Aerosol delivery apparatus and related methods

Abstract

To provide an aerosol delivery device functioning without direct contact with or thermal degradation of an aerosol precursor composition.SOLUTION: An aerosol delivery device 100 includes a heating chamber 106 having an aerosol precursor composition 108 disposed therein. A microwave radiation energy emitting device 110 is operably engaged with the heating chamber and is configured to heat the aerosol precursor composition therein with microwave radiation energy to form aerosol from the aerosol precursor composition. An outlet port 118 is formed in a housing of the aerosol delivery device and is in fluid communication with the heating chamber. In response to a suction force applied to the outlet port, the heating chamber causes the aerosol to be drawn out of the housing through the outlet port.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to an aerosol delivery device, and more particularly to a microwave radiation heating element configured to heat an aerosol precursor composition made from, derived from, or otherwise incorporating tobacco-related materials to form an inhalable substance for human consumption.

Background Art

[0002] Smoking devices have been proposed for many years as improved or alternative products to smoking products that require burning tobacco for use. Many of these devices are designed to provide sensations associated with smoking cigarettes, cigars or pipes, but are said not to deliver significant amounts of incomplete combustion and pyrolysis products resulting from the burning of tobacco.

[0003] For this purpose, 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 sensation of cigarettes, cigars or pipes without significantly burning the tobacco. See, for example, the various alternative smoking products, aerosol delivery devices and heat sources described in the background art of Collett et al.'s U.S. Patent No. 8,881,737, Robinson et al.'s U.S. Patent No. 7,726,320, Griffith, Jr. et al.'s U.S. Patent Application Publication No. 2013 / 0255702, Sebastian et al.'s U.S. Patent Application Publication No. 2014 / 0000638 and Sears et al.'s U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference.

[0004] These smoking products, flavor generators, and medicinal inhalers, which use electrical energy to generate heat for forming smoke or aerosols, often utilize a wick and coil configuration in combination with a power source such as a battery. More specifically, in this configuration, the coil is in direct contact with the wick and functions as a heating element. The coil is configured to conduct current from the battery and heat a limited amount of aerosol precursor composition absorbed by the wick through direct contact. However, direct heating can lead to uneven heating of the aerosol precursor composition, and therefore the wick and coil configuration can cause thermal degradation of the aerosol precursor composition.

[0005] Therefore, it is desirable to provide an aerosol delivery device that extends the service life of the device and delivers aerosols with improved uniformity by using heat generated by an external energy source to heat the aerosol precursor composition to provide a cigarette, cigar, or pipe smoking sensation, preferably without direct contact with the aerosol precursor composition and without thermal degradation of the aerosol precursor composition. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] U.S. Patent No. 8,881,737 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] U.S. Patent Application Publication No. 2013 / 0255702 [Patent Document 4] U.S. Patent Application Publication No. 2014 / 0000638 [Patent Document 5] U.S. Patent Application Publication No. 2014 / 0096781 [Overview of the Initiative] [Means for solving the problem]

[0007] This disclosure relates to an aerosol delivery device configured to generate aerosols for human ingestion. In one embodiment, the aerosol delivery device is A heating chamber containing an aerosol precursor composition, A microwave radiant energy emitter operably engaged with a heating chamber and configured to heat an aerosol precursor composition within it by microwave radiant energy to form an aerosol from the aerosol precursor composition, A housing having an outlet port and communicating fluid to a heating chamber, Includes, The heating chamber responds to the suction force applied to the outlet port, causing the aerosol to be drawn out of the housing through the outlet port.

[0008] In another embodiment, the method for manufacturing an aerosol delivery device is: The microwave radiant energy emitter is operably engaged with a heating chamber configured to receive an aerosol precursor composition, wherein the microwave radiant energy emitter is configured to heat the aerosol precursor composition with the microwave radiant energy emitted thereby to form an aerosol from the aerosol precursor composition. Engaging a heating chamber with a housing having an outlet port, thereby enabling fluid communication between the outlet port and the heating chamber, and causing the heating chamber to draw aerosol out of the housing through the outlet port in response to an attractive force applied to the outlet port. Includes.

[0009] Therefore, this disclosure includes, but is not limited to, the following embodiments.

[0010] Embodiment 1: Aerosol delivery device, A heating chamber containing an aerosol precursor composition, A microwave radiant energy emitter operably engaged with a heating chamber and configured to heat an internal aerosol precursor composition with microwave radiant energy to form an aerosol from the aerosol precursor composition, A housing having an outlet port and communicating fluid to a heating chamber, Includes, An aerosol delivery device in which a heating chamber is used to draw an aerosol out of the housing through the outlet port in response to an suction force applied to the outlet port.

[0011] Embodiment 2: An aerosol delivery device according to any of the embodiments described above, or any combination of the embodiments described above, further comprising an aerosol precursor delivery configuration operably engaged with a heating chamber and configured to guide an aerosol precursor composition from a reservoir that contains an aerosol precursor composition and is in fluid communication with the aerosol precursor delivery configuration to the heating chamber.

[0012] Embodiment 3: An aerosol delivery apparatus of any of the above embodiments, or any combination of the above embodiments, comprising a microwave radiant energy emitter, the magnetron being configured to extend around a heating chamber and emit microwave radiant energy.

[0013] Embodiment 4: An aerosol delivery device according to any of the above embodiments, or any combination thereof, wherein the magnetron is located in an enclosure configured to substantially surround a heating chamber.

[0014] Embodiment 5: An aerosol delivery device according to any of the embodiments described above, or any combination thereof, comprising two or more reservoirs, each reservoir configured to contain a separate aerosol precursor composition, each of the two or more reservoirs being in fluid communication with an aerosol precursor delivery configuration, and capable of cooperating with the aerosol precursor delivery configuration to guide one of the separate aerosol precursor compositions from each of the two or more reservoirs into a heating chamber.

[0015] Embodiment 6: An aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, comprising a heating chamber and an air passage configured to allow airflow between the heating chamber and the outside air outside the housing or enclosure, defined within a housing or enclosure.

[0016] Embodiment 7: An aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, wherein the outlet port or airflow path includes an airflow shielding element configured to cooperate with the enclosure to confine microwave radiant energy within the enclosure.

[0017] Embodiment 8: An aerosol delivery device according to any of the embodiments described above, or any combination thereof, comprising a hose member having an engaging proximal end engaged with an outlet port and an opposite distal end engaged with a mouthpiece element, wherein the mouthpiece element and the hose member are in fluid communication with a heating chamber via the outlet port and receive an aerosol from there in response to an suction force applied to the mouthpiece element.

[0018] Embodiment 9: An aerosol delivery device of any of the foregoing embodiments, or any combination of the foregoing embodiments, comprising a controller element that communicates between a microwave radiation energy emitting device and a sensing element in contact with an aerosol precursor composition within a heating chamber, the sensing element being configured to sense the temperature of the aerosol precursor composition within the heating chamber, and the controller element adjusting the microwave radiation output by the microwave radiation energy emitting device in response to the sensed temperature to heat the aerosol precursor composition within the heating chamber to a maximum desired temperature.

[0019] Embodiment 10: An aerosol delivery device of any of the foregoing embodiments, or any combination of the foregoing embodiments, wherein the aerosol precursor composition is selected from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, plant-derived materials, and combinations thereof.

[0020] Embodiment 11: An aerosol delivery device of any of the foregoing embodiments, or any combination of the foregoing embodiments, wherein one component of the aerosol precursor composition is configured to prevent overheating of the aerosol precursor composition.

[0021] Embodiment 12: An aerosol delivery device of any of the foregoing embodiments, or any combination of the foregoing embodiments, comprising a wick engaged with the heating chamber, the wick communicating with the aerosol precursor composition, and the microwave radiation energy emitting device being configured to heat the wick such that the amount of aerosol formed by the wick is proportional to the amount of aerosol precursor composition drawn up by the wick.

[0022] Embodiment 13: An aerosol delivery apparatus according to any of the above embodiments, or any combination thereof, wherein the heating chamber comprises a first heating sub-chamber and a second heating sub-chamber, one of the first and second heating sub-chambers having a larger capacity with respect to the aerosol precursor composition than the other, the first and second heating sub-chambers being in fluid communication with an outlet port via a selector element, the selector element directing an aerosol from one of the first and second heating sub-chambers to the outlet port in response to an suction force applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction force, Aerosol delivery device.

[0023] Embodiment 14: An aerosol delivery apparatus according to any of the embodiments described above, or any combination thereof, comprising an aerosol precursor processing unit configured to fluidly communicate with a heating chamber to preheat an aerosol precursor composition to a preheating temperature, wherein the preheating temperature is lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is introduced into the heating chamber.

[0024] Embodiment 15: An aerosol delivery device according to any of the above embodiments, or any combination thereof, wherein the aerosol precursor processing unit includes a heating element or an aerosol forming element configured to interact with an aerosol precursor composition.

[0025] Embodiment 16: An aerosol delivery apparatus according to any of the embodiments described above, or any combination thereof, comprising an aerosol precursor processing unit that communicates with a heating chamber and is configured to preheat a substrate material accompanied by an associated aerosol precursor composition to a preheating temperature, wherein the preheating temperature is lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated substrate material is introduced into the heating chamber.

[0026] Embodiment 17: An aerosol delivery apparatus according to any of the embodiments described above, or any combination thereof, comprising an aerosol precursor processing unit communicating with a heating chamber and configured to preheat a film composed of an aerosol precursor composition to a preheating temperature, wherein the preheating temperature is lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated film is introduced into the heating chamber.

[0027] Embodiment 18: A method for manufacturing an aerosol delivery device, The microwave radiant energy emitter is operably engaged with a heating chamber configured to receive an aerosol precursor composition, wherein the microwave radiant energy emitter is configured to heat the aerosol precursor composition with the microwave radiant energy emitted thereby to form an aerosol from the aerosol precursor composition. Engaging a heating chamber with a housing having an outlet port, thereby enabling fluid communication between the outlet port and the heating chamber, and causing the heating chamber to draw aerosol out of the housing through the outlet port in response to an attractive force applied to the outlet port. A manufacturing method that includes this.

[0028] Embodiment 19: A method for manufacturing an aerosol delivery apparatus of any of the above embodiments, or any combination of the above embodiments, further comprising engaging an aerosol precursor delivery configuration that is in fluid communication with a heating chamber, wherein the aerosol precursor delivery configuration is configured to guide an aerosol precursor composition from a reservoir having an aerosol precursor composition inside into the heating chamber.

[0029] Embodiment 20: A method for manufacturing an aerosol delivery device of any of the above embodiments or any combination of the above embodiments, comprising operably engaging a microwave radiant energy emitter with a magnetron in a heating chamber, wherein the magnetron extends around the heating chamber and is configured to emit microwave radiant energy.

[0030] Embodiment 21: A method for manufacturing an aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, further comprising placing a magnetron in an enclosure configured to substantially surround a heating chamber.

[0031] Embodiment 22: A method for manufacturing an aerosol delivery device of any of the above embodiments, or any combination thereof, further comprising forming two or more reservoirs within a housing, each reservoir containing a separate aerosol precursor composition, each of the two or more reservoirs being in fluid communication with an aerosol precursor delivery configuration, and the aerosol precursor delivery configuration cooperating with the aerosol precursor delivery configuration to guide one of the separate aerosol precursor compositions from each of the two or more reservoirs into a heating chamber.

[0032] Embodiment 23: A method for manufacturing an aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, further comprising defining an air passage within a housing or enclosure, wherein the air passage is configured to allow airflow between a heating chamber and outside air outside the housing or enclosure.

[0033] Embodiment 24: A method for manufacturing an aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, further comprising placing an airflow shielding element in an outlet port or airflow channel, wherein the airflow shielding element is configured to cooperate with an enclosure to confine microwave radiant energy within the enclosure.

[0034] Embodiment 25: A method for manufacturing an aerosol delivery device of any of the embodiments described above, or any combination thereof, further comprising engaging the proximal end of a hose member with an outlet port and engaging the distal end opposite to the hose member with a mouthpiece element, wherein the mouthpiece element and the hose member are in fluid communication with a heating chamber via the outlet port and receive an aerosol from there in response to an suction force applied to the mouthpiece element.

[0035] Embodiment 26: A method for manufacturing an aerosol delivery device of any of the above embodiments or any combination of the above embodiments, further comprising operably engaging a controller element between a microwave radiant energy emitter and a sensing element that communicates with an aerosol precursor composition in a heating chamber, wherein the sensing element is configured to sense the temperature of the aerosol precursor composition in the heating chamber, and the controller element is configured to adjust the microwave radiant output of the microwave radiant energy emitter in response to the sensed temperature to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

[0036] Embodiment 27: A method for manufacturing an aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, further comprising selecting an aerosol precursor composition from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, plant-derived materials and combinations thereof.

[0037] Embodiment 28: A method for manufacturing an aerosol delivery device of any of the above embodiments, or any combination of the above embodiments, further comprising selecting an aerosol precursor composition such that one component of the aerosol precursor composition is configured to prevent overheating of the aerosol precursor composition.

[0038] Embodiment 29: A method for manufacturing an aerosol delivery device of any of the above embodiments or any combination of the above embodiments, further comprising engaging a wick with a heating chamber such that the wick communicates with an aerosol precursor composition, wherein a microwave radiant energy emitter is configured to heat the wick such that the amount of aerosol formed by the wick is proportional to the amount of aerosol precursor composition drawn up by the wick.

[0039] Embodiment 30: A method for manufacturing an aerosol delivery device of any of the embodiments described above, or any combination of the embodiments described above, further comprising defining a first heating sub-chamber and a second heating sub-chamber within a heating chamber, wherein one of the first and second heating sub-chambers has a larger capacity with respect to the aerosol precursor composition than the other, and the first and second heating sub-chambers are configured to selectively fluidize to an outlet port via a selector element, the selector element directing an aerosol from the heating sub-chamber that selectively communicates with the outlet port to the outlet port in response to an suction force applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction force.

[0040] Embodiment 31: A method for manufacturing an aerosol delivery device of any of the above embodiments or any combination of the above embodiments, further comprising engaging an aerosol precursor processing unit in fluid communication with a heating chamber, wherein the aerosol precursor processing unit is configured to preheat an aerosol precursor composition to a preheating temperature, the preheating temperature being lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is introduced into the heating chamber.

[0041] Embodiment 32: A method for manufacturing an aerosol delivery device of any of the above embodiments or any combination of the above embodiments, comprising arranging a heating element or aerosol forming element such that engaging an aerosol precursor processing unit interacts with the aerosol precursor composition before the preheated aerosol precursor composition is introduced into a heating chamber.

[0042] Embodiment 33: A method for manufacturing an aerosol delivery apparatus of any of the above embodiments, or any combination of the above embodiments, further comprising engaging an aerosol precursor processing unit in fluid communication with a heating chamber, wherein the aerosol precursor processing unit is configured to preheat a substrate material with an associated aerosol precursor composition to a preheating temperature, the preheating temperature being lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated substrate material is introduced into the heating chamber.

[0043] Embodiment 34: A method for manufacturing an aerosol delivery device of any of the above embodiments or any combination of the above embodiments, further comprising engaging an aerosol precursor processing unit that is in fluid communication with a heating chamber, wherein the aerosol precursor processing unit is configured to preheat a film composed of an aerosol precursor composition to a preheating temperature, the preheating temperature being lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated film is introduced into the heating chamber.

[0044] These and other features, aspects and advantages of the Disclosure will become apparent upon reading the following detailed description, along with the accompanying drawings which are briefly described below. The Disclosure includes any combination of two, three, four, or more features or elements described in the Disclosure or listed in one or more of the claims, whether such features or elements are expressly combined in the description of a particular embodiment of this Spec. or otherwise enumerated. The Disclosure is intended to be read as a whole in any aspect and embodiment, so that any separable features or elements of the Disclosure appear as intended to be combined, unless the context of the Disclosure clearly indicates otherwise.

[0045] This disclosure uses the general terminology described above, and the attached drawings will be referenced below, although these drawings are not necessarily drawn to scale. [Brief explanation of the drawing]

[0046] [Figure 1] A side view of an aerosol delivery device including a microwave radiant energy emitter according to an exemplary embodiment of the present disclosure is shown. [Figure 2A] The diagram shows a cross-sectional view of an aerosol generated in the heating chamber of an aerosol delivery device by microwave radiant energy generated by a microwave radiant energy emission device according to an exemplary embodiment of the present disclosure. [Figure 2B] The diagram shows a cross-sectional view of an aerosol generated in two heating chambers of an aerosol delivery device by microwave radiant energy generated by a microwave radiant energy emitter, according to an exemplary embodiment of the present disclosure. [Figure 3] The images show cross-sectional views of aerosol precursor compositions in two different reservoirs of an aerosol delivery device according to exemplary embodiments of the present disclosure. [Figure 4A] This disclosure shows an exemplary embodiment of an aerosol precursor processing apparatus. [Figure 4B]This disclosure shows an exemplary embodiment of an aerosol precursor processing apparatus. [Figure 4C] This disclosure shows an exemplary embodiment of an aerosol precursor processing apparatus. [Figure 5] A flowchart shows a method for manufacturing an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Modes for carrying out the invention]

[0047] This disclosure is described in further detail below with reference to its exemplary embodiments. These exemplary embodiments are described so as to ensure that this disclosure is thorough and complete and fully conveys the scope of this disclosure to those skilled in the art. In fact, this disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided so as to satisfy the applicable legal requirements of this disclosure. As used herein and in the appended claims, the singular forms "a," "an," and "the" refer to multiple subjects unless otherwise explicitly indicated in the context.

[0048] This disclosure relates to an aerosol delivery device that uses microwave radiant energy to heat a material (preferably without significantly burning the material) to form an inhalable substance. In some embodiments, the aerosol delivery device is considered a “tabletop” device, configured in size, shape, etc., similar to that of a conventional hookah. In other embodiments, however, the aerosol delivery device is considered a “handheld” device, configured in size, shape, etc., so as to be easily held in the hand of a consumer.

[0049] In certain preferred embodiments, an aerosol delivery device is characterized as a smoking product. As used herein, the term “smoking product” is intended to mean an article or device that provides some or all of the sensation of smoking a cigarette, cigar or pipe (e.g., the form of inhalation and exhalation, the type of taste or flavor, the sensory stimulation effect, the physical feel, the form of use, the visual stimulation such as that provided by a visible aerosol) without substantially burning any component of the article or device. As used herein, the term “smoking product” does not necessarily mean that, during operation, the article or device produces smoke in the sense of an aerosol resulting from the combustion or pyrolysis of tobacco, but rather that the article or device produces vapor resulting from the volatilization or vaporization of certain components of the article or device (e.g., vapor in an aerosol that may be considered a visible aerosol that may be considered as smoke). In some preferred embodiments, an article or device characterized as a smoking product incorporates tobacco and / or tobacco-derived components.

[0050] In various embodiments, the articles or apparatus of the present disclosure are also characterized by being vapor products, aerosol delivery articles, or drug delivery articles. Such articles or apparatus are configured to deliver one or more substances (e.g., flavors and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance is substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance is in aerosol form (i.e., suspended fine solid particles or droplets in a gas). For clarity, the term “aerosol” as used herein includes vapors, gases, and aerosols in forms or types suitable for human inhalation, whether visible or in a form that can be considered fuzzy.

[0051] The smoking product of this disclosure is subject to many of the physical actions performed by an individual when using conventional types of smoking products (e.g., cigarettes, cigars, or pipes, which are used by lighting and inhaling tobacco). For example, a user of the smoking product of this disclosure operates the product in the same way as conventional types of smoking products, inhaling one of the mouthpiece elements of the product to inhale the aerosol produced by the product, and inhaling at selected time intervals.

[0052] The smoking product of this disclosure includes any combination of a heat source (i.e., a microwave radiant energy emitting element), at least one control component (e.g., a configuration for operating, controlling, regulating and / or stopping power to the heat source to control heat generation, such as by controlling the microwave radiant energy emitted from the heat source to other components of the smoking product), an aerosol precursor composition (e.g., a liquid that can produce an aerosol when sufficiently heated, such as components commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece element (e.g., a defined airflow path through the smoking product so that the generated aerosol can be drawn out therefrom by inhalation).

[0053] Figure 1 provides one exemplary embodiment of an aerosol delivery device 100. As seen in the side view shown therein, the aerosol delivery device 100 includes a housing 102 and an enclosure 104 that are permanently or detachably connected in a functional relationship. The enclosure 104 fits around a first portion of the housing 102 and is configured in size and / or shape to substantially enclose the first portion of the housing 102 within it. In some examples, the first portion is the lower or base of the housing 102. For example, the enclosure 104 is molded to correspond to the external contour of the first portion of the housing 102 and is hinged to open and close. Thus, the first portion of the housing 102 fits into the molded shape of the enclosure 104 when the enclosure is hinged open and is fixedly held inside when the enclosure is hinged closed. Other types of engagements or connections between the housing 102 and the enclosure 104 are also conceivable.

[0054] In one embodiment, a heating chamber 106 configured to receive the aerosol precursor composition 108 defines a first portion of the housing 102. In some embodiments, an enclosure 104 substantially surrounds or encloses the heating chamber 106. The heating chamber 106 is a single heating chamber or, in some embodiments, is further divided into sub-chambers. For example, in one embodiment shown in Figure 1 and in more detail in Figure 2A, a single heating chamber 106 is provided. In another example, as another embodiment shown in Figure 2B, a first heating sub-chamber 106A and a second heating sub-chamber 106B are provided. In such an example, one of the first and second heating sub-chambers 106A-B is configured to have a larger volume for the aerosol precursor composition 108 than the other sub-chamber. In the example shown in Figure 2B, the second heating sub-chamber 106B has a larger volume for the aerosol precursor composition 108 than the first heating sub-chamber 106A. In other such examples, the first and second heating sub-chambers 106A-B are configured to have substantially similar volumes relative to the aerosol precursor composition 108.

[0055] In each example, the heating chamber 106 is operably engaged with a heat source, such as a microwave radiant energy emitter 110. In some embodiments, the microwave radiant energy emitter 110 includes a magnetron that generates microwave radiant energy 112. In some embodiments, the magnetron is preferably sized to fit the desired shape, size, etc., of the aerosol delivery device 100 so that the device can be easily operated without compromising the desired smoking experience. In other embodiments, the microwave radiant energy emitter 110 includes an antenna, coil, etc., configured to generate microwave radiant energy 112. In such cases, the material to be heated may be located in a different configuration / direction relative to the microwave source. For example, in the case of a coil, the material may be located inside (center of) the coil.

[0056] Therefore, the microwave radiant energy 112 emitted by the microwave radiant energy emitter 110 is configured to penetrate the heating chamber 106, heating the aerosol precursor composition 108 placed therein to form an aerosol 114. More specifically, in some embodiments, the microwave radiant energy 112 causes the polar molecules of the aerosol precursor composition 108 to rotate and generate thermal energy. As a result, the molecules in the aerosol precursor composition are uniformly excited and heated by the microwave radiant energy 112 such that thermal degradation of the aerosol precursor composition 108 is minimized during the formation of the aerosol 114 (i.e., no overheated particles are present), and the resulting aerosol 114 has more consistent vapor chemical properties than those produced by other types of heat sources such as electric heating elements (e.g., resistance heating coils).

[0057] In some embodiments, the microwave radiant energy emitter 110, and other embodiments of the aerosol delivery device 100 itself, are powered by a power supply. The power supply is configured to provide sufficient power, energy, or current to provide various functions of the aerosol delivery device 100, such as heating the aerosol precursor composition via the microwave radiant energy emitter 110, powering control components or systems, powering indicators, etc. Preferably, the power supply can take various embodiments that can supply sufficient power to each of the microwave radiant energy emitters 110 to rapidly heat the aerosol precursor composition 108 received in the heating chamber 106, from which an aerosol is formed, and power other components of the aerosol delivery device 100 through use over a desired duration. For example, in some examples, the aerosol delivery device 100, including the microwave radiant energy emitter 110, is powered via a standard household outlet (e.g., 120 AC volts). In another example, the aerosol delivery device 100 is powered by a battery with sufficient energy density. Therefore, when the aerosol delivery device 100 is connected to a power source, the microwave radiant energy emitter 110 is powered and controllable to heat the aerosol precursor composition 108 placed in the heating chamber 106.

[0058] The housing 102, enclosure 104, and / or heating chamber 106 are configured to contain the microwave radiant energy 112 emitted by the microwave radiant energy emitter 110. For example, the housing 102, enclosure 104, and / or heating chamber 106 are similar in materials and design to a Faraday cage to prevent the leakage of microwave radiant energy. An outlet port or orifice penetrating the surface of the housing 102, enclosure 104, and / or heating chamber 106 and in fluid communication with the outside of the housing 102 or enclosure 104 includes a shielding element 116 for containing the microwave radiant energy 112 within the aerosol delivery device 100. In these embodiments, the housing 102 of the aerosol delivery device 100 defines an outlet port 118, which is in fluid communication with the heating chamber 106. Thus, the shielding element 116 engages with the outlet port 118. The air passage 120 defined within the housing 102 and / or enclosure 104 also includes a shielding element 116. The shielding element 116 includes at least one layer of conductive material (e.g., aluminum mesh), but other materials, types and / or configurations of the shielding element 116 are possible.

[0059] The outlet port 118 is configured to receive suction force at the mouthpiece element 122 (i.e., from the consumer), and as a result, in response to the suction force, the aerosol 114 is drawn out of the housing 102 through the outlet port 118. A hose member 124 is engageable with the outlet port 118. As shown in Figure 1, for example, the proximal end of the hose member 122 engages with the outlet port 118, and the opposite distal end engages with the mouthpiece element 122. In this way, the mouthpiece element 122 and the hose member 124 are in fluid communication with the heating chamber 106 via the outlet port 118, receiving the aerosol 114 from there in response to the suction force applied to the mouthpiece element 122. In some embodiments, there are multiple outlet ports 118. For example, as shown in Figure 1, there are at least two outlet ports 118. In such an example, a hose member 124 having a mouthpiece element 122 engages with each available outlet port 118 of the housing 102 so that multiple consumers can use the aerosol delivery device 100 at the same time. Otherwise, unused outlet ports are capped or sealed to prevent aerosol from leaking out of the housing 102 or otherwise entering the housing 102 and diluting the aerosol.

[0060] In some embodiments, one or more heating subchambers 106A-B are configured to selectively communicate fluidly to their respective outlet ports 118. For example, selector elements (e.g., valves, flanges) placed within one or more heating subchambers 106A-B are configured to automatically respond to an suction force applied through the outlet port 118, thereby directing aerosols 114 from each heating subchamber 106A-B through the outlet port 118. Figure 2A illustrates such an example, where the selector element responds to or opens the second heating subchamber 106B in response to an suction force applied through its respective outlet port. In Figure 2A, for example, the selector element is not responding or is closed because the outlet port through which an suction force is applied is not engaged with the first heating subchamber 106A, and therefore no aerosols 114 are directed from it.

[0061] In other examples, the selector element is configured to respond manually to user selections. In these examples, a switch, button, lever, or other mechanism can be used to selectively control which heating sub-chambers 106A-B from which the aerosol 114 is directed.

[0062] The air passage 120 is configured to allow airflow between the heating chamber 106 and the outside air outside the housing 102 and / or enclosure 104. For example, as shown in Figure 1 and in more detail in Figure 2A, a single heating chamber 106 has an air passage 120 extending from inside the heating chamber 106, through inside the enclosure 104, and to the outside of the housing 102. In another example, as shown in Figure 2B, two heating chambers 106A-B each have separate air passages 120A-B extending from there to the outside of the housing 102. However, in yet another example (not shown), the air passages 120A-B extend from each heating chamber 106A-B, merge into a single passage within the enclosure 104, and one passage extends to the outside of the housing 102. In examples where multiple air passages 120 exist, there are shielding elements 116A-B associated with each passage.

[0063] Referring again to Figure 1, the aerosol precursor delivery configuration 126 is operably engaged with the heating chamber 106 and is configured to deliver the aerosol precursor composition 108 from the reservoir 128 to the heating chamber 106. In various embodiments, the aerosol precursor delivery configuration 126 is an internal flow tube, passage or other mechanism. For example, as shown in Figure 1, the aerosol precursor delivery configuration 126 is an air passage defined inside the housing 102 and is configured to guide the aerosol precursor composition 108 from the reservoir 128 through the housing 102 to the heating chamber 106 by gravity.

[0064] In other embodiments, the aerosol precursor delivery configuration 126 is also an aerosol delivery configuration in which the aerosol formed by the combination of vaporization of the aerosol precursor composition 108 and the outside air in the heating chamber 106 is delivered to the consumer via the same mechanism that transports the aerosol precursor composition 108 to the heating chamber 106. In these embodiments, the air passage 126 is configured to have an internal volume greater than the internal volume of the heating chamber 106 in order to provide headspace for the generated aerosol to expand and / or mature therein. In other embodiments not shown, the air passage 126 is configured as a flow tube engaged between the reservoir 128 and the heating chamber 106 in order to transport the aerosol precursor composition 108 from the reservoir 128 to the heating chamber 106 and to provide headspace for the generated aerosol to expand therein. Other similar mechanisms for delivering the aerosol precursor composition 108 and / or the generated aerosol are also conceivable.

[0065] The reservoir 128 is configured to contain an aerosol precursor composition 108 and to be in fluid communication with the aerosol precursor delivery configuration 126. Figure 1 shows a reservoir 128 configured to contain a first aerosol precursor composition 108. However, in some embodiments shown in Figure 3, there are two or more reservoirs 128A to B, each of which is configured to contain a separate aerosol precursor composition 108A to B, and each of the two or more reservoirs 128A to B is in fluid communication with and can cooperate with the aerosol precursor delivery configuration 126.

[0066] In some embodiments, for example, each of two or more reservoirs 128A to B contains a different aerosol precursor composition 108A to B. In such examples, a manual or automatic operating mechanism (not shown) can be provided to selectively operate the fluid communication between one or more of the reservoirs 128A to B and the aerosol precursor delivery configuration 126.

[0067] In other embodiments, for example, each of two or more reservoirs 128A-B contains the same or substantially similar aerosol precursor compositions 108A-B, the first reservoir 128A of the two or more reservoirs being a primary reservoir, and the second reservoir 128B of the two or more reservoirs being a secondary reservoir. In this example, the first or primary reservoir 128A is configured to be in fluid communication with the aerosol precursor delivery configuration 126, and the second or secondary reservoir 128B is configured to be in fluid communication with the aerosol precursor delivery configuration 126 only when the aerosol precursor composition 108A contained in the first reservoir 128A is depleted. In these examples, a manual or automatic operating mechanism (not shown) may be provided to detect the depletion of the aerosol precursor composition 108A contained in the first reservoir 128A and to activate fluid communication between the second reservoir 128B containing the aerosol precursor composition 108B and the aerosol precursor delivery configuration 126.

[0068] As a result, the aerosol precursor delivery configuration 126 is configured to deliver one of the separate aerosol precursor compositions 108A-B individually or in combination from each of two or more reservoirs 128A-B to the heating chamber 106. For example, two different aerosol precursor compositions 108A-B, housed in their respective reservoirs 128A-B, are delivered simultaneously but independently to their respective heating sub-chambers 106A-B. In such an example, each reservoir 128A-B is in fluid communication with a separate aerosol precursor delivery configuration, heating chamber, and outlet port. As a result of such a configuration, when multiple consumers use the aerosol delivery device 100 simultaneously, the aerosol delivery device 100 is configured to be customizable for each consumer, so that each consumer can select their own aerosol precursor composition 108 (e.g., menthol, crema, etc.) for an individualized experience.

[0069] In other such embodiments, for example, two different aerosol precursor compositions 108A-B, each housed in reservoirs 128A-B, are delivered simultaneously to the same heating chamber 106, thereby allowing the two different aerosol precursor compositions 108A-B to be combined within the heating chamber 106 before, during, and / or after aerosolization. As a result of such a configuration, the aerosol delivery device 100 is configured to be customizable for a single or multiple consumers, and consequently, various combinations of aerosol precursor compositions 108A-B result in a unique experience.

[0070] The reservoir 128 is configured as either a reusable reservoir or a removable and disposable reservoir. In one example, the reservoir 128 is reusable, and additional amounts of aerosol precursor composition 108 are added to the reservoir 128 as needed. In another example, once all of the aerosol precursor composition 108 contained within it has been used, the reservoir 128 is removed. A new reservoir 128 containing additional amounts of aerosol precursor composition is then engaged with the housing 102, where the reservoir 128 is either a disposable reservoir or a refillable and reusable reservoir. In either case, the reservoir 128 is engageable with the housing 102 via screw engagement, press-fit engagement, magnetic engagement, etc. Otherwise, the reservoir 128 is securely engaged with the housing 102 so that it cannot be removed from the housing 102 (i.e., in the case of a refillable or reusable reservoir). In any case, the reservoir 128 is in fluid communication with the aerosol precursor delivery configuration 126 so that the aerosol precursor composition 108 is delivered from there to the heating chamber 106.

[0071] To measure the amount of aerosol precursor composition 108 delivered to the heating chamber 106, one embodiment of the reservoir 128 includes a screen 130 having a grid structure that is fine enough to prevent the entire aerosol precursor composition 108 from being delivered to the heating chamber 106 at once, but large enough to allow the composition particles to flow at a limited rate. For example, as shown in Figure 1, the screen 130 is configured to extend substantially over or over the entire inner diameter of the housing 102 and is positioned adjacent to the reservoir 128. In another example, as shown in Figure 3, the screen 130 is positioned adjacent to both reservoirs 128A and B. However, screens for each reservoir 128A and B are also conceivable.

[0072] In some embodiments, the aerosol precursor composition 108, which may also be called a vapor precursor composition, comprises one or more different components. The different components of the aerosol precursor composition 108 are selected from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, plant-derived materials, and combinations thereof dispersed in a porous matrix or individual packets (e.g., substrates). In some non-limiting examples, one of the components of the aerosol precursor composition 108 comprises a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof). Additional representative types of aerosol precursor compositions are described in U.S. Patent No. 4,793,365 by Sensabaugh, Jr. et al., U.S. Patent No. 5,101,839 by Jakob et al., PCT International Publication No. 98 / 57556 by Biggs et al., and in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (1988) by RJ Reynolds Tobacco Company Monograph, and these disclosures are incorporated herein by reference.

[0073] The components of the aerosol precursor composition 108 are combined based on the specific effect each component has on the overall consumer experience. In some embodiments, components are selected that enable the aerosol delivery device 100 to provide some or all of the sensation of smoking a cigarette, cigar, or pipe (e.g., the form of inhalation and exhalation, the type of taste or flavor, the sensory stimulation effect, the physical feel, the form of use, the visual stimulation such as that provided by a visible aerosol). In other embodiments, components are also selected that enable the aerosol delivery device 100 to produce a uniformly heated aerosol 114 from the aerosol precursor composition 108. For example, the aerosol precursor composition 130 may include components that prevent overheating of the aerosol precursor composition 108, such as inert, non-volatile granules (e.g., boiling chips), or other nucleating surfaces that can absorb excess microwave radiation energy 112. Alternatively, the controller element 132 is configured to selectively control the microwave radiation energy emitter 110 to emit microwave radiation energy 112 at frequencies specific to one or more components of the aerosol precursor composition 108.

[0074] Some embodiments of the aerosol delivery device 100 include a controller element 132 that communicates between a microwave radiant energy emitter 110 and a sensing element 134 that communicates with an aerosol precursor composition 108 in a heating chamber 106. In some embodiments, the controller element 132 includes a microcontroller. In some embodiments, the sensing element 134 includes a fiber optic probe. As shown in Figure 1 and in more detail in Figure 2A, the controller element 132 is located within the enclosure 104 and the sensing element 134 is located within the heating chamber 106. In another example, as shown in Figure 2B, a single controller element 132 communicates between the microwave radiant energy emitter 110 and both sensing elements 134A and 134B located in the respective heating chambers 106A and B.

[0075] In some embodiments, the sensing element 134 is configured to sense the temperature, airflow velocity, pressure, aerosol precursor composition elements, or any combination thereof of the aerosol precursor composition 108 within the heating chamber 106. For example, if the sensing element 134 is configured to sense temperature, the controller element 132 adjusts the microwave radiation energy 112 in response to the sensed temperature to heat the aerosol precursor composition 108 to only the highest desired temperature. In this way, the controller element 132, working in conjunction with the sensing element 134, is configured to prevent overheating, underheating, etc., of the aerosol precursor composition 108.

[0076] In other embodiments, the sensing element 134 is also configured to sense the volume of the amount of aerosol precursor composition 108 contained in the heating chamber 106. For example, if there are two heating chambers 106A and B, the sensing elements 134A and B are each configured to sense the volume of aerosol precursor composition 108 in their respective heating chambers 106A and B. The controller element 132, in response to the sensed volume, prevents the aerosol precursor delivery configuration 126 from delivering any more aerosol precursor composition 108 to one or both of the heating chambers 106A and B when one or both of the heating chambers 106A and B are at their maximum volume. Thus, for example, a valve mechanism communicating with the controller element 132 is configured to limit the amount of aerosol precursor composition 108 delivered to one or both of the heating chambers 106A and B. Alternatively, if one of the heating chambers 106A to B is at its maximum capacity, the controller 132 responds to the sensed maximum capacity of that chamber by directing the aerosol precursor composition 108 to the other heating chamber 106A to B, which is not at its maximum capacity.

[0077] Furthermore, in various embodiments, the aerosol precursor composition transport element is positioned in a heating chamber 106 communicating with the aerosol precursor composition 108. For example, as shown in Figures 2A-2B, one embodiment of the aerosol precursor composition transport element includes a wick 136 formed from various materials (e.g., cotton and / or glass fiber) configured to transport (i.e., absorb and suction) the aerosol precursor composition 108. Depending on the material design of the wick, the wick 136 is configured to absorb a limited amount (i.e., a smoke-absorbing size) of the aerosol precursor composition 108 delivered to the heating chamber 106. The wick, having absorbed the liquid, is then heated by a microwave radiant energy emitter 110 to generate an aerosol 114. In addition, for example, a smoke-absorbing size of the aerosol precursor composition 108 may be delivered to the heating chamber 106 and the wick 136 by pumping, dripping, or other means. However, the implementation of the wick 136 is optional.

[0078] Therefore, during use, when the consumer inhales the mouthpiece element 122 of the aerosol delivery device 100, a certain amount of aerosol precursor composition 108 is introduced from the reservoir 128 to the heating chamber 106 by the aerosol precursor delivery configuration 126. Alternatively, the aerosol precursor composition 108 is already placed in the heating chamber 106 before inhalation. Then, the microwave radiant energy emitter 110 is activated (e.g., via a smoke absorption sensor or sensing element 134, etc.) and the components of the aerosol precursor composition 108 are vaporized or aerosolized in the heating chamber 106. In some embodiments, a controller element 132 is communicatively connected to the microwave radiant energy emitter 110 to control the microwave radiant energy 112 emitted therefrom. For example, if the sensing element 134 senses an aerosol precursor composition 108 in a heating chamber 106 that requires an increase in microwave radiation energy 112 to aerosolize (for example, due to the temperature, volume, pressure, etc. of the aerosol precursor composition), the controller element 132 can control the microwave radiation energy emitter 110 to emit enough microwave radiation energy 112 to aerosolize the aerosol precursor composition 108.

[0079] Furthermore, when the mouthpiece element 122 of the aerosol delivery device 100 is drawn in, outside air enters the air passage 120 and passes through the heating chamber 106. The drawn-in outside air mixes with the vapor / aerosol formed in the heating chamber 106 and / or the aerosol delivery configuration 126 to transport the aerosol 114. The formed aerosol 114 is drawn out of the heating chamber 106, passes through the aerosol delivery configuration 126, exits through the outlet port 118, goes through the hose member 124 and exits through the mouthpiece element 122 of the device 100. In some embodiments, aerosol 114 that is not drawn in through the outlet port 118 remains in or stays in the aerosol delivery configuration 126 and matures there.

[0080] An exemplary mechanism providing fume extraction capability is the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. in Freeport, Illinois. Further components may be optionally used in the aerosol delivery device 100 of this disclosure. For example, Sprinkel, Jr.'s U.S. Patent No. 5,261,424 discloses a piezoelectric sensor that may be associated with the mouth end of a device for detecting the movement of a user's lips and trigger heating related to smoke inhalation; McCafferty et al.'s U.S. Patent No. 5,372,148 discloses a smoke inhalation sensor for controlling the flow of energy to a heating load array in response to a pressure drop through a mouthpiece; Harris et al.'s U.S. Patent No. 5,967,148 discloses a receptacle in a smoking device that includes a discriminator for detecting non-uniformity of the infrared transmittance of an inserted component and a controller that performs a detection routine when the component is inserted into the receptacle; Fleischhauer et al.'s U.S. Patent No. 6,040,560 describes a defined, viable power cycle having multiple different phases; and Watkins et al.'s U.S. Patent No. 5,934,289 describes photonic-optronic (photonic-optr) The U.S. Patent No. 5,954,979 by Counts et al. discloses components of a smoking device, means for changing the inhalation resistance through a smoking device, the U.S. Patent No. 6,803,545 by Blake et al. discloses a specific battery configuration for use in a smoking device, the U.S. Patent No. 7,293,565 by Griffen et al. disclose various charging systems for use with a smoking device, the U.S. Patent No. 8,402,976 by Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and enable computer control of the device, the U.S. Patent No. 8,689,804 by Fernando et al. disclose an identification system for a smoking device, and Flick's International Publication No. 2010 / 003480 discloses a fluid flow sensing system indicating smoke inhalation using an aerosol generation system. All of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0081] Further descriptions of other control components, including microcontrollers, that may be useful in this smoking product are provided in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 by Brooks et al., U.S. Patent No. 5,372,148 by McCafferty et al., U.S. Patent No. 6,040,560 by Fleischhauer et al., and U.S. Patent No. 7,040,314 by Nguyen et al., all of which are incorporated herein by reference in their entirety.

[0082] Figures 4A to 4C show schematic diagrams of exemplary aerosol precursor processing units. The aerosol precursor processing unit is configured to preheat the aerosol precursor composition 108 before aerosolization of the aerosol precursor composition 108 by the apparatus 100. Alternatively, the aerosol precursor processing unit is configured to process the aerosol precursor composition 108 after preheating of the aerosol precursor composition 108 by the apparatus 100.

[0083] Referring to Figure 4A, the aerosol precursor processing unit 400A is shown. The aerosol precursor processing unit 400A is configured to be in fluid communication with the heating chamber 106. More specifically, the aerosol precursor processing unit 400A is configured to deliver the processed aerosol precursor composition to the heating chamber 106 via an outlet (not shown) communicating with the heating chamber 106, through an air channel (e.g., 120, Figures 2A-2B), or through an aerosol precursor delivery configuration (e.g., 126, Figure 1). The aerosol precursor processing unit 400A is configured to preheat the aerosol precursor composition 108 to a preheating temperature, which is lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition 108 before the processed (i.e., preheated) aerosol precursor composition is delivered to the heating chamber 106. Alternatively, the aerosol precursor composition 108 is preheated in the heating chamber 106 of the aerosol delivery device 100 and removed from the heating chamber 106 before vaporization / aerosolization of the aerosol precursor composition 108. At this point, the preheated aerosol precursor composition 108 is delivered to the aerosol precursor processing unit 400A (e.g., via the aerosol precursor delivery configuration 126) and vaporized. Outside air supplied through the inlet (not shown) of the aerosol precursor processing unit 400A mixes with the vaporized / aerosolized aerosol precursor composition to transport the aerosol to be ingested by the user.

[0084] In some embodiments, the aerosol precursor processing unit 400A includes a heating element or aerosol forming element configured to interact with an aerosol precursor composition supplied thereto. In one example, the heating element includes a hot plate. In another example, the heating element includes a coil heater 402. The coil heater 402 is configured as a resistive heating element that generates heat when an electric current is applied. Examples of materials forming the heating element 402 include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)2), and ceramics (e.g., positive temperature coefficient ceramics). To generate heat, the heating element 402 includes conductive heater terminals (e.g., positive and negative terminals) configured to pass an electric current through the heating element 402 and to be attached to appropriate wiring or circuits (not shown) to form an electrical connection between the heating element 402 and a battery or other power source. In other non-limiting examples, the heating element 402 is non-electric and generates heat to vaporize the aerosol precursor composition 108 via conduction, convection, and / or radiation.

[0085] In another embodiment, the aerosol precursor processing unit 400A includes a microwave radiant energy emitter configured to interact with the aerosol precursor composition supplied thereto and to preheat the aerosol precursor composition using the emitted microwave radiant energy.

[0086] A sensing element 404 located within the aerosol precursor processing unit 400A is configured to sense when the aerosol precursor composition 108 has been heated to a preheating temperature by the heating element 402. After the sensing element 404 senses that the preheating temperature has been reached, the electrical connection with the heating element 402 is released. In addition, if the aerosol precursor composition is preheated in the heating chamber 106 of the apparatus 100, the sensing element 404 is configured to sense when the maximum temperature has been reached, after which the heating element 402 is released.

[0087] Referring here to Figure 4B, the aerosol precursor processing unit 400B is shown. The aerosol precursor processing unit 400B is configured to be in fluid communication with the heating chamber 106. More specifically, the aerosol precursor processing unit 400B is configured to deliver the processed aerosol precursor composition to the heating chamber 106 via an outlet (not shown) communicating with the heating chamber 106, through an air channel (e.g., 120, Figures 2A-2B), or through an aerosol precursor delivery configuration (e.g., 126, Figure 1). The aerosol precursor processing unit 400B is configured to preheat the substrate material 406 with the aerosol precursor composition 108 to a preheating temperature, which is lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition 108 before the preheated substrate material 406 is delivered to the heating chamber 106.

[0088] In some embodiments, the aerosol precursor processing unit 400B includes a conventional microwave oven. Thus, the aerosol precursor processing unit 400B preheats the substrate 406 to a preheating temperature using control and / or sensing components provided in the conventional microwave oven. The preheated substrate 406 is then delivered to a heating chamber 106 for subsequent aerosolization by microwave radiation energy. Alternatively, the substrate 406 is delivered to a reservoir 128, and the aerosol precursor delivery configuration 126 delivers a limited amount thereof to the heating chamber 106.

[0089] Figure 4C shows the aerosol precursor processing unit 400C. The aerosol precursor processing unit 400C is configured to have fluid communication with the heating chamber 106. More specifically, the aerosol precursor processing unit 400C is configured to deliver the processed aerosol precursor composition to the heating chamber 106 via an outlet (not shown) communicating with the heating chamber 106, through an air channel (e.g., 120, Figures 2A-2B), or through an aerosol precursor delivery configuration (e.g., 126, Figure 1). The aerosol precursor processing unit 400C is configured to preheat a membrane 408 containing the aerosol precursor composition 108 to a preheating temperature, which is lower than the highest desired temperature for aerosol formation from the aerosol precursor composition 108 before the preheated membrane 408 is delivered to the heating chamber 106.

[0090] In some embodiments, the aerosol precursor processing unit 400C includes a conventional microwave oven, and the membrane 408 includes a disposable or reusable membrane. In one example, an aerosol precursor composition 108 is supplied to the membrane 408. The membrane 408 is sealed and then supplied to the aerosol precursor processing unit 400C. Thus, the aerosol precursor processing unit 400C preheats the membrane 408 to a preheating temperature using control and / or sensing components provided in the conventional microwave oven. The membrane 408 is supplied to the aerosol precursor processing unit 400C in a contracted state, but transitions to an expanded state as the aerosol precursor composition 108 inside is vaporized / aerosolized. The preheated and expanded membrane 408 can then be inhaled via a mouthpiece attachment or otherwise attached to an aerosol delivery device 100, enabling controlled delivery of the aerosol to the consumer. After the aerosol is delivered, the membrane 408 is either discarded (i.e., disposable) or left unsealed and filled with an additional amount of aerosol precursor composition 108 (i.e., reused multiple times).

[0091] In further embodiments not shown, the aerosol delivery device 100 is used to further evaporate aerosols generated by another mechanism. More specifically, the microwave radiant energy emitter 110 is configured to reduce the size of aerosol particles generated by the other mechanism so that the particles are small enough for inhalation (e.g., 2 microns in diameter). Some such mechanisms for generating aerosols include inkjet sprayers, which in various embodiments are configured to spray aerosol particles into the heating chamber 106 of the aerosol delivery device 100. For example, thermal printers or bubble jet® printers can spray aerosol particles with a diameter of about 4 to 40 microns, and piezoelectric printers can spray aerosol particles with a diameter of about 1 to 2 microns. Since aerosols composed of particles larger than 2 microns are generally not conveniently inhaled, the sprayed aerosols are further evaporated by the microwave radiant energy emitter 110 to reduce the particle size to an inhalable diameter, e.g., 2 microns or less.

[0092] Alternatively, a wick and / or coil configuration is provided inside the heating chamber 106 to generate an aerosol consisting of particles having individual diameters of approximately 200 to 500 nanometers. While the aerosol containing particles of this diameter is inhalable, in some embodiments, the microwave radiant energy emitter 110 is configured to further vaporize / aerosolize the aerosol 114.

[0093] Referring to Figure 5, a method for manufacturing an aerosol delivery device is shown. The method, generally referred to as 500, is used to manufacture an aerosol delivery device that generates aerosols using the microwave radiation energy of the precursor composition described above.

[0094] In step 502, a microwave radiant energy emitter (e.g., 110, Figure 1) is operably engaged with a heating chamber (e.g., 106, Figure 1) configured to receive an aerosol precursor composition (e.g., 108, Figure 1) inside. In some embodiments, the microwave radiant energy emitter is configured to heat the aerosol precursor composition with the microwave radiant energy it emits to form an aerosol from the aerosol precursor composition. The aerosol precursor composition is placed in the heating chamber.

[0095] In step 504, the heating chamber is engaged with a housing (e.g., 102, Figure 1) having an outlet port (e.g., 118, Figure 1), such that the outlet port is in fluid communication with the heating chamber, and the heating chamber is such that in response to an attractive force applied to the outlet port, an aerosol is drawn out of the housing through the outlet port.

[0096] Those skilled in the art, who have an interest in the teachings shown in the above description and the associated drawings, will likely envision many modifications and other embodiments of this disclosure. Therefore, it should be understood that this 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. While specific terms are used herein, they are used only in a general and descriptive sense and not for limitation.

Claims

1. Aerosol delivery device, A reservoir configured to contain an aerosol precursor composition, A heating chamber configured to receive an aerosol precursor composition from a reservoir, A wick configured to absorb the aerosol precursor composition delivered to the heating chamber, A microwave radiation emitter is configured to partially extend around a heating chamber, operably engaged, and emit microwave radiation to heat the aerosol precursor composition absorbed by the wick with microwave radiation, in order to form an aerosol from an aerosol precursor composition. A housing that fluidly communicates with a heating chamber, defining an outlet port formed in cooperation with the housing to contain microwave radiation within the heating chamber, wherein the heating chamber, in response to suction applied to the outlet port, draws an aerosol outward from the housing through the outlet port. Shielding elements are positioned relative to the wick and reservoir to contain microwave radiation within the housing. An aerosol delivery device equipped with the following features.

2. The apparatus according to claim 1, further comprising an aerosol precursor delivery configuration operably engaged with a heating chamber, the aerosol precursor delivery configuration configured to guide an aerosol precursor composition from a reservoir in fluid communication with the aerosol precursor delivery configuration to the heating chamber.

3. The apparatus according to claim 1, wherein the microwave radiation emitter is located within an enclosure configured to substantially surround the heating chamber.

4. The apparatus according to claim 3, further comprising two or more reservoirs, each reservoir configured to contain a separate aerosol precursor composition, each of the two or more reservoirs being in fluid communication with an aerosol precursor delivery configuration, and the aerosol precursor delivery configuration being able to cooperate with it to deliver one of the separate aerosol precursor compositions from each of the two or more reservoirs to a heating chamber.

5. The apparatus according to claim 4, further comprising an air passage defined within a housing or enclosure and configured to allow airflow between a heating chamber and ambient air outside the housing or enclosure.

6. The apparatus according to claim 5, wherein the airflow channel includes an airflow shielding element configured to cooperate with the enclosure to contain microwave radiation within the enclosure.

7. The apparatus according to claim 1, comprising a hose member having an engaging proximal end that engages with an outlet port and an opposite distal end that engages with a mouthpiece element, wherein the mouthpiece element and the hose member are in fluid communication with a heating chamber via the outlet port so as to receive an aerosol therefrom in response to suction applied to the mouthpiece element.

8. The apparatus according to claim 1, comprising a microwave radiation emitter and a controller element that communicates with a sensing element communicating with an aerosol precursor composition in a heating chamber, wherein the sensing element is configured to sense the temperature of the aerosol precursor composition in the heating chamber, and the controller element adjusts the microwave radiation output of the microwave radiation emitter in response to the sensed temperature to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

9. The apparatus according to claim 1, wherein the aerosol precursor composition is selected from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, plant-derived materials, and combinations thereof.

10. The apparatus according to claim 9, wherein one component of the aerosol precursor composition is configured to absorb excess radiation and prevent overheating of the aerosol precursor composition.

11. The apparatus according to claim 1, wherein the wick is engaged with a heating chamber, and the microwave radiation emitter is configured to heat the wick so that the amount of aerosol formed thereby is proportional to the amount of aerosol precursor composition absorbed by the wick.

12. The apparatus according to claim 1, wherein the heating chamber comprises a first heating sub-chamber and a second heating sub-chamber, one of the first and second heating sub-chambers having a larger capacity for the aerosol precursor composition than the other, the first and second heating sub-chambers being in fluid communication with an outlet port via a selector element, the selector element directing an aerosol from a selected one of the first and second heating sub-chambers to the outlet port in response to suction applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction.

13. The apparatus according to claim 1, comprising an aerosol precursor processing unit configured to fluidly communicate with a heating chamber and preheat an aerosol precursor composition to a preheating temperature, wherein the preheating temperature is lower than the maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is introduced into the heating chamber.

14. The apparatus according to claim 13, wherein the aerosol precursor processing unit comprises a heating element or an aerosol forming element configured to interact with an aerosol precursor composition.

15. The apparatus according to claim 1, comprising an aerosol precursor processing unit that communicates with a heating chamber and is configured to preheat a substrate material having an associated aerosol precursor composition to a preheating temperature, wherein the preheating temperature is lower than the maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated substrate material is introduced into the heating chamber.

16. The apparatus according to claim 1, comprising an aerosol precursor processing unit that communicates with a heating chamber and is configured to preheat a membrane composed of an aerosol precursor composition to a preheating temperature, wherein the preheating temperature is lower than the maximum desired temperature for forming an aerosol from the aerosol precursor composition before the preheated membrane is introduced into the heating chamber.

17. A method for making an aerosol delivery device, The microwave radiation emitter is operably engaged with a heating chamber configured to receive an aerosol precursor composition from a reservoir configured to contain the aerosol precursor composition, wherein the microwave radiation emitter extends at least partially around the heating chamber and is configured to heat the aerosol precursor composition absorbed by the wick with microwave radiation emitted thereby to form an aerosol from the aerosol precursor composition. The heating chamber is engaged with the housing, which defines an outlet port formed in cooperation with the housing to contain microwave radiation, so that the outlet port is in fluid communication with the heating chamber, and so that in response to suction applied to the outlet port, an aerosol is drawn outward from the housing through the outlet port. A method that includes [a certain feature].

18. The method according to claim 17, further comprising engaging an aerosol precursor delivery configuration that is in fluid communication with a heating chamber, wherein the aerosol precursor delivery configuration is configured to guide an aerosol precursor composition from a reservoir to the heating chamber.

19. The method according to claim 17, further comprising arranging the microwave radiation emitter in an enclosure configured to substantially surround the heating chamber.

20. The method according to claim 19, further comprising forming two or more reservoirs within a housing, each reservoir containing a separate aerosol precursor composition, each of the two or more reservoirs being in fluid communication with an aerosol precursor delivery configuration, and the aerosol precursor delivery configuration being able to cooperate with it to deliver one of the separate aerosol precursor compositions from each of the two or more reservoirs to a heating chamber.

21. The method according to claim 20, further comprising defining an air passage within a housing or enclosure, wherein the air passage is configured to allow airflow between a heating chamber and ambient air outside the housing or enclosure.

22. The method according to claim 21, further comprising arranging an airflow shielding element in the airflow channel, wherein the airflow shielding element is configured to cooperate with the enclosure to contain microwave radiation within the enclosure.

23. The method according to claim 17, further comprising engaging the proximal end of a hose member with an outlet port and engaging the distal end opposite to the hose member with a mouthpiece element, wherein the mouthpiece element and the hose member are in fluid communication with a heating chamber via the outlet port so as to receive an aerosol therefrom in response to suction applied to the mouthpiece element.

24. The method according to claim 17, further comprising operably engaging a controller element between a microwave radiation emitter and a sensing element communicating with an aerosol precursor composition in a heating chamber, wherein the sensing element is configured to sense the temperature of the aerosol precursor composition in the heating chamber, and the controller element is configured to adjust the microwave radiation output of the microwave radiation emitter in response to the sensed temperature to heat the aerosol precursor composition in the heating chamber to a maximum desired temperature.

25. The method according to claim 17, further comprising selecting an aerosol precursor composition from the group consisting of liquids, gels, solids, capsules, colloids, suspensions, plant-derived materials, and combinations thereof.

26. The method according to claim 25, further comprising selecting an aerosol precursor composition such that one of its components is configured to absorb excess radiation and prevent overheating of the aerosol precursor composition.

27. ​​The method of claim 17, further comprising engaging a wick with a heating chamber, wherein the microwave radiation emitter is configured to heat the wick so that the amount of aerosol formed thereon is proportional to the amount of aerosol precursor composition absorbed by the wick.

28. The method according to claim 17, further comprising defining a first heating sub-chamber and a second heating sub-chamber in a heating chamber, wherein one of the first and second heating sub-chambers has a larger capacity for the aerosol precursor composition than the other, the first and second heating sub-chambers are configured to selectively fluidize with an outlet port via a selector element, the selector element directs an aerosol from the heating sub-chamber selectively communicating with the outlet port to the outlet port in response to suction applied through the outlet port, the amount of aerosol corresponding to the magnitude of the suction.

29. The method according to claim 17, further comprising engaging an aerosol precursor processing unit in fluid communication with a heating chamber, wherein the aerosol precursor processing unit is configured to preheat an aerosol precursor composition to a preheating temperature, the preheating temperature being lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated aerosol precursor composition is introduced into the heating chamber.

30. The method according to claim 29, comprising arranging a heating element or aerosol forming element such that engaging the aerosol precursor processing unit interacts with the aerosol precursor composition before the preheated aerosol precursor composition is introduced into the heating chamber.

31. The method according to claim 17, further comprising engaging an aerosol precursor processing unit in fluid communication with a heating chamber, wherein the aerosol precursor processing unit is configured to preheat a substrate material having an associated aerosol precursor composition to a preheating temperature, the preheating temperature being lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated substrate material is introduced into the heating chamber.

32. The method according to claim 17, further comprising engaging an aerosol precursor processing unit in fluid communication with a heating chamber, wherein the aerosol precursor processing unit is configured to preheat a membrane comprising an aerosol precursor composition to a preheating temperature, the preheating temperature being lower than the highest desired temperature for forming an aerosol from the aerosol precursor composition before the preheated membrane is introduced into the heating chamber.

33. The aerosol delivery device according to claim 1, wherein the outlet port further comprises an airflow shielding element.

34. The aerosol delivery device according to claim 33, wherein the airflow shielding element is formed by bending at least a portion of the outlet port with respect to the longitudinal axis of the housing.

35. The aerosol delivery device according to claim 33, wherein the airflow shielding element is formed by at least one layer of conductive material.

36. The method according to claim 17, wherein the outlet port further comprises an airflow shielding element.

37. The method according to claim 36, wherein the airflow shielding element is formed by bending at least a portion of the outlet port with respect to the longitudinal axis of the housing.

38. The method according to claim 36, wherein the airflow shielding element is formed by at least one layer of conductive material.

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