and a distal end; a chamber in the outer housing accessible through an opening in the proximal end of the outer housing for receiving the cartridge therein, the chamber being defined by an inner frame having at least one bottom wall; an end cap positioned at a distal end of the outer housing; at least one sealing member positioned on the outer housing, the at least one sealing member configured to substantially prevent the passage of liquid around the at least one sealing member; 1. An aerosol delivery device comprising:

2. 10. The aerosol delivery device of claim 1, wherein at least one sealing member comprises an O-ring.

3. 10. The aerosol delivery device of claim 1, wherein at least one sealing member is positioned between the inner frame and at least one wall of the outer housing.

4. 4. The aerosol delivery device of claim 3, wherein the inner frame includes a groove formed on an outer surface thereof, and the at least one sealing member engages the groove.

5. 10. The aerosol delivery device of claim 1, wherein at least one sealing member is positioned between the end cap and at least one wall of the outer housing.

6. 6. The aerosol delivery device of claim 5, wherein the end cap includes a groove formed on an outer surface thereof, and the at least one sealing member engages the groove.

7. 10. The aerosol delivery device of claim 1, wherein at least one sealing member comprises a contact seal configured to form a seal between the bottom wall and one or more electrical connectors extending through the bottom wall.

8. 10. The aerosol delivery device of claim 1, wherein at least one sealing member comprises a pin seal configured to form a seal between the end cap and one or more external connection elements extending through the end cap.

9. 10. The aerosol delivery device of claim 1, wherein the at least one sealing member comprises a sensor seal that substantially surrounds a pressure sensor mounted on a printed circuit board.

10. 10. The aerosol delivery device of claim 9, wherein the sensor seal comprises a flexible member configured to deform upon application of a pressure differential.

11. 11. The aerosol delivery device of claim 10, wherein the sensor seal defines an enclosed volume around the pressure sensor and is configured to transmit a pressure differential to the pressure sensor.

12. 10. The aerosol delivery device of claim 1, wherein the outer housing includes a window formed therein, and the at least one sealing member is configured to substantially prevent passage of liquid through the window into the outer housing.

13. 13. The aerosol delivery device of claim 12, wherein the window is an optical window configured to provide the appearance of light therethrough.

14. 14. The aerosol delivery device of claim 13, wherein at least one sealing member is effective as a light guide.

15. 10. The aerosol delivery device of claim 1, wherein at least one sealing member is a selectively permeable vent material.

16. 10. The aerosol delivery device of claim 1, wherein at least one sealing member is configured as a membrane, sheet, or film.

17. 10. The aerosol delivery device of claim 1, wherein at least one sealing member is substantially permanently attached to the outer wall.

18. 10. The aerosol delivery device of claim 1, wherein at least one sealing member is configured as one or both of a venting material and a light-guiding material.

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