Aerosol dispensing device with improved fluid transfer

Abstract

To provide an aerosol delivery device, a method for forming such a device, and an element of such a device, especially, a device constituted for evaporation of a composition of an aerosol precursor.SOLUTION: A composition of an aerosol precursor is stored and / or transferred to a heater 134 by porous monolith 144 which may be, for example, porous glass or porous ceramic. The heater 134 may be a heating constitution of an outside part of the porous monolith 136, or may be placed substantially inside the porous monolith.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This disclosure relates to aerosol dispensing devices such as smoking devices, and more particularly to aerosol dispensing devices (for example, smoking devices commonly called e-cigarettes) that may utilize electrically generated heat for the generation of an aerosol. The smoking device may be configured to heat an aerosol precursor. This aerosol precursor may incorporate a substance that may be formed from or derived from tobacco, or otherwise incorporate tobacco, and this precursor is capable of forming an inhalable substance for human consumption. [Background technology]

[0002] Numerous smoking devices are proposed year after year as improvements to, or alternatives to, smoking products that require the combustion of tobacco for use. Many of these devices have been intentionally designed to provide a sensation associated with smoking cigarettes, cigars, or pipes, but without delivering large quantities of the incomplete combustion and pyrolysis products resulting from tobacco combustion. For this reason, many smoking products, flavor generators, and medicinal inhalers have been proposed. These utilize electrical energy to vaporize or heat volatile substances, or aim to provide the sensation of smoking cigarettes, cigars, or pipes without burning tobacco to a considerable extent. See, for example, the various alternative smoking devices, aerosol dispensing devices, and heat sources described in the background art of U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0255702 to Griffith Jr. et al., and U.S. Patent Publication No. 2014 / 0096781 to Sears et al. These documents are incorporated herein by reference. See, for example, the U.S. Patent Application Publication No. 2015 / 0216236 filed on February 3, 2014, to Bless et al., which is referenced by brand name and distributor, for various types of smoking devices, aerosol dispensing devices, and electrically powered heat sources. This document is incorporated herein by reference. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] U.S. Patent No. 7726320 [Patent Document 2] U.S. Patent Application Publication No. 2013 / 0255702 [Patent Document 3] U.S. Patent Application Publication No. 2014 / 0096781 [Patent Document 4] U.S. Patent Application Publication No. 2015 / 0216236 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] It is desirable to provide a storage section for aerosol precursor compositions for use in aerosol dispensing devices. The storage section is provided to improve the formation of the aerosol dispensing device. It is also desirable to provide an aerosol dispensing device that is ready to utilize such a storage section. [Means for solving the problem]

[0005] This disclosure relates to aerosol dispensing devices, methods for forming such devices, and elements of such devices. An aerosol dispensing device may incorporate one or more components or elements formed of a porous monolithic material. In one or more embodiments, the porous monolithic material may comprise porous glass. Specifically, the porous glass can be used as either or both a storage unit and a liquid transport element. In one or more further embodiments, the porous monolithic material may comprise porous ceramic. Specifically, the porous ceramic can be used as either or both a storage unit and a liquid transport element.

[0006] In one or more embodiments, the Disclosure may therefore provide an aerosol dispensing device comprising an outer housing, a storage section containing a liquid, a heater configured to vaporize the liquid, and a liquid transport element configured to supply the liquid to the heater. Specifically, one or both of the liquid transport element and the storage section are formed of a porous monolith, which may be one or both of porous glass and porous ceramic. In one or more embodiments, the aerosol dispensing device may be defined with respect to the following description. The following description is not limiting and may be combined in any number and / or order.

[0007] The heater may be printed on or annealed to the liquid conveying element.

[0008] The heater may be configured to heat an outer portion of the liquid conveying element. The heater may be configured to radiatively heat the liquid conveying element.

[0009] At least a portion of the liquid conveying element may be substantially flat, and the heater may be at least partially located on the substantially flat portion of the liquid conveying element.

[0010] Both the liquid conveying element and the storage portion may be formed of porous glass.

[0011] Both the liquid conveying element and the storage portion may be formed of porous ceramic.

[0012] One of the liquid conveying element and the storage portion may be formed of porous glass, and the other of the liquid conveying element and the storage portion may be formed of porous ceramic.

[0013] The storage portion and the liquid conveying element may be an integral element.

[0014] The storage portion may have a first porosity, and the liquid conveying element may have a second porosity different from the first porosity.

[0015] The porous glass may be provided with one or more etched portions.

[0016] The porous ceramic may be provided with one or more etched portions.

[0017] The liquid conveying element may be formed of porous glass, and may be substantially cylindrical.

[0018] The liquid conveying element may be formed of porous ceramic, and may be substantially cylindrical.

[0019] The heater can be a wire wound around at least a portion of the liquid transport element. The storage section can be made of porous glass, and the liquid transport element can be a fiber wick. The storage section can be made of porous ceramic, and the liquid transport element can be a fiber wick.

[0020] The storage section can be made of fibrous material, and the liquid transport element can be made of porous glass.

[0021] The storage section can be made of fibrous material, and the liquid transport element can be made of porous ceramic.

[0022] The storage section can be substantially cylindrical in shape with walls.

[0023] One or more parts of the fiber wick may be fluidly connected to the wall of the storage compartment.

[0024] The walls of the storage section may include one or more grooves.

[0025] This groove can have a different porosity than the rest of the storage section wall.

[0026] The storage section can be in the shape of a substantially hollow cylinder.

[0027] The liquid transport element may comprise a core and a shell.

[0028] The shell can be formed from porous glass.

[0029] The shell can be formed from porous ceramic.

[0030] The core can be formed from fibrous material.

[0031] The porous glass or porous ceramic shell may have ends on both sides, and the core of the liquid transport element may extend beyond the ends on both sides of the porous glass or porous ceramic shell.

[0032] The heater can be a wire, which can be wound around at least a portion of a porous glass or porous ceramic shell.

[0033] The outer housing may be equipped with an air inlet and a mouthpiece having an aerosol port.

[0034] The device may further include one or more of a power source, a pressure sensor, and a microcontroller.

[0035] One or more of the power supply, pressure sensor, and microcontroller may be located in separate control housings that can be connected to the outer housing.

[0036] In one or more embodiments, the disclosure may relate to atomizers that may be particularly suited for use in aerosol dispensing devices. In exemplary embodiments, an atomizer may comprise a substantially flat porous monolithic vapor substrate configured for the transfer of a liquid aerosol precursor composition, and a heater in a heating configuration of the substantially flat porous monolithic vapor substrate. In one or more embodiments, an atomizer may be defined with respect to the following description. The following description is not limiting and may be combined in any number and / or order.

[0037] Porous monolithic vapor substrates may be porous glass.

[0038] Porous monolithic vapor substrates may be porous ceramics.

[0039] The atomizer may include a porous glass storage section connected to a substantially flat porous glass vapor substrate.

[0040] A substantially flat porous glass vapor substrate may have a first porosity, and a porous glass storage section may have a second porosity different from the first porosity.

[0041] One or both of the substantially flat porous glass vapor substrate and the porous glass storage portion may include one or more etched portions.

[0042] The atomizer may comprise a porous ceramic reservoir connected to a substantially flat porous ceramic vapor substrate.

[0043] The atomizer may comprise a porous glass reservoir connected to a substantially flat porous ceramic vapor substrate.

[0044] The atomizer may comprise a porous ceramic reservoir connected to a substantially flat porous glass vapor substrate.

[0045] In one or more embodiments, the disclosure may relate to fluid transfer elements that may be particularly suitable for use in aerosol dispensing devices. In exemplary embodiments, the fluid transfer element may comprise an elongated core having a certain length and formed of a wick material, and a shell surrounding the elongated core along at least a portion of the length of the elongated core, the shell being formed of a porous monolith which may be porous glass or porous ceramic. Specifically, the wick material may be a fibrous material.

[0046] The present invention includes, without limitation, the following embodiments.

[0047] Embodiment 1: An aerosol dispensing device comprising an outer housing, a storage section containing liquid, a heater configured to vaporize the liquid, and a liquid transport element configured to supply the liquid to the heater, wherein one or both of the liquid transport element and the storage section are formed of porous glass.

[0048] Embodiment 2: An aerosol dispensing device according to either the above or below embodiment, wherein the heater is printed on or annealed to the liquid transport element.

[0049] Embodiment 3: An aerosol dispensing device according to either of the embodiments described above or below, wherein the heater is located within the radiant heating configuration of the liquid transport element.

[0050] Embodiment 4: An aerosol dispensing device according to either of the embodiments described above, wherein at least a portion of the liquid transport element is substantially flat, and the heater is at least partially located on the substantially flat portion of the liquid transport element.

[0051] Embodiment 5: An aerosol dispensing device according to either of the embodiments described above or below, wherein both the liquid transport element and the storage section are made of porous glass.

[0052] Embodiment 6: An aerosol dispensing device according to either of the embodiments described above or below, wherein the storage unit and the liquid transport element are an integrated element.

[0053] Embodiment 7: An aerosol dispensing device according to either of the embodiments described above or below, wherein the storage section has a first porosity and the liquid transport element has a second porosity different from the first porosity.

[0054] Embodiment 8: An aerosol dispensing device according to either of the embodiments described above or below, wherein the porous glass comprises one or more etched portions.

[0055] Embodiment 9: An aerosol dispensing device according to either of the embodiments described above, wherein the liquid transport element is formed of porous glass and the liquid transport element is substantially cylindrical.

[0056] Embodiment 10: An aerosol dispensing device according to either of the embodiments described above or below, wherein the heater is a wire wound around at least a portion of the liquid transport element.

[0057] Embodiment 11: An aerosol dispensing device according to either of the embodiments described above or below, wherein the storage section is made of porous glass and the liquid transport element is a fiber wick.

[0058] Embodiment 12: An aerosol dispensing device according to either of the embodiments described above or below, wherein the storage section is substantially cylindrical in shape with walls.

[0059] Embodiment 13: An aerosol dispensing device according to any of the embodiments described above or below, wherein one or more portions of a fiber wick are fluidly connected to the wall of a storage section.

[0060] Embodiment 14: An aerosol dispensing device according to either of the embodiments described above or below, wherein the wall of the storage section includes one or more grooves.

[0061] Embodiment 15: An aerosol dispensing device according to either of the embodiments described above or below, wherein one or more grooves have a different porosity than the rest of the wall of the storage section.

[0062] Embodiment 16: An aerosol dispensing device according to either of the embodiments described above or below, wherein the storage section is substantially in the shape of a hollow cylinder.

[0063] Embodiment 17: An aerosol dispensing device according to either of the embodiments described above, wherein the liquid transport element comprises a core and a shell.

[0064] Embodiment 18: An aerosol dispensing device according to either of the embodiments described above or below, wherein the shell is formed of porous glass.

[0065] Embodiment 19: An aerosol dispensing device according to either of the embodiments described above or below, wherein the core is formed of a fibrous material.

[0066] Embodiment 20: An aerosol dispensing device according to either of the embodiments described above or below, wherein the porous glass shell has ends on both sides, and the core of the liquid transport element extends beyond the ends on both sides of the porous glass shell.

[0067] Embodiment 21: An aerosol dispensing device according to either of the embodiments described above, wherein the heater is a wire wound around at least a portion of a porous glass shell.

[0068] Embodiment 22: An aerosol dispensing device according to either of the embodiments described above or below, wherein the outer housing is equipped with an air inlet and a suction port having an aerosol port.

[0069] Embodiment 23: An aerosol dispensing device according to any of the embodiments described above or below, wherein the device further comprises one or more of a power source, a pressure sensor, and a microcontroller.

[0070] Embodiment 24: An aerosol dispensing device as described in any of the above embodiments, wherein one or more of the power source, pressure sensor, and microcontroller are located in separate control housings that are connectable to the outer housing.

[0071] Embodiment 25: An atomizer comprising a vapor substrate formed of a porous monolith and configured for transferring a liquid aerosol precursor composition, and a heater in a heating configuration of the vapor substrate.

[0072] Embodiment 26: An atomizer according to either of the embodiments described above or below, further comprising a storage section.

[0073] Embodiment 27: An atomizer according to either of the embodiments described above or below, wherein the storage section is formed of a porous monolith.

[0074] Embodiment 28: An atomizer according to either of the embodiments described above or below, wherein the storage unit is connected to a vapor substrate.

[0075] Embodiment 29: An atomizer according to either of the embodiments described above or below, wherein the storage unit and the vapor substrate are an integrated element.

[0076] Embodiment 30: An atomizer according to either of the embodiments described above or below, wherein the vapor substrate has a first porosity and the storage section has a second porosity different from the first porosity.

[0077] Embodiment 31: An atomizer according to any of the embodiments described above or below, wherein one or both of the vapor substrate and the storage section include one or more etching sections.

[0078] Embodiment 32: An atomizer according to any of the embodiments described above or below, wherein one or both of the vapor substrate and the storage section are made of porous glass, one or both of the vapor substrate and the storage section are made of porous ceramic, or one of the vapor substrate and the storage section is made of porous glass and the other of the vapor substrate and the storage section is made of porous ceramic.

[0079] Embodiment 33: An atomizer according to either of the embodiments described above or below, wherein the storage section is made of porous glass and the vapor substrate is a fibrous wick.

[0080] Embodiment 34: An atomizer according to either of the embodiments described above or below, wherein the storage section is substantially cylindrical in shape with a wall.

[0081] Embodiment 35: An atomizer according to any of the embodiments described above or below, wherein one or more portions of the fiber wick are fluidly connected to the wall of the storage section.

[0082] Embodiment 36: An atomizer according to either of the embodiments described above, wherein the wall of the storage section includes one or more grooves.

[0083] Embodiment 37: An atomizer according to either of the embodiments described above or below, wherein one or more grooves have a different porosity than the rest of the wall of the storage section.

[0084] Embodiment 38: An atomizer according to either of the embodiments described above or below, wherein the storage section is substantially in the shape of a hollow cylinder.

[0085] Embodiment 39: An atomizer according to either of the embodiments described above or below, wherein the vapor substrate is substantially flat.

[0086] Embodiment 40: An atomizer according to either of the embodiments described above, wherein the heater is located at least partially on a substantially flat portion of the vapor substrate.

[0087] Embodiment 41: An atomizer according to either of the embodiments described above, wherein at least a portion of the heater is located inside the vapor substrate.

[0088] Embodiment 42: An atomizer according to either of the embodiments described above, wherein the vapor substrate is substantially in the form of a hollow tube, or the vapor substrate includes a channel formed inside.

[0089] Embodiment 43: An atomizer according to either of the embodiments described above or below, wherein the heater is printed on or annealed to a steam substrate.

[0090] Embodiment 44: An atomizer according to either of the embodiments described above or below, wherein the heater is configured to radiate heating of the vapor substrate.

[0091] Embodiment 45: An atomizer according to either of the embodiments described above, wherein the vapor substrate is formed of porous glass and the vapor substrate is substantially cylindrical.

[0092] Embodiment 46: An atomizer according to either of the embodiments described above or below, wherein the heater is a wire wound around at least a portion of the vapor substrate.

[0093] Embodiment 47: An atomizer according to either of the embodiments described above, wherein the vapor substrate comprises a core and a shell.

[0094] Embodiment 48: An atomizer according to either of the embodiments described above or below, wherein the shell is formed of porous glass.

[0095] Embodiment 49: An atomizer according to either of the embodiments described above or below, wherein the core is formed of a fibrous material.

[0096] Embodiment 50: An atomizer according to either of the embodiments described above or below, wherein the porous glass shell has ends on both sides, and the core of the liquid transport element extends beyond the ends on both sides of the porous glass shell.

[0097] Embodiment 51: An atomizer according to either of the embodiments described above or below, wherein the heater is a wire wound around at least a portion of a porous glass shell.

[0098] Embodiment 52: An aerosol dispensing device comprising an outer housing and an atomizer according to either of the embodiments described above or below.

[0099] Embodiment 53: A liquid transport element for an aerosol dispensing device, comprising: an elongated core having a certain length and formed of a wick material; and a shell surrounding the elongated core along at least a portion of the length of the elongated core, the shell being formed of a porous monolith.

[0100] Embodiment 54: A liquid transport element according to any of the above embodiments, wherein the wick material is a fibrous material.

[0101] These and other features, aspects, and advantages of the Disclosure will become apparent from reading the following detailed description, along with the accompanying drawings briefly shown below. The Invention includes any combination of two, three, four, or more of the embodiments described above, and any combination of two, three, four, or more of the features or elements described in the Disclosure, regardless of whether those features or elements are explicitly combined in the description of the particular embodiments herein. The Disclosure is intended to be read in whole so that any isolated features or elements of the Disclosed Invention can be seen as being combinable in any of its various aspects and embodiments, unless explicitly described otherwise in context.

[0102] Having described this disclosure using the general terminology mentioned above, I now refer to the attached drawings, which are not necessarily shown scaled to a constant ratio. [Brief explanation of the drawing]

[0103] [Figure 1] This is a partial breakaway view of an aerosol dispensing device comprising a cartridge and a control body including various elements that may be used in aerosol dispensing devices according to various embodiments of the present disclosure. [Figure 2] A perspective view of an atomizer according to one or more embodiments of the present disclosure, comprising a storage section and a liquid transport element, wherein one or both of the storage section and the liquid transport element are formed of a porous monolith and include porous glass and / or porous ceramic. [Figure 3] A partial cross-sectional view of an atomizer according to one or more embodiments of the present disclosure, comprising a storage section and a liquid transport element, wherein one or both of the storage section and the liquid transport element are formed of a porous monolith and include porous glass and / or porous ceramic. [Figure 4] This is a perspective view of a heater that may be used according to one or more embodiments of the present disclosure. [Figure 5]This is a partial cross-sectional view of a cartridge according to one or more embodiments of the present disclosure, which includes a storage section and a porous monolithic liquid transport element having heater wires for a heating configuration on the outer portion of the liquid transport element. [Figure 6] This figure shows a core / shell liquid transport element according to one or more embodiments of the present disclosure, having a shell formed of a porous monolith and a core optionally formed of a porous monolith or a different wick material. [Figure 7a] This is a perspective view of one or more embodiments of the atomizer of the present disclosure, which includes a storage section formed of a porous monolith that is substantially cylindrical in shape and incorporates liquid transport elements. [Figure 7b] Figure 7a is a bottom view of the atomizer. [Figure 8] This is a partial cross-sectional view of a cartridge according to one or more embodiments of the present disclosure, which includes a storage section and a porous monolithic liquid transport element having heater wires for a heating configuration in the inner portion of the liquid transport element. [Figure 9a] This is a cross-sectional view of a liquid transport element with a heater embedded inside. [Figure 9b] This is a cross-sectional view of a liquid transport element in the form of a substantially hollow tube, in which a heater is located within the cavity of the hollow tube. [Figure 9c] This is a cross-sectional view of a liquid transport element in which a heater is located within a cavity that is essentially in the form of a channel. [Modes for carrying out the invention]

[0104] This disclosure is described more fully hereby with reference to exemplary embodiments of the disclosure. These exemplary embodiments are described so as to be complete and self-contained and so as to fully convey the scope of the disclosure to those skilled in the art. Furthermore, this disclosure may be implemented in many different forms and should not be construed as being limited to the embodiments described herein. Rather, those embodiments are provided so as to satisfy the applicable legal requirements of this disclosure. Where used herein and in the appended claims, the singular forms "a," "an," and "the" include multiple references unless otherwise specified in context.

[0105] Embodiments of the present disclosure relate to an aerosol dispensing system, as described below.

[0106] The aerosol dispensing systems of the present disclosure use electrical energy to heat a material (preferably without burning the material to any significant degree and / or without significant chemical changes to the material) to form an inhalable substance, and the components of such systems are most preferably in the form of articles that are compact enough to be considered as a handheld device. That is, the use of components of preferred aerosol dispensing systems does not result in the production of smoke, i.e., smoke from the byproducts of the combustion or thermal decomposition of tobacco, but rather the use of these preferred systems results in the production of vapor / aerosol resulting from the volatilization or vaporization of certain components incorporated therein. In preferred embodiments, components of the aerosol dispensing systems may be characterized as e-cigarettes, and these e-cigarettes most preferably incorporate tobacco and / or tobacco-derived components, and thus transport tobacco-derived components in the form of an aerosol.

[0107] A particular preferred aerosol dispensing system aerosol generating piece can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the manner of inhalation and exhalation, the type of taste or aroma, the stimulating effect, the physical sensation, the manner of use, the visual stimuli such as the stimulation provided by a visible aerosol) by causing tobacco to glow and burn (and thus inhaling tobacco smoke) without any of its components burning to a considerable extent. For example, a user of the aerosol generating piece of the present disclosure may hold and use the piece as a smoker would use a traditional type of smoking article, inhaling one end of the piece to inhale the aerosol produced by the piece, and taking puffs or smokes at intervals of a chosen time. However, the devices described herein are not limited to devices that have a substantial shape and dimensions like a traditional cigarette. Rather, the devices may take any shape and may be substantially larger than a traditional cigarette.

[0108] The aerosol dispensing devices of this disclosure may also be characterized as vapor-generating devices or drug delivery devices. Thus, such devices or apparatus can be adapted to provide one or more substances (e.g., flavorings and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in the form of a vapor (i.e., a substance that is in the gas phase at temperatures below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For the purposes of simplification, the term “aerosol” as used herein is meant to include vapors, gases, and forms or types of aerosols suitable for human inhalation, whether visible or not, and whether or not they may be considered in a form that can be perceived as smoke-like.

[0109] The aerosol dispensing devices of this disclosure generally include a plurality of components provided within an outer body or shell, which may be referred to as a housing. The overall design of the outer body or shell can vary, and the form or configuration of the outer body, which can define the overall size and shape of the aerosol dispensing device, can also vary. In exemplary embodiments, an elongated body similar in shape to a cigarette or cigar may be formed from a single, integral housing, or the elongated housing may be formed from two or more divisible bodies. For example, an aerosol dispensing device may have a substantially cylindrical shape and thus comprise an elongated shell or body similar in shape to a conventional cigarette or cigar. In one embodiment, all the components of the aerosol dispensing device are contained within a single housing. Alternatively, an aerosol dispensing device may comprise two or more housings that are both coupled and divisible. For example, an aerosol dispensing device may hold a control body at one end. This control body comprises a housing that includes one or more components (e.g., a battery and various electronic devices for controlling the operation of the device). The aerosol dispensing device may also hold a removable outer body or shell at the other end. This outer body or shell contains aerosol forming components (for example, one or more aerosol precursor components such as a flavor and aerosol former, one or more heaters, and / or one or more wicks).

[0110] The aerosol dispensing devices of this disclosure may be formed in an outer housing or shell that is not substantially cylindrical in shape, but may be formed in dimensions that are substantially larger, i.e., may be substantially “palm-sized” so as to be held in the palm of a user's hand. The housing or shell may be configured to include a mouthpiece and / or may include a consumable element such as a liquid aerosol former and may be configured to receive another shell (e.g., a cartridge) which may include an evaporator or atomizer.

[0111] The aerosol dispensing devices of the present disclosure most preferably comprise several combinations of a power source (i.e., a power supply), at least one control component (means for operating, controlling, regulating, and stopping power for heating, such as by controlling the current flowing from the power source to other components of the device, e.g., a microcontroller or microprocessor), a heater or heating element (e.g., an electrically resistive heating element or other component, either alone or in combination with one or more further elements, which may generally be referred to as an "atomizer"), an aerosol precursor composition (e.g., a liquid that enables the generation of an aerosol when sufficient heat is applied, such as a material commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece or mouth area for enabling suction of the aerosol in the aerosol dispensing device (e.g., a defined airflow path through the device such that the generated aerosol can be drawn out thereafter when suctioned).

[0112] More specific forms, configurations, and arrangements of components within the aerosol dispensing systems of this disclosure will become apparent in light of the further disclosures provided below herein. Furthermore, the selection and arrangement of components of various aerosol dispensing systems can be understood by considering commercially available electronic aerosol dispensing devices, such as the representative products referenced in the background art section of this disclosure.

[0113] Figure 1 provides one exemplary embodiment of an aerosol dispensing device 100 illustrating components that may be used in an aerosol dispensing device according to the present disclosure. As seen in the cutaway view shown in Figure 1, the aerosol dispensing device 100 may comprise a control body 102 and a cartridge 104 that can be permanently or removablely aligned in a functional relationship. The engagement between the control body 102 and the cartridge 104 may be press-fit, screw-in, interference fit, magnetic, etc., as shown. Specifically, connecting components such as those further described herein may be used. For example, the control body may include a coupler adapted to engage with a connector on the cartridge.

[0114] In certain embodiments, one or both of the control unit 102 and the cartridge 104 may be referred to as disposable or reusable. For example, the control unit may have a replaceable battery or a rechargeable battery, and thus can be combined with any type of recharging technology, including connection to a normal electrical output, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer, such as through a Universal Serial Bus (USB) cable. For example, an adapter having a USB connector at one end and a control unit connector at the other end is disclosed in U.S. Patent Application Publication 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0115] Furthermore, in some embodiments, the cartridge may comprise a disposable cartridge, such as the one disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0116] As shown in Figure 1, the control body 102 can be formed by a control body shell 101 that can include control components 106 (e.g., printed circuit boards (PCBs), integrated circuits, memory components, microcontrollers, etc.), a flow sensor 108, a battery 110, and LEDs 112, and such components can be arranged in various ways. Further indicators (e.g., haptic feedback components, audio feedback components, etc.) may be included in addition to or alternative to the LEDs. Components that provide visible stimuli or indicators, such as light-emitting diode (LED) components, as well as further representative types of their configurations and uses, are described in U.S. Patent No. 5,154,192 to Sprinkel et al., U.S. Patent No. 8,499,766 to Newton, and U.S. Patent No. 8,539,959 to Scatterday, and U.S. Patent Application No. 14 / 173,266 to Sears et al., filed February 5, 2014. These documents are incorporated herein by reference.

[0117] The cartridge 104 may be formed of a cartridge shell 103 that encloses a storage section 144. The storage section 144 is in fluid communication with a liquid transport element 136 adapted to transport the aerosol precursor composition stored in the storage section housing to the heater 134 by capillary action or otherwise. Various embodiments of materials configured to generate heat when an electric current is passed through them may be used to form the resistive heating element 134. Exemplary materials that can form a wire coil include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-added molybdenum silicide (Mo(Si,Al)2), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), and ceramics (e.g., ceramics with positive or negative temperature coefficients). As further described herein, the heater may include a laser diode and include various materials configured to provide electromagnetic radiation.

[0118] An opening 128 may be present in the cartridge shell 103 (e.g., mouthpiece) to allow the aerosol formed from the cartridge 104 to exit. Such a component is representative of the components that may be present in the cartridge and is not intended to limit the scope of cartridge components covered by this disclosure.

[0119] The cartridge 104 may also include one or more electronic components 150. These electronic components 150 may include integrated circuits, memory components, sensors, and the like. The electronic components 150 may be adapted to communicate with the control components 106 and / or external devices by wired or wireless means. The electronic components 150 may be located anywhere within the cartridge 104 or its base 140.

[0120] Although the control component 106 and the flow sensor 108 are shown separately, it should be understood that the control component and the flow sensor can be combined as an electronic circuit board, with an airflow sensor directly mounted on this board. Furthermore, the electronic circuit board may be positioned horizontally to the display in Figure 1. In this configuration, the electronic circuit board can be elongated parallel to the central axis of the control body. In some embodiments, the airflow sensor may have its own circuit board or other base elements to which the airflow sensor can be mounted. In some embodiments, a flexible circuit board may be used. A flexible circuit board may have a substantially cylindrical shape and can be configured in a variety of shapes.

[0121] The control body 102 and the cartridge 104 may include components adapted to facilitate fluid engagement between them. As shown in Figure 1, the control body 102 may include a coupler 124 having a cavity 125 inside. The cartridge 104 may include a base 140 adapted to engage with the coupler 124, and may also include a projection 141 adapted to fit into the cavity 125. Such engagement facilitates a stable connection between the control body 102 and the cartridge 104 and can also establish an electrical connection between the battery 110, the control components 106 in the control body, and the heater 134 in the cartridge. Furthermore, the control body shell 101 may include an air intake 118. This air intake 118 may be a notch in the shell, at which point the air intake 118 is connected to the coupler 124. This allows air around the coupler to pass into the shell, thus through the cavity 125 of the coupler and into the cartridge through the projection 141.

[0122] Couplers and bases useful in accordance with this disclosure are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al. The disclosures of that document are incorporated herein by reference in their entirety. For example, a coupler as shown in Figure 1 may define an outer circumference 126 configured to mate with an inner circumference 142 of a base 140. In one embodiment, the inner circumference of the base may define a radius that is approximately equal to or slightly larger than the radius of the outer circumference of the coupler. Furthermore, the coupler 124 may define one or more protrusions 129 on the outer circumference 126 configured to engage with one or more recesses 178 defined in the inner circumference of the base. However, various other embodiments of structure, shape, and components may be used to connect a base to a coupler. In some embodiments, the connection between the base 140 of the cartridge 104 and the coupler 124 of the control body 102 may be substantially permanent, while in other embodiments, the connection between them may be detachable, for example, so that the control body can be reused with one or more additional cartridges that may be disposable and / or refillable.

[0123] In some embodiments, the aerosol dispensing device 100 may be substantially rod-shaped, substantially tubular, or substantially cylindrical. In other embodiments, further shapes and dimensions are included, for example, rectangular or triangular cross-sections, multifaceted shapes, etc.

[0124] The storage section 144 shown in Figure 1 can take any design configured to hold liquid, such as a container or bulk, which is configured to absorb and / or adsorb liquid. For example, it could be a fibrous storage section or a porous monolith, as described herein. As shown in Figure 1, the storage section 144 may comprise one or more layers of nonwoven fibers substantially formed in the shape of a tube surrounding the inside of the cartridge shell 103. The aerosol precursor composition can be held within the storage section 144. For example, liquid components can be sorbed and held by the storage section 144. The storage section 144 can be fluidly connected to a liquid transport element 136. The liquid transport element 136 can transport the aerosol precursor composition stored within the storage section 144 to a heating element 134 via capillary action. In this embodiment, the heating element 134 is in the form of a metal wire coil. Thus, the heating element 134 is the heating component of the liquid transport element 136.

[0125] During use, when the user inhales into the device 100, the airflow is detected by the sensor 108, the heating element 134 is activated, and the components for the aerosol precursor composition are vaporized by the heating element 134. By inhaling into the mouthpiece of the device 100, ambient air enters the air intake 118 and passes through the cavity 125 in the coupler 124 and the central opening of the projection 141 of the base 140. Inside the cartridge 104, the inhaled air combines with the formed vapor to form an aerosol. The aerosol is then drawn out from the heating element 134 through the mouth opening 128 of the mouthpiece of the device 100 by capillary action, suction, or other means.

[0126] Input elements may be included in an aerosol dispensing device. Inputs may be included to allow a user to control the device's functions and / or to provide output information to the user. Any component, or any combination of components, may be used as an input to control the device's functions. For example, one or more push buttons may be used as described in U.S. Patent Application No. 14 / 193,961, filed February 28, 2014, to Worm et al., which is incorporated herein by reference. Similarly, a touchscreen may be used as described in U.S. Patent Application No. 14 / 643,626, filed March 10, 2015, to Sears et al., which is incorporated herein by reference. As a further example, components applied for the recognition of actions based on specific movements of an aerosol dispensing device may be used as inputs. See U.S. Patent Application No. 14 / 565,137, filed December 9, 2014, to Henry et al. This document is incorporated herein by reference.

[0127] In some embodiments, the input may comprise a computer or computer device, such as a smartphone or tablet. Specifically, the aerosol dispensing device may be wired to a computer or other device, such as via the use of a USB cord or a similar protocol. The aerosol dispensing device may also communicate with a computer or other device acting as an input, albeit via wireless communication. See, for example, the System and Method for Controlling a Device via Read Requests, as described in U.S. Patent Application No. 14 / 327,776, filed July 10, 2014, to Ampolini et al. The disclosures of that document are incorporated herein by reference. In such embodiments, an app or other computer program may be used in conjunction with a computer or other computer device to input control instructions to the aerosol dispensing device. Such control instructions may include, for example, the ability to form an aerosol of a particular composition by selecting the nicotine content and / or the content of further flavorings to be included.

[0128] Various components of the aerosol dispensing device relating to this disclosure can be selected from components described in the said art and available for commercial use. An example of a battery that can be used in accordance with this disclosure is described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al. The disclosure of that document is incorporated herein by reference in whole.

[0129] An aerosol dispensing device may incorporate a sensor or detector to control the power supply to a heating element when aerosol generation is desired (for example, when inhaled during use). For example, a scheme or method is provided for turning off the power supply to the heating element when the aerosol dispensing device is not inhaled during use, and for turning on the power supply so that heat generation by the heating element is activated or triggered while inhaling.

[0130] Further representative types of detection mechanisms or detection systems, their structure and configuration, their components, and general methods of operation are described in U.S. Patent No. 5,261424 to Sprinkel, Jr., U.S. Patent No. 5,372148 to McCafferty et al., and PCT International Publication No. 2010 / 003480 to Flick. These documents are incorporated herein by reference.

[0131] The aerosol dispensing device most preferably incorporates a control mechanism for controlling the amount of power supplied to the heat-generating element during suction. Representative types of electronic components, their structure and configuration, their characteristics, and general methods of operation are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent No. 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., U.S. Patent No. 8,205,622 to Pan, U.S. Patent Publication No. 2009 / 0230117 to Fernando et al., U.S. Patent Publication No. 2014 / 0060554 to Collett et al., U.S. Patent Publication No. 2014 / 0270727 to Ampolini et al., and U.S. Patent Application No. 14 / 209,191 to Henry et al., filed on March 13, 2014. These documents are incorporated herein by reference.

[0132] Typical types of substrates, storage units, or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Publication No. 2014 / 0261487 to Chapman et al., U.S. Patent Publication No. 2014 / 0059780 to Davis et al., and U.S. Patent Application No. 14 / 170,838 filed February 3, 2014, to Bless et al. These documents are incorporated herein by reference. Furthermore, various wick materials found in certain types of e-cigarettes, as well as the composition and operation of these wick materials, are described in U.S. Patent No. 8,910,640. This document is incorporated herein by reference.

[0133] With respect to aerosol dispensing systems characterized as electronic cigarettes, the composition of the aerosol precursor most preferably incorporates tobacco or components derived from tobacco. In one respect, tobacco may be provided as parts or pieces of tobacco, such as finely ground, milled, or powdered tobacco flakes. In another respect, tobacco may be provided in the form of an extract, such as a spray-dried extract, which incorporates a large amount of the water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of an extract with a relatively high nicotine content, which also incorporates small amounts of other extracted components derived from tobacco. In another respect, components derived from tobacco may be provided in a relatively pure form, such as certain flavoring agents derived from tobacco. In one respect, a component derived from tobacco, and a component that can be used in a highly purified or essentially pure form, is nicotine (e.g., pharmaceutical-grade nicotine).

[0134] Aerosol precursor compositions, also referred to as vapor precursor compositions, may comprise a variety of components, including, for example, polyhydric alcohols (e.g., glycerin, propylene, glycol, or mixtures thereof), nicotine, tobacco, tobacco extract, and / or flavorings. Representative types of aerosol precursor compositions and structures are also described and characterized in U.S. Patent No. 7,217320 to Robinson et al., U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Publication No. 2013 / 0213417 to Chong et al., U.S. Patent Publication No. 2014 / 0060554 to Collett et al., U.S. Patent Publication No. 2015 / 0020823 to Lipowicz et al., and U.S. Patent Publication No. 2015 / 0020830 to Koller, as well as International Publication No. 2014 / 182736 to Bowen et al. The disclosures of these documents are incorporated herein by reference. Other aerosol precursors that may be used include the aerosol precursors incorporated into the VUSE(R) product by RJReynolds Vapor Company, the BLU(TM) product by Lorillard Technologies, the MISTIC MENTHOL product by Mistic Ecigs, and the VYPE product by CN Creative Ltd. Still preferred are the so-called "smoke juices" for e-cigarettes, available from Johnson Creek Enterprises LLC.

[0135] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating piece provides acceptable sensation and desired performance characteristics. For example, it is quite preferable that a sufficient amount of aerosol-forming material (e.g., glycerin and / or propylene glycol) is used to provide, in many respects, the production of a visible, mainstream aerosol that resembles the appearance of cigarette smoke. The amount of aerosol precursor in the aerosol generating system may be based on factors such as the desired number of inhalations per aerosol generating piece. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system, and especially into the aerosol generating piece, is less than about 2 g, usually less than about 1.5 g, often less than about 1 g, and frequently less than about 0.5 g.

[0136] Further features, controls, or components that can be incorporated into the aerosol dispensing system of this disclosure are as follows: U.S. Patent No. 5,967,148 to Harris et al., U.S. Patent No. 5,934,289 to Watkins et al., U.S. Patent No. 5,954,979 to Counts et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,402,976 to Fernando et al., U.S. Patent Application Publication No. 20 This is described in U.S. Patent Publication No. 10 / 0163063, U.S. Patent Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent Publication No. 2013 / 0298905 to Leven et al., U.S. Patent Publication No. 2013 / 0180553 to Kim et al., U.S. Patent Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Publication No. 2014 / 0261495 to Novak et al., and U.S. Patent Publication No. 2014 / 0261408 to DePiano et al. These documents are incorporated herein by reference.

[0137] The foregoing description of the use of the apparatus can be applied to various embodiments described herein through minor modifications. These modifications may be apparent to those skilled in the art in light of further disclosures provided herein. However, the above description of use is not intended to limit the use of the apparatus, but is provided to satisfy all the necessary disclosure requirements of this disclosure. Any elements shown in Figure 1 or otherwise described above in relation to the apparatus may be included in the aerosol dispensing device relating to this disclosure.

[0138] In one or more embodiments, the disclosure relates to the use of a porous monolithic material in one or more components of an aerosol dispensing device. As used herein, “porous monolithic material” or “porous monolith” is intended to mean comprising substantially a single unit, which may be a single piece, formed, constructed, or created without joints or seams, and which is substantially rigid and uniform as a whole, but not necessarily so. In some embodiments, the monolith according to the disclosure may be undifferentiated, i.e., formed from a single material, or may be formed from a plurality of permanently joined units, such as a sintered aggregate.

[0139] In some embodiments, the use of porous monoliths may particularly relate to the use of porous glass in components of aerosol dispensing devices. As used herein, “porous glass” is intended to refer to glass having a three-dimensional interconnected porous microstructure. This term may particularly exclude materials formed from bundles of glass fibers (i.e., woven or nonwoven). For this reason, porous glass may exclude fibrous glass. Porous glass may also be called controlled pore glass (CPG) and may be known by the trade name VYCOR(R). Porous glass suitable for use relating to this disclosure can be prepared, for example, by known methods such as the separation of a metastable phase of borosilicate glass, one of the formed phases, via a sol-gel process or by sintering glass powder, followed by the extraction of a liquid (e.g., extraction of an acidic substance, or extraction of an acidic and alkaline substance together). Porous glass can be high-silica glass, such as containing 90% or more, 95%, 96% or more, or 98% or more by weight of silica. Porous glass materials and methods for preparing porous glass that can be made suitable for use relating to this disclosure are described in U.S. Patent No. 2,106,744 to Hood et al., U.S. Patent No. 2,215,039 to Hood et al., U.S. Patent No. 3,485,687 to Chapman et al., U.S. Patent No. 4,657,875 to Nakashima et al., U.S. Patent No. 9,003,833 to Kotani et al., U.S. Patent Application Publication No. 2013 / 0045853 to Kotani et al., U.S. Patent Application Publication No. 2013 / 0067957 to Zhang et al., U.S. Patent Application Publication No. 2013 / 0068725 to Takashima et al., and U.S. Patent Application Publication No. 2014 / 0075993 to Himanshu. The disclosures in these documents are incorporated herein by reference. The term porous “glass” may be used herein, but this shall not be construed as limiting the scope of this disclosure by meaning that “glass” can encompass a variety of silica-based materials.

[0140] In some embodiments, porous glass can be defined in terms of the average pore size of the porous glass. For example, the porous glass can have an average pore size of from about 1 nm to about 1000 μm, from about 2 nm to about 500 μm, from about 5 nm to about 200 μm, or from about 10 nm to about 100 μm. In certain embodiments, porous glasses for use according to the present disclosure can be distinguished based on average pore size. For example, small-pore porous glass can have an average pore size of from 1 nm to 500 nm, medium-pore porous glass can have an average pore size of from 500 nm to 10 μm, and large-pore porous glass can have an average pore size of from 10 μm to 1000 μm. In some embodiments, large-pore porous glass may preferably be useful as a storage element, and small-pore porous glass and / or medium-pore porous glass may preferably be useful as a transport element.

[0141] In some embodiments, porous glass can also be defined in terms of the surface area of the porous glass. For example, porous glass can have at least 100 m 2 / g, at least 150 m 2 / g, at least 200 m 2 / g, or at least 250 m 2 / g, about 100 m 2 / g to about 600 m 2 / g, about 150 m 2 / g to about 500 m 2 / g, or about 200 m 2 / g to about 450 m 2 / g, and other surface areas.

[0142] Porous glass can, in some embodiments, be defined in terms of its porosity (i.e., the percentage of the volume of material surrounded by pores). For example, porous glass may have porosities of at least 20%, at least 25%, or at least 30%, about 20% to about 80%, about 25% to about 70%, or about 30% to about 60% by volume. In certain embodiments, lower porosities may be desirable, such as porosities of about 5% to about 50%, about 10% to about 40%, or about 15% to about 30% by volume.

[0143] In some embodiments, porous glass can be further defined with respect to its density. For example, porous glass may have a density of 0.25 g / cm³. 3 Approximately 3g / cm³ 3 , about 0.5g / cm 3 Approximately 2.5 g / cm³ 3 , or approximately 0.75 g / cm³ 3 Approximately 2g / cm³ 3 It can have a density of .

[0144] In some embodiments, the use of porous monoliths relates particularly to the use of porous ceramics in components of aerosol dispensing devices. As used herein, “porous ceramic” is intended to refer to a ceramic material having a three-dimensional interconnected porous microstructure. Porous ceramic materials and methods for forming porous ceramics that are suitable for use relating to this disclosure are described in U.S. Patent No. 3,090,094 to Schwartzwalder et al., U.S. Patent No. 3,833,386 to Frisch et al., U.S. Patent No. 4,814,300 to Helferich, U.S. Patent No. 5,171,720 to Kawakami, U.S. Patent No. 5,185,110 to Kunikazu et al., U.S. Patent No. 5,227,342 to Anderson et al., U.S. Patent No. 5,645,891 to Liu et al., U.S. Patent No. 5,750,449 to Niihara et al., U.S. Patent No. 6,753,282 to Fleischmann et al., U.S. Patent No. 7,208,108 to Otsuka et al., U.S. Patent No. 7,537,716 to Matsunaga et al., and U.S. Patent No. 8,609,235 to Hotta et al. The disclosures of these documents are incorporated herein by reference. The term "porous ceramic" may be used herein, but this shall not be construed as limiting the scope of the disclosure by meaning that "ceramic" can encompass a variety of alumina-based materials.

[0145] Similarly, in some embodiments, porous ceramics can be defined with respect to the average pore size of the porous ceramic. For example, porous ceramics may have average pore sizes of about 1 nm to about 1000 μm, about 2 nm to about 500 μm, about 5 nm to about 200 μm, and about 10 nm to about 100 μm. In certain embodiments, porous ceramics for use according to the Disclosure can be distinguished based on the average pore size. For example, small-pore porous ceramics may have an average pore size of 1 nm to 500 nm, medium-pore porous ceramics may have an average pore size of 500 nm to 10 μm, and large-pore porous ceramics may have an average pore size of 10 μm to 1000 μm. In some embodiments, large-pore porous ceramics may preferably be useful as storage elements, and small-pore porous ceramics and / or medium-pore porous ceramics may preferably be useful as transport elements.

[0146] Porous ceramics can also be defined in some embodiments with respect to the surface area of ​​porous glass. For example, a porous ceramic may have at least 100 m 2 / g, at least 150m 2 / g, at least 200m 2 / g, or at least 250m 2 / g, about 100m 2 From / g to approximately 600m 2 / g, approx. 150m 2 From / g to approximately 500m 2 / g, or approximately 200m 2 From / g to approximately 450m 2 It can have a surface area such as / g.

[0147] Porous ceramics can, in some embodiments, be defined in terms of their porosity (i.e., the percentage of the volume of material surrounded by pores). For example, a porous ceramic may have a porosity of at least 20%, at least 25%, or at least 30%, about 20% to about 80%, about 25% to about 70%, or about 30% to about 60% by volume. In certain embodiments, lower porosities may be desirable, such as porosities of about 5% to about 50%, about 10% to about 40%, or about 15% to about 30% by volume.

[0148] In some embodiments, porous ceramics can be further defined with respect to their density. For example, a porous ceramic may have a density of 0.25 g / cm³. 3 Approximately 3g / cm³ 3 , about 0.5g / cm 3 Approximately 2.5 g / cm³ 3 , or approximately 0.75 g / cm³ 3 Approximately 2g / cm³ 3 It can have a density of .

[0149] While silica-based materials (e.g., porous glass) and alumina-based materials (e.g., porous ceramics) may be discussed separately herein, it should be understood that in some embodiments, the porous monolith may include a variety of aluminosilicate materials. For example, various zeolites may be used in accordance with this disclosure.

[0150] Porous monoliths used in accordance with this disclosure can be provided in a variety of sizes and shapes. Preferably, the porous monolith may be substantially elongated, substantially flat or planar, substantially curved (e.g., “U-shaped”), substantially walled cylinder, or any other shape suitable for use in accordance with this disclosure.

[0151] In one or more embodiments, the porous monoliths according to the Disclosure can be characterized with respect to the capillary suction rate. In non-limiting examples, the capillary suction rate can be calculated by measuring the mass of a known liquid taken up, and the rate (in mg / s) can be measured using a microbalance tensile meter or similar instrument. Preferably, the capillary suction rate is substantially within a range of the desired mass of aerosol produced over the duration of a single puff in an aerosol forming device containing a porous monolith. The capillary suction rate can be, for example, within a range of about 0.05 mg / s to about 15 mg / s, about 0.1 mg / s to about 12 mg / s, or about 0.5 mg / s to about 10 mg / s. The capillary suction rate may vary based on the liquid being transported by capillary action. In some embodiments, the capillary suction rate described herein may refer to substantially pure water, substantially pure glycerol, substantially pure propylene glycol, a mixture of water and glycerol, a mixture of water and propylene glycol, a mixture of glycerol and propylene glycol, or a mixture of water, glycerol, and propylene glycol. The capillary suction rate may also vary based on the use of porous monoliths. For example, a porous monolith used as a liquid transport element may have a greater capillary suction rate than a porous monolith used as a storage unit. The capillary suction rate may also vary by controlling one or more of the pore size, the distribution of pore size, and wetting properties, as well as the composition of the material being capillarily drawn up.

[0152] An exemplary embodiment of the present disclosure relating to a porous monolith is shown in Figure 2. As seen in Figure 2, the liquid transport element 236 is surrounded by and in contact with the storage section 244. In some embodiments, the liquid transport element or storage section can be characterized as a vapor substrate. The term “vapor substrate” thus refers to a substrate that stores and / or transports a liquid for vaporization and can be in contact with a heater to vaporize at least a portion of the liquid stored and / or transported by the vapor substrate. For example, a single porous monolith may function as a storage section that can be in direct contact with a heater to form vapor without requiring another liquid transport element (or wick). In such an example, the storage section can be considered a vapor substrate. In other embodiments, another liquid transport element may be in contact with a heater and also with a separate storage section, thereby allowing the liquid to be transported from the storage section to the heater for vaporization. In such an example, the liquid transport element can be considered a vapor substrate. Where a storage unit is described otherwise herein, it should be understood that such a storage unit may be appropriately characterized as a vapor substrate. Similarly, where a liquid transport element is described otherwise herein, it should be understood that such a liquid transport element may be appropriately characterized as a vapor substrate.

[0153] In one or more embodiments, the porous monolith may comprise porous glass. For example, one or both of the liquid transport element 236 and the storage section 244 may be made of porous glass as described herein. For illustrative purposes, both the liquid transport element 236 and the storage section 244 may be formed of porous glass, and preferably each of them may be formed of a different porous glass (i.e., a first porous glass and a second porous glass). In one or more embodiments, the first porous glass and the second porous glass may differ in one or more characteristics that may affect the storage and / or transport capacity of each porous glass. For example, the first porous glass and the second porous glass may differ in one or more of the density, porosity, surface area, and average pore size. The distinction between the liquid transport element 236 and the storage section 244 is sufficient to provide a gradient for capillary suction, and the capillary suction capacity is greater in the liquid transport element than in the storage section. Such a configuration may be characterized as a gradient porous or two-porous configuration.

[0154] In further embodiments, the porous monolith may comprise a porous ceramic. Thus, one or both of the liquid transport element 236 and the storage section 244 may be made of porous ceramic. Again, one of the liquid transport element 236 and the storage section 244 may be formed of porous glass, and the other of the liquid transport element and the storage section may be formed of porous ceramic. Thus, the porous glass and the porous ceramic may have properties that are substantially matched to provide substantially identical flow characteristics, or the porous glass and the porous ceramic may have substantially different properties to provide substantially different flow characteristics.

[0155] The heater 234 is positioned relative to the liquid transport element 236 so as to be configured for vaporizing a liquid aerosol precursor material stored in the storage section 244 and transported from the storage section 244 to the heater by a liquid transport element. The heater 234 can be, for example, a printed microheater, an annealed microheater, a flat ribbon heater, or any similar configuration suitable for vaporizing aerosol precursor compositions as otherwise described herein. The heater 234 may be in direct contact with the liquid transport element 236 or it may be in a radiant heating configuration relative to the liquid transport element, i.e., very close but not in direct contact with the liquid transport element. When the liquid aerosol precursor material vaporizes on the surface of the liquid transport element 236 due to heating by the heater 234, additional liquid can be drawn out by capillary action from the storage section 244 to the vicinity of the heater 234 by the liquid transport element, filling the area where the liquid has been used up by vaporization.

[0156] In some embodiments, one or more etched areas (i.e., grooves or channels) may be present in either the storage section 244 or the liquid transport element 236. While grooves or channels may be formed by an etching process, the use of the term “etching” is not limited to the process of forming grooves or channels. As shown in Figure 2, a first set of grooves 256 is etched into the liquid transport element 236 around the heater 234. The first set of grooves 256 is useful in limiting direct contact of the liquid aerosol precursor composition with the heater 234. For this reason, if desired, the porous monolith (particularly the heater area) may be insulated, coated, or sealed to prevent the liquid aerosol precursor composition from coming into direct contact with the heater. Direct contact of the liquid aerosol precursor composition with the heater could act to damage the heater. In one or more embodiments, a second set of grooves 254 may be etched onto the surface of the storage section 244 so that the liquid aerosol precursor composition is substantially directed towards the central area of ​​the heater where Joule heating is maximized. Although not shown, it should be understood that the second set of grooves 254 may be substantially aligned with and / or interconnected with the first set of grooves 256. Similarly, the presence of the second set of grooves 254 is not a prerequisite for the presence of the first set of grooves 256, nor is it the other way around.

[0157] The combination of the heater 234, the liquid transport element 236, and the storage unit 244 may be characterized as an atomizer 20. In one or more embodiments, the storage unit 244 may not be present in the atomizer 20.

[0158] Although the storage section 244 and the liquid transport element 236 are shown as separate elements, such separation is not necessary. In some embodiments, a single porous monolithic substrate may be used, and the storage area and the liquid transport area may be distinguished by treatment of the area.

[0159] Furthermore, while the storage section 244 and the liquid transport element 236 are shown in Figure 2 as substantially flat, other shapes are also included. For example, one or both of the storage section and the liquid transport element may individually be cylindrical, flat, oval, circular, square, rectangular, etc. Preferably, at least a portion of the surface of the liquid transport element is substantially smooth to provide a place for the heater. Such an embodiment is illustrated in Figure 3, where the storage section 344 is substantially half a cylinder. The liquid transport element 336 is an inset of the smooth surface 344a of the storage section, although the liquid transport element may be laminated on the smooth surface of the storage section. As seen in Figure 3, the heater 334 is positioned on the liquid transport element 336, and the etching section 356 is located within the liquid transport element.

[0160] An exemplary heater 434 is shown in Figure 4, and such embodiments may particularly relate to so-called microheaters, such as those described in U.S. Patent Application Publication No. 2014 / 0060554 to Collett et al., which is incorporated herein by reference. As shown in Figure 4, the heater 434 may comprise a heater substrate 434a on which heater traces 434b are provided. The heater substrate 434a is preferably a chemically stable, heat-resistant material (e.g., silicon or glass), and the heater traces 434b may be a material suitable for rapid heating, such as a heating wire, as otherwise described herein.

[0161] The atomizer 20, as shown in Figure 2, can be incorporated into a cartridge 104, for example, as seen in Figure 1. The atomizer 20 can be included in the positions of the heater 134, the liquid transport element 136, and optionally the storage unit 144. In some embodiments, the atomizer 20 can be simply included in addition to the further elements shown in Figure 1.

[0162] In one or more embodiments, the porous monolith may be used solely as a liquid transport element.

[0163] For example, as shown in Figure 5, the cartridge 504 is formed of a shell 503 and a storage section 544 that holds the composition of the liquid aerosol precursor. The storage section 544 may be a fibrous mat from which the liquid is absorbed, or it may be a container with appropriate holes inside for receiving the liquid transport element 536. The liquid transport element 536 is formed of a porous monolith and also has respective ends 536a and 536b extending into the storage section 544. A heater 534 in the form of a resistive heating wire is wound around the liquid transport element 536 in its approximately intermediate section 536c, and the wire includes terminals 535 for forming an electrical connection to a power source. In some embodiments, the liquid transport element 536 may be porous glass. In further embodiments, the liquid transport element 536 may be porous ceramic. In one or more embodiments, one or both of the liquid transport element 536 and the storage section 544 can be made of porous glass, or one or both of the liquid transport element and the storage section can be made of porous ceramic. In some embodiments, one of the liquid transport element 536 and the storage section 544 can be made of porous glass, and the other of the liquid transport element and the storage section can be made of porous ceramic.

[0164] In some embodiments, the liquid transport element according to the Disclosure may be substantially in the form of a core / shell. For example, as shown in Figure 6, the core 636a may be surrounded at least a portion thereof by a shell 636b, the portion of which may be formed of a porous monolith. If desired, the core 636a may also be formed of a porous monolith. For example, the core 636a may be formed of porous glass having one or more properties different from the porous glass forming the shell 636b, thereby providing characteristic properties of the combined element. Specifically, the core 636a may be formed of porous glass configured to improve liquid storage, and the shell 636b may be formed of porous glass configured to improve liquid transport for rapid capillary suction to a heater 634. This heater 634 may be a wire substantially wound around the shell. In some embodiments, the core 636a may be formed of a material different from porous glass, such as a fibrous material. As a non-limiting example, the core 636a may be formed from fiberglass, cotton, cellulose acetate, or a similar material. In some embodiments, one or both of the core 636a and the shell 636b may be formed from porous ceramic. In further embodiments, one of the core 636a and the shell 636b may be formed from porous glass, and the other of the core and shell may be formed from porous ceramic.

[0165] As shown in Figure 6, the porous monolithic shell 636b has ends 636b' and 636b'' on both sides, and the core 636a is sized such that the core 636a extends beyond both ends of the porous monolithic shell. One or both of the ends 636a' and 636a'' of the core 636a can be positioned within an aerosol dispensing device so as to extend into a storage section (e.g., a fibrous mat or bulk liquid storage container), thereby drawing the liquid into the shell 636b by capillary action, which in turn allows the liquid to be vaporized by a heater 634. As previously mentioned, the heater 634 may include terminals 635 for forming an electrical connection to a power source. Such a core / shell design can be particularly advantageous because the high heat provided by the heating wire can prevent the core material from potentially scorching. Similarly, during use, the airflow for moving the formed vapor may substantially pass through the porous monolithic shell, with little to no airflow passing through the core material.

[0166] The combination of elements in Figure 6 can be collectively characterized as atomizer 60.

[0167] In any case, it should be understood that one or more elements (for example, core 636a, and / or shell 636b, and / or heater 634) may be used separately from the unit in combination with one or more further embodiments described herein.

[0168] In one or more embodiments, a porous monolith can be used as a storage section that can be substantially cylindrical in shape. For example, Figures 7a and 7b show an atomizer 70 having a storage section 744 formed of a cylindrical porous monolith. The storage section 744 has walls 745 of varying thickness, and a central opening 746 is defined by the walls. The liquid transport element 736 is configured to have a central portion 736c and respective end portions 736a' and 736a'' extending outward from this central portion. The respective end portions 736a' and 736a'' are configured to be fluidly connected to the walls 745 of the storage section 744. One or both of the liquid transport element 736 and the storage section 744 can be formed of porous glass. For example, the liquid transport element 736 may be formed of porous glass having one or more properties different from those of the porous glass forming the storage section 744. In some embodiments, the liquid transport element 736 may be formed of a fibrous material and may therefore be called a fibrous wick. A heater 734 in the form of a wire wound around the central portion 736c of the liquid transport element 736 may include terminals 735 for forming an electrical connection to a power source. In one or more embodiments, one or both of the liquid transport element 736 and the storage section 744 may be formed of porous ceramic. In some embodiments, one of the liquid transport element 736 and the storage section 744 may be formed of porous glass, and the other of the liquid transport element and the storage section may be formed of porous ceramic.

[0169] In some embodiments, the wall 745 of the storage section may include one or more grooves 744a. The respective end portions 736a' and 736a'' of the liquid transport element 736 may engage with the storage section 744 in the grooves 744a, in particular. If desired, the grooves 744a may be configured to have one or more properties different from the rest of the storage section, such as having different porosity. In this manner, the liquid stored in the storage section 744 may be preferentially directed towards the grooves 744a taken by the liquid transport element 736 for transport to the heater 734.

[0170] While the elements in Figures 7a and 7b are shown as a unit forming the atomizer 70, it should be understood that one or more elements (e.g., a storage unit 744, and / or a liquid transport element 736, and / or a heater 734) may be used separately from the unit in combination with one or more further embodiments described herein.

[0171] In one or more embodiments, the porous monolith forming the liquid transport element may have a heating element contained within it. For example, as shown in Figure 8, the cartridge 804 is formed of a shell 803 and a storage section 844 that holds a composition of liquid aerosol precursor. The storage section 844 may be a fibrous mat from which the liquid is absorbed, or it may be a wall-shaped container with appropriate holes inside for receiving the liquid transport element 836. The liquid transport element 836 is formed of a porous monolith and also has respective ends 836a and 836b extending into the storage section 844. A heater 834 in the form of a resistive heating wire is located within the liquid transport element 836, and the wire includes terminals 835 for forming an electrical connection to a power source. A flow tube 839 may be included and useful for directing air through the liquid transport element 836 so that vapors emitted by internal heating of the liquid transport element by the heater 834 are carried in the air to form an aerosol that can be drawn out by the consumer. In some embodiments, the liquid transport element 836 can be made of porous glass. In further embodiments, the liquid transport element 836 can be made of porous ceramic. In one or more embodiments, one or both of the liquid transport element 836 and the storage section 844 can be made of porous glass, or one or both of the liquid transport element and the storage section can be made of porous ceramic. In some embodiments, one of the liquid transport element 836 and the storage section 844 can be made of porous glass, and the other of the liquid transport element and the storage section can be made of porous ceramic. Furthermore, the liquid transport element 844 can be made of porous glass or porous ceramic, and the storage section 844 can be a fibrous mat or a storage container.

[0172] The heater 834 can be incorporated into the liquid transport element 836 in various ways. In some embodiments, the heater can be embedded within a porous monolith. For example, the porous monolith can be formed together with the heater in place so that the heater is substantially confined within the liquid transport element. In the representation in Figure 9a, for example, the heater 934 is embedded within the liquid transport element 936, with the end of the heater extending outward from the liquid transport element to form an electrical connection with a terminal (see element 835 in Figure 8). In some embodiments, the porous monolith can be hollow, substantially tubular, have internally formed slots, channels, etc., or otherwise contain a cavity in which the heater is positioned so that it is substantially inside the liquid transport element. For example, in Figure 9b, the liquid transport element 936 is a hollow tube, and the heater 934 is located within a cavity 937 of the hollow tube. In Figure 9c, for example, the liquid transport element 936 includes a cavity 937 in the form of a channel substantially along at least a portion of the length of the liquid transport element, and the heater 934 is located within the cavity.

[0173] In one or more embodiments, a heater located inside a liquid transport element may be in direct contact with at least a portion of the liquid transport element, thereby providing conductive heating to it. In one or more embodiments, a heater located inside a liquid transport element may be substantially, predominantly, or almost completely radiative in relation to the liquid transport element. A substantially radiative relationship may mean that radiative heating occurs, but does not provide the majority of the heating. For example, less than 50% of the heating is radiative, but a measurable amount of heating is due to radiation. A predominantly radiative relationship may mean that radiative heating provides the majority of the heating, but not all of it. That is, more than 50% of the heating is due to radiation. An almost complete radiative relationship may mean that at least 90%, preferably at least 95%, more preferably at least 98%, or at least 99% of the heating is due to radiation.

[0174] In some embodiments, the disclosure may further provide methods for preparing an aerosol dispensing device or components useful for an aerosol dispensing device. Such methods may include providing a porous monolith in the form of a storage unit and / or a liquid transport element, and combining the porous monolith storage unit and / or liquid transport element with a heater and optionally with one or more further components described herein as useful for an aerosol dispensing device. One or both of the storage unit and the liquid transport element may be porous glass. One or both of the storage unit and the liquid transport element may be porous ceramic. One of the storage unit and the liquid transport element may be porous glass, and the other of the storage unit and the liquid transport element may be porous ceramic. In one or more embodiments, one of the storage unit and the liquid transport element may be a fibrous material.

[0175] Many variations and other embodiments of this disclosure will come to mind for those skilled in the art, who benefit from the teachings provided in the foregoing description and the accompanying drawings. Therefore, it should be understood that this disclosure is not limited to any specific embodiment disclosed herein, and that variations and other embodiments are intended to be included within the scope of the appended claims. Certain terms are used herein, but these terms are used in a general and descriptive sense only and are not intended to be limiting.

Claims

1. Atomizer for an aerosol dispensing device, A single porous monolith formed from ceramic, the single porous monolith having a first area configured as a storage area for holding the aerosol precursor composition, and a second area configured as a liquid transfer area defining a substantially flat outer surface portion, wherein the liquid transfer area is configured to transfer the aerosol precursor composition from the storage area to the substantially flat outer surface portion, A vaporizing element is positioned on the substantially flat outer surface portion of a liquid transfer area of ​​a single porous monolith so as to be configured for vaporizing the aerosol precursor composition on the substantially flat outer surface portion of the liquid transfer area, such that the vaporizing element is in direct contact with the aerosol precursor composition being transferred to the substantially flat outer surface portion, Equipped with, An atomizer in which the vaporizing element is in complete direct contact with a substantially flat outer surface portion of the liquid transfer area.

2. The atomizer according to claim 1, wherein a single porous monolith has a substantially square or substantially rectangular cross-section.

3. The atomizer according to claim 1, wherein the vaporization element is printed on a substantially flat outer surface portion of the liquid transfer area of ​​a single porous monolith.

4. The atomizer according to claim 1, wherein the vaporization element is a flat ribbon heater.

5. The atomizer according to claim 1, further comprising a storage section separated from a single porous monolith.

6. The atomizer according to claim 5, wherein a first area of ​​a single porous monolith, which is configured as a storage area for holding an aerosol precursor composition, is further configured to receive the aerosol precursor composition from a storage area separated from the single porous monolith.

7. The atomizer according to claim 5, wherein a single porous monolith includes one or more etched portions.

8. Aerosol dispensing device, Outer housing and A single porous monolith formed from ceramic, the single porous monolith having a first area configured as a storage area for holding the aerosol precursor composition, and a second area configured as a liquid transfer area defining a substantially flat outer surface portion, wherein the liquid transfer area is configured to transfer the aerosol precursor composition from the storage area to the substantially flat outer surface portion, A vaporizing element is positioned on the substantially flat outer surface portion of a liquid transfer area of ​​a single porous monolith so as to be configured to vaporize the aerosol precursor composition to form vapor on the substantially flat outer surface portion of the liquid transfer area, and such vaporizing element is positioned in direct contact with the aerosol precursor composition being transferred to the substantially flat outer surface portion. Equipped with, An aerosol dispensing device in which the vaporizing element is in complete direct contact with a substantially flat outer surface portion of the liquid transfer area.

9. The aerosol dispensing device according to claim 8, further comprising an air inlet, a suction port, and an aerosol port formed in the suction port.

10. The aerosol dispensing device according to claim 9, wherein the airflow passing between the air inlet and the aerosol port is configured to substantially pass through a substantially flat outer surface portion of a single porous monolith.

11. The aerosol dispensing device according to claim 8, wherein a single porous monolith has a substantially square or substantially rectangular cross-section.

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