RU2806174C1 - Aerosol delivery device containing atomizer with wireless heating, and corresponding method - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: group of inventions relates to aerosol delivery devices made with the possibility of wireless heating of an atomizer. The aerosol delivery device contains substrate including an aerosol precursor composition, an atomizer, an electricity source, and a wireless electricity transmitter made with the possibility of reception of electric current from the electricity source and possibility of wireless heating of the atomizer. The atomizer contains an induction receiver located near substrate but not in a direct contact with it and made with the possibility of heat generation, when being impacted by an oscillatory magnetic field, and possibility of heating of the aerosol precursor composition for aerosol formation.

EFFECT: efficiency of aerosol generation is increased without energy loss, aerosol taste is improved, possibility of cartridge reuse is provided.

17 cl, 13 dwg

Description

BACKGROUND OF THE ART

Field of technology

The present invention relates to aerosol delivery devices such as e-cigarettes and cigarettes that use heating rather than combustion of tobacco, and in particular to an aerosol delivery device comprising a wirelessly heated atomizer. The atomizer may be configured to heat an aerosol precursor composition, which may be made or derived from or otherwise include tobacco, to form an inhalable substance for human consumption.

Description of the prior art

Over the years, many smoking devices have been proposed as improvements to smoking products or alternatives to smoking products that require combustion of tobacco for use. Many of these devices are specifically designed to provide the sensations associated with smoking a cigarette, cigar or pipe, but without transmitting the significant amounts of incomplete combustion and pyrolysis products that result from the combustion of tobacco. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that use electricity to vaporize or heat a volatile substance or attempt to provide the sensation of smoking a cigarette, cigar, or pipe without significantly burning the tobacco. For example, various known alternative smoking articles, aerosol delivery devices and heat generating sources are described in US Patent No. 8,881,737 (Collett et al.), US Patent Application Publications No. 2013/0255702 (Griffith Jr. et al.), US Pat. No. 2014/0000638 (Sebastian et al.), No. 2014/0096781 (Sears et al.), No. 2014/0096782 (Ampolini et al.), and No. 2015/0059780 (Davis et al.), which are incorporated herein by reference in their entirety. In addition, various embodiments of the products and heating structures are described in the prior art sections of U.S. Patent No. 5,388,594 (Counts et al.) and No. 8,079,371 (Robinson et al.), which are incorporated herein by reference in their entirety.

Various embodiments of aerosol delivery devices utilize an atomizer to generate an aerosol from the aerosol precursor composition. These atomizers often use resistive heating to generate heat. In this regard, atomizers may have a heating element comprising a coil or other element that generates heat through electrical resistance associated with the material through which the electric current passes. Electrical current is typically directed through the heating element through direct electrical connections such as wires or connectors. However, the formation of such electrical connections can complicate the assembly of the aerosol delivery device and add potential points of failure. Additionally, in some embodiments of the invention, the aerosol delivery device may include a control housing, which may contain a power source, and a cartridge, which may contain an atomizer. These embodiments may require electrical connections between the cartridge and the control housing, which can further complicate the design of the aerosol delivery device. Thus, improvements to aerosol delivery devices may be required.

DISCLOSURE OF THE INVENTION

The present invention relates to aerosol delivery devices for producing an aerosol, which in some embodiments may be referred to as electronic cigarettes or cigarettes that use heating rather than combustion of tobacco. As described herein, aerosol delivery devices may comprise an induction receiver and an induction transmitter that can interact to form an electrical transformer. The induction transmitter may include a coil configured to produce an oscillating magnetic field (eg, a magnetic field that changes periodically over time) when alternating current is passed through it. The induction receiver may be at least partially located within the induction transmitter and contain conductive material. Thus, by passing alternating current through the induction transmitter, Foucault currents can be generated in the induction receiver through induction. Foucault currents passing through the resistance of the material forming the induction receiver can heat it by Joule heating. Thus, the induction receiver, which may form the atomizer, can be heated by wireless heating to form an aerosol from the aerosol precursor composition located in the vicinity of the induction receiver. As used herein, wireless heating refers to heating occurring through an atomizer that is not electrically connected to a power source.

In one aspect of the present invention, an aerosol delivery device is provided. The aerosol delivery device may comprise a support containing an aerosol precursor composition. An induction receiver can be located near the substrate. The induction receiver may be configured to generate heat when the receiver is exposed to an oscillatory magnetic field and to heat the aerosol precursor composition to form an aerosol.

In some embodiments of the invention, the induction receiver may be porous. The aerosol delivery device may further comprise an induction transmitter configured to generate an oscillating magnetic field. The induction transmitter may be configured to at least partially surround the induction receiver. The induction transmitter may form a tubular structure or a helical structure.

In some embodiments of the invention, the aerosol delivery device may further comprise a control housing containing an induction transmitter, and a cartridge containing an induction receiver and a substrate. The aerosol precursor composition may contain one or more solid tobacco materials, semi-solid tobacco materials, and liquid aerosol precursor compositions. The control housing may further comprise an outer housing, a power source, a controller, a flow sensor, and an indicator.

In a further aspect, a method of assembling an aerosol delivery device is provided. The method may include providing a support containing the aerosol precursor composition. Additionally, the method may include providing an induction receiver. The method may further include positioning the substrate adjacent to the induction receiver. The induction receiver may be configured to generate heat when subjected to an oscillatory magnetic field and to heat the aerosol precursor composition to form an aerosol.

In some embodiments of the invention, positioning the substrate adjacent to the induction receiver may include positioning the substrate in direct contact with the induction receiver. Positioning the substrate adjacent to the induction receiver may include positioning the substrate within the induction receiver. In addition, the method may include loading a substrate with an aerosol precursor composition, wherein the aerosol precursor composition may include a liquid aerosol precursor composition.

In some embodiments, the method may further include providing an induction transmitter. Additionally, the method may include positioning the induction transmitter to at least partially surround the induction receiver. The location of the induction transmitter may include positioning the induction transmitter so that it is not in direct contact with the induction receiver.

In some embodiments of the invention, the method may further include forming a cartridge containing a substrate and an induction receiver. In addition, the method may include forming a control housing containing an induction transmitter. Positioning the induction transmitter so that it at least partially surrounds the induction receiver may include connecting the cartridge to the control housing. Formation of the control body may include connecting the electrical power source to the induction transmitter.

In a further aspect, an aerosol delivery device is provided. The aerosol delivery device may comprise a cartridge. The cartridge may contain an aerosol precursor composition and an atomizer. The aerosol delivery device may further comprise a control housing containing a power source and a wireless power transmitter. The wireless power transmitter may be configured to receive electrical current from a power source and to wirelessly heat the atomizer. The atomizer may be configured to heat the aerosol precursor composition to form an aerosol.

In some embodiments, the wireless power transmitter may include an induction transmitter and the atomizer may include an induction receiver. The induction transmitter may be configured to at least partially surround the induction receiver.

Another aspect of the invention provides a method for generating an aerosol. The method may include providing a cartridge. The cartridge may contain an aerosol precursor composition and an atomizer. The method may further include providing a control housing comprising a power source and a wireless power transmitter. Additionally, the method may include directing electrical current from a power source to a wireless power transmitter. Moreover, the method may include wirelessly heating the atomizer using a wireless electrical transmitter to heat the aerosol precursor composition to form an aerosol.

The invention includes, but is not limited to, the following embodiments.

Embodiment 1: An aerosol delivery device comprising:

an aerosol precursor composition;

atomizer;

source of electricity and

wireless power transmitter,

wherein the wireless electricity transmitter is configured to receive electric current from a source of electricity and the ability to wirelessly heat the atomizer,

and the atomizer is configured to heat the aerosol precursor composition to form an aerosol.

Embodiment 2: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the wireless power transmitter includes an induction transmitter and the atomizer includes an induction receiver.

Embodiment 3: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the induction transmitter is configured to at least partially surround the induction receiver.

Embodiment 4: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the support comprises an aerosol precursor composition,

wherein the atomizer contains an induction receiver located near the substrate,

and the induction receiver is configured to generate heat when exposed to an oscillatory magnetic field and the ability to heat the aerosol precursor composition to form an aerosol.

Embodiment 5: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the induction receiver is porous.

Embodiment 6: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the wireless power transmitter comprises an induction transmitter configured to generate an oscillating magnetic field.

Embodiment 7: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the induction transmitter is configured to at least partially surround the induction receiver.

Embodiment 8: An aerosol delivery device according to any preceding or subsequent embodiment, in which the induction transmitter forms a tubular structure or a helical structure.

Embodiment 9: An aerosol delivery device according to any preceding or subsequent embodiment, having a control body containing an induction transmitter and a power source, and a cartridge containing an induction receiver and a substrate.

Embodiment 10: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the aerosol precursor composition contains one or more solid tobacco materials, semi-solid tobacco materials, and liquid aerosol precursor compositions.

Embodiment 11: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the control housing further comprises an outer housing, a controller, a flow sensor and an indicator.

Embodiment 12: A method for assembling an aerosol delivery device, comprising:

providing a support containing the aerosol precursor composition;

providing an induction receiver and

location of the substrate near the induction receiver,

wherein the induction receiver is configured to generate heat when exposed to an oscillatory magnetic field and the ability to heat the aerosol precursor composition to form an aerosol.

Embodiment 13: The method according to any preceding or subsequent embodiment, wherein positioning the substrate adjacent to the induction receiver includes positioning the substrate in direct contact with the induction receiver.

Embodiment 14: The method according to any preceding or subsequent embodiment, wherein positioning the substrate adjacent to the induction receiver includes positioning the substrate within the induction receiver.

Embodiment 15: A method according to any preceding or subsequent embodiment, further comprising filling a substrate with an aerosol precursor composition, wherein the aerosol precursor composition comprises a liquid aerosol precursor composition.

Embodiment 16: The method according to any preceding or subsequent embodiment, further comprising providing an induction transmitter; And

positioning the induction transmitter so that it at least partially surrounds the induction receiver.

Embodiment 17: The method according to any preceding or subsequent embodiment, wherein the arrangement of the induction transmitter includes the arrangement of the induction transmitter so that it is not in direct contact with the induction receiver.

Embodiment 18: The method according to any preceding or subsequent embodiment, further comprising forming a cartridge containing a substrate and an induction receiver.

Embodiment 19: The method according to any preceding or subsequent embodiment, further comprising forming a control body containing an induction transmitter.

Embodiment 20: A method according to any preceding or subsequent embodiment, wherein forming a control body includes connecting a power source to an inductive transmitter.

Embodiment 21: An aerosol delivery device comprising:

a substrate containing an aerosol precursor composition; And

induction receiver located near the substrate,

wherein the induction receiver is configured to generate heat when exposed to an oscillatory magnetic field and the ability to heat the aerosol precursor composition to form an aerosol.

Embodiment 22: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the induction receiver is porous.

Embodiment 23: An aerosol delivery device according to any preceding or subsequent embodiment, further comprising an induction transmitter configured to generate an oscillatory magnetic field.

Embodiment 24: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the induction transmitter is configured to at least partially surround the induction receiver.

Embodiment 25: An aerosol delivery device according to any preceding or subsequent embodiment, in which the induction transmitter forms a tubular structure or a helical structure.

Embodiment 26: An aerosol delivery device according to any preceding or subsequent embodiment, having a control body comprising an induction transmitter and a cartridge containing an induction receiver and a substrate.

Embodiment 27: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the aerosol precursor composition contains one or more solid tobacco materials, semi-solid tobacco materials, and liquid aerosol precursor compositions.

Embodiment 28: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the control housing further comprises an outer housing, a power supply, a controller, a flow sensor, and an indicator.

Embodiment 29: A method for assembling an aerosol delivery device, comprising:

providing a support containing the aerosol precursor composition;

providing an induction receiver and

location of the substrate near the induction receiver,

wherein the induction receiver is configured to generate heat when exposed to an oscillatory magnetic field and the ability to heat the aerosol precursor composition to form an aerosol.

Embodiment 30: The method according to any preceding or subsequent embodiment, wherein positioning the substrate adjacent to the induction receiver includes positioning the substrate in direct contact with the induction receiver.

Embodiment 31: The method according to any preceding or subsequent embodiment, wherein positioning the substrate adjacent to the induction receiver includes positioning the substrate inside the induction receiver.

Embodiment 32: A method according to any preceding or subsequent embodiment, further comprising filling a substrate with an aerosol precursor composition, wherein the aerosol precursor composition comprises a liquid aerosol precursor composition.

Embodiment 33: The method according to any preceding or subsequent embodiment, further comprising providing an induction transmitter; And

positioning the induction transmitter so that it at least partially surrounds the induction receiver.

Embodiment 34: The method according to any preceding or subsequent embodiment, wherein the arrangement of the induction transmitter includes the arrangement of the induction transmitter so that it is not in direct contact with the induction receiver.

Embodiment 35: The method according to any preceding or subsequent embodiment, further comprising forming a cartridge comprising a substrate and an induction receiver.

Embodiment 36: The method according to any preceding or subsequent embodiment, further comprising forming a control body containing an induction transmitter.

Embodiment 37: A method according to any preceding or subsequent embodiment, wherein forming a control body includes connecting a power source to an inductive transmitter.

Embodiment 38: An aerosol delivery device comprising:

cartridge which contains:

an aerosol precursor composition and

atomizer and

a control housing containing a power source and a wireless power transmitter,

wherein the wireless electricity transmitter is configured to receive electric current from a source of electricity and the ability to wirelessly heat the atomizer,

and the atomizer is configured to heat the aerosol precursor composition to form an aerosol.

Embodiment 39: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the wireless power transmitter includes an induction transmitter and the atomizer includes an induction receiver.

Embodiment 40: An aerosol delivery device according to any preceding or subsequent embodiment, wherein the induction transmitter is configured to at least partially surround the induction receiver.

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 invention includes any combination of two, three, four or more of the embodiments described above, as well as combinations of any two, three, four or more features or elements set forth in the present specification, whether or not such features or elements are expressly combined in specific description of the embodiment presented in this application. This specification is intended to be read in its entirety, such that any separable features or elements of the invention described in any of its various aspects and embodiments are to be considered interchangeable unless the context clearly indicates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

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

Fig. 1 is a perspective view of an aerosol delivery device including a cartridge and a control body, the cartridge and the control body being connected to each other in accordance with an exemplary embodiment of the present invention;

Fig. 2 is a perspective view of the aerosol delivery device shown in FIG. 1, in which the cartridge and the control body are disconnected from each other in accordance with an exemplary embodiment of the present invention;

Fig. 3 is an exploded view of the aerosol delivery device shown in FIG. 1, in which the induction transmitter of the control body forms a tubular structure in accordance with an exemplary embodiment of the present invention;

Fig. 4 is a sectional view of the control housing shown in FIG. 3;

Fig. 5 is a sectional view of the control housing shown in FIG. 1, in which the induction transmitter forms a helical structure in accordance with an exemplary embodiment of the present invention;

Fig. 6 is an exploded view of the cartridge shown in FIG. 1, in which a cartridge substrate protrudes into an interior compartment formed by a container according to a first exemplary embodiment of the present invention;

Fig. 7 is a sectional view of the cartridge shown in FIG. 6;

Fig. 8 is a sectional view of the cartridge shown in FIG. 1, comprising a reservoir substrate disposed in an internal compartment formed by a container in accordance with a second exemplary embodiment of the present invention;

Fig. 9 is a sectional view of the cartridge shown in FIG. 1, comprising a substrate in contact with an induction receiver according to a third exemplary embodiment of the present invention;

Fig. 10 is a sectional view of the cartridge shown in FIG. 1, comprising an electronic control component according to a fourth exemplary embodiment of the present invention;

Fig. 11 is a cross-sectional view of the aerosol delivery device shown in FIG. 1, containing the cartridge shown in FIG. 6, and the control housing shown in FIG. 3, in accordance with an exemplary embodiment of the present invention;

Fig. 12 schematically illustrates a method for assembling an aerosol delivery device in accordance with an exemplary embodiment of the present invention; And

Fig. 13 schematically depicts a method for producing an aerosol in accordance with an exemplary embodiment of the present invention.

IMPLEMENTATION OF THE INVENTION

The following provides a more detailed description of the present invention with reference to exemplary embodiments thereof. These exemplary embodiments have been described in such a manner that the present invention is presented in a comprehensive and complete manner to fully disclose its scope to those skilled in the art. It should be noted that the present invention can be implemented in various forms and should not be construed as limited to the embodiments described in this application; More precisely, these embodiments are presented in such a way that the present invention satisfies the relevant legal requirements. As used in the specification and the appended claims, the singular forms include the plural forms unless the context clearly dictates otherwise.

The present invention relates to aerosol delivery devices. Aerosol delivery devices may use electrical energy to heat the material (preferably without burning the material to any significant extent) to form an inhalable substance; such products most preferably being compact enough to be considered portable devices. The aerosol delivery device may provide some or all of the sensations (eg, inhalation and exhalation rituals, types of tastes or aromas, organoleptic effects, physical sensation, usage rituals, visual cues such as those created by a visible aerosol, etc.) of smoking a cigarette, cigar or tube without burning to any significant extent any component of the product or device. The aerosol delivery device may not produce smoke in the sense that the aerosol is not generated from by-products of combustion or pyrolysis of tobacco, but rather the article or device most preferably produces vapor (including vapor in aerosols that may be considered visible aerosols and may be described as smoke-like) resulting from the vaporization of certain components of an article or device, although in other embodiments the aerosol may not be visible. In the most preferred embodiments of the invention, aerosol delivery devices may contain tobacco and/or tobacco-derived components. Thus, the aerosol delivery device may be characterized as an electronic smoking product such as an electronic cigarette. In another embodiment, the aerosol delivery device may be characterized as a cigarette that uses heating of tobacco rather than combustion. In addition, it should be noted that the description of the mechanisms, components, elements, apparatus, devices and methods disclosed in this application are presented in relation to embodiments of the invention relating to aerosol delivery mechanisms, by way of example only and can be implemented and used in various other products and methods.

The aerosol delivery devices of the present invention can also be characterized as vapor generating products or drug delivery products. Thus, such articles or devices may be adapted to deliver one or more substances (eg, flavoring agents and/or pharmaceutical active ingredients) in an inhalation form or state. For example, inhalable substances may be substantially in the form of a vapor (ie, a substance in a gaseous phase at a temperature that is lower than its critical point). In an alternative embodiment of the invention, the inhalable substances may be in the form of an aerosol (ie, a suspension of fine solid particles or liquid droplets in a gas). For the purpose of simplicity, as used herein, the term “aerosol” refers to vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not they are visible or in a form that may be considered smoke-like.

The proposed aerosol delivery devices, when in use, can be subject to various physical impacts caused by a person using a traditional type of smoking product (for example, a cigarette, cigar or pipe that is consumed by lighting and inhaling tobacco). For example, a user of the aerosol delivery device of the present invention may hold the article in a manner similar to a traditional type of smoking article, take a puff from one end of the article to inhale the aerosol produced by the article, take puffs at selected time intervals, and the like.

The aerosol delivery devices of the invention typically comprise a number of components located within an outer housing or shell. The overall design of the outer body or shell may vary, and the format or configuration of the outer body, which may define the overall size and shape of the smoking article, may also vary. Typically, an elongated body, shaped like a cigarette or cigar, can be made from a single solid shell; or the elongated body may be formed from two or more separate components. For example, the aerosol delivery device may comprise an elongated casing or body, which may be substantially tubular in shape and suitably resemble the shape of a conventional cigarette or cigar. In one exemplary embodiment, all components of the aerosol delivery device are located within a single outer housing or shell. In an alternative embodiment of the invention, the aerosol delivery device may comprise two or more shells that are connected to each other and are removable. For example, at one end of the aerosol delivery device there may be a control housing that contains an enclosure containing one or more reusable components (for example, a rechargeable battery and various electronics for controlling the operation of the product), and at the other end of the device there may be a shell containing a replaceable part (for example, a replaceable cartridge containing flavoring additives) is attached with the possibility of detachment. More specific formats, configurations and arrangements of components in an integral shell or in a removable multi-component shell will become apparent in light of the further disclosure of the invention presented in this application. In addition, various aerosol delivery device designs and component arrangements can be understood upon consideration of commercially available aerosol delivery devices.

The aerosol delivery devices of the present invention most preferably comprise some combination of a power source (i.e., a source of electrical power), at least one controller (e.g., means for actuating, controlling, regulating, and stopping electrical power to generate heat, for example, by controlling the electrical current flowing from the power source to other components of the aerosol delivery device), a heater or heat generating component (e.g., an electrical resistive heating element or a component commonly referred to as an "atomizer"), an aerosol precursor composition (e.g., typically a liquid, capable of producing an aerosol when exposed to sufficient heat, such as the ingredients commonly referred to as "smoking juice", "e-liquid" and "e-juice", and/or solid or semi-solid tobacco material) and the area or end of the mouthpiece to permit puffing from an aerosol delivery device for the purpose of inhaling the aerosol (eg, a predetermined path for air flow through the article such that the generated aerosol can be extracted therethrough when puffed).

The alignment of components within a proposed aerosol delivery device may vary. In specific embodiments of the invention, the aerosol precursor composition may be located near the end of the aerosol delivery device, which may be configured to be positioned near the user's mouth so as to maximize delivery of the aerosol to the user. However, other configurations are not excluded. Typically, the heating element may be located sufficiently close to the aerosol precursor composition so that heat from the heating element can vaporize the aerosol precursor (as well as one or more flavorants, drugs, or the like that may likewise be provided for delivery to the 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 formed in a physical form suitable for inhalation by the consumer. It should be noted that the above terms should be considered interchangeable, so that forms of the above term such as "release, release, releases or released" include forms such as "form or form, formation or formation, forms or forms and formed or educated." In particular, the inhalable substance is released in the form of a vapor or aerosol, or a mixture thereof, such terms also being used interchangeably in this application except where otherwise indicated.

As discussed above, the aerosol delivery device may include a battery or other electrical source (e.g., a capacitor) to supply sufficient electrical current to provide various functionality of the aerosol delivery device, such as powering a heater, powering control systems, powering indicators, and the like. The power source may be configured in accordance with various embodiments. In a preferred embodiment of the invention, the electrical power source is configured to supply sufficient energy to quickly heat the heating element to generate an aerosol and power the aerosol delivery device for use for the required period of time. The electrical power source is preferably sized to fit comfortably within the aerosol delivery device such that the aerosol delivery device can be conveniently operated. In addition, the preferred source of electricity is made quite light and does not interfere with the smoking process.

More specific formats, configurations and arrangements of components within an aerosol delivery device in accordance with the present invention will become apparent in light of the further disclosure of the invention presented below. In addition, the selection of various components of the aerosol delivery device can be understood after considering commercially available aerosol delivery devices. In addition, the arrangement of components in the aerosol delivery device may also be understood by consideration of commercially available electronic aerosol delivery devices.

As described later in this application, the present invention relates to aerosol delivery devices. Aerosol delivery devices may be configured to heat the aerosol precursor composition to form an aerosol. In some embodiments, aerosol delivery devices may comprise heating, rather than combustion, tobacco devices configured to heat a solid aerosol precursor composition (extruded tobacco rod) or a semi-solid aerosol precursor composition (eg, tobacco paste with glycerin). In another embodiment, the aerosol delivery devices may be configured to heat and form an aerosol from the aerosol precursor composition in a fluid form (eg, a liquid aerosol precursor composition). Such aerosol delivery devices may include so-called electronic cigarettes.

Regardless of the type of aerosol precursor composition to be heated, the aerosol delivery devices may include a heating element configured to heat the aerosol precursor composition. In some embodiments of the invention, the heating element may comprise a resistive heating element. Resistive heating elements may be configured to generate heat when electrical current is passed through them. Such heating elements often contain metallic material and are configured to generate heat as a result of electrical resistance associated with the passage of electric current through them. Such resistive heating elements may be located adjacent to the aerosol precursor composition. For example, in some embodiments of the invention, resistive heating elements may comprise one or more spools of wire wound around a fluid transport element (e.g., a wick, which may comprise porous ceramic, carbon, cellulose acetate, polyethylene terephthalate, fiberglass, or porous sintered glass) that is made with the ability to pass through the aerosol precursor composition. In an alternative embodiment, the heating element may be positioned in contact with the solid or semi-solid aerosol precursor composition. Such configurations may heat the aerosol precursor composition to form an aerosol.

In some embodiments, the aerosol delivery devices may include a control housing and a cartridge. The control body may be reusable, while the cartridge may be limited-use and/or disposable. The cartridge may contain an aerosol precursor composition. To effect heating of the aerosol precursor composition, a heating element may also be located in the cartridge. The controller may contain a power source that may be rechargeable or replaceable, and thus the control body can be reused with many cartridges.

Although the aerosol delivery devices described above can be used to heat an aerosol precursor composition to form an aerosol, such configurations may have one or more disadvantages. In this regard, the resistive heating elements may comprise wires forming one or more coils that contact the aerosol precursor composition. For example, as described above, coils may surround a liquid transport element (eg, a wick) to heat and aerosolize the aerosol precursor composition directed to the heating element through the liquid transport element. However, because the coils form a relatively small surface area, some of the aerosol precursor composition may be heated to an unnecessarily high degree during aerosol production, resulting in energy loss. Alternatively or additionally, some portion of the aerosol precursor composition that is not in contact with the heating element coils may not be heated sufficiently to produce an aerosol. Accordingly, insufficient aerosol production or aerosol production with energy loss may occur.

Additionally, as noted above, resistive heating elements produce heat when electrical current is passed through them. Accordingly, due to the positioning of the heating element in contact with the aerosol precursor composition, charring of the aerosol precursor composition may occur. The cause of such charring may be the heat produced by the heating element and/or electricity passing through the aerosol precursor composition at the location of the heating element. Charring may result in a gradual accumulation of material on the heating element. Such accumulation of material may adversely affect the taste of the aerosol produced from the aerosol precursor composition.

As described above, aerosol delivery devices may include a control housing containing an electrical power source, and a cartridge containing a resistive heating element and an aerosol precursor composition. To supply electrical current to the resistive heating element, the control housing and the cartridge may include electrical connectors configured to interact with each other when the cartridge is connected to the control housing. However, the use of such electrical connectors may add further complexity and cost to these aerosol delivery devices. In addition, in embodiments of aerosol delivery devices containing a liquid aerosol precursor composition, leakage of the composition may occur at connectors or other connectors within the cartridge.

It is therefore an object of the present invention to provide aerosol delivery devices that avoid some or all of the problems described above. In this regard, FIG. 1 illustrates an aerosol delivery device 100 according to an exemplary embodiment of the present invention. The aerosol delivery device 100 may include a cartridge 200 and a control housing 300. The cartridge 200 and the control housing 300 may be permanently aligned or removably aligned during operation. In this regard, FIG. 1 depicts the aerosol delivery device 100 in a connected configuration, and FIG. 2 shows the aerosol delivery device in a disconnected configuration. The cartridge 200 may be coupled to the control housing 300 through various mechanisms, including threaded interaction, press fit interaction, interference fit, magnetic interaction, and the like. The aerosol delivery device 100 may be substantially rod-shaped, substantially tubular, or substantially cylindrical. in some embodiments, when the cartridge 200 and control housing 300 are in an assembled state.

In specific embodiments of the invention, the cartridge 200 and/or the control housing 300 may be disposable or reusable. For example, control housing 300 may contain a replaceable battery or a rechargeable battery and thus may be combined with any type of charger, including connection to a typical AC electrical outlet, connection to a vehicle charger (i.e., cigarette lighter receptacle), and connection to a computer, for example, via a universal serial bus cable (USB, universal serial bus). Additionally, in some embodiments, the cartridge 200 may include a disposable cartridge, as described in US Patent No. 8,910,639 (Chang et al.), which is incorporated herein by reference in its entirety.

In fig. 3 is an exploded view of the control housing 300 of the aerosol delivery device 100 in accordance with an exemplary embodiment of the present invention. As shown in the drawing, control housing 300 may include an induction transmitter 302A, an outer housing 304, a flow sensor 310 (e.g., a puff sensor or pressure switch), a controller 312, a spacer 314, an electrical power source 316 (e.g., a battery, which may be rechargeable). , and/or a capacitor), a circuit board with an indicator 318 (eg, a light-emitting diode (LED)), a connecting circuit 320, and an end cap. Examples of power sources are described in US Patent Application Publication No. 2010/0028766 (Peckerar et al.), which is incorporated herein by reference in its entirety.

With respect to the flow sensor 310, corresponding current control components and other current control components, including various microcontrollers, sensors and switches, for aerosol delivery devices are described in US Pat. No. 4,735,217 (Gerth et al.), No. 4,922,901 (Brooks et al.) , No. 4,947,874 (Brooks et al.), No. 4,947,875 (Brooks et al.), No. 5,372,148 (McCafferty et al.), No. 6,040,560 (Fleischhauer et al.), No. 7,040,314 ( Nguyen et al.) and No. 8,205,622 (Pan), which are incorporated herein by reference in their entirety. In addition, control circuits are described in US Patent Application Publication No. 2014/0270727 (Ampolini et al.), which is incorporated herein by reference in its entirety.

In one embodiment, indicator 318 may include one or more light-emitting diodes. Indicator 318 may be communicatively coupled to controller 312 via interconnect circuit 320 and may illuminate, for example, when a user takes a puff through a cartridge (e.g., cartridge 200 shown in FIG. 2) coupled to control housing 300, which may be detected by flow sensor 310. End cap 322 may be configured to provide visibility of the glow produced by the indicator 318 underneath. Accordingly, the indicator 318 may glow during use of the aerosol delivery device 100 to simulate the burning end of a smoking article. However, in other embodiments of the invention, the indicator 318 may be present in a different number, may have other shapes, and may even be an opening in the outer housing (such as to allow sound release when such indicators are present).

Other additional components can be used in the proposed aerosol delivery device. For example, US Pat. No. 5,154,192 (Sprinkel et al.) describes indicators for smoking articles; U.S. Patent No. 5,261,424 (Sprinkel Jr.) describes piezoelectric sensors that can be coupled to the mouthpiece end of the device to detect puff-related lip activity of a user and then trigger heating; US Pat. No. 5,372,148 (McCafferty et al.) discloses a puff sensor for controlling the flow of energy into a heating load matrix in response to a drop in mouthpiece pressure; US Pat. No. 5,967,148 (Harris et al.) describes receptacles in a smoking device that include an identifier that detects a discontinuity in the infrared transmittance of an inserted component and a controller that executes a detection routine when said component is inserted into the receptacle; US Pat. No. 6,040,560 (Fleischhauer et al.) describes a predetermined executable power on/off cycle with multiple different phases; US Patent No. 5,934,289 (Watkins et al.) describes photonic-optocoupler components; US Patent No. 5,954,979 (Counts et al.) describes a means for varying the resistance to draw through a smoking device; US Pat. No. 6,803,545 (Blake et al.) discloses specific battery configurations for use in smoking devices; US Patent No. 7,293,565 (Griffen et al.) describes various charging systems for use with smoking devices; U.S. Patent No. 8,402,976 (Fernando et al.) discloses a computer interface means for smoking devices to facilitate charging and enable computer control of smoking devices; US Patent No. 8,689,804 (Fernando et al.) describes identification systems for smoking devices; and international patent WO 2010/003480 (Flick) describes a system for detecting fluid flow indicating puffiness in an aerosol generation system; all of the above inventions are incorporated by reference in their entirety into this application. Additional examples of components related to electronic products for aerosol delivery and describing materials or components that can be used in this product are set forth in US Pat. No. 4,735,217 (Gerth et al.), No. 5,249,586 (Morgan et al.) , No. 5,666,977 (Higgins et al.); No. 6,053,176 (Adams et al.); No. 6 164 287 (White); No. 6 196 218 (Voges); No. 6,810,883 (Felter et al.); No. 6 854 461 (Nichols); No. 7,832,410 (Hon); No. 7 513 253 (Kobayashi); No. 7 896 006 (Hamano); No. 6,772,756 (Shayan); No. 8,156,944, No. 8,375,957 (Hon); No. 8,794,231 (Thorens et al.), No. 8,851,083 (Oglesby et al.), No. 8,915,254 and No. 8,925,555 (Monsees et al.); US Patent Application Publications No. 2006/0196518 and No. 2009/0188490 (Hon), No. 2010/0024834 (Oglesby et al.), No. 2010/0307518 (Wang), No. 2014/0261408 (DePiano et al.); publications of international patent applications WO 2010/091593 (Hon) and WO 2013/089551 (Foo), which are incorporated herein by reference in their entirety. Additionally, U.S. Patent Application No. 14/881,392 (Worm et al.), filed Oct. 13, 2015, discloses capsules that can be included in aerosol delivery devices and pocket-shaped configurations for aerosol delivery devices, which application is incorporated herein by reference in its entirety. Various materials described in the above-mentioned documents may be included in the present devices according to various embodiments, and all of the above descriptions are incorporated by reference in their entirety herein.

Each of the components of the control housing 300 may be at least partially located in the outer housing 304. The outer housing 304 may extend from the interacting end 304' to the outer end 304''. An end cap 322 may be located at and in engagement with the outer end 304'' of the outer housing 304. Thus, end cap 322, which may be translucent or transparent, may be illuminated by indicator 318 to simulate the burning end of a smoking article or to perform other functions as described above. The opposite interacting end 304' of the outer housing 304 may be configured to interact with the cartridge 200.

In fig. 4 is a schematic view of a partial cross-section of the control housing 300 proximate the interacting end 304' of the outer housing 304. As shown in the drawing, the induction transmitter 302A may extend proximate the interacting end 304' of the outer housing 304. In one embodiment of the invention, as shown in FIG. 3 and 4, the induction transmitter 302A may be formed into a tubular structure. As shown in FIG. 4, induction transmitter 302A may include a coil support 303 and a coil 305. The coil support 303, which may form a tubular structure, may be configured to support the coil 305 such that the coil 305 does not come into contact with the induction receiver or other structures and therefore did not create a short circuit. The coil support 303 may comprise a non-conductive material that may be substantially permeable to the oscillatory magnetic field generated by the coil 305. The coil 305 may be embedded in or otherwise coupled to the coil support 303. In the illustrated embodiment, the coil 305 interacts with the inner surface of the coil support 303 in such a way as to reduce any losses associated with the transmission of the oscillatory magnetic field to the induction receiver. However, in other embodiments, the coil may be located on the outer surface of the coil support or may be completely embedded in the coil support. Additionally, in some embodiments, the coil may include electrically conductive tracks on a coil support or wire. In any embodiment, the coil may form a twisted structure.

In an alternative embodiment of the invention, as shown in FIG. 5, the induction transmitter 302B may form a helical structure. In each embodiment, induction transmitter 302 may define an internal chamber 324 around which it extends.

As shown in FIG. 3-5, in some embodiments of the invention, induction transmitter 302 may be coupled to support member 326. Support member 326 may be configured to interact with induction transmitter 302 and to support induction transmitter 302 within the outer housing 304. For example, induction transmitter 302 may be embedded in or otherwise coupled to support member 326 such that the induction transmitter is stationary within the outer housing 304. As a further example, induction transmitter 302 may be injection molded into support member 304.

The support member 326 may interact with the interior surface of the outer housing 304 to ensure alignment of the support member with the outer housing. Therefore, as a result of the fixed connection between the support member 326 and the induction transmitter 320, the longitudinal axis of the induction transmitter can be substantially parallel to the longitudinal axis of the outer housing 304. Thus, the induction transmitter 302 may not contact the outer housing 304 so as to avoid transmission of electric current. from the induction transmitter to the outer casing. However, in some embodiments, an additional insulator 328 may be located between the inductive transmitter 302 and the outer housing 304, as shown in FIG. 5 to prevent contact between them. It should be noted that insulator 328 and support member 326 may comprise any non-conductive material, such as an insulating polymer (eg, plastic or cellulose), glass, rubber, and porcelain. In an alternative embodiment, the induction transmitter 302 may be in contact with the outer housing 304 in those embodiments in which the outer housing is made of a non-conductive material such as plastic, glass, rubber, or porcelain.

As described below in more detail, the induction transmitter 302 may be configured to receive electrical current from the electrical power source 316 and to wirelessly heat the cartridge 200 (shown, for example, in FIG. 2). Thus, as shown in FIG. 4 and 5, induction transmitter 302 may include electrical connectors 330 configured to supply electrical current. For example, electrical connectors 330 may couple induction transmitter 302 to controller 312. Thus, current from electrical power source 316 may be selectively directed to inductive transmitter 302 when controlled by controller 312. For example, controller 312 may route electrical current from electrical power source 316 (see , for example, Fig. 3) to the inductive transmitter 302 when the sensor 310 detects the flow of a puff performed through the aerosol delivery device 100. Electrical connectors 330 may include, for example, connectors, wires, or some other connector embodiment configured to transmit electrical current therethrough. In addition, electrical connectors 330 may include a negative electrical connector and a positive electrical connector.

In some embodiments, the electrical power source 316 may include a battery and/or a capacitor that can supply direct current. As described herein, operation of the aerosol delivery device may require the application of alternating current to the induction transmitter 302 to produce an oscillating magnetic field to generate Foucault currents in the induction receiver. Accordingly, in some embodiments, controller 312 or a separate component of control housing 300 may include an inverter or inverter circuit configured to convert direct current supplied by power source 316 into alternating current supplied to inductive transmitter 302.

In fig. 6 is an exploded view of the first embodiment of the cartridge 200A. As shown in the drawing, cartridge 200A may include an induction receiver 202, an outer housing 204, a container 206, a sealing member 208, and a backing 210. The outer housing 204 may extend from a interacting end 204' to an outer end 204''. Some or all of the remaining components of the cartridge 200A may be located at least partially within the outer housing 204.

The cartridge 200A may further include a mouthpiece 212. The mouthpiece 212 may be integral with the outer housing 204 or container 206 or may be a separate component. The mouthpiece 212 may be located at the outer end 204'' of the outer housing 204.

In fig. 7 is a cross-sectional view of cartridge 200A in an assembled configuration. As shown in the drawing, container 206 may be located within the outer housing 204. Additionally, sealing member 208 may be in contact with container 206 to form an inner compartment 214. As shown in FIG. 7, in some embodiments of the invention, the sealing element 208 may further cooperate with the outer housing 204.

In some embodiments, sealing member 208 may comprise a resilient material, such as rubber or silicone material. In this embodiment, the sealing element 208 may be compressed to form an airtight seal with the container 206 and/or the outer housing 204. To further improve the seal, an adhesive may be applied between the sealing element 208 and the container 206 and/or the outer housing 204. In another embodiment of the invention, the sealing element 208 may comprise a non-elastic material, such as a plastic or metal material. In these embodiments, sealing member 208 may be bonded or welded (e.g., by ultrasonic welding) to container 206 and/or outer housing 204. Accordingly, by one or more of these mechanisms, sealing member 208 may substantially completely seal interior compartment 214 .

Induction receiver 202 may be in engagement with sealing element 208. In one embodiment, induction receiver 202 may be partially embedded in sealing element 208. For example, induction receiver 202 may be injection molded into sealing element 208 such that a seal is formed between them. sealing and connection. Thus, the sealing element 208 can hold the induction receiver in the desired position. For example, induction receiver 202 may be positioned such that its longitudinal axis is substantially coaxial with the longitudinal axis of outer housing 204.

In addition, the substrate 210 may cooperate with the sealing element 208. In one embodiment, the substrate 210 may extend through the sealing element 208. In this regard, the sealing element 208 may define an opening 216 extending therethrough, in which the substrate 210 is located. Thus, the substrate 210 may protrude into the interior compartment 214. For example, as shown in FIG. 7, the end of the substrate 210 may be located in a pocket 218 defined by the container 206. Accordingly, the container 206 and the sealing element 208 may interact with the substrate 210 and jointly support the substrate in a desired position. For example, the longitudinal axis of the substrate 210 may be located substantially coaxial with the longitudinal axis of the induction receiver 202. Thus, as shown, in some embodiments of the invention, the substrate 210 may be located adjacent to, but not in contact with, the induction receiver 202. By preventing contact between the substrate 210 and the induction receiver 202, the induction coil can remain substantially free of residual material accumulating thereon during use and, therefore, the cartridge can be refilled with the aerosol precursor composition and/or new substrate as needed, or otherwise reused. . However, as described below, direct contact between the substrate and the induction receiver may be preferred in some embodiments.

The substrate 210 may contain an aerosol precursor composition. The aerosol precursor composition may contain one or more solid tobacco materials, semi-solid tobacco materials, and liquid aerosol precursor compositions. For example, solid tobacco materials and semi-solid tobacco materials can be used in embodiments of the aerosol delivery device 100, forming so-called cigarettes using heating rather than combustion of tobacco. In turn, as a further example, aerosol precursor compositions in fluid form (eg, liquid) can be used in embodiments of the aerosol delivery device 100 forming so-called electronic cigarettes.

Typical components and compositions of liquid aerosol precursor are presented and characterized in US Patent No. 7,726,320 (Robinson et al.), US Patent Application Publications No. 2013/0008457 (Zheng et al.), No. 2013/0213417 (Chong et al.), No. 2015/0020823 (Lipowicz et al.) and No. 2015/0020830 (Koller), as well as in international patent WO 2014/182736 (Bowen et al.) and US patent No. 8,881,737 (Collett et al.), the contents of which incorporated herein by reference. Other aerosol precursors that may be used in an aerosol delivery device include the aerosol precursors included in R. J. Reynolds Vapor Company's VUSE® product, Lorillard Technologies' BLUTM product, Mistic Ecigs' MISTIC MENTHOL product, and CN Creative Ltd.'s VYPE product. Also desirable are the so-called "smoking juices" for electronic cigarettes manufactured by Johnson Creek Enterprises LLC. Embodiments of effervescent materials that can be used with an aerosol precursor are described by way of example in US Patent Application Publication No. 2012/0055494 (Hunt et al.), the contents of which are incorporated herein by reference. In addition, the use of effervescent materials is described, for example, in US patent No. 4,639,368 (Niazi et al.), No. 5,178,878 (Wehling et al.), No. 5,223,264 (Wehling et al.), No. 6,974,590 (Pather et al.), No. 7,381,667 (Bergquist et al.), No. 8,424,541 (Crawford et al.), and No. 8,627,828 (Strickland et al.); as well as US Patent Application Publications No. 2010/0018539 (Brinkley et al.) and No. 2010/0170522 (Sun et al.) and PCT International Patent WO 97/06786 (Johnson et al.), which are incorporated herein by reference. .

Typical components and compositions of solid and semi-solid aerosol precursor are described in US Pat. No. 8,424,538 (Thomas et al.), No. 8,464,726 (Sebastian et al.); US Patent Application Publications No. 2015/0083150 (Conner et al.), No. 2015/0157052 (Ademe et al.); and US Patent Application No. 14/755205, filed June 30, 2015 (Nordskog et al.).

In embodiments of the cartridge 200 in which the aerosol precursor composition contains a liquid or other fluid, the substrate 210 may be configured to retain the aerosol precursor composition and release vapor therefrom when exposed to heat from the induction receiver 202, as described below. . In some embodiments, the substrate 210 may hold a sufficient amount of the aerosol precursor composition for a desired period of time. In other embodiments, it may be preferable to provide a cartridge 200 with increased capacity of the aerosol precursor composition. Examples of materials that may be used in the substrate 210 in embodiments of the invention in which the substrate is configured to hold a liquid aerosol precursor composition include porous ceramic, carbon, cellulose acetate, polyethylene terephthalate, fiberglass, or porous sintered glass.

In this regard, as shown by way of example in FIG. 6 and 7, in one embodiment, container 206 may comprise a reservoir and interior compartment 214 may be configured to contain a liquid aerosol precursor composition. In this embodiment, the substrate 210 may include a liquid transport element (eg, a wick) configured to receive the aerosol precursor composition from the internal container 214 and to transport the aerosol precursor composition thereon. Accordingly, the aerosol precursor composition may be transferred from the inner container 214 to locations along the longitudinal length of the substrate 210 around which the induction receiver 202 extends.

It should be understood that the embodiment of cartridge 200A shown in FIG. 7 is provided by way of example only. In this regard, various alternative embodiments of the cartridge 200 are presented herein by way of further example. It should be noted that although the embodiments of the cartridge 200 are described separately in this application, the corresponding components and elements of these cartridges may be combined unless otherwise indicated.

As an example, in FIG. 8 depicts a second embodiment of cartridge 200B in which sealing element 208B is located proximate the outer end 204'' of the outer housing 204 opposite the interacting end 204'. In this embodiment, the container 206B may include an opening 216B extending therethrough, and the sealing member 208B may define a pocket 218B for supporting the substrate 210 in substantially the same manner as described above. Accordingly, the sealing element 208 may be located at either the interacting end 204' of the container 206 (see, for example, container 200A in FIG. 7) or at the outer end 204'' of the container 206B (see, for example, container 200B in FIG. 8).

In some embodiments, the container may be substantially sealed such that leakage of the aerosol precursor composition is substantially prevented. However, as shown in FIG. 8, in some embodiments, the cartridge 200B may further include a reservoir substrate 220. It should be noted that the reservoir substrate 220 may be used in any of the cartridges described herein that include an internal compartment 214.

In one embodiment of the invention, reservoir substrate 220 may comprise multiple layers of nonwoven fibers formed substantially into the shape of a tube that completely or partially encloses substrate 210 in interior compartment 220. In other embodiments, reservoir substrate 220 may comprise porous ceramic, carbon, cellulose acetate, polyethylene terephthalate, fiberglass or porous sintered glass. Thus, the liquid aerosol precursor composition can be retained by the reservoir substrate 220 through sorption action. Due to the contact between the reservoir substrate 220 and the substrate 210, they are fluidly coupled to each other. Thus, the substrate 210 may be configured to transport the aerosol precursor composition from the reservoir substrate 220 in the internal compartment 214 by capillary forces or other transport mechanisms to locations along the longitudinal length of the substrate 210 outside the internal compartment.

As noted above, in some cartridge embodiments (see, for example, cartridges 200A, 200B in FIGS. 7 and 8), the substrate 210 may be located adjacent to, but not in contact with, the induction receiver 202. This configuration can prevent residual material from accumulating on the induction receiver due to the absence of direct contact between them. However, in other embodiments of the invention, as shown in the third embodiment of cartridge 200C shown in FIG. 9, the substrate 210C may be in contact with the induction receiver 202. Use of such a configuration may provide a relatively larger substrate 210C that can contain a relatively larger amount of the aerosol precursor composition without the need to increase the size of the induction receiver 202. Additionally, direct contact between the induction receiver and the substrate may promote the transfer of heat from the induction receiver to the substrate by convection, which can be significantly more efficient than radiation heating used in those embodiments of the invention in which there is no direct contact between them. Accordingly, it should be understood that each of the embodiments of the cartridges described herein may involve direct contact between the induction receiver and the substrate and/or aerosol precursor composition. Providing direct contact between the substrate 210C and the induction receiver 202 can be used, by way of example, in embodiments of the invention in which the aerosol precursor composition contains solid tobacco material or semi-solid tobacco material that may be less susceptible to the gradual accumulation of residual material on the induction receiver. than a liquid aerosol precursor composition.

In the cartridge embodiments 200A, 200B shown in FIGS. 6-8, the backing 210 projects into the inner compartment 214. However, in other embodiments of the invention, the cartridge may not define the inner compartment. For example, the cartridge 200C shown in FIG. 9, Does not contain internal compartment. In this regard, the substrate 210C may contain a sufficient amount of the aerosol precursor composition such that the use of an internal compartment may not be required in some embodiments of the invention. Thus, for example, induction receiver 202 and substrate 210C may be substantially the same in extent such that their longitudinal ends terminate at substantially the same points. In this regard, the induction receiver 202 and/or the substrate 210C may be located in a pocket 222C defined by the outer housing 204C or otherwise interacting (eg, directly interacting) with the outer housing. Thus, in some embodiments, the cartridge 200C may form a relatively simple configuration that may not include a container, sealing member, or interior compartment. Such a configuration may reduce the complexity and/or cost of the container 200C.

As described above, in some embodiments, the substrate 210C may not protrude into the interior compartment, but instead may terminate, for example, in the vicinity of the outer housing 204C. As further described above with reference to FIG. 9, in one embodiment, the cartridge 200C may not include a container or internal compartment. However, as shown in FIG. 10, in another embodiment, the cartridge 200D may include a container 206D defining an internal compartment 214 without a backing 210D protruding into said compartment. In this regard, the induction receiver 202 and the substrate 210D may be brought into contact with the container or outer casing. For example, in FIG. 10, an induction receiver 202 and a substrate 210D are in cooperation with a container 206D. As another example, as described above, induction receiver 202 may be partially embedded in container 206D. In addition, the substrate 210D may cooperate with the pocket 222D formed by the capacitance 206D.

By configuring the cartridge 200D such that the substrate 210D does not protrude into the interior compartment 214, the compartment can perform a function other than that of a reservoir for the aerosol precursor composition. For example, as shown in FIG. 10, in some embodiments, cartridge 200D may include an electronic control component 224D. As described below, the electronic control component 224D may be used in authenticating the cartridge 200D or used for other purposes.

As stated above, each of the cartridges 200 of the present invention is configured to operate in conjunction with the control housing 300 to produce an aerosol. As an example, in FIG. 11 depicts cartridge 200A in engagement with control housing 300. As shown in the figure, when control housing 300 is in engagement with cartridge 200A, induction transmitter 302A may at least partially surround, preferably substantially surround, and more preferably completely surround induction receiver 202 (for example, by passing around its outer surface). In addition, the induction transmitter 302A may extend along at least a portion of the longitudinal length of the induction receiver 202, preferably extend along most of the longitudinal length of the induction receiver, and most preferably extend along substantially the entire longitudinal length of the induction receiver.

Accordingly, the induction receiver 202 may be located in the inner chamber 324 around which the induction transmitter 302A extends. Accordingly, when the user draws air through the mouthpiece 212 of the cartridge 200A, the pressure sensor 310 can detect the puff. Thus, controller 312 can direct electrical current from power source 316 (see, for example, FIG. 3) to inductive transmitter 302A. The inductive transmitter 302A may thereby produce an oscillating magnetic field. By housing the induction receiver 202 in the inner chamber 324, the induction receiver can be exposed to the oscillatory magnetic field generated by the induction transmitter 302A.

In particular, the induction transmitter 302A and the induction receiver 202 may form an electrical transformer. A change in the electrical current in the induction transmitter 302A, which is directed to it from the electric power source 316 (see, for example, FIG. 3) using the controller 312, can generate an alternating electromagnetic field that penetrates the induction receiver 202, resulting in the formation of Foucault's currents. An alternating electromagnetic field may be generated by directing an alternating current to the inductive transmitter 302. As discussed above, in some embodiments, the controller 312 may include an inverter or inverter circuit configured to convert the direct current supplied by the electrical power source 316 into alternating current supplied to induction transmitter 302A.

Foucault currents passing through the material forming the induction receiver 202 can heat the induction receiver due to the Joule thermal effect, in which the amount of heat produced is proportional to the square of the current multiplied by the electrical resistance of the induction receiver material. In embodiments of induction receiver 202 containing magnetic materials, heat may also be generated through magnetic hysteresis losses. Several factors contribute to an increase in the temperature of the induction receiver 202, including, but not limited to, proximity to the induction transmitter 302, magnetic field distribution, electrical resistance of the induction receiver material, saturation flux density, surface effects or field penetration depth, hysteresis losses, magnetic susceptibility, magnetic permeability, and dipole moment of the material.

In this regard, both induction receiver 202 and induction transmitter 302A may contain electrically conductive material. As an example, induction transmitter 302 and/or induction receiver 202 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 ceramics or glass , with one or more conductive materials included therein. In another embodiment, the induction receiver may contain conductive particles or objects of any different sizes located in a reservoir filled with the aerosol precursor composition. In some embodiments, the induction receiver may be coated with or otherwise comprise a thermally conductive passivation layer (eg, a thin layer of glass) to prevent direct contact with the aerosol precursor composition.

Accordingly, the induction receiver 202 may be heated. The heat produced by the induction receiver 202 may heat the substrate 210 containing the aerosol precursor composition so as to form an aerosol 402. Accordingly, the induction receiver 202 may include an atomizer. By positioning the induction receiver 202 around the substrate 210 at a substantially equal distance from it (eg, by aligning the longitudinal axes of the substrate and the induction receiver), the substrate and the aerosol precursor composition can be heated substantially uniformly.

Aerosol 402 may move around or through induction receiver 202 and induction transmitter 302A. For example, as shown, in one embodiment, induction receiver 202 may include a mesh, screen, coil, rope, or other porous structure defining a plurality of holes extending therethrough. In other embodiments, the induction receiver may comprise a rod embedded in a substrate or otherwise in contact with the aerosol precursor composition, a plurality of grains or particles embedded in the substrate or otherwise in contact with the aerosol precursor composition, or a sintered structure. In each of these embodiments, the aerosol 402 can freely pass through the induction receiver 202 and/or the substrate to allow the aerosol to pass through the mouthpiece to the user.

Aerosol 402 may be mixed with air 404 entering through inlets 332, which may be provided in control housing 300 (eg, outer housing 304). Accordingly, air and aerosol 406 mixed with each other can be directed towards the user. For example, the mixed air and aerosol 406 may be directed toward the user through one or more through holes 226 provided in the outer housing 204 of the cartridge 200A. In some embodiments, the sealing element 208 may further include through holes 228 extending therethrough, which may be aligned with through holes 226 extending through the outer housing 204. However, it should be understood that the flow pattern through the aerosol delivery device 100 may differ from the specific configuration. described above is within the scope of the present invention.

As noted above, in some embodiments, cartridge 200 may further include an electronic control component. For example, the cartridge 200D shown in FIG. 10 includes an electronic control component 224D. The electronic control component 224D may be configured to authenticate the cartridge 200D. In this regard, in some embodiments of the invention, the electronic control component 224D may be configured to output code to the control housing 300, which can be analyzed by the controller 312 (see, for example, FIG. 3). Thus, for example, the controller 312 may send electrical current to the inductive transmitter 302 only after confirming the authenticity of the cartridge 200D. In some embodiments, the electronic control component may include connectors that connect to the control housing. More preferably, the electronic control component 224D may include a radio frequency identification (RFID) chip configured to wirelessly transmit a code or other information to the control housing. Thus, the aerosol delivery device 100 can be used without the need for electrical connectors to interact between the cartridge and the control housing. In addition, various examples of electronic control components and the functions performed by these components are described in US Patent Application Publication No. 2014/0096782 (Sears et al.), which is incorporated herein by reference in its entirety.

As described above, the present invention relates to an aerosol delivery device having a control housing comprising a wireless power transmitter configured to receive electrical current from a power source and to wirelessly heat the atomizer. It should be noted that various wireless heating methods can be used to heat the aerosol precursor composition, which may be in a reservoir and/or in contact with a substrate. In some embodiments, the atomizer may be wirelessly heated without transmitting electrical current to the atomizer.

In some embodiments described above, the wireless power transmitter may include an induction transmitter and the atomizer may include an induction receiver. In this way, Foucault currents can be induced in the induction receiver to generate heat. As noted above, the induction transmitter may be configured to at least partially surround the induction receiver. As a further example, in other embodiments of the invention, the atomizer may be heated using wireless heating, such as radiant heating, acoustic heating, photonic heating (eg, via laser), and/or microwave heating.

However, in other embodiments of the invention, various other methods and mechanisms may be used to wirelessly heat the atomizer. For example, electrical current may be supplied to the atomizer via wireless transmission, and such wireless power transmission methods may be used with any atomizer embodiment such as wire coil resistive heating elements. Exemplary embodiments of wireless power transmission methods and mechanisms are presented in US Patent Application No. 14/814866 (Sebastian et al.), filed July 31, 2015, which is incorporated herein by reference in its entirety.

It should be noted that while the present invention generally describes heating a substrate containing an aerosol precursor composition that is located adjacent to an induction receiver to form an aerosol, in other embodiments, the induction receiver may be configured to heat an aerosol precursor composition directed (e.g., delivered) to him. For example, patent applications No. 14/309282, filed June 19, 2014, No. 14/524778, filed October 27, 2014, and No. 14/289101, filed May 28, 2014, (Brammer et al.) describe mechanisms and methods for delivering a liquid aerosol precursor composition, which are incorporated herein by reference in their entirety. Such mechanisms and methods for delivering a liquid aerosol precursor composition can be used to direct the aerosol precursor composition from a reservoir to an induction receiver to generate an aerosol. In a further embodiment of the invention, the induction receiver may comprise a hollow needle coupled to a reservoir, wherein the aerosol precursor composition may be drawn into the needle by capillary action to refill the needle as the needle evaporates the aerosol precursor composition. It should be noted that while exemplary shapes and configurations of an induction receiver and an induction transmitter are described herein, various other configurations and shapes may be used.

In addition, a method for assembling an aerosol delivery device is provided. As shown in FIG. 12, the method may include providing a substrate containing the aerosol precursor composition at step 502. The method may further include providing an induction receiver at step 504. Additionally, the method may include positioning the substrate adjacent to the induction receiver at step 506. The induction receiver may be configured to exposure to an oscillating magnetic field and the ability to heat the aerosol precursor composition to form an aerosol.

In some embodiments, positioning the substrate adjacent to the induction receiver at step 506 may include positioning the substrate in direct contact with the induction receiver. Additionally, positioning the substrate adjacent to the induction receiver at step 506 may include positioning the substrate within the induction receiver. The method may further include loading the substrate with the aerosol precursor composition. The aerosol precursor composition may comprise a liquid aerosol precursor composition.

Additionally, the method may include providing an induction transmitter and positioning the induction transmitter to at least partially surround an induction receiver. The location of the induction transmitter may include positioning the induction transmitter so that it is not in direct contact with the induction receiver.

The method may further include forming a cartridge containing a substrate and an induction receiver. In addition, the method may include forming a control housing containing an induction transmitter. Positioning the induction transmitter so that it at least partially surrounds the induction receiver may include connecting the cartridge to the control housing. In addition, the formation of the control body may include connecting the electrical power source to the induction transmitter.

In a further embodiment of the invention, a method for generating an aerosol is provided. As shown in FIG. 13, the method may include providing a cartridge at 602. The cartridge may comprise an aerosol precursor composition and an atomizer. The method may further include providing a control body at 604. The control body may include a power source and a wireless power transmitter. Additionally, the method may include directing electrical current from the electrical power source to the wireless electrical power transmitter at step 606. Moreover, the method may include wirelessly heating the atomizer using the wireless electrical power transmitter to heat the aerosol precursor composition to form an aerosol at step 608.

Many modifications and other embodiments of the present invention may become apparent to one skilled in the art upon examination of the present invention as set forth in the foregoing descriptions and accompanying drawings. Thus, it should be noted that the present invention is not intended to be limited to the specific embodiments described herein, and that modifications and other embodiments are included within the scope of protection of the present invention as defined by the appended claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (24)

1. An aerosol delivery device containing: a support including an aerosol precursor composition; atomizer; source of electricity and a wireless electricity transmitter configured to receive electric current from a source of electricity and the ability to wirelessly heat the atomizer, wherein the atomizer contains an induction receiver located near the substrate, but without direct contact with it and configured to generate heat when exposed to an oscillatory magnetic field and the ability heating the aerosol precursor composition to form an aerosol. 2. The aerosol delivery device according to claim 1, wherein the wireless power transmitter comprises an induction transmitter. 3. The aerosol delivery device according to claim 2, wherein the induction transmitter is configured to at least partially surround the induction receiver. 4. The aerosol delivery device according to claim 1, in which the induction receiver is porous. 5. The aerosol delivery device according to claim 1, wherein the wireless power transmitter comprises an induction transmitter configured to generate an oscillating magnetic field. 6. The aerosol delivery device of claim 5, wherein the induction transmitter is configured to at least partially surround the induction receiver. 7. An aerosol delivery device according to any one of claims. 5 and 6, in which the induction transmitter forms a tubular structure or a helical structure. 8. An aerosol delivery device according to any one of claims. 5-7, having a control housing containing an induction transmitter and a power source, and a cartridge containing an induction receiver and a substrate. 9. An aerosol delivery device according to any one of claims. 1-8, wherein the aerosol precursor composition comprises one or more of a solid tobacco material, a semi-solid tobacco material, and a liquid aerosol precursor composition. 10. An aerosol delivery device according to any one of claims. 8 and 9, in which the control housing further includes an outer housing, a controller, a flow sensor and an indicator. 11. A method for assembling an aerosol delivery device, including: positioning the substrate containing the aerosol precursor composition close to the induction receiver, but without direct contact with it, wherein the induction receiver is configured to generate heat when exposed to an oscillatory magnetic field and the ability to heat the aerosol precursor composition to form an aerosol. 12. The method of claim 11, wherein positioning the substrate adjacent to, but not in direct contact with, the induction receiver includes positioning the substrate within the induction receiver. 13. Method according to any one of paragraphs. 11, 12, further comprising filling the substrate with an aerosol precursor composition, wherein the aerosol precursor composition comprises a liquid aerosol precursor composition. 14. Method according to any one of paragraphs. 11-13, additionally including positioning the induction transmitter so that it at least partially surrounds the induction receiver. 15. The method of claim 14, further comprising forming a cartridge containing a substrate and an induction receiver. 16. The method according to claim 15, further including the formation of a control housing containing an induction transmitter. 17. The method of claim 16, wherein forming the control body includes connecting a source of electrical power to an induction transmitter.

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