RU2793312C2 - Aerosol delivery apparatus containing a ceramic wick element - Google Patents

Abstract

FIELD: smoking devices.

SUBSTANCE: present invention relates to aerosol delivery apparatuses such as smoking articles, and, in particular, to aerosol delivery apparatuses capable of utilising the heat generated by electricity to produce an aerosol (e.g., to smoking articles usually referred to as electronic cigarettes). The aerosol delivery apparatus comprises a casing formed at least partially by an external wall; a flow tube located inside relative to the external wall of the casing and containing at least one ventilation passage made in the wall thereof and configured to ensure the passage of air flow through said passage and essentially prevent the passage of a liquid flow through said passage; a space formed between the external wall of the casing and the flow tube, wherein the space is configured to retain the liquid composition of an aerosol precursor; a path for an air flow through the apparatus between the connecting end of the casing and the mouthpiece end of the casing, passing at least partially through the flow tube; an atomiser formed by a heater combined with a ceramic wick, wherein the ceramic wick is in sealing interaction with the flow tube so that at least part of the ceramic wick is in the path for an air flow, and at least part of the ceramic wick is in fluid communication with the space formed between the external wall of the casing and the flow tube; and a sealing element located between the ceramic wick and the flow tube and configured to form sealing interaction.

EFFECT: provided vapour-forming unit of an aerosol delivery apparatus configured to ensure improved vapour formation and/or improved integration into the power supply unit, as well as provided aerosol delivery apparatuses manufactured using such vapour-forming units.

23 cl, 6 dwg

Description

FIELD OF TECHNOLOGY

[0001] The present invention relates to aerosol delivery devices such as smoking articles, and in particular to aerosol delivery devices that can use electrically generated heat to produce an aerosol (e.g., smoking products commonly referred to as electronic cigarettes). Smoking articles may be configured to heat an aerosol precursor, which may include materials that may be made or derived from tobacco, or otherwise include tobacco, said precursor being capable of forming an inhalable substance for human consumption.

BACKGROUND OF THE INVENTION

[0002] Over the years, many smoking devices have been proposed as an improvement or alternative to smoking products that require the combustion of tobacco. It is understood that many of these devices have been designed to provide the sensations associated with smoking cigarettes, cigars or smoking pipes, but without delivering the significant amounts of incomplete combustion and pyrolysis products that result from tobacco combustion. To this end, a variety of smoking products, flavor generators, and medical inhalers have been proposed that use electrical energy to vaporize or heat volatile material, or attempt to provide the sensation of smoking cigarettes, cigars, or pipes without substantially burning tobacco. See, for example, various alternative smoking articles, aerosol delivery devices, and heat sources set forth in the prior art as described in U.S. Patent Nos. 7,726,320 by Robinson et al. Jr. et al. and No. 2014/0096781 by Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically driven heat sources referenced by trade name and source of commercial information in U.S. Patent Application No. 14/170,838 by Bless et al., filed 3 February 2014, which is hereby incorporated by reference in its entirety.

[0003] It is preferred to provide a vaporizing unit of an aerosol delivery device configured to provide improved vaporization and/or improved integration into a power supply. It is also preferred to provide aerosol delivery devices manufactured using such vaporizing units.

DISCLOSURE OF THE INVENTION

[0004] The present invention relates to aerosol delivery devices, methods for making such devices, and elements of these devices. Aerosol delivery devices may in particular combine ceramic wicks to form vapor generating units which may be combined with power packs to form aerosol delivery devices.

[0005] In one or more embodiments, the present invention may provide an aerosol delivery device that includes at least a vaporizing unit. The vaporization unit may operate in a manner similar to cartridges and/or containers known for use in aerosol delivery devices. As an exemplary implementation, the vaporizing unit of an aerosol delivery device may comprise:

a casing formed at least partially by the outer wall;

a flow tube located inside with respect to the outer wall of the casing;

an annular space formed between the outer wall of the casing and the flow tube;

an airflow path through the device between the casing connection end and the mouthpiece end of the casing, extending at least partially through the flow tube;

an atomizer formed by a heater integrated with a ceramic wick, the ceramic wick being in sealing engagement with the flow tube such that at least a portion of the ceramic wick is in the airflow path and at least a portion of the ceramic wick is in fluid communication with the annular a space formed between the outer wall of the casing and the flow tube; And

a sealing element located between the ceramic wick and the flow tube and configured to form a sealing engagement.

[0006] In various embodiments, the aerosol delivery device can be made essentially in the form of a tubular or cylindrical body. In particular, the path for air flow through the vaporization unit may be substantially aligned with the longitudinal axis of the vessel (eg, the annulus). Thus, an aerosol delivery device may be further defined with respect to one or more of the following, which may be combined in any number or order.

[0007] The flow tube may include at least one vent provided in its wall, wherein said at least one vent is configured to allow air flow through and substantially prevent liquid flow through. In particular, at least one ventilation passage made in the wall of the flow tube may be located near the mouth end of the casing.

[0008] The aerosol delivery device may also include a mouthpiece in engagement with the mouthpiece end of the housing and in engagement with the end of the flow tube.

[0009] The aerosol delivery device may also include a connector that interacts with the connecting end of the housing.

[0010] The ceramic wick may be substantially solid.

[0011] The heater may be a resistive heating wire located around the outer surface of a substantially solid ceramic wick.

[0012] The substantially solid ceramic wick may have a longitudinal axis that is substantially perpendicular to the longitudinal axis of the casing.

[0013] A substantially solid ceramic wick may extend transversely through the flow tube from the first end of the ceramic wick to the second end of the ceramic wick, and the sealing member may be in sealing engagement with the ceramic wick near the first end of the ceramic wick and the second end of the ceramic wick.

[0014] The ceramic wick may have a hollow interior defining a passage extending between the first end of the ceramic wick and the second end of the ceramic wick.

[0015] The heater may be located within a passage formed in the hollow interior of the ceramic wick.

[0016] The second end of the hollow ceramic wick can interact with the free end of the flow tube.

[0017] The first end of the hollow ceramic wick may be connected to a connector cooperating with the connecting end of the housing.

[0018] The sealing member may form a sealing engagement between the free end of the flow tube and the second end of the ceramic wick, and the second sealing member may form a sealing engagement between the first end of the hollow ceramic wick and the connector.

[0019] In one or more embodiments, an aerosol delivery device as disclosed herein may comprise a vaporizing unit, wherein the reservoir and airflow path through the vaporizing unit is substantially misaligned. More specifically, the reservoir may be offset from the airflow path through the steam generation unit. As an exemplary implementation, the vaporizing unit of an aerosol delivery device may comprise the following:

a casing containing an airflow inlet and an airflow outlet;

a liquid storage container inside the casing formed by the flexible outer wall and having an opening formed therein; And

an atomizer inside the casing, containing a ceramic wick, containing an end interacting with an opening formed in a container for storing liquid, and essentially a central part interacting with a heater, wherein essentially the central part of the ceramic wick and the heater are in the air flow path between the inlet for airflow and casing airflow outlet.

[0020] In additional embodiments, the aerosol delivery device may be further defined with respect to one or more of the following, which may be combined in any number or order.

[0021] The ceramic wick may be substantially rod-shaped.

[0022] The ceramic wick may have a longitudinal axis, the liquid storage container may have a longitudinal axis, and the longitudinal axes of the ceramic wick and the liquid storage container may be substantially parallel.

[0023] The longitudinal axes of the ceramic wick and the liquid storage container may be substantially perpendicular to the longitudinal axis of the airflow path between the airflow inlet and the airflow outlet of the case.

[0024] The airflow outlet may include a mouthpiece extending outward from the case.

[0025] The housing may include a main body that is substantially aligned with the axis of the airflow path and a protrusion extending substantially perpendicular from the main body, the protrusion containing a fluid storage container.

[0026] The aerosol delivery device may also include a power supply unit that is configured to be coupled to the housing, the power supply unit comprising a power source.

[0027] The power supply may be configured to be coupled to the case such that the case is outside of the power supply when connected.

[0028] The power supply may be configured to be coupled to the case such that the case is entirely within the power supply when connected.

[0029] The power supply may include a mouthpiece.

[0030] The shroud can be configured to be inserted into the power supply such that the airflow exiting the shroud is substantially aligned with the aerosol inlet to the mouthpiece.

[0031] The mouthpiece can be movable between an open position, in which the generated aerosol can pass through it, and a closed position, in which the passage of the generated aerosol through it is essentially prevented.

[0032] The present invention includes, without limitation, the following embodiments:

[0033] Embodiment 1: An aerosol delivery device, comprising: a casing formed at least in part by an outer wall; a flow tube located inside with respect to the outer wall of the casing; an annular space formed between the outer wall of the casing and the flow tube; an airflow path through the device between the casing connection end and the mouthpiece end of the casing, extending at least partially through the flow tube; an atomizer formed by a heater integrated with a ceramic wick, the ceramic wick being in sealing engagement with the flow tube such that at least a portion of the ceramic wick is in the airflow path and at least a portion of the ceramic wick is in fluid communication with the annular a space formed between the outer wall of the casing and the flow tube; and a sealing member positioned between the ceramic wick and the flow tube and configured to form a sealing engagement.

[0034] Embodiment 2: An aerosol delivery device according to any preceding embodiment, wherein the flow tube comprises at least one ventilation passageway formed in its wall, said at least one ventilation passageway being configured to allow airflow to pass through. and substantially preventing liquid flow therethrough.

[0035] Embodiment 3: An aerosol delivery device according to any preceding embodiment, wherein said at least one ventilation passage formed in the wall of the flow tube is located near the mouth end of the housing.

[0036] Embodiment 4: An aerosol delivery device according to any preceding embodiment, also comprising a mouthpiece cooperating with the mouthpiece end of the casing and cooperating with the end of the flow tube.

[0037] Embodiment 5: An aerosol delivery device according to any preceding embodiment, also comprising a connector cooperating with a connecting end of the housing.

[0038] Embodiment 6: The aerosol delivery device of any preceding embodiment, wherein the ceramic wick is substantially solid.

[0039] Embodiment 7: The aerosol delivery device of any preceding embodiment, wherein the heater is a resistive heating wire located around the outer surface of the ceramic wick.

[0040] Embodiment 8: The aerosol delivery device of any preceding embodiment, wherein the ceramic wick has a longitudinal axis that is substantially perpendicular to the longitudinal axis of the housing.

[0041] Embodiment 9: The aerosol delivery device of any preceding embodiment, wherein the ceramic wick extends transversely through the flow tube between the first end of the ceramic wick and the second end of the ceramic wick, and wherein the sealing member is in sealing engagement with the ceramic wick near the first the end of the ceramic wick; and the second end of the ceramic wick.

[0042] Embodiment 10: The aerosol delivery device of any preceding embodiment, wherein the ceramic wick has a hollow interior defining a passage extending between the first end of the ceramic wick and the second end of the ceramic wick.

[0043] Embodiment 11: The aerosol delivery device of any previous embodiment, wherein the heater is located within a passage formed in the hollow interior of the ceramic wick.

[0044] Embodiment 12: The aerosol delivery device of any preceding embodiment, wherein the second end of the ceramic wick engages with the free end of the flow tube.

[0045] Embodiment 13: An aerosol delivery device according to any previous embodiment, wherein the first end of the ceramic wick is connected to a connector cooperating with the connecting end of the case.

[0046] Embodiment 14: The aerosol delivery device of any preceding embodiment, wherein the sealing member forms a sealing engagement between the free end of the flow tube and the second end of the ceramic wick, and wherein the second sealing member forms a sealing engagement between the first end of the hollow ceramic wick and connector.

[0047] Embodiment 15: An aerosol delivery device comprising: a casing containing an airflow inlet and an airflow outlet; a liquid storage container inside the casing formed by the flexible outer wall and having an opening formed therein; and an atomizer inside the casing, containing a ceramic wick, containing an end interacting with an opening formed in a container for storing liquid, and essentially a central part interacting with a heater, wherein essentially the central part of the ceramic wick and the heater are in the air flow path between the inlet for airflow and airflow outlet casing.

[0048] Embodiment 16: The aerosol delivery device of any preceding embodiment, wherein the ceramic wick is substantially rod-shaped.

[0049] Embodiment 17: The aerosol delivery device of any previous embodiment, wherein the ceramic wick has a longitudinal axis, the liquid storage container has a longitudinal axis, and the longitudinal axes of the ceramic wick and the liquid storage container are substantially parallel.

[0050] Embodiment 18: The aerosol delivery device of any preceding embodiment, wherein the longitudinal axes of the ceramic wick and the liquid storage container are substantially perpendicular to the longitudinal axis of the airflow path between the airflow inlet and the casing airflow outlet.

[0051] Embodiment 19: The aerosol delivery device of any preceding embodiment, wherein the airflow outlet comprises a mouthpiece extending outward from the case.

[0052] Embodiment 20: The aerosol delivery device of any preceding embodiment, wherein the housing comprises a main body that is substantially aligned with the axis of the airflow path and a protrusion extending substantially perpendicular from the main body, the protrusion comprising a container for liquid storage.

[0053] Embodiment 21: The aerosol delivery device of any previous embodiment, also comprising a power supply that is operable to be connected to the case, the power supply comprising a power source.

[0054] Embodiment 22: The aerosol delivery device of any preceding embodiment, wherein the power supply is configured to be coupled to the case such that the case is outside of the power supply when connected.

[0055] Embodiment 23: The aerosol delivery device of any preceding embodiment, wherein the power supply is operable to be coupled to the case such that the case is entirely within the power supply when connected.

[0056] Embodiment 24: The aerosol delivery device of any preceding embodiment, wherein the power supply includes a mouthpiece.

[0057] Embodiment 25: The aerosol delivery device of any preceding embodiment, wherein the housing is insertable into the power supply such that airflow exiting the housing is substantially aligned with the aerosol inlet to the mouthpiece.

[0058] Embodiment 26: The aerosol delivery device of any preceding embodiment wherein the mouthpiece is movable between an open position in which generated aerosol can pass through it and a closed position in which passage of generated aerosol through it is substantially prevented .

[0059] These and other features, aspects and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four or more of the above embodiments, as well as combinations of any two, three, four or more features or elements set forth herein, whether or not such features or elements are explicitly combined in description of a specific implementation option presented in this document. The present description is intended to be read taking all elements into account, such that any separable features or elements of the described invention in any of its various aspects and embodiments are to be considered combinable unless the context clearly indicates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Having thus described the invention in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, in which:

[0061] in FIG. 1 is a partial sectional view of an aerosol delivery device comprising a cartridge and a power pack containing various elements that may be used in an aerosol delivery device according to various embodiments of the disclosure of the present invention;

[0062] in FIG. 2 shows a view of a vaporizing unit that is substantially tubular or cylindrical in shape for use in an aerosol delivery device according to various embodiments of the disclosure of the present invention;

[0063] in FIG. 3 is a partial sectional view of a vaporizing unit showing its internal structure according to various embodiments of the disclosure of the present invention;

[0064] in FIG. 4 is a partial view of a vaporizing unit showing the relative position between the flow tube, connector and wick according to various embodiments of the disclosure of the present invention;

[0065] in FIG. 5 is a partial sectional view of a vaporizing unit showing its internal structure according to various embodiments of the disclosure of the present invention;

[0066] in FIG. 6 shows a view of a power supply unit suitable for being combined with a vaporizing unit according to various embodiments of the disclosure of the present invention;

[0067] in FIG. 7 is an illustration of an aerosol delivery device comprising a power supply and a vaporizer according to various embodiments of the disclosure of the present invention;

[0068] in FIG. 8 shows an illustration of an aerosol delivery device comprising a power supply and a vaporizer according to various embodiments of the disclosure of the present invention;

[0069] in FIG. 9 is a partial cross-sectional view of a vaporizing unit showing its internal structure according to various embodiments of the disclosure of the present invention;

[0070] in FIG. 10 is a partial sectional view of a vaporizing unit showing its internal structure according to various embodiments of the disclosure of the present invention; And

[0071] in FIG. 11 is a partial sectional view of an aerosol delivery device showing a vaporization unit combined with a power supply according to various embodiments of the disclosure of the present invention.

IMPLEMENTATION OF THE INVENTION

[0072] Hereinafter, the present invention will be described in more detail with reference to examples of its implementations. These examples of implementations are described in such a way that this disclosure thoroughly, completely and entirely conveys the scope of the invention for a person skilled in the art. Indeed, the present invention may be embodied in a variety of different forms and should not be construed as being limited to the embodiments described herein; on the contrary, these embodiments are presented in such a way that the present invention satisfies the relevant legal requirements. As used in the description and in the appended claims, the singular forms include the plural forms, unless the context clearly states otherwise.

[0073] As described below, embodiments of the present invention relate to aerosol delivery systems. Aerosol delivery systems according to the disclosure of the present invention use electrical energy to heat the material (preferably without burning the material to any significant extent and/or without significant chemical change of the material) to form an inhalable substance; the components of such systems are in the form of products that are most preferably compact enough to be considered "portable" devices. In other words, the use of components of the preferred aerosol delivery systems does not result in the production of smoke—i.e. by-products of combustion or pyrolysis of tobacco, but rather the use of these preferred systems results in the production of fumes resulting from the volatilization or evaporation of certain components that make up their composition. In preferred embodiments, components of aerosol delivery systems can be characterized as e-cigarettes, whereby such e-cigarettes most preferably contain tobacco and/or tobacco-derived components, and thus deliver tobacco-derived components in the form of an aerosol.

[0074] The aerosol-generating articles of certain preferred aerosol delivery systems can create a variety of sensations (e.g., inhalation and exhalation rituals, types of flavors or aromas, organoleptic effects, physical sensation, rituals of use, visual stimuli such as those created by visible aerosol, and the like. ) smoking a cigarette, cigar or pipe, which is achieved by kindling and burning tobacco (and thus inhaling tobacco smoke), without actually burning to any significant extent any of its components. For example, a user of the aerosol generating means according to the disclosure of the present invention can hold and use the means in a manner similar to how a smoker uses a traditional type of smoking article, puffing through one end of said means to inhale the aerosol generated by this tool, taking or making puffs at selected intervals. etc.

[0075] The proposed aerosol delivery devices can also be characterized as vaping or drug delivery devices. Thus, such articles or devices may be adapted to deliver one or more substances (eg flavors and/or pharmaceutical active ingredients) in a respirable form or condition. For example, inhalable substances may be essentially in the form of a vapor (eg, a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, respirable substances may be in the form of an aerosol (ie suspension of fine solid particles or liquid droplets in a gas). For the sake of simplicity, the term "aerosol" as used herein is intended to refer to vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not they are visible and whether or not they are in a form that can considered "smoke-like".

[0076] The proposed aerosol delivery devices generally comprise a number of components located within an outer housing or shell, which may be referred to as a housing. The overall design of the outer housing or shell may vary, and the configuration or parameters of the outer housing, which may determine the overall size and shape of the aerosol delivery device, may vary. Typically, an elongated body resembling the shape of a cigarette or cigar may be formed from one single casing, or an elongated casing may be formed from two or more separable casings. For example, the aerosol delivery device may comprise an elongated shell or body that may be substantially tubular in shape and thus resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are housed in a single housing. Alternatively, the aerosol delivery device may comprise two or more shrouds that are connected and releasable. For example, an aerosol delivery device may have at one end a control housing (or power supply) containing a housing containing one or more components (for example, a battery and various electronics to control the operation of this product), and at the other end of the device, it may be detachably attached to an outer casing or sheath containing the aerosol-forming components (e.g., one or more aerosol precursor components such as flavors and aerosol-forming agents, one or more heaters, and/or one or more wicks).

[0077] The aerosol delivery devices of the present invention may be formed by an outer casing or shell that is not substantially tubular, but may be substantially large. The case or shell may be configured to contain a mouthpiece and/or may be configured to receive a separate shell (e.g., cartridge or container) that may contain consumable items such as a liquid aerosol-forming agent and may contain a vaporizer or atomizer.

[0078] The aerosol delivery devices of the present invention most preferably comprise some combination of a power source (i.e. power supply), at least one control component (e.g. , by controlling the electrical current flowing from an energy source to other components of the product, such as a microcontroller or microprocessor), a heater or a heat generating link (for example, an electrical resistive heating element or other component that, by itself or in combination with one or more additional elements may be generically referred to as an "atomizer"), an aerosol precursor composition (e.g., typically a liquid capable of producing an aerosol when sufficient heat is directed therein, such as ingredients commonly referred to as "smoking juice", "electronic cigarette liquid" and "juice for electronic cigarettes"), and a mouthpiece or mouthpiece region to allow inhalation from the aerosol delivery device to inhale the aerosol (e.g., a predetermined airflow path through the article so that the generated aerosol can be drawn through it upon inhalation).

[0079] More specific parameters, configurations and arrangements of components in the aerosol delivery systems according to the disclosure of the present invention will be understood based on the description of the invention below in this document. In addition, the selection and location of the various components of aerosol delivery systems can be judged by considering commercially available electronic aerosol delivery devices, such as the typical products presented in the background section of the disclosure of the present invention.

[0080] One embodiment of an aerosol delivery device 100 illustrating components that can be used in an aerosol delivery device according to the present invention is shown in FIG. 1. As can be seen from the illustrated sectional view, the aerosol delivery device 100 may include a power supply unit 102 and a cartridge 104 that may be either permanently connected or operably disconnected. The engagement of power supply 112 and cartridge 104 may be by press fit (as shown), threaded engagement, interference fit, magnetic engagement, or the like. In particular, compound components such as those described hereinafter can be used. For example, the power supply may include a connector that is configured to interact with a connector on the cartridge.

[0081] In particular embodiments, one or both of the power supply 102 and cartridge 104 may be referred to as disposable or reusable. For example, the power supply may have a replaceable battery or a rechargeable battery, and thus may be combined with any type of charger, including connection to a typical electrical outlet, connection to a car charger (i.e., cigarette lighter receptacle), and connection to a computer. such as via a Universal Serial Bus (USB) cable. For example, an adapter including a USB connector on one end and a power supply connector on the opposite end is disclosed in Novak et al. Also, in some embodiments, the cartridge may be a disposable cartridge as described in US Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference.

[0082] As shown in FIG. 1, the power supply 102 may be formed by a power supply shell 101, which may include a control component 106 (for example, a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller, or the like), a flow sensor 108, a battery 110, and an LED 112. , and such components can be inconsistently aligned. Additional indicators (eg, tactile feedback components, auditory feedback components, or the like) may be included in addition to or as an alternative to the LED. Additional specific types of components that provide visual signals or indicators, such as Light Emitting Diode (LED) components, as well as their construction and use, are described in U.S. Patent Nos. 5,154,192 by Sprinkel et al. by Scatterday, and US Patent Application Publication No. 2015/0020825 by Galloway et al. and US Patent Application Publication No. 2015/0216233 by Sears et al., which are incorporated herein by reference.

[0083] The cartridge 104 may be formed by a cartridge shell 103 including a reservoir 144 in fluid communication with a liquid transfer element 136 configured to wick transfer or otherwise transport the aerosol precursor composition stored in the reservoir housing to the heater 134. The fluid transfer element may be formed from one or more materials capable of transferring fluid, such as through capillary action. The fluid transfer element may be formed from, for example, fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose cloth, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass balls, glass ceramic balls, capillary tubes, and the like. similar. Thus, a fluid transfer element can be any material that contains an open-cell network (ie, multiple pores that are interconnected such that fluid can flow from one pore to another in multiple directions through the element). To form the resistive heating element 134, various embodiments of materials configured to generate heat when an electric current is passed through them can be used. Examples of materials from which the wire helix can be formed include kanthal (FeCrAl); nichrome; molybdenum disilicide (MoSi ₂ ); molybdenum silicide (MoSi); aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ); titanium, platinum, silver, palladium, graphite, and graphite-based materials (eg, carbon-based foam and yarn); as well as ceramics (for example, ceramics with a positive or negative coefficient of thermal expansion).

[0084] An opening 128 may be provided in the cartridge shell 103 (e.g., at the tip of the mouthpiece) to allow the generated aerosol to escape from the cartridge 104. Such components are a typical example of components that may be present in a cartridge and are not intended to limit the scope of cartridge components, covered by the disclosure of the present invention.

[0085] The cartridge 104 may also contain one or more electronic components 150, which may include an integrated circuit, a memory component, a sensor, or the like. The electronic component 150 may be configured to communicate with the control component 106 and/or with an external device via wired or wireless means. The electronic component 150 may be located anywhere in the cartridge 104 or its base 140.

[0086] 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 air flow sensor attached directly to it. Additionally, the electronic circuit board may be positioned horizontally with respect to the image in FIG. 1, namely, the electronic circuit board may be arranged longitudinally, parallel to the central axis of the power supply. In some embodiments, the airflow sensor may include its own circuit board or other base element to which it may be attached. In some embodiments, a flexible circuit board may be used. The flexible circuit board can be formed into various shapes, including substantially tubular shapes.

[0087] Power supply unit 102 and cartridge 104 may include components adapted to facilitate fluid transfer interaction therebetween. As shown in FIG. 1, the power supply 102 may include a connector 124 having a cavity 125. The cartridge 104 may include a base 140 configured to interact with the connector 124 and may include a protrusion 141 configured to fit into the cavity 125. Such interaction may facilitate a stable connection between the power supply 102 and the cartridge 104; and establishing an electrical connection between the battery 110 and the control component 106 in the power supply and the heater 134 in the cartridge. Also, the power supply shell 101 may include an air intake 118, which may be a recess in the shell in which it is connected to the connector, which allows air from the environment to pass around the connector into the shell, where it then passes through the cavity 125 of the connector into the cartridge. through ledge 141.

[0088] A connector and base suitable for use in accordance with the disclosure of the present invention are described in US Patent Application Publication No. 2014/0261495 by Novak et al., the disclosure of which is incorporated herein by reference in its entirety. For example, a connector as shown in FIG. 1 may define an outer periphery 126 configured to mate with an inner periphery 142 of the base 140. In one embodiment, the inner periphery of the base may have a radius substantially equal to or slightly greater than the radius of the outer periphery of the connector. Also, the connecting element 124 may form one or more protrusions 129 on the outer periphery 126, configured to interact with one or more recesses 178 formed on the inner periphery of the base. However, various other designs, shapes, and components may be used to connect the base to the connector. In some embodiments, the connection between the base 140 of the cartridge 104 and the connector 124 of the power supply 102 may be substantially permanent, while in other implementations, the connection between them may be releasable, so that, for example, the power supply can be reused with one or more additional cartridges, which may be disposable and/or refillable.

[0089] In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped, or substantially tubular, or substantially cylindrical. In other embodiments, other shapes and sizes are covered, such as rectangular or triangular in cross section, polyhedral shapes, or the like. In particular, power supply 102 may not be substantially rod-shaped, and may rather be substantially rectangular, circular, or some other shape. Similarly, the power pack 102 may be substantially larger than the power pack, which is expected to be substantially the size of a conventional cigarette.

[0090] The reservoir 144 shown in FIG. 1 may be a container (eg, formed from walls substantially impermeable to the aerosol precursor composition) or a fibrous container. The walls of the container may be flexible and may be deformable. In an alternative embodiment, the walls of the container may be substantially rigid. In an exemplary implementation, the reservoir 144 may contain one or more layers of non-woven fibers and may be essentially formed in the form of a tube, covering the inside of the shell 103 of the cartridge. The aerosol precursor composition may be retained in reservoir 144. Liquid components, for example, may be retained in reservoir 144 in a sorption capacity (ie, when reservoir 144 contains fibrous material). The reservoir 144 may be fluidly connected to the fluid transfer element 136 . In this embodiment, the liquid transfer element 136 can transfer the aerosol precursor composition stored in the reservoir 144 through capillary action to the heating element 134, which is a coil of metal wire. Typically, the heating element 134 forms a heating circuit with the liquid transfer element 136 .

[0091] Under application conditions where a user is puffing on article 100, airflow is detected by flow sensor 108 and heating element 134 is activated and components of the aerosol precursor composition are vaporized by heating element 134. Puffing at the mouth end of article 100 causes ambient air to enter into the air inlet 118 and its passage through the cavity 125 in the connecting element 124 and the central opening of the protrusion 141 of the base 140. In the cartridge 104, the drawn air combines with the generated vapor to form an aerosol, which is removed by suction, drawing or otherwise puffing from the heating element 134 and exits the mouthpiece hole 128 at the mouthpiece end of article 100.

[0092] An input element may be included in the aerosol delivery device. An input may be included to allow the user to control device functions and/or to display information to the user. Any component or combination of components can be used as an input to control a device function. For example, one or more push buttons can be used as described in US Publication No. 2015/0245658 by Worm et al., which is incorporated herein by reference. A touch screen may be used as described in US Patent Application No. 14/643,626 to Sears et al., filed March 10, 2015, which is incorporated herein by reference. As a further example, components capable of recognizing gestures based on specific movements of the aerosol delivery device can be used as input. See US Publication No. 2016/0158782 by Henry et al., which is incorporated herein by reference.

[0093] In some embodiments, the input may comprise a computer or a computing device such as a smartphone or tablet. In particular, the aerosol delivery device may be connected to a computer or other device via wires, such as using a USB wire or similar protocol. The aerosol delivery device may also be associated with a computer or other device acting as an input via a wireless connection. See, for example, systems and methods for controlling a device through a read request as described in US Publication No. 2016/0007561 by Ampolini et al., the disclosure of which is incorporated herein by reference. In such embodiments, an application or other computer program may be used in conjunction with a computer or other computing device to enter control instructions into the aerosol delivery device, such control instructions including, for example, the ability to generate an aerosol of a particular composition by selecting the nicotine content and/or the content of additional flavors to be included.

[0094] Various components of the aerosol delivery device according to the disclosure of the present invention can be selected from components described in the prior art and available on the market. Examples of batteries that can be used in accordance with the present invention are described in US Patent Application Publication No. 2010/0028766 by Peckerar et al., the disclosure of which is incorporated herein by reference.

[0095] The aerosol delivery device may include a sensor or detector to control the direction of electricity to the heat generating element when aerosol generation is required (eg, when puffed during use). Also, for example, a procedure or method is provided for turning off the direction of electricity to the heat generating element when the aerosol delivery device is not puffed during use, and turning on the direction of electricity to activate or start generating heat by the heat generating element during puffing. Additional representative types of recognition or detection mechanisms, their designs and configurations, their components, and general methods for controlling them are described in US Pat. Flick, which are incorporated into this document by reference.

[0096] The aerosol delivery device most preferably may include a control mechanism to control the amount of electricity supplied to the heat generating element during the puff. The characteristic types of electronic components, their structure and configuration, their features, and general methods of their operation are described in U.S. Patent Nos. 4,735,217 to Gerth et al. Fleischhauer et al., Nguyen et al. 7,040,314 and Pan 8,205,622, and U.S. Patent Application Publication No. 2009/0230117 Fernando et al. and No. 2014/0270727 by Ampolini et al., and U.S. Patent Application Publication No. 2015/0257445 by Henry et al., all of which are incorporated herein by reference.

[0097] Specific types of substrates, reservoirs, or other components for supporting the aerosol precursor are described in US Pat. Davis et al. and No. 2015/0216232 by Bless et al., which are incorporated herein by reference. Also, various absorbent materials and the design and operation of these absorbent materials in certain types of electronic cigarettes are described in US Pat. No. 8,910,640 by Sears et al., which is incorporated herein by reference.

[0098] For aerosol delivery systems that are characterized as electronic cigarettes, aerosol precursor compositions most preferably contain tobacco or components derived from tobacco. In one instance, the tobacco may be provided in the form of tobacco pieces or pieces such as finely ground, ground or powdered tobacco flake. Alternatively, the tobacco may be provided in the form of an extract, such as a spray-dried extract, which includes a plurality of water-soluble tobacco components. Alternatively, tobacco extracts may be in the form of relatively high nicotine content extracts that also include small amounts of other extracted tobacco-derived components. Alternatively, tobacco-derived components may be provided in a relatively pure form, such as specific flavoring agents that are tobacco-derived. In yet another instance, the component that is derived from tobacco and that can be used in a highly purified or substantially pure form is nicotine (eg, pharmaceutical grade nicotine).

[0099] An aerosol precursor composition, also referred to as a vapor precursor composition, may contain various components, including, for example, a polyhydric alcohol (eg, glycerol, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, and/or flavors. Specific types of aerosol precursor components and formulations are also known and described in US Pat. No. 7,217,320 by Robinson et al., and in US Patent Application Publication No. 2013/0008457 by Zheng et al.; No. 2013/0213417 by Chong et al.; No. 2014/0060554 by Collett et al.; No. 2015/0020823 by Lipowicz et al.; and No. 2015/0020830 by Koller, as well as WO 2014/182736 by Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include the aerosol precursors that are included in R.J.'s VUSE® product. Reynolds Vapor Company, BLUTM product from Lorillard Technologies, MISTIC MENTHOL product from Mistic Ecigs, and VYPE product from CN Creative Ltd. Also preferred are so-called "smoke juices" for e-cigarettes, which are available from Johnson Creek Enterprises LLC.

[00100] The amount of aerosol precursor that is included in the aerosol delivery system is such that the aerosol generating article provides acceptable sensory and desired performance. For example, it is most preferred that sufficient aerosolizing material (eg, glycerol and/or propylene glycol) be used to generate a visible mainstream aerosol that in many cases resembles the appearance of tobacco smoke. The amount of aerosol precursor in the aerosol generating system may depend on factors such as the desired number of puffs on the aerosol generating article. Typically, the amount of aerosol precursor included in an aerosol delivery system, and in particular in an aerosol generating article, is less than about 2 g, generally less than about 1.5 g, often less than about 1 g, and typically less than about 0.5 g

[00101] In addition, other features, control components or components that can be included in the aerosol delivery systems according to the disclosure of the present invention are described in US patent No. 5.967,148 by Harris and others; No. 5,934,289 by Watkins et al.; No. 5,954,979 by Counts et al.; No. 6.040,560 by Fleischhauer et al.; No. 8.365,742 by Hon; No. 8,402,976 by Fernando et al.; in US Patent Application Publication No. 2010/0163063 by Fernando et al.; No. 2013/0192623 by Tucker et al.; No. 2013/0298905 by Leven et al.; No. 2013/0180553 by Kim et al.; No. 2014/0000638 by Sebastian et al. and No. 2014/0261495 by Novak et al. and No. 2014/0261408 by DePiano et al., which are incorporated herein by reference.

[00102] The foregoing description of the use of the product may be applied to the various embodiments described herein with minor modifications that may be apparent to one of ordinary skill in the art in light of the additional disclosure provided herein. The above description of use, however, is not intended to limit the use of said product, but is provided to meet all necessary requirements of the disclosure of the present invention. Any of the elements shown in the product, as shown in FIG. 1, or otherwise described above, may be included in an aerosol delivery device according to the disclosure of the present invention.

[00103] According to one or more embodiments, the present invention may specifically relate to aerosol delivery devices that are configured to provide increased vapor production. This increase can be due to many factors. In some embodiments, the liquid transfer element (ie, wick or wick element) may be formed partially or entirely from a ceramic material, in particular a porous ceramic. Examples of ceramic materials suitable for use in accordance with embodiments of the disclosure of the present invention are described, for example, in US patent application No. 14/988,109, filed January 5, 2016, and US patent publication No. 2014/0123989 by LaMothe, the disclosures of which are included to this document by reference. The porous ceramic may form a substantially solid wick, i. e. is one monolithic material, and not a bundle of individual fibers, as is known from the prior art.

[00104] In some embodiments, the heating element may be configured for increased vaporization, such as resulting from an increased heating temperature that can be tolerated by the use of a ceramic wick, or resulting from a larger heating surface (such as having more turns of a resistive heating element). wire wrapped around a ceramic wick). In some embodiments, increased steam production may refer to a larger reservoir capacity - i.e. having a larger volume of the aerosol precursor composition to provide increased overall vapor production for the cartridge or vessel.

[00105] In some embodiments, the present invention may relate to an aerosol delivery device and, in particular, to a vaporization unit. A vaporizing unit may be referred to as a vessel in light of the ability to store a relatively large volume of aerosol precursor composition in its reservoir. The term "vessel" is not to be construed as limiting, and the block may be characterized as being a cartridge. In general, the steam generating unit can be combined with a power supply. Alternatively, the steam generation unit may have an energy generating element incorporated therein.

[00106] As can be seen from FIG. 2, the device may include a vaporizing block 204, which may include a casing 203, which is formed at least partially by the outer wall 205. The vaporizing block 204 may also include a connector 240, which may be located on the connecting end 243 of the casing 203. Mouthpiece 227, which may be located on the mouthpiece end 230 of the housing 203.

[00107] The internal structure of the steam generating unit 204 is visible in FIG. 3. In particular, the flow tube 245 is located inside the outer wall 205 of the housing 203. The flow tube 245 may be formed from any suitable material such as metal, polymer, ceramic compositions. The flow tube 245 is preferably formed from a material that does not lose its properties at the temperatures reached near the heater, and thus is heat resistant. The location of the flow tube 245 and the outer wall 205 of the housing 203 may define an annular space 247 between them. The annulus 247 can function as a reservoir for the aerosol precursor composition during operation. The annulus 247 may be substantially free of other materials except for the aerosol precursor composition. However, in some embodiments, fibrous material may be included in the annulus 247 if at least a portion of the aerosol precursor composition is to be sorptively retained. The airflow path 257 may pass through the vaporizing block 204 and may extend, in particular, between the connecting end 243 of the casing 203 and the mouth end 230 of the casing 203. The airflow path 257 extends at least partially through the flow tube 245. However, the path 257 for airflow may also pass through additional elements of the device, such as through the internal channel 228 of the mouthpiece 227 and/or the connector 240. Connectors and airflow paths through them suitable for use in accordance with the disclosure of the present invention are described in U.S. Patent Application Publication No. 2015 /0245658 by Worm et al., which is incorporated herein by reference.

[00108] Steam generation unit 204 of FIG. 3 may also include a heater 234 and a wick 236, which can be generally described as an atomizer or an atomizer unit. Heat 234 and wick 236 interact with flow tube 245 such that the aerosol precursor composition in annulus 247 is carried by the wick to the heater, where it vaporizes within the flow tube or within a space that is in fluid communication with the flow tube (e.g., located immediately adjacent to the end of the flow tube). Accordingly, at least a portion of the wick 236 is in the airflow path 257 and at least a portion of the wick is in fluid communication with the annulus 247. The interaction between the wick 236 and the flow tube 245 can be characterized as a sealing interaction in that the wick passes through an opening 246 formed in the flow tube such that passage of the aerosol precursor composition from the annulus 247 through the opening is substantially prevented except through the wick itself.

[00109] In some embodiments, sealing interaction can be simplified by using a sealing element 248 that can be located between the wick 236 and the flow tube 247. The sealing element 248 can interact with the wick 236 and the flow tube 245 in various ways, and only one sealing an element or a plurality of sealing elements may be used. The location of the wick 236, flow tube 245, sealing element 248 and connector 240 is shown in FIG. 4. In the embodiment shown, wick 236 is substantially located between flow tube 245 and connector 240. Opening 246 (see FIG. 3) in flow tube 245 is in the form of a cutout at the end of the wall of the flow tube. A suitable notch may be formed in the connector 240. The wick 236 extends through the notch on one side or both sides of the flow tube 245 and the sealing member 246 fills any space between the outer surface of the wick and the inner surface of the notch in the flow tube (and optionally in the connector). As shown in the drawing, the sealing element 246 also functions as a sealing element between the end of the flow tube 245 and the connector 240 to effectively seal the connection of the two elements. In other words, flow tube 245 may extend completely between mouthpiece 227 and connector 240. Seal member 248 may be formed from any suitable sealing material such as silicone, rubber, or other resilient material.

[00110] With reference to FIG. 3, flow tube 245 may include a vent passage that may be formed by one or more vent passages or vents 251. Vent passage 251 may be configured to equalize pressure within annulus 247 as fluid therein becomes depleted. In some implementations, the ventilation passage 251 may include a cover 252 of the ventilation passage. Cover 252 ventilation passage may be made of microporous material. Preferably, the vent cover 252 is operable to allow gas (eg, air) to pass through while substantially preventing liquid from passing through. The ventilation passage may be located at various locations along the flow tube 245 and, in particular, may be provided near the mutual connection of the flow tube and the mouthpiece 227. The flow tube 245 may interact with or abut against the mouthpiece 227 at the first end of the flow tube and interact with the connector 240 or rest against it at the other end of the flow tube.

[00111] In one or more embodiments, the heater 234 may particularly be in the form of a resistive heating wire that may be wound or otherwise located around the outer surface of the wick 236. Thus, steam is generated around the outer portion of the wick 236 to be removed when suction by air passing through the wick and heater 234 and into the path 257 for the air flow. Wick 236 in particular may have a longitudinal axis that is substantially perpendicular to the longitudinal axis of housing 203. In some embodiments, wick 236 may extend transversely through flow tube 245 between first wick end 236a and second wick end 236b. In addition, the sealing member 248 may be in sealing engagement with the wick 236 near the first wick end 236a and the second wick end 236b. The first and second ends (236a, 236b) of the wick may extend past the sealing member 248 or may be substantially flush with the sealing member as long as the aerosol precursor composition in the annulus 247 is able to achieve fluid engagement with the ends of the wick.

[00112] Electrical leads (234a, 234b) may be in electrical connection with heater 234 and may extend through connector 240 so as to facilitate electrical connection to a power source. A printed circuit board (PCB) 250 or the like may be included in the vaporizing unit 204 and may be particularly located within the connector 240 so as to isolate the electronic component from the liquid in the annulus 247 and vapor (and possibly condensed liquid) during operation. ) in flow tube 245. PCB 250 may provide control functions for the steam generating unit and/or send/receive information from a controller (see item 106 in FIG. 1), which may be in an additional housing to which the steam generating unit may be connected.

[00113] Additional embodiments of the vaporization unit 304 are covered by this disclosure with respect to the embodiment shown in FIG. 5. As can be seen from the drawing, the vaporization block 304 is similar in many respects to the vaporization block 204 shown in FIG. 3. In particular, the vaporizing block 304 includes a casing 303 that is formed at least in part by an outer wall 305. The vaporizing block 304 may also include a connector 340 that may be located at the connecting end 343 of the casing 303. The mouthpiece 327 may be located at the mouth end 330 casing 303.

[00114] Vaporizing block 304 also includes a ceramic wick 336, but the wick has a hollow interior defining an open passage 337 extending between first wick end 336a and second wick end 336b. The wick 336 and the open passage 337 passing through it may have a longitudinal axis that is substantially parallel to the longitudinal axis of the casing 303.

[00115] The heater 334 may be located within the open passage 337 of the wick 336 and may in particular form a heating circuit with the inner surface 336c of the wick. The heater 334 may be in the form of a wire coil or may take any additional circuitry suitable for heating the aerosol precursor composition transferred from the annulus 347 between the flow tube 345 and the outer wall 305 of the housing 303.

[00116] The flow tube 345 in the embodiment shown extends from a first end 345a that interacts with the mouthpiece 327 to a second end 345b (i.e., the free end) that interacts with the second end 336b of the wick 336. The first end 336a of the wick 336 likewise interacts with the connector 340. Thus, the outer surface 336d of the wick 336 is exposed to the annular surface 347 and thus the aerosol precursor composition stored therein such that the aerosol precursor composition passes through the wick wall to the heater 334 located in the hollow interior of the wick .

[00117] Wick 336 may interact to form a seal with flow tube 345 and/or connector 340. As shown in FIG. 5, a first sealing member 348a is positioned circumferentially between the wick 336 and connector 340. Similarly, a second sealing member 348b is positioned circumferentially between the wick 336 and part of the flow tube 345 (eg, near the second end 345b of the flow tube). The first sealing element 348a and the second sealing element 348b are located at a distance from each other so that the outer surface 336d of the wick 336 is open between them.

[00118] The airflow path 357 may pass through the vaporizing block 204 and may extend, in particular, between the connecting end 343 of the casing 303 and the mouth end 330 of the casing. The airflow path 357 extends at least partially through the flow tube 345. However, the airflow path 357 may also pass through additional components of the device, such as through the internal passage 328 of the mouthpiece 327 and/or the connector 340. More specifically, the vaporizing unit 304 may be configured such that air enters through connector 340, passes through open passage 337 in succession, through wick 336, passes through flow tube 345, and passes through internal passage 328 of mouthpiece 327.

[00119] Electrical leads (334a, 334b) may be in electrical connection with heater 334 and may extend through connector 340 so as to facilitate electrical connection to a power source. A printed circuit board (PCB) 350 or the like may be provided with a vapor generating unit 304 and may particularly be located within the connector 340 so as to isolate the electronic component from the liquid in the annulus 347 and the vapor in the wick 336 during operation. PCB 250 may provide control functions for the steam generating unit and/or may send/receive information from a controller (see element 106 in FIG. 1), which may be in an additional housing to which the steam generating unit may be connected.

[00120] As can be seen from FIG. 1, cartridge 104 can be configured to be attached to power supply 102 to form an aerosol delivery device 100 that is substantially rod-shaped and that may particularly resemble a traditional cigarette. In some embodiments, a vaporizing unit as described herein may be configured to be combined with a power supply or a power supply that is relatively large. Thus, the reservoir of the vaporization unit may be larger to hold a larger volume of the aerosol precursor composition. An example implementation of the power supply 402 is shown in FIG. 6. Power supply 402 may include any or all of the elements described with respect to power supply 102 shown in FIG. 1. In particular, the power supply 402 may comprise at least a power supply. Power supply 402 may also include a controller (eg, a PCB containing a microcontroller) and/or a sensor and/or feedback element (eg, an element that produces light, sound, and/or vibration) and/or a data entry screen. The vaporizing unit may be combined with the power unit 402 in various ways. Power supplies of similar design and suitable for use in accordance with the disclosure of the present invention are described in US Patent Application Publication No. 2016/0050975; US Patent Application No. 14/981,051, filed December 25, 2015, and US Patent Application No. 15/202,947, filed July 6, 2016, which are incorporated herein by reference.

[00121] FIG. 7 shows an aerosol delivery device 500 comprising a power supply 502 and an attached vaporizer 504. The vaporizer 504 is generally cylindrical in shape and includes a housing 503, a connector 540 forming a connection with the power supply 502, and a mouthpiece 527. As shown in FIG. 7 compared to FIG. 1, it can be seen that vaporizing block 504 is relatively large in size and thus can accommodate a larger volume of aerosol precursor composition. Similarly, the power supply 502 is relatively large in size and thus can provide a larger power supply. Thus, the aerosol delivery device of FIG. 7 may provide more puffs on the device and/or a greater total mass of delivered aerosol relative to the device of FIG. 1 between charging the power supply and refilling and changing the steam generating unit 504.

[00122] Since the vaporizing block (204, 304, 504) may be substantially cylindrical and elongated, the block may assume various shapes in light of changes in its internal structure. For example, in FIG. 8 shows an aerosol delivery device 600 comprising a power supply unit 602 and an attached vaporization unit 604, the vaporization unit being relatively short and having a side extension. Thus, the common steam generating unit 604 may have a side dimension that is closer to the side dimension of the power unit 602. For example, the overall width of the steam generating unit 604 may be from about 50% to about 99%, from about 60% to about 98%, or from about 70% to about 97% of the total width of the power unit 602.

[00123] The components of the vaporizing block 604 are further shown in FIG. 9. In an exemplary embodiment, the vaporizing unit 604 includes a casing 603 defined by an outer wall 605. The casing 603 includes an airflow inlet 607 and an airflow outlet 609. The airflow inlet 607 may pass through a connector 640, which may be integral in the housing 603. Alternatively, a separate connector may be integrated with the housing 603 and the airflow inlet to the housing may be located near the attachment of the separate connector. to the casing. Airflow outlet 609 may be defined by a wall that may, during operation, form flow tube 645. Airflow outlet 609 may also include a mouthpiece 627 extending outwardly from housing 603. In the embodiment shown in FIG. 9, the top of housing 603 is formed by a cover 670 that includes an integral mouthpiece 627 and an integral flow tube 645. However, in other embodiments, each of the cover 670, mouthpiece 627, and flow tube 645 may be separate elements that are formed with the possibility of association; the cap 670 may be integrally formed with the mouthpiece 627 while the flow tube 645 is a separate element; cap 670 may be integrally formed with flow tube 645 while mouthpiece 627 is a separate element; or the mouthpiece 627 and flow tube 645 may be integral, while the cap is a separate element. If desired, cover 670 may be integral with housing 603. In any of the alternative implementations, the three elements may be combined so as to provide an equivalent structure to that shown in FIG. 9.

[00124] Vaporization block 604, as shown in the embodiment of FIG. 9 also includes a fluid storage container 644 located within the housing 603. The fluid storage container 644 may be formed by a flexible outer wall 653 that has an opening 654 formed therein. The flexible outer wall 653 may be formed from a compliant material that can hold the required volume of liquid without breaking and which is otherwise essentially inert to the various components of the aerosol precursor composition that is stored therein. Non-limiting examples of suitable materials for forming a flexible outer wall include polyvinyl chloride (PVC), urethanes, rubberized nylon, polyethylene, polypropylene, and the like.

[00125] The opening 654 in the liquid storage container 644 may be configured to interact with the ceramic wick 636. The wick 636 may be substantially solid, meaning that while the wick may be porous, it is not hollow in the sense that it has an extended continuous channel passing through the wick from one end to the other end. In some embodiments, the wick 636 may be substantially rod-shaped. As seen from FIG. 9, the wick 636 includes a cooperating end 636a that is at least partially inserted into an opening 654 in a liquid storage container 644. Interacting end 636a of wick 636 can only be held in hole 654 by friction. As shown, clip 649 surrounds the outer surface of the liquid storage container 644 near opening 654 to form a sealing engagement between the wick 636 and the liquid storage container. In the embodiment shown, the wick 636 has a longitudinal axis and the liquid storage container 644 has a longitudinal axis, the longitudinal axes of the wick and the liquid storage container being substantially parallel. The longitudinal axes may be substantially perpendicular to the longitudinal axis of the airflow path between the airflow inlet 607 and the airflow outlet 609 of the casing 603.

[00126] The heater 634 is located substantially in the central portion 636c of the wick 636, a portion of which is at least partially located within the airflow path that encompasses the airflow inlet 607 and the airflow outlet 609. The airflow path may include a connector 640, a flow tube 645, and a mouthpiece 627. As shown in FIG. 9, the lower end of the flow tube 645 may substantially abut against the wick 636 in a region surrounding its central portion 636c such that substantially all of the vapor produced by the heater 634 evaporating the aerosol precursor composition passing from the liquid storage container 644 through the wick may be removed by suction through the flow tube without substantially entering other areas of the vaporizing block 604. The wick 636 also includes a free end 636b, and the free end of the wick may include a lip 636e to ensure a secure fit of the wick within the casing 603. As in the embodiments described above, the steam generating unit 604 also includes a PCB 650 and electrical leads 634a and 634b connecting the heater 634 to a power source.

[00127] As can be seen from FIG. 9, the housing 603 of the vaporizing unit 604 can be characterized as comprising two combined housings. The main body 603a may be substantially aligned with the axis of the airflow path through the casing 603, and the main body may include a connector 640, a flow tube 645, and a mouthpiece 627. The casing 603 may also include a protrusion 603b that extends substantially perpendicular from the main body 603a. This ledge 603b may contain a container 644 for storing liquid. The wick 636 can be aligned such that a wick part is in the main body 603a and a wick part is in the projection 603b.

[00128] As described above, the steam generating unit 604 may be connected to a power supply (see FIG. 8), and the power supply may specifically comprise a power supply. In some embodiments, the steam generating unit 604 may be coupled to the power supply 602 such that the steam generating unit is located external to the power supply when connected. Although a portion of the connector 640 may be located internal to the power supply 602 in some embodiments, the remainder of the main body 603a and extension 603b of the shroud 603 are located external to the power supply. However, in other embodiments, the steam generating unit is configured to be connected to the power supply such that the steam generating unit is completely inside with respect to the power supply when the two elements are connected. Such an implementation is shown in FIG. 10 and 11.

[00129] Vaporization block 704 shown in FIG. 10 is constructed in a similar manner to the steam generating unit 604 shown in FIG. 9. Specifically, the vaporizing unit 704 includes a casing 703 defined by an outer wall 705. The casing 703 includes an airflow inlet 707 and an airflow outlet 709. In some embodiments, an airflow inlet 707 may be formed in a PCB 750 located in a recess 705a in the lower portion of the outer wall 705. In some embodiments, the PCB 750 may be omitted and the recess 705a may be sized to function as a air flow.

[00130] Vaporization block 704, as shown in the embodiment of FIG. 10 also includes a fluid storage container 744 located within the housing 703. The fluid storage container 744 may be formed by a flexible outer wall 753 that has an opening 754 formed therein. 744a, which is sized to accept a ceramic wick 736 that may be substantially solid. Similar to the embodiment shown in FIG. 9, the wick 736 includes a cooperating end (not visible in FIG. 10) that is at least partially inserted into the opening 754 defined by the neck 744a of the liquid storage container 744, and the neck 744a may form a wick seal 736 with a clip 749.

[00131] In the embodiment shown, the wick 736 has a longitudinal axis and the liquid storage container 744 has a longitudinal axis, the longitudinal axes of the wick and the liquid storage container being substantially parallel. Moreover, the longitudinal axes may be substantially perpendicular to the longitudinal axis of the airflow path between the airflow inlet 707 and the airflow outlet 709 of the casing 703.

[00132] The heater 734 is located substantially in the central portion 736 c of the wick 736, a portion of which is at least partially located within the airflow path that encompasses the airflow inlet 707 and the airflow outlet 709. As shown in FIG. 10, housing 703 may include insulating walls 705b and 705c extending inwardly from outer wall 705 of the housing. The insulating walls (705b, 705c) may include recesses that substantially conform to the outer contour of the wick 736. In some embodiments, more than two insulating walls may be used. Alternatively, only one insulating wall 705c may be provided. The insulating walls (705b, 705c) during operation isolate the region surrounding its central portion 736c of the wick 736 so that substantially all of the vapor generated by the heater 734 evaporating the aerosol precursor composition passing from the liquid storage container 744 through the wick can be removed. suction through the airflow outlet 709 without substantially entering other areas of the vaporizing block 704. The wick 736 also includes a free end 736b, and the free end of the wick may include a lip 736e to ensure a secure fit of the wick within the housing 703. As shown in the drawing, the lip 736e during operation protects the free end 736b of the wick 736 between the outer wall 705 of the casing 703 and one of the insulating walls 705b. Steam generating unit 704 is shown in FIG. 10 substantially with half of the outer wall 705 of the housing 703 removed to show the internal components of the device. The outer wall 705, in some implementations, may be formed from two halves that are essentially their mirror image. The two halves that form the outer wall 705 may be glued, soldered, or otherwise combined to prevent separation and remove the internal components of the vaporizing unit 704. Alternatively, the two halves that form the outer wall 705 may be detachable so that that the wick 736 and/or the heater 734 and/or the heater 734 and/or the liquid storage container 744 can be removed and replaced (or refilled in relation to the liquid storage container).

[00133] Electrical leads 734a and 734b connect heater 734 to PCB 750, which may include appropriate leads to form an electrical connection to a power source in the power supply. To this end, the steam generating unit 704 can be configured to be inserted into a power supply.

[00134] FIG. 11 shows an aerosol delivery device 700 that includes a vaporizing unit 704 essentially as described with respect to FIG. 10 inserted into the power supply 702 through opening 781. The steam generating block 704 may be replaceable by removal and reinsertion through opening 781, as indicated by arrow A, the vaporizing block may be a non-replaceable block that is inserted during manufacture without deletion by the user. The vaporizing unit 704, when inserted into the power unit 702, may be at least partially located within the power unit. In some embodiments, the steam generating unit 704, when inserted into the power unit 702, may be fully inserted into the power unit such that the outer wall 705 forming the housing of the steam generating unit is entirely within the power unit. In some embodiments, a decal 792 or the like may be included in the vaporizer 704 to facilitate removal of the vaporiser, and at least a portion of such a decal or the like may be positioned external to the power supply 702 while the vaporiser housing still completely located inside with respect to the power supply 702.

[00135] The power supply unit 702 may include electrical connectors 783a, 783b aligned with the steam generating unit 704 to deliver electrical energy to electrical outputs 734a, 734b (e.g., directly or via intermediate connectors on PCB 750) from power supply 710 in the power supply. The power supply 702 may also include a control component 706, which may be in the form of a PCB including suitable microcontroller functions. The sensor 708 may be included in the power unit 702 and may be in fluid communication with an air inlet 785 through which air can be drawn from the environment, through the power unit 702 and into the airflow inlet 707 of the vaporizing unit 704. Sensor 708, detecting airflow may activate a power supply 710 to deliver energy to a heater 734 in the steam generating unit 704. Sensor 708 may be combined with a controller 706.

[00136] The power unit 702 of the aerosol delivery device 700 may include a mouthpiece 727. An aerosol inlet 787 may be formed in the power unit 702 above the airflow outlet 709 of the vaporizing unit 704. Thus, when the vaporizing unit 704 is inserted into the power unit 702, the output 709 for the air flow of the casing 703 is substantially aligned with the entrance 787 for the aerosol. Under conditions of use, the aerosol precursor composition from the liquid storage container 744 passes through the ceramic wick 736 to the heater 734 where it vaporizes and mixes with the air passing through the air inlet 785 and the airflow inlet 707 to form an aerosol that passes to the outside. from the outlet 709 for the air flow and into the inlet 787 for the aerosol. From the aerosol inlet 787, the generated aerosol passes through the hollow interior 727a of the mouthpiece 727 to exit the mouthpiece end 727b of the mouthpiece.

[00137] The mouthpiece 727 of the aerosol delivery device 700 may be stationary. In some embodiments, the mouthpiece 727 may be movable between an open position (as shown in FIG. 11), in which the generated aerosol may pass through the hollow interior 727a to the mouthpiece end 727b of the mouthpiece, and a closed position, in which the passage of the generated aerosol essentially prevented through it. Preferably, the aerosol delivery device 700 may be configured to include a switch 789 such that when the mouthpiece 727 is not in position to allow aerosol to pass through, the aerosol delivery device may be disabled. In the embodiment shown, the mouthpiece 727 may be foldable and thus rotatable about the central sleeve 727c to be folded substantially flat relative to the power pack 702 to be in the closed position and unfolded to the expanded position for use. . The folding action may substantially seal the aerosol inlet 787 from the hollow interior 727c of the mouthpiece, and the folding action may activate the switch 789, if desired. In the embodiment shown in FIG. 11, the power supply 702 includes a receptacle 791 in which the mouthpiece 727 may be substantially recessed and which may be configured to substantially cover the mouthpiece end 727b of the mouthpiece to prevent contamination during non-use.

[00138] Many modifications and other embodiments of the invention will become apparent to a person skilled in the art to which the present disclosure pertains, which takes advantage of the teachings presented in the above descriptions and associated drawings. Thus, it is to be understood that the invention is not to be limited to the specific embodiments disclosed herein, and that modifications and other embodiments are to be included within the scope of the appended claims. Although specific terms are used in this document, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (34)

1. An aerosol delivery device, comprising: a casing formed at least partially by the outer wall; a flow tube located inside with respect to the outer wall of the casing and containing at least one ventilation passage made in its wall and configured to allow air flow through it and essentially prevent liquid flow through it; a space formed between the outer wall of the housing and the flow tube, the space configured to hold the liquid aerosol precursor composition; an airflow path through the device between the casing connection end and the mouthpiece end of the casing, extending at least partially through the flow tube; an atomizer formed by a heater combined with a ceramic wick, the ceramic wick being in sealing engagement with the flow tube such that at least a portion of the ceramic wick is in the airflow path and at least a portion of the ceramic wick is in fluid communication with the space formed between the outer wall of the casing and the flow tube; And a sealing element located between the ceramic wick and the flow tube and configured to form a sealing interaction. 2. The apparatus of claim. 1, wherein said at least one ventilation passage made in the wall of the flow tube is located near the mouth end of the casing. 3. The device according to claim 1 or 2, also containing a mouthpiece interacting with the mouthpiece end of the casing and interacting with the end of the flow tube. 4. The device according to any one of paragraphs. 1-3, also containing a connector that interacts with the connecting end of the casing. 5. The device according to any one of paragraphs. 1-4 in which the ceramic wick is substantially solid. 6. The apparatus of claim. 5, wherein the heater is a resistive heating wire located around the outer surface of the ceramic wick. 7. The device of claim. 5, in which the ceramic wick has a longitudinal axis that is essentially perpendicular to the longitudinal axis of the casing. 8. The device of claim. 5, in which the ceramic wick passes transversely through the flow tube between the first end of the ceramic wick and the second end of the ceramic wick, and in which the sealing element is in sealing engagement with the ceramic wick near the first end of the ceramic wick and the second end of the ceramic wick . 9. The device according to any one of paragraphs. 1-8, wherein the ceramic wick has a hollow interior defining a passage extending between the first end of the ceramic wick and the second end of the ceramic wick. 10. The apparatus of claim. 9, wherein the heater is located within a passage formed in the hollow interior of the ceramic wick. 11. The device of claim 9, wherein the second end of the ceramic wick engages with the free end of the flow tube. 12. The apparatus of claim 11 wherein the first end of the ceramic wick is connected to a connector cooperating at the end of the housing connector. 13. The apparatus of claim 12, wherein the sealing element forms a sealing engagement between the free end of the flow tube and the second end of the ceramic wick, and wherein the second sealing element forms a sealing engagement between the first end of the ceramic wick and the connector. 14. An aerosol delivery device, comprising: a casing containing an air flow inlet and an air flow outlet; a liquid storage container inside the casing formed by the flexible outer wall and having an opening formed therein; And an atomizer inside the casing, containing a ceramic wick, containing an end interacting with an opening formed in a container for storing liquid, and essentially a central part interacting with a heater, wherein essentially the central part of the ceramic wick and the heater are in the air flow path between the inlet for airflow and airflow outlet housing; wherein the ceramic wick has a longitudinal axis, the liquid storage container has a longitudinal axis, wherein the longitudinal axes of the ceramic wick and the liquid storage container are substantially parallel; And the longitudinal axes of the ceramic wick and the liquid storage container are substantially perpendicular to the longitudinal axis of the airflow path between the airflow inlet and the airflow outlet of the casing. 15. The device of claim 14 wherein the ceramic wick is substantially rod-shaped. 16. The apparatus of claim 14 or 15, wherein the airflow outlet comprises a mouthpiece extending outwardly from the housing. 17. The device according to any one of paragraphs. 14-16 wherein the housing comprises a main body that is substantially aligned with the axis of the airflow path and a protrusion extending substantially perpendicular from the main body, the protrusion comprising a fluid storage container. 18. The device according to any one of paragraphs. 14-17, also containing a power supply that is configured to be connected to the housing, and the power supply contains a power source. 19. The apparatus of claim 18, wherein the power supply is configured to be coupled to the housing such that the housing is external to the power supply when connected. 20. The apparatus of claim 18, wherein the power supply is operable to be coupled to the housing such that the housing is entirely within the power supply when connected. 21. The apparatus of claim 18, wherein the power supply includes a mouthpiece. 22. The apparatus of claim 21, wherein the housing is insertable into the power supply such that the airflow exiting the housing is substantially aligned with the aerosol inlet to the mouthpiece. 23. The apparatus of claim 21, wherein the mouthpiece is movable between an open position, in which the generated aerosol is allowed to pass through, and a closed position, in which the generated aerosol is substantially prevented from passing through it.

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