BR112019009676B1 - INDUCTION-BASED AEROSOL DELIVERY DEVICE AND CONTROL BODY - Google Patents

Abstract

An aerosol delivery device is provided that includes a substrate configured to carry an aerosol precursor composition, and a resonant transformer including a transmitter coupler and a resonant receiver coupler that are positioned in close proximity to the substrate. The aerosol delivery device also includes a pulse width modulation (PWM) inverter configured to drive the resonant transformer. The PWM inverter includes a bridge circuit coupled to the transmitter coupler, and a PWM controller incorporated as an integrated circuit and configured to send a PWM signal to the bridge circuit configured to drive the transmitter coupler to generate an oscillating magnetic field and induce an AC voltage in the resonant receiver coupler when exposed to the oscillating magnetic field. The alternating voltage causes the resonant receiver coupler to generate heat and thereby vaporize the components of the aerosol precursor composition.

Description

TECHNOLOGICAL FIELD

[001] The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices that can use electrically generated heat to produce aerosol (for example, smoking articles commonly referred to as electronic cigarettes). The smoking articles may be configured to heat an aerosol precursor, which may incorporate materials that may be made or derived from, or otherwise incorporate tobacco, the precursor being capable of forming an inhalable substance for human consumption.

FUNDAMENTALS

[002] Many devices have been proposed over the years as improvements or alternatives to tobacco products that require the combustion of tobacco for use. Many of these devices are supposedly designed to provide the sensations associated with smoking cigarettes, cigars or pipes, but without delivering considerable amounts of incomplete combustion and pyrolysis products that result from burning tobacco. To this end, numerous alternative smoking products, flavor generators and medicated inhalers have been proposed which utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar or pipe smoking without burning tobacco to a significant degree. See, for example, the various smoking articles, aerosol delivery devices, and alternative heat generation sources set forth in the prior art described in U.S. Pat. 8,881,737 to Collett et al., US Patent Application Publication No. 2013/0255702 by Griffith Jr. et al., US Patent Application Publication No. 2014/0000638 to Sebastian et al., US Patent Application Publication No. 2014/0096781 to Sears et al., US Patent Application Publication No. 2014/0096782 to Ampolini et al., US Patent Application Publication No. 2015/0059780 to Davis et al. and US Patent Application No. Watson et al., Serial 15/222,615, filed July 28, 2016, all incorporated herein by reference. See also, for example, the various product implementations and heating configurations described in the fundamentals sections of US Patent No. 5,388,594 to Counts et al. and 8,079,371 to Robinson et al., which are incorporated by reference.

[003] Various implementations of aerosol delivery devices employ an atomizer to produce an aerosol from an aerosol precursor composition. Such atomizers often employ direct resistive heating to produce heat. In this regard, atomizers may include a heating element comprising a coil or other member that produces heat through electrical resistance associated with the material through which an electrical current is directed. Electrical current is typically directed through the heating element through direct electrical connections such as wires or connectors. However, forming such electrical connections can complicate aerosol delivery device assembly and add potential points of failure. Furthermore, in some implementations, the aerosol delivery device may include a control body, which may include a power source, and a cartridge, which may include the atomizer. In these implementations, electrical connections between the cartridge and the control body may be required, which may further complicate the design of the aerosol delivery device. Thus, advances in aerosol delivery devices may be desirable.

BRIEF SUMMARY

[004] The present disclosure relates to aerosol delivery devices configured to produce aerosol and which aerosol delivery devices, in some implementations, may be referred to as electronic cigarettes or heatless cigarettes. As described below, aerosol delivery devices can include a resonant transformer including a transmitter coupler (sometimes referred to as an inductive transmitter) and a resonant receiver coupler (sometimes referred to as an inductive receiver). The transmitter coupling device may include a coil configured to create an oscillating magnetic field (a magnetic field that varies periodically with time) when alternating current is directed therethrough. The resonant receiver coupler may be at least partially received within the transmitter coupler and may include a conductive material. Thus, by directing the alternating current through the transmitter coupler, eddy currents can be generated in the resonant receiver coupler via induction. Eddy currents flowing through the resistance of the material defining the resonant receiver coupling device can heat it up by Joule heating. In this way, the resonant receiver coupling device, which may define an atomizer, can be wirelessly heated to form an aerosol from an aerosol precursor composition positioned in proximity of the resonant receiver coupling device. Cordless heating, as used herein, refers to heating that occurs through an atomizer that is not physically electrically connected to the (electrical) power source. For more information, see US Patent Application No. of Davis et al. Serial 14/934,763, filed November 6, 2015, and U.S. Patent Application No. de Série 15/002,056 of Sur, filed January 20, 2016, both of which are incorporated herein by reference.

[005] The present disclosure includes, without limitation, the following example implementations.

[006] Implementation of Example 1: An aerosol delivery device comprising a substrate configured to carry an aerosol precursor composition; a resonant transformer including a transmitter coupler and a resonant receiver coupler that is positioned in proximity to the substrate; and a pulse width modulation (PWM) inverter configured to drive the resonant transformer, the PWM inverter comprising: a bridge circuit coupled to the transmitter coupler; and a PWM controller incorporated as an integrated circuit and configured to output a PWM signal to the bridge circuit configured to drive the transmitter coupling device to generate an oscillating magnetic field and induce an alternating voltage in the resonant receiver coupling device when exposed to the oscillating magnetic field, the alternating voltage causing the resonant receiver coupling device to generate heat and thereby vaporize the aerosol precursor composition components.

[007] Example Implementation 2: The aerosol delivery device of any preceding example implementation, or any combination of any preceding example implementations, wherein the aerosol delivery device further comprises a power source including a rechargeable supercapacitor, rechargeable solid-state battery or rechargeable lithium-ion battery, and configured to power the PWM inverter.

[008] Example Implementation 3: The aerosol delivery device of any previous example implementation, or any combination of any previous example implementations, wherein the aerosol delivery device further comprises a constant voltage regulator between the power source and the PWM inverter, and configured to maintain a constant voltage level in the PWM inverter.

[009] Example Implementation 4: The aerosol delivery device of any preceding example implementation, or any combination of any prior example implementations, wherein the aerosol delivery device further comprises a power source including a rechargeable supercapacitor, and configured to power the PWM inverter.

[0010] Example Implementation 5: The aerosol delivery device of any preceding example implementation, or any combination of any prior example implementations, wherein the power source further includes terminals connectable with a power source from which the rechargeable supercapacitor is chargeable.

[0011] Example Implementation 6: The aerosol delivery device of any foregoing example implementation, or any combination of any foregoing example implementations, wherein the power source further comprises the power source, and the power source is or includes a rechargeable solid-state battery or rechargeable lithium-ion battery.

[0012] Example Implementation 7: The aerosol delivery device of any prior example implementation, or any combination of any prior example implementations, wherein the bridge circuit is a half bridge composed of a pair of transistors and a pair of diodes.

[0013] Example Implementation 8: The aerosol delivery device of any preceding example implementation, or any combination of any of the preceding example implementations, wherein the aerosol delivery device further comprises a Hall-effect current sensor positioned in proximity to the resonant receiver coupling device and configured to produce a measurement of an alternating current induced therein; and a microprocessor configured to receive measurement and control operation of at least one functional element of the aerosol delivery device in response thereto.

[0014] Example Implementation 9: The aerosol delivery device of any preceding example implementation, or any combination of any of the preceding example implementations, wherein the aerosol delivery device further comprises a high-pass filter coupled to the resonant receiver coupling device and configured to filter any forward voltage component from the induced alternating voltage in the resonant receiver coupling device; and a non-inverting amplifier circuit coupled to the high-pass filter and configured to amplify the filtered alternating voltage.

[0015] Example Implementation 10: The aerosol delivery device of any prior example implementation, or any combination of any prior example implementations, wherein the transmitter coupling device is configured to at least partially surround the resonant receiver coupling device.

[0016] Example Implementation 11: The aerosol delivery device of any preceding example implementation, or any combination of any prior example implementations, wherein the transmitter coupling device defines a tubular or coiled configuration.

[0017] Implementation of Example 12: A control body coupled or attachable to a cartridge that is equipped with a resonant receiver coupling device that is positioned in proximity to a substrate configured to carry an aerosol precursor composition, the control body comprising a transmitter coupling device that with the resonant receiver coupling device forms a resonant transformer when the control body is coupled to the cartridge; and a pulse width modulation (PWM) inverter configured to drive the resonant transformer, the PWM inverter comprising: a bridge circuit coupled to the transmitter coupler; and a PWM controller incorporated as an integrated circuit and configured to output a PWM signal to the bridge circuit configured to drive the transmitter coupling device to generate an oscillating magnetic field and induce an alternating voltage in the resonant receiver coupling device when exposed to the oscillating magnetic field, the alternating voltage causing the resonant receiver coupling device to generate heat and thereby vaporize the aerosol precursor composition components.

[0018] Example Implementation 13: The control body of any foregoing example implementation, or any combination of any foregoing example implementations, wherein the control body further comprises a power source including a rechargeable supercapacitor, rechargeable solid-state battery or rechargeable lithium-ion battery, and configured to power the PWM inverter.

[0019] Example Implementation 14: The control body of any previous example implementation, or any combination of any previous example implementations, wherein the control body further comprises a constant voltage regulator between the power source and the PWM inverter, and configured to maintain a constant voltage level in the PWM inverter.

[0020] Example Implementation 15: The control body of any preceding example implementation, or any combination of any preceding example implementations, wherein the control body further comprises a power source including a rechargeable supercapacitor, and configured to power the PWM inverter.

[0021] Example Implementation 16: The control body of any foregoing example implementation, or any combination of any foregoing example implementations, wherein the power source further includes terminals connectable to a power source from which the rechargeable supercapacitor is chargeable.

[0022] Example Implementation 17: The control body of any foregoing example implementation, or any combination of any foregoing example implementations, wherein the power source further comprises the power source, and the power source is or includes a rechargeable solid-state battery or rechargeable lithium-ion battery.

[0023] Example Implementation 18: The control body of any preceding example implementation, or any combination of any preceding example implementations, wherein the bridge circuit is a half bridge composed of a pair of transistors and a pair of diodes.

[0024] Example Implementation 19: The control body of any prior example implementation, or any combination of any prior example implementations, wherein the transmitter coupling device is configured to at least partially surround the resonant receiver coupling device.

[0025] Example Implementation 20: The control body of any prior example implementation, or any combination of any prior example implementations, wherein the transmitter coupling device defines a tubular or coiled configuration.

[0026] These and other features, aspects and advantages of the present disclosure will become apparent from reading the following detailed description together with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined or otherwise referred to in a specific example implementation described herein. This disclosure is intended to be read holistically, so that any separable features or elements of the disclosure, in any of its aspects and example implementations, should be viewed as combinable, unless the context of the disclosure clearly dictates otherwise.

[0027] It will therefore be appreciated that this Brief Summary is provided merely for the purpose of summarizing some example implementations, so as to provide a basic understanding of some aspects of the disclosure. Accordingly, it will be appreciated that the example implementations described above are examples only and should not be construed to restrict the scope or spirit of the disclosure in any way. Other example implementations, aspects and advantages will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of some described example implementations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Having thus described the disclosure in the aforementioned general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0029] Figure 1 illustrates a perspective view of an aerosol delivery device comprising a cartridge and a control body, wherein the cartridge and the control body are coupled together in accordance with an exemplary implementation of the present disclosure;

[0030] Figure 2 illustrates a perspective view of the aerosol delivery device of Figure 1 in which the cartridge and the control body are disengaged from each other in accordance with an exemplary implementation of the present disclosure;

[0031] Figure 3 illustrates an exploded view of the control body of Figure 1 in which a transmitter coupling device thereof defines a tubular configuration in accordance with an exemplary implementation of the present disclosure;

[0032] Figure 4 illustrates a sectional view through the control body of Figure 3;

[0033] Figure 5 illustrates a sectional view through the control body of Figure 1 in which a transmitter coupling device thereof defines a coiled configuration in accordance with an exemplary implementation of the present disclosure;

[0034] Figure 6 illustrates an exploded view of the cartridge of Figure 1 in which a substrate thereof extends into an internal compartment defined by a container according to a first exemplary implementation of the present disclosure;

[0035] Figure 7 illustrates a sectional view through the cartridge of Figure 6;

[0036] Figure 8 illustrates a sectional view through the cartridge of Figure 1 including a reservoir substrate in an internal compartment defined by a container according to a second exemplary implementation of the present disclosure;

[0037] Figure 9 illustrates a sectional view through the cartridge of Figure 1 including a substrate in contact with a resonant receiver coupler according to a third exemplary implementation of the present disclosure;

[0038] Figure 10 illustrates a sectional view through the cartridge of Figure 1 including an electronic control component according to a fourth exemplary implementation of the present disclosure;

[0039] Figure 11 illustrates a sectional view through the aerosol delivery device of Figure 1 including the cartridge of Figure 6 and the control body of Figure 3 in accordance with an exemplary implementation of the present disclosure;

[0040] Figures 12, 13 and 14 illustrate circuitry and other components of the aerosol delivery device according to example implementations;

[0041] Figure 15 schematically illustrates a method for assembling an aerosol delivery device according to an exemplary implementation of the present disclosure; It is

[0042] Figure 16 schematically illustrates a method for aerosolization according to an exemplary implementation of the present disclosure.

DETAILED DESCRIPTION

[0043] The present disclosure will now be described in more detail below with reference to example implementations thereof. These example implementations are described so that this disclosure is exhaustive and complete and fully conveys the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be incorporated in many different forms and should not be construed as limited to the implementations set forth herein; rather, these implementations are provided for such disclosure to satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms "a", "an", "the" and the like include plural references unless the context clearly indicates otherwise. In addition, while reference may be made to quantitative measurements, values, geometric relationships or the like, unless otherwise noted, any one or more of these, if not all, may be absolute or approximate to account for acceptable variations that may occur, such as those due to engineering tolerances or the like.

[0044] As described below, example implementations of the present disclosure relate to aerosol delivery devices. Aerosol delivery devices in accordance with the present disclosure utilize electrical energy to heat a material (preferably without burning the material to any significant degree) to form an inhalable substance; and the components of such systems are in the form of articles, most preferably compact enough to be considered portable devices. That is, the use of preferred aerosol delivery device components does not result in the production of smoke in the sense that the aerosol results primarily from by-products of tobacco combustion or pyrolysis, but rather, the use of these preferred systems results in the production of vapors resulting from the volatilization or vaporization of certain components incorporated therein. In some example implementations, aerosol delivery device components can be characterized as electronic cigarettes, and these electronic cigarettes preferably incorporate tobacco and/or tobacco-derived components and thereby deliver tobacco-derived components in aerosol form.

[0045] Aerosol generation pieces of certain favorite aerosol delivery devices can provide many of the sensations (eg inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical sensation, visual tips such as those provided by visible and similar aerosol) of smoking a cigarette, cigar or pipe that is used to light up and burn (and burn tabacos Therefore, inhale tobacco smoke), without any substantial degree of combustion of any component. For example, the user of an aerosol generating piece of the present invention can hold and use that piece much like a smoker using a traditional type of smoking article, suck on one end of that piece to inhale aerosol produced by that piece, take or suck puffs at selected intervals of time, and so on.

[0046] Although systems are generally described here in terms of implementations associated with aerosol delivery devices, such as so-called "electronic cigarettes", it should be understood that the mechanisms, components, features and methods can be incorporated in many different forms and associated with a variety of articles. For example, the description provided herein may be employed in conjunction with implementations of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), warm-no-burn cigarettes, and related packaging for any of the products disclosed herein. Therefore, it should be understood that the description of mechanisms, components, resources and methods disclosed herein are discussed in terms of implementations relating to aerosol delivery devices by way of example only, and may be incorporated and used in various other products and methods.

[0047] The aerosol delivery devices of the present disclosure can also be characterized as being vapor generating articles or drug delivery articles. Thus, such articles or devices can be adapted to provide one or more substances (e.g. flavors and/or active pharmaceutical ingredients) in an inhalable form or state. For example, inhalable substances may be substantially in the form of a vapor (i.e., a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, inhalable substances may be in the form of an aerosol (ie a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol", as used herein, is intended to include vapors, gases and aerosols in a form or type suitable for human inhalation, visible or otherwise, and in a form that may or may not be considered to be smoke.

[0048] In use, the aerosol delivery devices of the present disclosure can be subjected to many of the physical actions employed by an individual in using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is utilized by lighting and inhaling tobacco). For example, the user of an aerosol delivery device of the present disclosure can hold that article very similar to a traditional type of smoking article, suck on one end of that article to inhale aerosol produced by that article, take puffs at selected time intervals, etc.

[0049] Aerosol delivery devices of the present disclosure generally include various components provided within an outer body or housing, which may be referred to as a housing. The overall design of the outer body or housing can vary, and the shape or configuration of the outer body which can define the overall size and shape of the aerosol delivery device can vary. Typically, an elongated body similar to the shape of a cigarette or cigar may be formed from a single unitary housing or the elongated housing may be formed of two or more separable bodies. For example, an aerosol delivery device may comprise an elongated housing or body which may be substantially tubular in shape and, as such, resemble the shape of a conventional cigarette or cigar. In one example, all aerosol delivery device components are contained within a housing. Alternatively, an aerosol delivery device may comprise two or more housings which are joined together and are separable. For example, an aerosol delivery device may have at one end a control body comprising a housing containing one or more reusable components (e.g., an accumulator such as a rechargeable battery and/or rechargeable supercapacitor, and various electronics for controlling the operation of that article), and at the other end and removablely attachable thereto, an outer body or housing containing a disposable portion (e.g., a disposable aroma-containing cartridge). More specific shapes, configurations and arrangements of components within the single housing unit type or within a multi-piece separable housing unit type will be apparent in light of the further description provided herein. Additionally, various aerosol delivery device designs and component arrangements can be appreciated after consideration of commercially available electronic aerosol delivery devices.

[0050] Aerosol delivery devices of the present disclosure most preferably comprise some combination of an energy source (i.e., an electrical energy source), at least one control component (e.g., means for actuating, controlling, regulating, and stopping heat generation, such as controlling the flow of electrical current from the energy source to other components of the article - e.g., a microprocessor, individually or as part of a microcontroller), a heater or heat generator (e.g., an electrical resistance heating element or other component, alone or in combination with one or more additional elements may be commonly referred to as an "atomizer"), an aerosol precursor composition (e.g., generally a liquid capable of producing an aerosol upon the application of sufficient heat, such as ingredients commonly referred to as "smoke juice", "e-liquid" and "e-juice"), and a mouth end region or tip to allow sucking of the aerosol device for aerosol inhalation (e.g., an airflow path defined through the article such that the aerosol generated ssol can be removed from it after sucking).

[0051] The alignment of components within the aerosol delivery device of the present disclosure may vary. In specific implementations, the aerosol precursor composition may be located near one end of the aerosol delivery device which may be configured to be positioned near a user's mouth so as to maximize aerosol delivery to the user. Other configurations, however, are not excluded. Generally, the heating element can be positioned close enough to the aerosol precursor composition so that the heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorings, medicaments or the like which can likewise be provided for delivery to a user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, released or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are intended to be interchangeable, so that references to liberate, liberate, releases or liberated include form or generate, form or generate, form or generate, and formed or generated. Specifically, an inhalable substance is delivered in the form of a vapor or aerosol or mixture thereof, which terms are also used interchangeably herein unless otherwise specified.

[0052] As noted above, the aerosol delivery device may incorporate a battery or other source of electrical energy to provide sufficient current flow to provide various functionality to the aerosol delivery device, such as powering a heater, powering control systems, powering indicators, and the like. The power source can take on multiple implementations. Preferably, the energy source is capable of supplying sufficient energy to rapidly heat the heating element to provide for aerosol formation and power the aerosol delivery device through use for a desired period of time. The power source is preferably sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Additionally, a preferred energy source is of sufficiently light weight so as not to detract from a desirable smoking experience.

[0053] More specific shapes, configurations, and arrangements of components within the aerosol delivery device of the present disclosure will be apparent in light of the additional disclosure provided below. Additionally, the selection of various aerosol delivery device components can be appreciated after consideration of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device can also be appreciated after consideration of commercially available electronic aerosol delivery devices.

[0054] As described below, the present disclosure relates to aerosol delivery devices. Aerosol delivery devices can be configured to heat an aerosol precursor composition to produce an aerosol. In some implementations, aerosol delivery devices may comprise non-burn heating devices configured to heat a solid aerosol precursor composition (an extruded tobacco rod) or a semi-solid aerosol precursor composition (e.g., a glycerin-loaded tobacco paste). In another implementation, the aerosol delivery devices can be configured to heat and produce an aerosol from a fluid aerosol precursor composition (e.g., a liquid aerosol precursor composition). Such aerosol delivery devices may include so-called electronic cigarettes.

[0055] Regardless of the type of heated aerosol precursor composition, aerosol delivery devices may include a heating element configured to heat the aerosol precursor composition. In some implementations, the heating element may comprise a resistive heating element. Resistive heating elements can be configured to produce heat when an electrical current is directed through them. Such heating elements often comprise a metallic material and are configured to produce heat as a result of electrical resistance associated with the passage of an electrical current therethrough. Such resistive heating elements can be positioned in close proximity to the aerosol precursor composition. For example, in some implementations, resistive heating elements may comprise one or more coils of wire wrapped around a liquid transport member (e.g., a wick, which may comprise a porous ceramic, carbon, cellulose acetate, polyethylene terephthalate, fiberglass, or porous sintered glass) configured to suck an aerosol precursor composition therethrough. Alternatively, the heating element can be positioned in contact with a solid or semi-solid aerosol precursor composition. Such configurations can heat the aerosol precursor composition to produce an aerosol.

[0056] In some implementations, aerosol delivery devices may include a control body and a cartridge. The control body can be reusable, while the cartridge can be configured for a limited number of uses and/or configured to be disposable. The cartridge can include the aerosol precursor composition. In order to heat the aerosol precursor composition, the heating element can also be positioned in the cartridge. The control body may include a power source, which may be rechargeable or replaceable, and in this way the control body may be reused with multiple cartridges.

[0057] Although the aerosol delivery devices described above can be used to heat an aerosol precursor composition to produce aerosol, such configurations can suffer from one or more disadvantages. In this regard, the resistive heating elements may comprise a wire defining one or more coils contacting the aerosol precursor composition. For example, as noted above, the coils may surround a liquid transport element (e.g., a wick) to heat and aerosolize an aerosol precursor composition directed to the heating element through the liquid transport element. However, as a result of the coils defining a relatively small surface area, some of the aerosol precursor composition can be heated to an unnecessarily high level during aerosolization, thereby wasting energy. Alternatively or additionally, part of the aerosol precursor composition that is not in contact with the heating element coils may be heated to an extent insufficient for aerosolization. Thus, insufficient aerosolization may occur, or aerosolization with wasted energy may occur.

[0058] Furthermore, as noted above, resistive heating elements produce heat when electrical current is directed through them. Consequently, as a result of positioning the heating element in contact with the aerosol precursor composition, charring of the aerosol precursor composition may occur. Such charring can occur as a result of heat produced by the heating element and/or as a result of electricity passing through the aerosol precursor composition in the heating element. Charring can result in material buildup on the heating element. This buildup of material can adversely affect the taste of the aerosol produced from the precursor aerosol composition.

[0059] As described above, aerosol delivery devices may comprise a control body including a power source and a cartridge comprising a resistive heating element and an aerosol precursor composition. In order to direct electrical current to the resistive heating element, the control body and the cartridge may include electrical connectors configured to engage one another when the cartridge is engaged with the control body. However, the use of such electrical connectors can further complicate and increase the cost of such aerosol delivery devices. Additionally, in implementations of aerosol delivery devices including a fluid aerosol precursor composition, its leakage may occur at terminals or other connectors within the cartridge.

[0060] Thus, implementations of the present disclosure are directed to aerosol delivery devices that can avoid some or all of the problems noted above. In this regard, Figure 1 illustrates an aerosol delivery device 100 in accordance with an exemplary implementation of the present disclosure. The aerosol delivery device can include a cartridge 102 and a control body 104. The cartridge and control body can be permanently or prominently aligned in a functional relationship. In this regard, Figure 1 illustrates the aerosol delivery device in a coupled configuration, while Figure 2 illustrates the aerosol delivery device in an uncoupled configuration. Various mechanisms can connect the cartridge to the control body to result in a threaded engagement, press fit engagement, interference fit, magnetic engagement, or the like. The aerosol delivery device may be substantially rod-shaped, substantially tubular-shaped, or substantially cylindrical-shaped in some implementations when the cartridge and control body are in an assembled configuration.

[0061] In specific implementations, one or both of the cartridge 102 and the control body 104 may be referred to as being disposable or reusable. For example, the control body may have a replaceable battery or a rechargeable battery, solid-state battery, thin-film solid-state battery, rechargeable supercapacitor, or the like, and thus may be combined with any type of charging technology, including connection to a wall charger, connection to a car charger (i.e., a cigarette lighter receptacle), and connection to a computer, such as via a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0 , 3.1, USB Type-C), connection to a photovoltaic cell (sometimes referred to as a solar cell) or solar cell solar panel, or wireless radio frequency (RF) based charger. Furthermore, in some implementations, cartridge 102 may comprise a single-use cartridge, as disclosed in U.S. Patent No. 8910639 to Chang et al., which is incorporated herein by reference in its entirety.

[0062] Figure 3 illustrates an exploded view of the control body 104 of the aerosol delivery device 100 according to an example implementation of the present disclosure. As illustrated, the control body may comprise a transmitter coupling device 302, an outer body 304, a flow sensor 306 (e.g. a breath sensor or pressure switch), a control component 308 (e.g. a microprocessor, individually or as part of a microcontroller), a spacer 310, a power source 312 (e.g. a battery, which may be rechargeable and/or a rechargeable supercapacitor), a circuit board with an indicator 314 (eg, a light-emitting diode (LED)), a connector circuit 316, and an end cap 318. Examples of power supplies are described in US Pat. 9,484,155 to Peckerar et al. and US Patent Application No. of Series 14/918,926 of Sur et al., filed on October 21, 2015, the disclosures of which are incorporated herein by reference in their respective entireties.

[0063] With respect to the flow sensor 306, representative current regulation components and other current control components including various microcontrollers, sensors and switches for aerosol delivery devices are described in US Patent No. 4,735,217 to Gerth et al., US Pat. 4,922,901, 4,947,874 and 4,947,875, all issued to Brooks et al., US Patent No. 5,372,148 to McCafferty et al., US Patent No. 6,040,560 to Fleischhauer et al., US Patent No. 7,040,314 to Nguyen et al. and US Patent No. 8,205,622 to Pan, all of which are hereby incorporated by reference in their entirety. Reference is also made to the control schemes described in US Patent No. 9,423,152 to Ampolini et al., which is hereby incorporated by reference in its entirety.

[0064] In one implementation, the indicator 314 may comprise one or more light-emitting diodes, point-based quantum light-emitting diodes, or the like. The indicator may be in communication with the control component 308 through the connector circuit 316 and be illuminated, for example, when a user sucks a cartridge (e.g. cartridge 102 of Figure 2) coupled to the control body 104, as sensed by the flow sensor 306. The end cap 318 may be adapted to make the illumination provided by the indicator visible. Therefore, the indicator can be illuminated during use of the aerosol delivery device 100 to simulate the lit end of a smoking article. However, in other implementations, the indicator may be provided in varying numbers and may take different forms and may even be an opening in the outer body (such as for releasing sound when such indicators are present).

[0065] Still other components may be used in the aerosol delivery device of the present disclosure. For example, US Patent No. 5,154,192 to Sprinkel et al. disseminates indicators for tobacco articles; US Patent No. 5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can be associated with the mouth end of a device to detect user lip activity associated with taking a suck and then trigger heating of a heating device; US Patent No. 5,372,148 to McCafferty et al. discloses a blow sensor for controlling energy flow to a heating load array in response to pressure drop across a nozzle; US Patent No. 5,967,148 to Harris et al. discloses receptacles in a smoking device that include an identifier that detects a non-uniformity in the infrared transmissivity of an inserted component and a controller that executes a detection routine when the component is inserted into the receptacle; US Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with multiple differential phases; US Patent No. 5,934,289 to Watkins et al. discloses photonic-optronic components; US Patent No. 5,954,979 to Counts et al. discloses means for changing resistance to sucking through a smoking device; US Patent No. 6,803,545 to Blake et al. discloses specific battery configurations for use in smoking devices; US Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; US Patent No. 8,402,976 to Fernando et al. discloses computer interface means for smoking devices to facilitate charging and allow computer control of the device; US Patent No. 8,689,804 to Fernando et al. discloses identification systems for smoking devices; and PCT Patent Application Publication No. WO 2010/003480 to Flick discloses a fluid flow detection system indicative of an inhalation in an aerosol generating system; all foregoing disclosures are hereby incorporated by reference in their entirety.

[0066] Other examples of components relating to electronic aerosol delivery articles and disclosing materials or components that may be used in this article include US Patent No. 4,735,217 to Gerth et al.; US Patent No. 5,249,586 to Morgan et al.; US Patent No. 5,666,977 to Higgins et al; US Patent No. 6,053,176 to Adams et al.; US Patent 6,164,287 to White; US Patent 6,196,218 to Voges; US Patent No. 6,810,883 to Felter et al.; US Patent No. 6,854,461 to Nichols; US Patent No. Hon 7,832,410; US Patent No. 7,513,253 to Kobayashi; US Patent No. 7,896,006 to Hamano; US Patent No. 6,772,756 to Shayan; US Patent No. Hon's 8,156,944 and 8,375,957; US Patent No. 8,794,231 to Thorens et al.; US Patent No. 8,851,083 to Oglesby et al.; US Patent No. 8,915,254 and 8,925,555 to Monsees et al.; US Patent No. 9,220,302 to DePiano et al.; US Patent Application Publication No. 2006/0196518 and 2009/0188490 of Hon; US Patent Application Publication No. 2010/0024834 to Oglesby et al.; US Patent Application Publication No. 2010/0307518 to Wang; PCT Patent Application Publication No. WO 2010/091593 to Hon; and PCT Patent Application Publication No. WO 2013/089551 to Foo, each of which is incorporated herein by reference in its entirety. Additionally, US Patent Application No. To be. 14/881,392 to Worm et al., filed October 13, 2015, discloses capsules that can be included in aerosol delivery devices and chain-shaped configurations for aerosol delivery devices and are incorporated herein by reference in their entirety. A variety of materials disclosed by the foregoing documents may be incorporated into the present devices in various implementations, and all of the foregoing disclosures are hereby incorporated by reference in their entirety.

[0067] Each of the components of the control body 104 can be at least partially received in the outer body 304. The outer body can extend from an engagement end 304' to an outer end 304”. End cap 318 may be positioned on, and engaged with, the outer end of the outer body. In this way, the end cap, which may be translucent or transparent, may be illuminated by indicator 314 in order to simulate the lit end of a smoking article or perform other functions as described above. The opposite engagement end of the outer body may be configured to engage cartridge 102.

[0068] Figure 4 schematically illustrates a partial sectional view through the control body 104 near the engagement end 304' of the outer body 304. As illustrated, the transmitter coupling device 302 may extend near the engagement end of the outer body. In one implementation, as illustrated in Figures 3 and 4, the transmitter coupler may define a tubular configuration. As illustrated in Figure 4, the transmitter coupling device may include a coil holder 402 and a coil 404. The coil holder, which may define a tubular configuration, may be configured to support the coil so that the coil does not come into contact with, and thereby short circuit, the resonant receiver coupler or other structures. The coil holder may comprise a non-conductive material which may be substantially transparent to the oscillating magnetic field produced by the coil. The coil may be embedded in, or otherwise coupled to, the coil holder. In the illustrated implementation, the coil is engaged with an inner surface of the coil holder in order to reduce any losses associated with transmitting the oscillating magnetic field to the resonant receiver coupling device. However, in other implementations, the coil may be positioned on an outer surface of the coil holder or fully recessed into the coil holder. Furthermore, in some implementations, the coil may comprise an electrical trace printed on or otherwise attached to the coil holder, or a wire. In either implementation, the coil can define a helical configuration.

[0069] In an alternative implementation, as illustrated in Figure 5, the transmitter coupler 302 may include the coil 404 without the coil holder 402. In each implementation, the transmitter coupler may define an inner chamber 406 over which the transmitter coupler extends.

[0070] As further illustrated in Figures 35, in some implementations, the transmitter coupling device 302 may be coupled to a support member 320. The support member may be configured to engage the transmitter coupling device and support the transmitter coupling device within the outer body 304. For example, the transmitter coupling device may be embedded in, or otherwise coupled to, the support member such that the transmitter coupling device is fixedly positioned within the outer body. By way of another example, the transmitter coupling device may be injection molded into the support member.

[0071] The support member 320 may engage an inner surface of the outer body 304 to provide alignment of the support member relative to the outer body. Thus, as a result of the fixed coupling between the support member and the transmitter coupler 302, a longitudinal axis of the transmitter coupler can extend substantially parallel to a longitudinal axis of the outer body. Thus, the transmitter coupling device can be positioned out of contact with the outer body so as to avoid transmission of current from the transmitter coupling device to the outer body. However, in some implementations, as shown in Figure 5, an optional isolator 502 may be positioned between the transmitter coupler 302 and the outer body 304 to prevent contact between them. As can be understood, the insulator and support member can comprise any non-conducting material such as an insulating polymer (e.g. plastic or cellulose), glass, rubber and porcelain. Alternatively, the transmitter coupling device may contact the outer body in implementations where the outer body is formed from a non-conductive material such as plastic, glass, rubber, or porcelain.

[0072] As described in detail below, the transmitter coupling device 302 may be configured to receive an electrical current from the power source 312 and wirelessly heat the cartridge 102 (see, for example, Figure 2 ). Thus, as illustrated in Figures 4 and 5, the transmitter coupler may include electrical connectors 408 configured to supply electrical current thereto. For example, electrical connectors can connect the transmitter docking device to the control component. Thus, current from the power source can be selectively directed to the transmitter coupling device as controlled by the control component. For example, the control component 312 can direct current from the power source (see, for example, Figure 3) to the transmitter coupling device when a suck in the aerosol delivery device 100 is detected by the flow sensor 306. The electrical connectors can comprise, by way of example, terminals, wires, or any other connector implementation configured to transmit electrical current therethrough. Additionally, electrical connectors can include a negative electrical connector and a positive electrical connector.

[0073] In some implementations, power source 312 may comprise a battery and/or a rechargeable supercapacitor, which may provide direct current. As described elsewhere herein, operation of the aerosol delivery device may require directing alternating current to the transmitter coupler 302 to produce an oscillating magnetic field in order to induce eddy currents in the resonant receiver coupler. Accordingly, in some implementations, control component 308 of control body 104 may include an inverter or inverter circuit configured to transform direct current supplied by the power source to alternating current supplied to the transmitter coupler.

[0074] Figure 6 illustrates an exploded view of a cartridge 600 which in some examples may correspond to the cartridge 102 of Figure 1. As illustrated, the cartridge 600 may include a resonant receiver coupling device 602, an outer body 604, a container 606, a sealing member 608 and a substrate 610. The outer body 604 may extend between an engaging end 604' and an outer end 604”. Some or all of the remaining components of cartridge 600 may be positioned at least partially within outer body 604.

[0075] The cartridge 600 may additionally include a mouthpiece 612. The mouthpiece 612 may be an integral part of the outer body 604 or the container 606 or a separate component. Nozzle 612 can be positioned on outer end 604' of outer body 604.

[0076] Figure 7 illustrates a sectional view through the cartridge 600 in an assembled configuration. As illustrated, container 606 can be received within outer body 604. Additionally, sealing member 608 can be engaged with container 606 to define an inner compartment 614. As further illustrated in Figure 7, in some implementations, sealing member 608 can additionally engage outer body 604.

[0077] In some implementations, the sealing member 608 may comprise an elastic material, such as a rubber or silicone material. In these implementations, the sealing material 608 can compress to form a tight seal with the container 606 and/or the outer body 604. An adhesive can be used to further improve the seal between the sealing member 608 and the container 606 and/or the outer body 604. In another implementation, the sealing member 608 can comprise an inelastic material, such as a plastic material or a metallic material. In these implementations, the sealing member 608 can be adhered or welded (e.g., via ultrasonic welding) to the container 606 and/or the outer body 604. Therefore, through one or more of these mechanisms, the sealing member 608 can substantially seal the inner compartment 614.

[0078] The resonant receiver coupling device 602 may be engaged with the sealing member 608. In one implementation, the resonant receiver coupling device 602 may be partially embedded in the sealing member 608. For example, the resonant receiver coupling device 602 may be injection molded into the sealing member 608 such that a tight seal and connection is formed therebetween. Therefore, the sealing member 608 can retain the resonant receiver coupling device in a desired position. For example, the resonant receiver coupler 602 can be positioned such that a longitudinal axis of the resonant receiver coupler extends substantially coaxially with a longitudinal axis of outer body 604.

[0079] Furthermore, the substrate 610 may engage the sealing member 608. In one implementation, the substrate 610 may extend through the sealing member 608. In this regard, the sealing member 608 may define an opening 616 extending therethrough and through which the substrate 610 is received. In this way, substrate 610 can extend into inner compartment 614. For example, as illustrated in Figure 7, one end of substrate 610 can be received in a pocket 618 defined by container 606. Accordingly, container 606 and sealing member 608 can each engage substrate 610 and cooperatively hold the substrate in a desired position. For example, a longitudinal axis of substrate 610 can be positioned substantially coaxial with a longitudinal axis of resonant receiver coupler 602. Thus, as illustrated, in some implementations, substrate 610 can be positioned close to, but out of contact with, resonant receiver coupler 602. By avoiding direct contact between substrate 610 and resonant receiver coupler 602, the induction coil can remain substantially free of debris buildup and therefore the cartridge can optionally be refilled with aerosol precursor composition and/or a new substrate or otherwise reused. However, as discussed below, direct contact between the substrate and the resonant receiver coupler may be preferable in some implementations.

[0080] Substrate 610 may include an aerosol precursor composition. The aerosol precursor composition can comprise one or more of a solid tobacco material, a semi-solid tobacco material and a liquid aerosol precursor composition. For example, solid tobacco materials and semi-solid tobacco materials can be used in implementations of aerosol delivery device 100 that define so-called heat-not-burn cigarettes. Conversely, by way of further example, fluid (e.g., liquid) aerosol precursor compositions may be employed in aerosol delivery device implementations that define so-called electronic cigarettes.

[0081] Representative types of liquid aerosol precursor components and formulations are shown and characterized in US Patent No. 7,726,320 to Robinson et al., US Patent No. 9,254,002 to Chong et al.; and US Patent Application Publications Nos. 2013/0008457 to Zheng et al.; 2015/0020823 to Lipowicz et al.; and 2015/0020830 to Koller, as well as to PCT Patent Application Publication No. WO 2014/182736 to Bowen et al.; and US Patent No. 8,881,737 to Collett et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be employed include the aerosol precursors that have been incorporated into the VUSE® product by RJ Reynolds Vapor Company, the BLU product from Imperial Tobacco Group PLC, the MISTIC MENTHOL product from Mistic Ecigs and the VYPE product from CN Creative Ltd. Also desirable are so-called “smoke juices” for e-cigarettes that are available from Johnson Creek Enterprises LLC. Implementations of effervescent materials can be used with the aerosol precursor, and are described, by way of example, in U.S. Patent Application Publication No. 2012/0055494 to Hunt et al., which is incorporated herein by reference. Furthermore, the use of effervescent materials is described, for example, in US Patent No. 4,639,368 to Niazi et al.; US Patent No. 5,178,878 to Wehling et al.; US Patent No. 5,223,264 to Wehling et al.; US Patent No. 6,974,590 to Pather et al.; US Patent No. 7,381,667 to Bergquist et al; US Patent No. 8,424,541 to Crawford et al; US Patent No. 8,627,828 to Strickland et al.; and US Patent No. 9307787 to Sun et al., as well as US Patent Application Publication No. 2010/0018539 to Brinkley et al.; and PCT Patent Application Publication No. WO 97/06786 to Johnson et al., all of which are incorporated herein by reference.

[0082] Representative types of solid and semi-solid aerosol precursor compositions and formulations are described in US Patent No. 8,424,538 to Thomas et al.; US Patent No. 8,464,726 to Sebastian et al.; US Patent Application Publication No. 2015/0083150 to Conner et al; US Patent Application Publication No. 2015/0157052 to Ademe et al.; and US Patent Application No. of Serial 14/755, 205 to Nordskog et al., filed June 30, 2015, all of which are incorporated herein by reference.

[0083] In implementations of the cartridge 102 where the aerosol precursor composition comprises a liquid or other fluid, the substrate 610 may be configured to retain the aerosol precursor composition within it and release a vapor therefrom when heat is applied thereto by the resonant receiver coupling device 602 in the manner described below. In some implementations, substrate 610 can retain a sufficient amount of aerosol precursor composition to last for a desired length. In other implementations, it may be preferable to provide cartridge 102 with increased aerosol precursor composition capacity. Examples of materials that may be employed in substrate 610 in implementations where the substrate is configured to contain a fluid aerosol precursor composition include a porous ceramic, carbon, cellulose acetate, polyethylene terephthalate, fiberglass, and sintered porous glass.

[0084] In this regard, as illustrated by way of example in Figures 6 and 7, in one implementation, the container 606 may comprise a reservoir and the inner compartment 614 may be configured to receive the liquid aerosol precursor composition. In this implementation, substrate 610 may comprise a liquid transport member (e.g., a wick) configured to receive the aerosol precursor composition from the internal compartment 614 and transport the aerosol precursor composition therethrough. Accordingly, the aerosol precursor composition can be transported from the internal compartment 614 to locations along the longitudinal length of the substrate 610, over which the resonant receiver coupling device 602 extends.

[0085] As can be understood, the implementation of the cartridge 600 illustrated in Figure 7 is provided for example purposes only. In this regard, several alternative implementations of cartridges 102 are provided here by way of another example. Note that although the implementations of cartridge 102 are described separately herein, each of the respective components and features thereof may be combined in any manner except as otherwise indicated herein.

[0086] Figure 8 illustrates another cartridge 800 that in some examples may correspond to the cartridge 102 of Figure 1. The cartridge 800 is similar to the cartridge 700, but in which the sealing member 708 is positioned in the vicinity of the outer end 604” of the outer body 604, as opposed to the engagement end 604'. In this implementation, container 806 can include opening 816 extending therethrough and sealing member 808 can define pocket 818 so as to support substrate 610 in substantially the same manner as described above. Accordingly, the sealing member 608 can be positioned on the engaging end 604' of the container 606, (see Figure 7), or the sealing member 808 can be positioned on the outer end 604' of the container 806 (see Figure 8).

[0087] In some implementations, the container may be sufficiently sealed such that leakage of the aerosol precursor composition is substantially prevented. However, as illustrated in Figure 8, in some implementations, cartridge 800 may further comprise a reservoir substrate 820. As can be understood, reservoir substrate 820 may be used in any of the cartridges disclosed herein including an internal compartment 614.

[0088] In one implementation, the reservoir substrate 820 may comprise a plurality of layers of nonwoven fibers formed substantially in the shape of a tube that wholly or partially surrounds the substrate 610 within the inner compartment 820. In other implementations, the reservoir substrate 820 may comprise a porous ceramic, carbon, cellulose acetate, polyethylene terephthalate, fiberglass, or porous sintered glass. In this way, a liquid aerosol precursor composition can be expectedly retained by the reservoir substrate 820. As a result of contact between the reservoir substrate 820 and the reservoir, the reservoir substrate is in fluid communication with the substrate 610. Thus, the substrate 610 can be configured to transport the liquid aerosol precursor composition from the reservoir substrate 820 into the internal compartment 614 via capillary action or other liquid transport mechanisms to locations along the longitudinal length of the substrate 610 outside the internal compartment.

[0089] As noted above, in some implementations of the cartridge 600, 800, the substrate 610 can be positioned close to, but out of contact with, the resonant receiver coupling device 602. Such a configuration can prevent the accumulation of residues in the resonant receiver coupling device due to the lack of direct contact between them. However, in other implementations, substrate 610 may contact the resonant receiver coupler. In this regard, Figure 9 illustrates yet another cartridge 900 which in some examples may correspond to the cartridge 102 of Figure 1, similar to the cartridges 600, 800 but in which the substrate 910 can contact the resonant receptor coupler 602. Use of this configuration can allow for a relatively larger substrate 910 which can contain a relatively larger amount of the aerosol precursor composition without necessarily increasing the size of the resonant receiver coupler 602 In addition, direct contact between the resonant receiver coupler and the substrate can facilitate heat transfer from the resonant receiver coupler to the substrate via convection, which can be significantly more efficient than radiant heating employed in implementations where there is no direct contact between them. Accordingly, it should be understood that each of the cartridge implementations disclosed herein may include direct contact between the resonant receiver coupling device and the substrate and/or aerosol precursor composition. Providing direct contact between the substrate 910 and the resonant receiver coupler 602 may be employed, by way of example, in implementations where the aerosol precursor composition comprises a solid tobacco material or a semi-solid tobacco material, which may be less likely to cause debris to accumulate in the resonant receiver coupler than a liquid aerosol precursor composition.

[0090] In the implementations of the cartridges 600, 800 illustrated in Figures 6-8, the substrate 610 extends into the internal compartment 614. However, in other implementations, the cartridge may not define an internal compartment. For example, the cartridge 900 illustrated in Figure 9 does not include an internal compartment. In this regard, substrate 910 may comprise a sufficient amount of the aerosol precursor composition such that the use of an internal compartment may not be necessary in some implementations. Thus, for example, resonant receiver coupler 602 and substrate 910 can be substantially coextensive, such that their longitudinal ends terminate at substantially the same points. In this regard, substrate resonant receiver coupler 602 and/or substrate 910 may be received in a pocket 922 defined by outer body 904 or otherwise engaged (e.g., directly engaged) with the outer body. Thus, in some implementations, cartridge 900 may define a relatively simple configuration that may not include a container, sealing member, or internal compartment. Such a configuration can reduce the complexity and/or cost of the 900 cartridge.

[0091] As described above, in some implementations, the substrate 910 may not extend into an internal compartment and may instead terminate, for example, in close proximity to the external body 904. As further described above with respect to Figure 9, in one implementation, the cartridge 900 may not include a container or an internal compartment. However, in another implementation, the cartridge may include the container defining the internal compartment without the substrate extending into the compartment. This is shown in Figure 10, which illustrates yet another cartridge 1000 that may correspond to cartridge 104 of Figure 1. As shown, cartridge 1000 may include container 1006 that defines internal compartment 614 without substrate 1010 extending into the compartment. In this regard, the resonant receiver coupler 602 and the substrate 1010 can be engaged with the container or outer body. For example, in Figure 10, resonant receiver coupler 602 and substrate 1010 are each engaged with container 1006. As a further example, as described above, resonant receiver coupler 602 may be partially embedded in container 1006. Furthermore, substrate 1010 may engage a pocket 1022 defined by container 1006.

[0092] By configuring the cartridge 1000 such that the substrate 1010 does not extend into the inner compartment 614, the compartment can be used for purposes other than a reservoir for the aerosol precursor composition. For example, as illustrated in Figure 10, in some implementations, the cartridge 1000 may include an electronic control component 1024. As described below, the electronic control component 1024 may be used in authenticating the cartridge 1000 or used for other purposes.

[0093] As noted above, each of the cartridges 102 of the present disclosure is configured to work in conjunction with the control body 104 to produce an aerosol. By way of example, Figure 11 illustrates the cartridge 600 engaged with the control body 104. As illustrated, when the control body 104 is engaged with the cartridge 600, the transmitter coupling device 302 can at least partially surround, preferably substantially surround, and more preferably completely surround the resonant receiver coupling device 602 (e.g., by extending around its circumference). Furthermore, the transmitter coupler 302 may extend along at least a portion of the longitudinal length of the resonant receiver coupler 602, and preferably extend along most of the longitudinal length of the resonant receiver coupler, and more preferably extend substantially all of the longitudinal length of the resonant receiver coupler.

[0094] Accordingly, the resonant receiver coupler 602 can be positioned within the inner chamber 406, over which the transmitter coupler 302 extends. Therefore, when a user draws a suck on the nozzle 612 of the cartridge 600, the pressure sensor 306 can detect the suck. In this way, control component 308 can direct current from power source 312 (see, for example, Figure 3) to transmitter coupler 302. Transmitter coupler 302 can thus produce an oscillating magnetic field. As a result of the resonant receiver coupler 602 being received in the inner chamber 406, the resonant receiver coupler can be exposed to the oscillating magnetic field produced by the transmitter coupler 302.

[0095] In particular, the transmitter coupler 302 and the resonant receiver coupler 602 can form an electrical transformer. In some examples, the resonant transformer and associated circuitry including the PWM inverter can be configured to operate in accordance with a suitable wireless power transfer standard, such as the Qi interface standard developed by the Wireless Power Consortium (WPC), the Power Matters Alliance (PMA) interface standard developed by the PMA, the Rezence interface standard developed by the Wireless Power Alliance (A4WP), and the like.

[0096] According to example implementations, a change in current in the transmitter coupling device 302, as directed from the power source 312 (see, for example, Figure 3) by the control component 308, may produce an alternating electromagnetic field that penetrates the resonant receiver coupling device 602, thereby generating electrical eddy currents within the resonant receiver coupling device. The alternating electromagnetic field can be produced by directing alternating current to transmitter coupling device 302. As noted above, in some implementations, control component 308 can include an inverter or inverter circuit configured to transform direct current supplied by power source 312 to alternating current that is supplied to transmitter coupling device 302.

[0097] Eddy currents flowing in the material defining the resonant receiver coupling device 602 can heat the resonant receiver coupling device through the Joule effect, where the amount of heat produced is proportional to the square of the electric current times the electrical resistance of the resonant receiver coupling material. In implementations of resonant receiver coupler 602 comprising magnetic materials, heat may also be generated by magnetic hysteresis losses. Several factors contribute to the temperature rise of the resonant receiver coupler 602 including, but not limited to, proximity to the transmitter coupler 302, magnetic field distribution, electrical resistivity of the resonant receiver coupler material, saturation flux density, skin effects or depth, hysteresis losses, magnetic susceptibility, magnetic permeability, and dipole moment of the material.

[0098] In this regard, both the resonant receiver coupler 602 and the transmitter coupler 302 may comprise an electrically conductive material. By way of example, the transmitter coupler 302 and/or the resonant receiver coupler 602 may comprise various conductive materials including metals such as copper and aluminum, alloys of conductive materials (e.g., diamagnetic, paramagnetic, or ferromagnetic materials), or other materials such as a ceramic or glass with one or more conductive materials embedded therein. In another implementation, the resonant receiver coupling device may comprise conductive particles or objects of any one of several sizes received in a reservoir filled with the aerosol precursor composition. In some implementations, the resonant receiver coupling may be coated with or otherwise include a thermally conductive passivation layer (e.g., a thin layer of glass) to prevent direct contact with the aerosol precursor composition.

[0099] Therefore, the resonant receiver coupler 602 can be heated. The heat produced by the resonant receiver coupling device 602 can heat the substrate 610 including the aerosol precursor composition, such that an aerosol 1102 is produced. Therefore, the resonant receiver coupling device 602 can comprise an atomizer. By positioning the resonant receiver coupler 602 around the substrate 610 at a substantially uniform distance therefrom (e.g., by aligning the longitudinal axes of the substrate and the resonant receiver coupler), the substrate and aerosol precursor composition can be substantially uniformly heated.

[00100] The aerosol 1102 may circulate around or through the resonant receiver coupler 602 and the transmitter coupler 302. For example, as illustrated, in one implementation, the resonant receiver coupler 602 may comprise a mesh, screen, helix, braid or other porous structure defining a plurality of apertures extending therethrough. In other implementations, the resonant receiver coupling device may comprise a rod embedded in a substrate or otherwise in contact with an aerosol precursor composition, a plurality of beads or particles embedded in a substrate or otherwise in contact with an aerosol precursor composition, or a sintered structure. In each of these implementations, the aerosol 1102 can freely pass through the resonant receiver coupler 602 and/or the substrate to allow the aerosol to pass through the mouthpiece to the user.

[00101] The aerosol 1102 can mix with the air 1104 entering through the inlets 410 (see, for example, Figure 4), which can be defined in the control body 104 (for example, in the outer body 304). Consequently, an intermixed air and aerosol 1106 can be directed at the user. For example, the intermixed air and aerosol 1106 may be directed to the user through one or more through holes 626 defined in the outer body 604 of the cartridge 600. In some implementations, the sealing member 608 may additionally include through holes 628 extending therethrough which may be aligned with the through holes 626 defined through the outer body 604. However, as can be understood, the flow pattern through the Aerosol delivery device 100 can vary from the particular configuration described above in any number of ways without departing from the scope of the present disclosure.

[00102] As noted above, in some implementations, the cartridge 102 may further comprise a second electronic control component. For example, the cartridge 1000 illustrated in Figure 10 includes the second control component 1024. The second control component 1024 can be configured to allow authentication of the cartridge 1000. In this regard, in some implementations, the second control component 1024 can be configured to issue a code to the control body 104, which the (first) control component 308 (see, for example, Figure 3) can parse. Thus, for example, control component 308 may direct current to transmitter coupler 302 only when cartridge 1000 is verified as authentic. In some implementations, the second control component may include terminals that connect to the control body. More preferably, the second control component 1024 may comprise a radio frequency identification (RFID) chip configured to wirelessly transmit a code or other information to the control body 104. In this way, the aerosol delivery device 100 may be used without requiring engagement of electrical connectors between the cartridge and the control body. In addition, several examples of control components and functions performed in this way are described in U.S. Patent Application Publication No. 2014/0096782 to Sears et al., which is incorporated herein by reference in its entirety.

[00103] As indicated above, in some implementations, the control component 308 of the control body 104 may include an inverter or inverter circuit configured to transform direct current supplied by power source 312 to alternating current that is supplied to transmitter coupling device 302. Figures 12, 13 and 14 illustrate circuits 1200 and other components of aerosol delivery device 100 in accordance with example implementations of the present disclosure. As shown, the aerosol delivery device includes a substrate 610 configured to carry an aerosol precursor composition, and circuitry including a resonant transformer 1202 including a transmitter coupler 302 and a resonant receiver coupler 602 that is positioned in proximity to the substrate. And the control component 308 of the aerosol delivery device includes a pulse width modulation (PWM) inverter 1204 configured to drive the resonant transformer.

[00104] As shown, the PWM inverter 1204 includes a bridge circuit 1206 coupled to the transmitter coupling device 302, and which in some examples is a half bridge composed of a pair of transistors such as metal-oxide-semiconductor field-effect transistors (MOSFETs) and a pair of diodes. The PWM inverter also includes a 1208 PWM controller coupled to the bridge circuit. According to some examples, the PWM controller is incorporated as an integrated circuit and configured to send a PWM signal to the bridge circuit configured to drive the transmitter coupler to generate an oscillating magnetic field and induce an alternating voltage in the resonant receiver coupler 602 when exposed to the oscillating magnetic field. This AC voltage causes the resonant receiver coupler to generate heat and thereby vaporize the components of the aerosol precursor composition. Examples of suitable PWM controllers include Texas Instruments bq500210 and bq500212A controllers, STMicroelectronics STWBC series controllers, and the like.

[00105] As also shown, in some examples, the aerosol delivery device 100 further includes a power source 312, such as a rechargeable supercapacitor, rechargeable solid state battery or rechargeable lithium-ion battery, configured to power the PWM inverter 1204. In some additional examples, the aerosol delivery device further includes a constant voltage regulator 1210 between the power source and the PWM inverter, and configured to maintain a constant voltage level in the PWM inverter. Examples of suitable dimmers include switching dimmers, linear dimmers such as low drop dimmers (LDO) and the like.

[00106] Figure 13 illustrates a power source 1300 that may correspond to power source 312 in some examples. As shown, in some examples, the power source includes a rechargeable supercapacitor 1302 configured to power the PWM inverter 1204. In some additional examples, the power source further includes terminals 1304 connectable to a power source 1306 from which the rechargeable supercapacitor is chargeable. As indicated above, for example, control body 104 can be combined with any type of charging technology (eg, wall charger, car charger, computer, photovoltaic cell, solar cell solar panel, RF-based wireless charger). And in yet other examples, the power source further includes the power source, and the power source is or includes a rechargeable solid-state battery or a rechargeable lithium-ion battery.

[00107] Returning to Figure 12, in some examples, the aerosol delivery device 100 may further protect against the temperature of the resonant receiver coupler 602 reaching or exceeding a threshold temperature. In some of these examples, the control component 308 includes a microprocessor 1212 configured to receive a measurement of an alternating current induced in the resonant receiver coupler 602, such as from a Hall effect current sensor 1214 positioned in proximity to the resonant receiver coupler 602. This Hall effect current sensor may form part of the cartridge 102, or in some examples, the control body 104. The microprocessor may then control the operating at least one functional element of the aerosol delivery device in response to the measurement, such as reducing the temperature of the resonant receiver coupler 602 in cases where the measurement indicates a temperature equal to or greater than a threshold temperature. One way to reduce the temperature may be to include more air outlets in the aerosol delivery device, control may be to vent air out of the aerosol delivery device 100. Some examples of a suitable aerosol delivery device equipped with a Hall effect current sensor are described in U.S. Patent Application No. To be. 14/993,762 to Sur, filed January 12, 2016, which is incorporated herein by reference in its entirety.

[00108] As shown in Figure 14, in some examples, the aerosol delivery device further includes a high-pass filter 1402, and a non-inverting amplifier circuit 1404 coupled to the high-pass filter. In these examples, the high pass filter is coupled to the resonant receiver coupler 602 and configured to filter out any direct voltage component from the induced alternating voltage in the resonant receiver coupler. The non-inverting amplifier circuit is then configured to amplify the filtered AC voltage.

[00109] As described above, the present disclosure relates to an aerosol delivery device including a control body comprising a wireless power transmitter configured to receive an electric current from a power source and wirelessly heat an atomizer. As can be understood, various wireless heating techniques can be employed to heat an aerosol precursor composition which can be contained in a reservoir and/or in contact with a substrate. In some implementations, the atomizer can be heated wirelessly without transmitting electrical current to the atomizer.

[00110] In the implementations described above, the wireless power transmitter may comprise a transmitter coupling device, and the atomizer may comprise a resonant receiver coupling device. In this way, eddy currents can be induced in the resonant receiver coupler in order to produce heat. As noted above, the transmitter coupler may be configured to at least partially surround the resonant receiver coupler. By way of further example, in other implementations, the atomizer may be wirelessly heated using radiant heating, sonic heating, photonic heating (eg via a laser) and/or microwave heating.

[00111] However, various other techniques and mechanisms can be employed in other implementations to wirelessly heat an atomizer. For example, electrical current can be transmitted wirelessly to an atomizer, and such wireless energy transmission techniques can be employed with any atomizer implementation, such as wire coil resistive heating elements. Example implementations of wireless power transmission methods and mechanisms are provided in U.S. Patent Application No. of Série 14/814,866, granted to Sebastian et al., on July 31, 2015, which is hereby incorporated by reference in its entirety.

[00112] Note that while the present disclosure generally describes heating a substrate comprising an aerosol precursor composition positioned in proximity of the resonant receiver coupling device to produce an aerosol, in other implementations, the resonant receiver coupling device may be configured to heat an aerosol precursor composition directed (e.g., dispensed) thereto. For example, US Patent Application Publications Nos. 2015/0117842; 2015/0114409; and 2015/0117841, each to Brammer et al., describe fluid aerosol precursor composition delivery mechanisms and methods, which are incorporated herein by reference in their entirety. Such fluid aerosol precursor composition delivery mechanisms and methods may be employed to direct an aerosol precursor composition from a reservoir to the resonant receiver coupling device to produce an aerosol. In a further implementation, the resonant receiver coupling device may comprise a hollow needle connected to a reservoir, wherein capillary action directs the aerosol precursor composition into the needle to replenish the needle as the aerosol precursor composition vaporizes from the needle. Note further that while examples of shapes and configurations of the resonant receiver coupler and transmitter coupler are described herein, various other shapes and shapes may be employed.

[00113] Figure 15 illustrates various operations in a method 1500 for assembling an aerosol delivery device, in accordance with some example implementations. As illustrated in Figure 15, the method may include providing a substrate comprising an aerosol precursor composition at operation 1502. The method may further include providing a resonant receiver coupler at operation 1504. Additionally, the method may include positioning the substrate in proximity to the resonant receiver coupler at operation 1506. The resonant receiver coupler may be configured to be exposed to an oscillating magnetic field to heat the aerosol precursor composition to produce an aerosol .

[00114] In some implementations, positioning the substrate in close proximity to the resonant receiver coupler in operation 1506 may comprise positioning the substrate in direct contact with the resonant receiver coupler. Additionally, positioning the substrate in proximity to the resonant receiver coupler in operation 1506 may include positioning the substrate within the resonant receiver coupler. The method can additionally include filling the substrate with the aerosol precursor composition. The aerosol precursor composition may comprise a liquid aerosol precursor composition.

[00115] The method may further include providing a transmitter coupler and positioning the transmitter coupler such that the transmitter coupler at least partially surrounds the resonant receiver coupler. Positioning the transmitter coupler may include positioning the transmitter coupler out of direct contact with the resonant receiver coupler.

[00116] The method may further include forming a cartridge comprising the substrate and the resonant receiver coupler. Furthermore, the method may include forming a control body comprising the transmitter coupling device. Positioning the transmitter coupler such that the transmitter coupler at least partially surrounds the resonant receiver coupler may include coupling the cartridge to the control body. Additionally, formation of the control body may include coupling a power source to the transmitter coupling device.

[00117] Figure 16 illustrates various operations in a method 1600 for aerosolization, according to some example implementations. As illustrated in Figure 16, the method may include supplying a cartridge at operation 1602. The cartridge may include an aerosol precursor composition and an atomizer. The method may further include providing a control body at operation 1604. The control body may include a power source and a wireless power transmitter. The method may further include directing current from the power source to the wireless energy transmitter at operation 1606. Additionally, the method may include wirelessly heating the atomizer with the wireless energy transmitter to heat the aerosol precursor composition to produce an aerosol at operation 1608.

[00118] Many modifications and other implementations of the disclosure will come to the mind of one skilled in the art to which this disclosure belongs having the benefit of the teachings presented in the foregoing descriptions and associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific implementations disclosed herein and that modifications and other implementations are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and are not intended to be limiting.

Claims (15)

1. Aerosol delivery device FEATURED in that it comprises: a substrate (610; 920; 1010) configured to carry an aerosol precursor composition; a resonant transformer (1202) including a transmitter coupler (302) and a resonant receiver coupler (602) that is positioned in proximity to the substrate (610; 920; 1010); and a pulse width modulation inverter (1204) configured to drive the resonant transformer (1202), the pulse width modulation inverter (1204) comprising: a bridge circuit (1206) coupled to the transmitter coupling device (302), wherein the bridge circuit (1206) is a half bridge including a pair of transistors and a pair of diodes; and a pulse width modulation controller (1208) incorporated as an integrated circuit and configured to output a pulse width modulation signal to the bridge circuit (1206) configured to drive the transmitter coupling device (302) to generate an oscillating magnetic field and induce an alternating voltage in the resonant receiver coupling device (602) when exposed to the oscillating magnetic field, the alternating voltage causing the resonant receiver coupling device (602) to generate heat and thereby steam ize components of the aerosol precursor composition. 2. Aerosol delivery device, according to claim 1, characterized by the fact that it further comprises a power source (312; 1300) including a rechargeable supercapacitor (1302), rechargeable solid-state battery or rechargeable lithium-ion battery, and configured to power the pulse width modulation inverter (1204), particularly further comprising a constant voltage regulator (1210) between the power source (312; 1300) and the pulse width modulation inverter (1204), and configured to maintain a constant voltage level in the pulse width modulation inverter (1204). 3. Aerosol delivery device, according to claim 1 or 2, characterized by the fact that it further comprises a power source (312; 1300) including a rechargeable supercapacitor (1302), and configured to power the pulse width modulation inverter (1204), particularly by the fact that the power source (312; 1300) further includes terminals connectable (1304) to a power source (1 306) from which the rechargeable supercapacitor (1302) is chargeable, particularly where the power source (312; 1300) further comprises the power source (1306), and the power source (1306) is or includes a rechargeable solid-state battery or a rechargeable lithium-ion battery. 4. Aerosol delivery device according to any one of claims 1 to 3, FEATURED by the fact that it further comprises: a Hall effect current sensor (1214) positioned in proximity to the resonant receiver coupling device (602) and configured to produce a measurement of an alternating current induced therein; and a microprocessor (1212) configured to receive measurement and control operation of at least one functional element of the aerosol delivery device in response thereto. 5. Aerosol delivery device according to any one of claims 1 to 4, FEATURED by the fact that it further comprises: a high-pass filter (1402) coupled to the resonant receiver coupling device (602), and configured to filter any direct voltage component from the alternating voltage induced in the resonant receiver coupling device (602); and a non-inverting amplifier circuit (1404) coupled to the high-pass filter (1402), and configured to amplify the filtered AC voltage. 6. Aerosol delivery device according to any one of claims 1 to 5, FEATURED by the fact that the transmitter coupling device (302) is configured to at least partially surround the resonant receiver coupling device (602). 7. Aerosol delivery device, according to claim 6, characterized by the fact that the transmitter coupling device (302) defines a tubular or coiled configuration. 8. Control body coupled to or coupling to a cartridge (102; 600; 800; 900; 1000) that is equipped with a resonant receiver coupling device (602) that is positioned in close proximity to a substrate (610; 920; 1010) configured to carry an aerosol precursor composition, the control body characterized by the fact that it comprises: a transmitter coupling device (302) which, with the resonant receiver coupling device (602), forms a resonant transformer (1202) when the control body is coupled to the cartridge (102; 600; 800; 900; 1000); and a pulse width modulation inverter (1204) configured to drive the resonant transformer (1202), the pulse width modulation inverter (1204) comprising: a bridge circuit (1206) coupled to the transmitter coupling device (302), wherein the bridge circuit (1206) is a half bridge including a pair of transistors and a pair of diodes; and a pulse width modulation controller (1208) incorporated as an integrated circuit and configured to output a pulse width modulation signal to the bridge circuit (1206) configured to drive the transmitter coupling device (302) to generate an oscillating magnetic field and induce an alternating voltage in the resonant receiver coupling device (602) when exposed to the oscillating magnetic field, the alternating voltage causing the resonant receiver coupling device (602) to generate heat and thereby steam ize components of the aerosol precursor composition. 9. Control body, according to claim 8, characterized by the fact that it further comprises a power source (312; 1300) including a rechargeable supercapacitor (1302), rechargeable solid state battery or rechargeable lithium-ion battery, and configured to power the pulse width modulation inverter (1204). 10. Control body, according to claim 9, characterized by the fact that it further comprises a constant voltage regulator (1210) between the power source (312; 1300) and the pulse width modulation inverter (1204), and configured to maintain a constant voltage level in the pulse width modulation inverter (1204). 11. Control body, according to any one of claims 8 to 10, characterized by the fact that it further comprises a power source (312; 1300) including a rechargeable supercapacitor (1302), and configured to power the pulse width modulation inverter (1204). 12. Control body, according to claim 11, characterized by the fact that the power source (312; 1300) further includes connectable terminals (1304) to a power source (1306) from which the rechargeable supercapacitor (1302) is chargeable. 13. Control body, according to claim 12, characterized by the fact that the power source (312; 1300) further comprises the power source (1306), and the power source (1306) is or includes a rechargeable solid-state battery or a rechargeable lithium-ion battery. 14. Control body, according to any one of claims 8 to 13, characterized by the fact that the transmitter coupling device (302) is configured to at least partially surround the resonant receiver coupling device (602). 15. Control body, according to claim 14, characterized by the fact that the transmitter coupling device (302) defines a tubular or coiled configuration.