U.S. patent application number 14/170838 was filed with the patent office on 2015-08-06 for aerosol delivery device comprising multiple outer bodies and related assembly method.
This patent application is currently assigned to R.J. Reynolds Tobacco Company. The applicant listed for this patent is R.J. Reynolds Tobacco Company. Invention is credited to Frederic Philippe Ampolini, Alfred Charles Bless, Michael Ryan Galloway, Michael Andrew Liberti, Timothy Brian Nestor.
Application Number | 20150216232 14/170838 |
Document ID | / |
Family ID | 53753715 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150216232 |
Kind Code |
A1 |
Bless; Alfred Charles ; et
al. |
August 6, 2015 |
Aerosol Delivery Device Comprising Multiple Outer Bodies and
Related Assembly Method
Abstract
The present disclosure relates to an aerosol delivery device.
The aerosol delivery device may include a first outer body, a
second outer body, and a coupler received therebetween. A securing
mechanism may couple the outer bodies together to retain the
aerosol delivery device in an assembled configuration. Related
assembly methods are also provided.
Inventors: |
Bless; Alfred Charles;
(Asheboro, NC) ; Liberti; Michael Andrew;
(Clemmons, NC) ; Nestor; Timothy Brian; (Advance,
NC) ; Ampolini; Frederic Philippe; (Winston-Salem,
NC) ; Galloway; Michael Ryan; (Winston-Salem,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R.J. Reynolds Tobacco Company |
Winston-Salem |
NC |
US |
|
|
Assignee: |
R.J. Reynolds Tobacco
Company
Winston-Salem
NC
|
Family ID: |
53753715 |
Appl. No.: |
14/170838 |
Filed: |
February 3, 2014 |
Current U.S.
Class: |
131/328 ;
131/329; 285/344 |
Current CPC
Class: |
A24F 47/008
20130101 |
International
Class: |
A24F 47/00 20060101
A24F047/00 |
Claims
1. An aerosol delivery device, comprising: a first outer body
defining an inlet aperture; a second outer body; a power source
positioned in the first outer body; an atomizer positioned in the
second outer body; and a coupler positioned between, and engaged
with, the first outer body and the second outer body, the coupler
defining a coupler inlet and a longitudinal channel, the coupler
being configured to receive air from the inlet aperture defined in
the first outer body through the coupler inlet and to direct the
air through the longitudinal channel to the second outer body.
2. The aerosol delivery device of claim 1, further comprising at
least one securing mechanism configured to substantially
irreversibly secure the first outer body to the second outer
body.
3. The aerosol delivery device of claim 2, wherein the at least one
securing mechanism comprises a wrapper extending at least partially
around the first outer body, the second outer body, and the
coupler.
4. The aerosol delivery device of claim 1, further comprising a
reservoir substrate and a flow director positioned in the second
outer body, the flow director extending at least partially through
the reservoir substrate.
5. The aerosol delivery device of claim 4, wherein the coupler
defines a nipple and the flow director engages the nipple of the
coupler.
6. The aerosol delivery device of claim 4, further comprising a
mouthpiece defining a nipple, wherein the flow director engages the
nipple of the mouthpiece.
7. The aerosol delivery device of claim 4, wherein the flow
director defines a transverse aperture extending therethrough, the
atomizer extending through the transverse aperture.
8. The aerosol delivery device of claim 1, further comprising a
plurality of electrical connectors extending from the atomizer
through the coupler to the power source.
9. The aerosol delivery device of claim 1, wherein the atomizer
comprises a heating element and a liquid transport element defining
a center portion and first and second opposing arms extending
therefrom, the heating element being coupled to the center portion
of the liquid transport element.
10. The aerosol delivery device of claim 1, wherein the coupler
defines a rib, the rib separating the first outer body from the
second outer body.
11. A method for assembling an aerosol delivery device, the method
comprising: positioning a power source in a first outer body
defining an inlet aperture; positioning an atomizer in a second
outer body; and engaging a coupler defining a coupler inlet and a
longitudinal channel with the first outer body and the second outer
body such that the coupler is positioned to receive air from the
inlet aperture defined in the first outer body through the coupler
inlet and to direct the air through the longitudinal channel to the
second outer body.
12. The method of claim 11, further comprising substantially
irreversibly securing the first outer body to the second outer body
with a securing mechanism.
13. The method of claim 11, wherein substantially irreversibly
securing the first outer body to the second outer body with the
securing mechanism comprises wrapping a wrapper at least partially
around the first outer body, the second outer body, and the
coupler.
14. The method of claim 11, further comprising positioning a
reservoir substrate and a flow director in the second outer body
such that the flow director extends at least partially through the
reservoir substrate.
15. The method of claim 14, wherein positioning the atomizer in the
second outer body comprises inserting the atomizer through a
transverse aperture extending through the flow director.
16. The method of claim 14, further comprising coupling the flow
director to a nipple of the coupler.
17. The method of claim 14, further comprising coupling the flow
director to a nipple of a mouthpiece.
18. The method of claim 11, further comprising inserting a
plurality of electrical connectors through the coupler; and
connecting the electrical connectors to the power source and the
atomizer.
19. The method of claim 11, further comprising coupling a heating
element to a center portion of a liquid transport element to form
the atomizer; and folding first and second opposing arms of the
liquid transport element extending from the center section away
from the coupler.
20. The method of claim 11, wherein engaging the coupler with the
first outer body and the second outer body comprises engaging a rib
of the coupler with the first outer body and the second outer
body.
21. A coupler for an aerosol delivery device, the coupler
comprising: a first engagement portion configured to engage a first
outer body; a second engagement portion configured to engage a
second outer body; a coupler inlet defined through a peripheral
surface of the first engagement portion; and a longitudinal channel
in fluid communication with the coupler inlet and extending through
the second engagement portion to a coupler outlet opening.
22. The coupler of claim 21, further comprising a pressure port
opening in fluid communication with at least one of the coupler
inlet and the longitudinal channel and extending through the first
engagement portion.
23. The coupler of claim 21, wherein the coupler inlet is defined
between first and second grooves configured to respectively receive
a gasket.
24. The coupler of claim 21, further comprising a recessed portion
at the peripheral surface of the first engagement portion, the
coupler inlet being defined through the recessed portion.
25. The coupler of claim 21, further comprising a nipple configured
to engage a flow director, the longitudinal channel extending
through the nipple.
Description
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to aerosol delivery devices
such as smoking articles, and more particularly, to aerosol
delivery devices that include multiple outer bodies. The aerosol
delivery device incorporates an aerosol formation device or an
atomizer. A typical atomizer is configured to heat an aerosol
precursor including components that may be made or derived from
tobacco or otherwise incorporate tobacco using an electrically
powered resistance heater. As a result, the aerosol delivery device
provides an inhalable substance for human consumption.
BACKGROUND
[0002] Many smoking devices have been proposed through the years as
improvements upon, or alternatives to, smoking products that
require combusting tobacco for use. Many of those devices
purportedly have been designed to provide the sensations associated
with cigarette, cigar, or pipe smoking, but without delivering
considerable quantities of incomplete combustion and pyrolysis
products that result from the burning of tobacco. To this end,
there have been proposed numerous smoking products, flavor
generators, and medicinal inhalers that 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
alternative smoking articles, aerosol delivery devices and heat
generating sources set forth in the background art described in
U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat. Pub. No.
2013/0255702 to Griffith Jr. et al., U.S. Pat. Pub. No.
2014/0000638 to Sebastian et al., U.S. patent application Ser. No.
13/602,871 to Collett et al., filed Sep. 4, 2012, U.S. patent
application Ser. No. 13/647,000 to Sears et al., filed Oct. 8,
2012, U.S. patent application Ser. No. 13/826,929 to Ampolini et
al., filed Mar. 14, 2013, and U.S. patent application Ser. No.
14/011,992 to Davis et al., filed Aug. 28, 2013, which are
incorporated herein by reference in their entirety.
[0003] Certain existing embodiments of aerosol delivery devices
include a single, unitary, elongated outer housing that is
substantially tubular in shape. In these embodiments, all of the
components of the aerosol delivery device are at least partially
contained within the single outer housing. However, it would be
desirable to provide an alternate form or configuration of an
aerosol delivery device that enhances user experience or allows for
alternative manufacturing techniques. Thus, advances with respect
to configurations of aerosol delivery devices and methods of
assembly thereof may be desirable.
BRIEF SUMMARY OF THE DISCLOSURE
[0004] The present disclosure relates to aerosol delivery devices
configured to produce aerosol. Certain types of these devices can
be characterized as electronic cigarettes. In one aspect an aerosol
delivery device is provided. The aerosol delivery device may
include a first outer body defining an inlet aperture, a second
outer body, a power source positioned in the first outer body, an
atomizer positioned in the second outer body, and a coupler
positioned between, and engaged with, the first outer body and the
second outer body. The coupler may define a coupler inlet and a
longitudinal channel. The coupler may be configured to receive air
from the inlet aperture defined in the first outer body through the
coupler inlet and to direct the air through the longitudinal
channel to the second outer body.
[0005] In some embodiments the aerosol delivery device may further
include at least one securing mechanism configured to substantially
irreversibly secure the first outer body to the second outer body.
The at least one securing mechanism may be a wrapper extending at
least partially around the first outer body, the second outer body,
and the coupler. The aerosol delivery device may additionally
include a reservoir substrate and a flow director positioned in the
second outer body, the flow director may extend at least partially
through the reservoir substrate. The flow director may define a
transverse aperture extending therethrough, and the atomizer may
extend through the transverse aperture.
[0006] In some embodiments a plurality of electrical connectors may
extend from the atomizer through the coupler to the power source.
The atomizer may include a heating element and a liquid transport
element defining a center portion and first and second opposing
arms extending therefrom, the heating element may be coupled to the
center portion of the liquid transport element. The coupler may
define a nipple and the flow director may engage the nipple of the
coupler. Accordingly, the positioning of the components is such
that an airflow passageway is created.
[0007] In some embodiments the aerosol delivery device may
additional include a mouthpiece defining a nipple, and the flow
director may engage the nipple of the mouthpiece. The coupler may
define a rib, and the rib may separate the first outer body from
the second outer body. One of the first outer body and the second
outer body may define an inlet aperture aligned with a recessed
portion of the coupler.
[0008] In an additional aspect, a method for assembling an aerosol
delivery device is provided. The method may include positioning a
power source in a first outer body defining an inlet aperture,
positioning an atomizer in a second outer body, and engaging a
coupler defining a coupler inlet and a longitudinal channel with
the first outer body and the second outer body such that the
coupler is positioned to receive air from the inlet aperture
defined in the first outer body through the coupler inlet and to
direct the air through the longitudinal channel to the second outer
body.
[0009] In some embodiments, the method may further include
substantially irreversibly securing the first outer body to the
second outer body with a securing mechanism. Substantially
irreversibly securing the first outer body to the second outer body
with the securing mechanism may include wrapping a wrapper at least
partially around the first outer body, the second outer body, and
the coupler. The method may additionally include positioning a
reservoir substrate and a flow director in the second outer body
such that the flow director extends at least partially through the
reservoir substrate. Positioning the atomizer in the second outer
body may include inserting the atomizer through a transverse
aperture extending through the flow director.
[0010] In some embodiments the method may additionally include
inserting a plurality of electrical connectors through the coupler
and connecting the electrical connectors to the power source and
the atomizer. Additionally, the method may include coupling a
heating element to a center portion of a liquid transport element
to form the atomizer and folding first and second opposing arms of
the liquid transport element extending from the center section away
from the coupler. Further, the method may include coupling the flow
director to a nipple of the coupler. The method may also include
coupling the flow director to a nipple of a mouthpiece. Engaging
the coupler with the first outer body and the second outer body may
include engaging a rib of the coupler with the first outer body and
the second outer body. Engaging the coupler with the first outer
body may include aligning an inlet aperture defined through the
first outer body with a recessed portion of the coupler.
[0011] In an additional embodiment a coupler for an aerosol
delivery device is provided. The coupler may include a first
engagement portion configured to engage a first outer body, a
second engagement portion configured to engage a second outer body,
a coupler inlet defined through a peripheral surface of the first
engagement portion, and a longitudinal channel in fluid
communication with the coupler inlet and extending through the
second engagement portion to a coupler outlet opening.
[0012] In some embodiments the coupler may additionally include a
pressure port opening in fluid communication with at least one of
the coupler inlet and the longitudinal channel and extending
through the first engagement portion. The coupler inlet may be
defined between first and second grooves configured to respectively
receive a gasket). Further, the coupler may include a recessed
portion at the peripheral surface of the first engagement portion,
and the coupler inlet may be defined through the recessed portion.
Additionally, the coupler may include a nipple configured to engage
a flow director, and the longitudinal channel may extend through
the nipple.
[0013] These and other features, aspects, and advantages of the
disclosure will be apparent from a reading of the following
detailed description together with the accompanying drawings, which
are briefly described below. The invention includes any combination
of two, three, four, or more of the above-noted embodiments as well
as combinations of any two, three, four, or more features or
elements set forth in this disclosure, regardless of whether such
features or elements are expressly combined in a specific
embodiment description herein. This disclosure is intended to be
read holistically such that any separable features or elements of
the disclosed invention, in any of its various aspects and
embodiments, should be viewed as intended to be combinable unless
the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE FIGURES
[0014] Having thus described the disclosure in the foregoing
general terms, reference will now be made to the accompanying
drawings, which are not necessarily drawn to scale, and
wherein:
[0015] FIG. 1 illustrates a side view of an aerosol delivery device
in an assembled configuration, the aerosol delivery device having
the general configuration of what can be characterized as an
electronic cigarette, and comprising a first outer body, a second
outer body, and a coupler positioned therebetween according to an
example embodiment of the present disclosure;
[0016] FIG. 2 illustrates a partially exploded side view of the
aerosol delivery device of FIG. 1 according to an example
embodiment of the present disclosure;
[0017] FIG. 3 illustrates a side view of the aerosol delivery
device of FIG. 1 in an assembled configuration, wherein the aerosol
delivery device further comprises a wrapper according to an example
embodiment of the present disclosure;
[0018] FIG. 4 illustrates an exploded perspective view of the
aerosol delivery device of FIG. 1 according to an example
embodiment of the present disclosure;
[0019] FIG. 5 illustrates a modified sectional view through the
aerosol delivery device of FIG. 1 at the first outer body and the
coupler according to an example embodiment of the present
disclosure;
[0020] FIG. 6 illustrates a sectional view through the coupler of
FIG. 1 along line A-A from FIG. 5 according to an example
embodiment of the present disclosure;
[0021] FIG. 7 illustrates a bottom view of an atomizer, a flow
director, a mouthpiece, and the coupler of the aerosol delivery
device of FIG. 1 according to an example embodiment of the present
disclosure;
[0022] FIG. 8 illustrates a side view of the flow director of FIG.
7 according to an example embodiment of the present disclosure;
[0023] FIG. 9 illustrates an end view of the flow director and the
atomizer of FIG. 7 according to an example embodiment of the
present disclosure;
[0024] FIG. 10 illustrates an end view of the coupler of the
aerosol delivery device of FIG. 1 according to an example
embodiment of the present disclosure;
[0025] FIG. 11 schematically illustrates a method for assembling an
aerosol delivery device according to an example embodiment of the
present disclosure; and
[0026] FIG. 12 schematically illustrates a controller according to
an example embodiment of the present disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] The present disclosure will now be described more fully
hereinafter with reference to exemplary embodiments thereof. These
exemplary embodiments are described so that this disclosure will be
thorough and complete, and will fully convey the scope of the
disclosure to those skilled in the art. Indeed, the disclosure may
be embodied in many different forms and should not be construed as
limited to the embodiments set forth herein; rather, these
embodiments are provided so that this disclosure will satisfy
applicable legal requirements. As used in the specification, and in
the appended claims, the singular forms "a", "an", "the", include
plural variations unless the context clearly dictates
otherwise.
[0028] As described hereinafter, embodiments of the present
disclosure relate to aerosol delivery devices. Aerosol delivery
devices according to the present disclosure may use electrical
energy to heat a material (preferably without combusting the
material to any significant degree) to form an inhalable substance;
such articles most preferably being sufficiently compact to be
considered "hand-held" devices. An aerosol delivery device may
provide some or all of the sensations (e.g., inhalation and
exhalation rituals, types of tastes or flavors, organoleptic
effects, physical feel, use rituals, visual cues such as those
provided by visible aerosol, and the like) of smoking a cigarette,
cigar, or pipe, without any substantial degree of combustion of any
component of that article or device. The aerosol delivery device
may not produce smoke in the sense of the aerosol resulting from
by-products of combustion or pyrolysis of tobacco, but rather, that
the article or device most preferably yields vapors (including
vapors within aerosols that can be considered to be visible
aerosols that might be considered to be described as smoke-like)
resulting from volatilization or vaporization of certain components
of the article or device. In highly preferred embodiments, aerosol
delivery devices may incorporate tobacco and/or components derived
from tobacco. As such, the aerosol delivery device can be
characterized as an electronic cigarette.
[0029] Aerosol delivery devices of the present disclosure also can
be characterized as being vapor-producing articles or medicament
delivery articles. Thus, such articles or devices can be adapted so
as to provide one or more substances (e.g., flavors and/or
pharmaceutical active ingredients) in an inhalable form or state.
For example, inhalable substances can be substantially in the form
of a vapor (i.e., a substance that is in the gas phase at a
temperature lower than its critical point). Alternatively,
inhalable substances can be in the form of an aerosol (i.e., a
suspension of fine solid particles or liquid droplets in a gas).
For purposes of simplicity, the term "aerosol" as used herein is
meant to include vapors, gases and aerosols of a form or type
suitable for human inhalation, whether or not visible, and whether
or not of a form that might be considered to be smoke-like.
[0030] In use, aerosol delivery devices of the present disclosure
may 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 employed by lighting and inhaling
tobacco). For example, the user of an aerosol delivery device of
the present disclosure can hold that article much like a
traditional type of smoking article, draw on one end of that
article for inhalation of aerosol produced by that article, take
puffs at selected intervals of time, etc.
[0031] The aerosol delivery device most preferably comprises two or
more outer bodies or shells. Existing embodiments of aerosol
delivery devices including multiple outer bodies or shells are
typically configured such that the two or more shells are
separable. For example, an aerosol delivery device can possess at
one end a control body comprising an outer body or shell containing
one or more reusable components (e.g., a rechargeable battery and
various electronics for controlling the operation of that article),
and at the other end and removably attached thereto an outer body
or shell containing a disposable portion (e.g., a disposable
flavor-containing cartridge).
[0032] However, as described hereinafter, embodiments of the
present disclosure relate to aerosol delivery devices comprising
multiple shells or outer bodies that may not configured to be
separable. In this regard, the aerosol delivery devices of the
present disclosure may be disposable in some embodiments. However,
in other embodiments the aerosol delivery devices of the present
disclosure may be reusable. For example, a power source (e.g., a
battery) provided therein may be replaceable or the aerosol
delivery device may include a rechargeable battery that may be
recharged with any type of recharging technology, including
connection to a typical alternating current electrical outlet,
connection to a car charger (e.g., cigarette lighter receptacle),
and connection to a computer, such as through a universal serial
bus (USB) connection or cable. Further, a refilling port or other
mechanism may allow for refilling an aerosol precursor composition
in some embodiments.
[0033] Aerosol delivery devices of the present disclosure most
preferably comprise some combination of a power source (i.e., an
electrical power source), at least one control component (e.g.,
means for actuating, controlling, regulating and/or ceasing power
for heat generation, such as by controlling electrical current flow
from the power source to other components of the aerosol delivery
device), a heater or heat generation component (e.g., an electrical
resistance heating element or component commonly referred to as an
"atomizer"), and an aerosol precursor composition (e.g., commonly a
liquid capable of yielding an aerosol upon application of
sufficient heat, such as ingredients commonly referred to as "smoke
juice," "e-liquid" and "e-juice"), and a mouthend region or tip for
allowing draw upon the aerosol delivery device for aerosol
inhalation (e.g., a defined air flow path through the article such
that aerosol generated can be withdrawn therefrom upon draw).
Exemplary formulations for aerosol precursor materials that may be
used according to the present disclosure are described in U.S. Pat.
Pub. No. 2013/0008457 to Zheng et al. and U.S. Pat. Pub. No.
2013/0213417 to Chong et al., the disclosures of which are
incorporated herein by reference in their entirety.
[0034] Alignment of the components within the aerosol delivery
device of the present disclosure can vary. In specific embodiments,
the aerosol precursor composition can be located near an end of the
aerosol delivery device which may be configured to be positioned
proximal to the mouth of a user so as to maximize aerosol delivery
to the user. Other configurations, however, are not excluded.
Generally, the heating element can be positioned sufficiently near
the aerosol precursor composition so that heat from the heating
element can volatilize the aerosol precursor (as well as one or
more flavorants, medicaments, or the like that may 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 meant to be interchangeable such
that reference to release, releasing, releases, or released
includes form or generate, forming or generating, forms or
generates, and formed or generated. Specifically, an inhalable
substance is released in the form of a vapor or aerosol or mixture
thereof.
[0035] As noted above, the aerosol delivery device may incorporate
a battery or other electrical power source to provide current flow
sufficient to provide various functionalities to the aerosol
delivery device, such as powering of a heater, powering of control
systems, powering of indicators, and the like. The power source can
take on various embodiments. Preferably, the power source is able
to deliver sufficient power to rapidly heat the heating element to
provide for aerosol formation and power the aerosol delivery device
through use for a desired duration of time. The power source
preferably is sized to fit conveniently within the aerosol delivery
device so that the aerosol delivery device can be easily handled.
Additionally, a preferred power source is of a sufficiently light
weight to not detract from a desirable smoking experience.
[0036] More specific formats, configurations and arrangements of
components within the aerosol delivery device of the present
disclosure will be evident in light of the further disclosure
provided hereinafter. Additionally, the selection of various
aerosol delivery device components can be appreciated upon
consideration of the commercially available electronic aerosol
delivery devices, such as those representative products listed in
the background art section of the present disclosure. Further, the
arrangement of the components within the aerosol delivery device
can also be appreciated upon consideration of the commercially
available electronic aerosol delivery devices, such as those
representative products listed in the background art section of the
present disclosure.
[0037] One example embodiment of an aerosol delivery device 100
according to the present disclosure is illustrated in FIG. 1. In
particular, FIG. 1 illustrates the aerosol delivery device 100 in
an assembled configuration. As illustrated, the aerosol delivery
device 100 may include a first outer body 102, a second outer body
104, and a coupler 106 positioned between and engaged with the
first and second outer bodies. In some embodiments the first outer
body 102, the second outer body 104, and/or the coupler 106 may be
formed from plastic (e.g., polycarbonate or acrylonitrile butadiene
styrene (ABS)), metal (e.g., stainless steel or aluminum),
paperboard, cardboard, ceramic, fiberglass, glass (e.g., a
resilient glass), or a graphite composite. In some embodiments
various attributes of the outer bodies 102, 104 may be similar to
those employed in the control body and cartridge of the VUSE.RTM.
product available from R. J. Reynolds Tobacco Company. Note that
while the aerosol delivery device discussed herein is generally
described as having two outer bodies and a coupler, additional
outer bodies may be employed when respectively connected by an
additional coupler.
[0038] The coupler 106 may couple the first outer body 102 to the
second outer body 104 in an assembled configuration, as illustrated
in FIG. 1. In this regard, as illustrated in FIG. 2, the coupler
106 may include a first engagement portion 108, a second engagement
portion 110, and a rib 112 positioned therebetween. The first
engagement portion 108 of the coupler 106 may be configured to
engage an inner end 102A of the first outer body 102 (e.g., by
insertion therein). In this regard, one or more gaskets 114 (e.g.,
one or more suitably sized seals, washers, O-rings, or other gasket
means for providing sealing and/or resilience, which may comprise
rubber, silicone or other sealant material that is non-reactive
with the aerosol forming components) may be positioned in
respective grooves 114A (see, FIG. 6) in the first engagement
portion 108 of the coupler 106 and configured to engage an inner
surface of the first outer body 102. Similarly, the second
engagement portion 110 of the coupler 106 may be configured to
engage an inner end 104A of the second outer body 104 (e.g., by
insertion therein). In this regard, one or more gaskets 116 may be
positioned in respective grooves 116A (see, FIG. 6) in the second
engagement portion 110 of the coupler and configured to engage an
inner surface of the second outer body 104.
[0039] Accordingly, in some embodiments a press-fit arrangement may
be employed to connect the outer bodies 102, 104 to the coupler
106. However, various other connection mechanisms may be employed
to couple the outer bodies to the coupler. For example, threaded
engagement, an interference fit, magnetic engagement or other
connection mechanisms and arrangements may be employed in other
embodiments.
[0040] The rib 112 of the coupler 106 may be configured to abut the
inner end 102A of the first outer body 102 and the inner end 104A
of the second outer body 104. Accordingly, as illustrated in FIG.
1, the rib 112 may separate the first outer body 102 from the
second outer body 104. As such, the first outer body 102 and the
second outer body 104 may be prevented from making a physical
connection (i.e., the first outer body does not directly contact
the second outer body). In some embodiments, as illustrated in FIG.
1, the rib 112 may be configured to match an outer profile of the
first outer body 102 and the second outer body 104. In this regard,
in cylindrical embodiments of the aerosol delivery device 100, the
diameter of the rib 112 may be substantially equal to the diameters
of the first outer body 102 and the second outer body 104.
[0041] The outer bodies 102, 104 may be configured to house and
protect a plurality of components received therein, as discussed
hereinafter. The outer bodies 102, 104 may thus define any of a
plurality of shapes and configurations. However, as described
above, in some embodiments it may be preferable to provide the
aerosol delivery device with a size, shape, and/or configuration
resembling a smoking article such as a cigarette or cigar. Thus, in
some embodiments the outer bodies 102, 104 may be generally
cylindrical and the aerosol delivery device 100 may define an
elongated cylindrical configuration as a result of coupler 106
engaging the inner ends 102A, 104A of the outer bodies 102, 104.
The aerosol delivery device 100 may thus be described as
substantially rod-like, substantially tubular shaped, or
substantially cylindrically shaped in some embodiments when in the
assembled configuration. Accordingly, the typical size, shape and
general appearance of the aerosol delivery device 100 may be
comparable to commercially available electronic cigarettes.
[0042] In some embodiments the outer bodies 102, 104 may define a
majority of an outer surface extending along a longitudinal length
of the aerosol delivery device 100, which may receive a wrapper
thereon, as discussed below. In this regard, in one embodiment the
outer bodies may define at least 75%, preferably at least 90%, and
most preferably 95% of the outer surface extending along a
longitudinal length of the aerosol delivery device, depending on
the length of the dimensions of the end cap 118 and the mouthpiece
120. Further, in some embodiments the first outer body 102 and the
second outer body 104 may define substantially the same
longitudinal length. However, in other embodiments the outer bodies
102, 104 may define differing longitudinal lengths. For example, a
ratio of a longitudinal length of the first outer body 102 to a
longitudinal length of the second outer body 104 may be from about
2:1 to about 1:2, from about 3:5 to about 5:3, or from about 4:5 to
about 5:4. In this regard, in some embodiments the dimensions of
the first outer body 102 may be similar to that of a filter element
and the dimensions of the second outer body 104 may be similar to
that of a tobacco rod of a traditional cigarette in some
embodiments. This configuration may provide adequate room in the
second outer body 104 for a power source, which may be included
therein as discussed hereinafter.
[0043] As illustrated in FIGS. 1 and 2, an end cap 118 may be
coupled to the first outer body 102 at an outer end 102B thereof.
Further, a mouthpiece 120 may be coupled to an outer end 104B of
the second outer body 104. In some embodiments the outer end 102B
of the first outer body 102 and/or the outer end 104B of the second
outer body 104B may define a chamfer at the inner surface thereof,
which may facilitate respective coupling of the end cap 118 and the
mouthpiece 120 thereto.
[0044] Briefly, the end cap 118 may be configured to cover and
substantially prevent access to the outer end 104B of the second
outer body 104 and, in some embodiments, provide for output of
illumination therethrough. The mouthpiece 120 may be configured to
receive a user draw thereon during use to direct aerosol to the
user. In some embodiments a sealant or adhesive such as a room
temperature vulcanizing (RTV) sealant, a silicone resin, or a
polysiloxane, may seal the end cap 118 to the first outer body 102
and/or seal the mouthpiece 120 to the second outer body 104. The
mouthpiece 120 may be textured and/or shaped as desired. Example
embodiments of mouthpieces that may be employed in the aerosol
delivery device of the present disclosure are provided in U.S. Pat.
Pub. No. 2013/0276802 to Scatterday.
[0045] As illustrated in FIG. 3, in some embodiments a wrapper 122
(e.g., a label or an overwrap) may at least partially surround the
outer bodies 102, 104. For example, the wrapper 122 may include an
overlapping or abutting seam. In one embodiment the wrapper 122 may
comprise a single layer of a material (e.g., plastic, paper, or
foil). Alternatively, the wrapper 122 may comprise a multi-layer
lamination (e.g., a lamination of plastic, paper, and/or foil). The
wrapper 122 may include indicia on an outer surface thereof. For
example, the indicia may include information such as a product
identifier, which may be formed by ink applied to one or more of
the layers of the wrapper 122. The indicia on the wrapper 122
likewise may include texturing, coloring, and/or other physical
attributes that may provide a desired appearance to the device,
such as resembling a conventional cigarette or a conventional
electronic cigarette. Example embodiments of wrappers which may be
employed in the aerosol delivery device of the present disclosure
are provided in U.S. Pat. Pub. No. 2013/0284190 to Scatterday et
al., which is incorporated herein by reference in its entirety.
[0046] The wrapper 122 may include an adhesive at an inner surface
thereof or adhesive may otherwise be positioned between the wrapper
and the outer bodies 102, 104. Thus, the wrapper 122 may be secured
to an outer surface of the outer bodies 102, 104. In this regard,
embodiments of the present disclosure may include at least one
securing mechanism configured to substantially irreversibly secure
the first outer body 102 to the second outer body 104. In some
embodiments the securing mechanism may comprise the above-described
wrapper 122. Thus, when adhered to the first outer body 102 and the
second outer body 104, the wrapper 122 may act as a structural
member that assists in retaining the coupling between the outer
bodies via the coupler 106. For example, in the illustrated
embodiment, the wrapper 122 extends from the outer end 102B of the
first outer body 102 to the outer end 104B of the second outer body
104, such that coupling between the wrapper and the first and
second outer bodies retains the aerosol delivery device 100 in the
assembled configuration. Additionally, in embodiments in which the
coupler 106 includes the rib 112, contact between the wrapper 122
and the rib may further assist in maintaining the aerosol delivery
device in the assembled configuration. Further, in some embodiments
the wrapper 122 may extend at least partially over the end cap 118
to secure the end cap to the first outer body 102 and/or extend at
least partially over the mouthpiece 120 to secure the mouthpiece to
the second outer body 104.
[0047] Although the securing mechanism is described above as
comprising the wrapper 122, various other embodiments of securing
mechanisms configured to substantially irreversibly secure the
first outer body 102 to the second outer body 104 may be employed.
Thus, for example, the securing mechanism may comprise sealant
applied between the coupler 106 and one or both of the outer bodies
102, 104. By way of further example, the securing mechanism may
comprise single-use connectors at the coupler 106 configured to
engage the outer bodies 102, 104. In another embodiment the
securing mechanism may comprise other connection mechanisms (e.g.,
welds, crimps, or solder), that cause portions of the outer bodies
102, 104 to engage the coupler 106. Note that substantially
irreversibly secured, as used herein, refers to a configuration in
which the outer bodies 102, 104 may not be separated from one
another without damaging the securing mechanism and/or without
preventing recoupling of the referenced components. Thus, for
example, the wrapper 122 may be torn or otherwise damaged if the
outer bodies 102, 104 of the aerosol delivery device 100 were to be
separated.
[0048] FIG. 4 illustrates an exploded view of the aerosol delivery
device 100. As illustrated, the aerosol delivery device 100 may
include a plurality of additional components as described in
greater detail hereinafter. In this regard, the aerosol delivery
device 100 may additionally include a mouthpiece shipping plug 124
which may be configured to engage and protect the mouthpiece 120
prior to use of the aerosol delivery device. For example, the
mouthpiece shipping plug 120 may prevent the entry of contaminants
into the mouthpiece 120. Thus, the mouthpiece shipping plug 120 may
be removed prior to use of the aerosol delivery device 100.
[0049] Further, a plurality of components may be positioned in one
or both of the first outer body 102 and the second outer body 104.
In this regard, a reservoir substrate 126, an atomizer 128, and a
flow director 130 (e.g., a flow tube or other structure defining an
airflow passage) may be positioned in the second outer body 104.
The atomizer 128 may include a liquid transport element 132 with a
heating element 134 coupled thereto.
[0050] Further, a power source 136 and an electrical circuit 138
may be positioned in the first outer body 102. Examples of power
sources are described in U.S. Pat. App. Pub. No. 2010/0028766 by
Peckerar et al., the disclosure of which is incorporated herein by
reference in its entirety. The electrical circuit 138 may include a
control module 140, a spacer 142, and/or a safety switch 144 in
some embodiments. One or more electrical connectors 146 (e.g.,
electrical wires) may be configured to electrically connect the
atomizer 128 to the power source 136. In this regard, the
electrical connectors 146 may extend between the first outer body
102 and the second outer body 104 through the coupler 106 in the
assembled configuration. In one embodiment one or more electrical
couplers 148 (e.g., brass couplers, solder, crimped couplers, or
wound wires) may be employed to couple the electrical connectors
146 to the heating element 134. Thus, in some embodiments the
electrical couplers 148 may be received in the second outer body
104.
[0051] In terms of operation of the aerosol delivery device 100, a
user may draw on the mouthpiece 120. Accordingly, air may enter the
aerosol delivery device 100 through an inlet aperture. For example,
in the illustrated embodiment, an inlet aperture 150 (see, e.g.,
FIG. 1) is defined in the first outer body 102. However, in other
embodiments the inlet aperture may be defined in the second outer
body. Note that in embodiments of the aerosol delivery device 100
including the wrapper 122, a cutout 152 (see, FIG. 3) may align
with the inlet aperture 150 such that the inlet aperture is not
blocked. Alternatively, the wrapper may be substantially
air-permeable, particularly in the area adjacent the inlet
aperture, so as to allow sufficient air passage therethrough and
into the aperture.
[0052] Air entering through the inlet aperture 150 in the first
outer body 102 may be directed through the coupler 106 to the
second outer body 104. In this regard, as illustrated in FIG. 5,
the inlet aperture 150 may align with a recessed portion 154
defined at a peripheral surface 155 of the first engagement portion
108 of the coupler 106. Note that alignment of the recessed portion
154 of the coupler 106 may only require longitudinal alignment of
the inlet aperture 150 with the recessed portion, along the
longitudinal length of the aerosol delivery device 100. In this
regard, in some embodiments the recessed portion 154 may extend
around the peripheral surface 155 of the coupler 106 (e.g., around
the entirety of the circumference thereof). Further, as
illustrated, in some embodiments the inlet aperture 150 and the
recessed portion 154 may be configured to align when the inner end
102A of the first outer body 102 abuts the rib 112. Accordingly,
alignment of the inlet aperture 150 with the recessed portion 154
may be substantially easily achieved during assembly. Air received
in the recessed portion 154 of the coupler 106 may be directed
through one or more coupler inlet(s) 156 defined in the coupler 106
at the recessed portion.
[0053] FIG. 6 illustrates a cross-sectional view through the
coupler 106 along line A-A in FIG. 5. As illustrated in FIG. 6, the
coupler inlet 156 may connect to a longitudinal channel 158
extending along at least a portion of the longitudinal length of
the coupler 106. Further, a pressure port 160 may additionally be
in communication with the coupler inlet 156 and/or the longitudinal
channel 158. The pressure port 160 may extend to a pressure port
opening 162 positioned inside the first outer body 102 when the
coupler 106 is connected thereto.
[0054] Accordingly, the control module 140 (see, FIG. 4) may detect
when a user draws on the mouthpiece 120. In this regard, the
control module 140 may comprise a sensor configured to detect a
puff. For example, a pressure sensor may be used to detect a
pressure drop accompanying a draw on the mouthpiece 120.
Representative current regulating components and other current
controlling components including various microcontrollers for
aerosol delivery devices are described in U.S. Pat. No. 4,735,217
to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and
4,947,875, all to Brooks et al., U.S. Pat. No. 5,372,148 to
McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al.,
U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.
8,205,622 to Pan, all of which are incorporated herein by reference
in their entireties. Reference also is made to the control schemes
described in U.S. application Ser. No. 13/837,542 to Ampolini et
al., filed Mar. 15, 2013, which is incorporated herein by reference
in its entirety. In some embodiments, a pressure sensor and a
microcontroller may be combined in control module 140.
[0055] Thus, as a result of the control module 140 being positioned
in the first outer body 102, a drop in pressure may be detected
when a user draws on the aerosol delivery device 100. In this
regard, the first outer body 102 may be substantially sealed as a
result of the end cap 118 being positioned at the outer end 102B
and the gaskets 114 being positioned at the inner end 102A of the
outer body (see, e.g., FIG. 4). Thereby, the pressure drop
associated with the puff on the aerosol delivery device 100 may be
detected, but airflow through the first outer body 102 may be
substantially avoided, since the first outer body is substantially
sealed other than at the pressure port 160.
[0056] Airflow in the above described manner is designed to avoid
airflow past the power source 136. Further, note that a size of the
pressure port opening 162 (e.g., a diameter thereof) may be smaller
than a diameter of a coupler outlet opening 164 (see, FIG. 6) in
communication with the second outer body 104. Accordingly, a
Venturi effect may be created during a draw on the aerosol delivery
device 100, which further assists in preventing airflow through the
first outer body 102 while still allowing detection of a pressure
drop therein.
[0057] Thus, as noted above, the control module 140 may sense a
puff on the aerosol delivery device 100. When the puff is sensed,
control module 140 may direct current from the power source 136
through the electrical connectors 146 to the heating element 134.
Thus, as described in greater detail below, the heating element 134
may vaporize an aerosol precursor composition directed from the
reservoir substrate 126 to the heating element via the liquid
transport element 132. Accordingly, the heating element 134 may
vaporize the aerosol precursor composition directed to an
aerosolization zone from the reservoir substrate 126 by the liquid
transport element 132 and air and the entrained vapor (e.g., the
components of the aerosol precursor composition in an inhalable
form) may be directed to a user drawing thereon.
[0058] The safety switch 144 may be configured to control or stop
the flow of current to the heating element 134 under certain
circumstances. For example, the safety switch may be configured to
stop the flow of current to the heating element 134 after a
predetermined length of time, regardless of whether a detected puff
continues, in order to prevent the heating element 134 from
overheating. Accordingly, issues with respect to the aerosol
delivery device 100 overheating may be avoided.
[0059] In some embodiments the control module 140 may perform
additional functions. For example, the control module 140 may also
include an optional indicator (e.g., a light emitting diode (LED)).
The indicator may illuminate, for example, during a user drawing on
the aerosol delivery device, as detected by the control module 140.
The end cap 118 may be adapted to make visible the illumination
provided thereunder by the indicator. Accordingly, the indicator
may illuminate during use of the aerosol delivery device 100 to
simulate the lit end of a smoking article. However, in other
embodiments the indicator can be provided in varying numbers and
can take on different shapes and can even be an opening in the
outer body (such as for release of sound when such indicators are
present).
[0060] As noted above, air received through the inlet aperture 150
in the first outer body 102 may be directed through the recessed
portion 154, the coupler inlet 156, and the longitudinal channel
158 extending along at least a portion of the longitudinal length
of the coupler 106. Thereby, the air may be directed to the flow
director 130. The flow director 130 may define a tubular
configuration or other structure in which an air passageway is
defined therethrough. In this regard, as illustrated in FIGS. 5 and
6, the coupler 106 may define a nipple 166.
[0061] Further, as illustrated in FIG. 7, the nipple 166 may couple
to the flow director 130. For example, the flow director 130 may
extend over the nipple 166 to provide for engagement therebetween.
In this regard, the flow director 130 may comprise a flexible,
resilient material such as fiberglass which may deform (e.g.,
stretch) slightly to allow for receipt of the nipple 166 therein
and fit snuggly over the nipple and form a seal therewith.
Accordingly, air received from the coupler 106 may be directed
through a longitudinal aperture 168 defined through the flow
director 130.
[0062] Thus, drawn air through the device is directed past the
heating element 134. More particularly, as illustrated in FIG. 8,
the flow director 130 may define a transverse aperture 170
extending therethrough. As illustrated, the transverse aperture 170
may extend substantially perpendicularly to the longitudinal
aperture 168. As illustrated in FIG. 7, the atomizer 128 may extend
through the transverse aperture 170. Thereby, the heating element
134 may be positioned in the longitudinal aperture 168 extending
along the length of the flow director 130. More particularly, the
heating element 134 may extend transversely relative to the
longitudinal aperture 168 such that at least a portion of the
heating element is positioned in the longitudinal aperture.
[0063] In some embodiments, in order to facilitate insertion of the
atomizer 128 in the transverse aperture 170, a slit 172 may be
defined in the flow director 130. The slit 172 may extend from an
outer surface of the flow director 130 to the transverse aperture
170. For example, as illustrated in FIG. 7, the slit 172 may define
a V-shape. Thereby, during assembly, the flow director 130 may be
folded at the slit 172 to facilitate insertion of the atomizer 128
into the transverse aperture 170, rather than inserted lengthwise
through the transverse aperture 170. For example, the heating
element 134 may catch on the flow director 130 during lengthwise
insertion of the atomizer 128 when longitudinal insertion is
employed. Thus, use of the slit 172 may expedite assembly of the
aerosol delivery device 100 by allowing for coupling of the
atomizer 128 to the flow director 130 without requiring lengthwise
insertion of the atomizer 128 through the transverse aperture
170.
[0064] Following insertion of the atomizer 128 into the transverse
aperture 170, the flow director 130 may be folded back into the
original longitudinal (e.g., tubular) configuration. Accordingly,
as illustrated in FIG. 9, the heating element 134 may be at least
partially positioned within the longitudinal aperture 168 extending
through the flow director 130. Thus, drawn air received from the
coupler 106 during a user puff may be directed by the flow director
130 past the heating element 134 before being directed by the
longitudinal aperture 168 to the mouthpiece 120, as illustrated in
FIG. 7. In this regard, the mouthpiece 120 may define a nipple 174.
Thus, the flow director 130 may extend over the nipple 174 to
provide for engagement therebetween. As noted above, the flow
director 130 may comprise a flexible, resilient material such as
fiberglass which may deform (e.g., stretch) slightly to allow for
receipt of the nipple 174 therein. Accordingly, air traveling
through the longitudinal aperture 168 defined through the flow
director 130 may be directed through the mouthpiece 120 and to a
user's mouth.
[0065] As illustrated in FIG. 9, the flow director 130 may extend
at least partially through the reservoir substrate 126 so as to
define an air passageway therethrough. Further, as illustrated in
FIGS. 8 and 9, the liquid transport element 132 may define a center
portion 176 and first and second opposing arms 178A, 178B extending
therefrom. The heating element 134 may be coupled to the center
portion 176 of the liquid transport element 132.
[0066] The opposing arms 178A, 178B of the liquid transport element
134 may be configured to direct an aerosol precursor composition to
the heating element 134. In this regard, the reservoir substrate
126 may be configured to hold (e.g., support, carry, and/or store)
an aerosol precursor composition therein. The aerosol precursor
composition, also referred to as a vapor precursor composition, may
comprise a variety of components including, by way of example, a
polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture
thereof), nicotine, tobacco, tobacco extract, and/or flavorants.
Various components that may be included in the aerosol precursor
composition are described in U.S. Pat. No. 7,726,320 to Robinson et
al., which is incorporated herein by reference in its entirety.
Additional representative types of aerosol precursor compositions
are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.;
U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs
et al.; and Chemical and Biological Studies on New Cigarette
Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds
Tobacco Company Monograph (1988); the disclosures of which are
incorporated herein by reference in their entireties. Other aerosol
precursors which may be employed in the aerosol delivery device 100
include the aerosol precursors included in the VUSE.RTM. product by
R. J. Reynolds Vapor Company, the BLU.TM. product by Lorillard
Technologies, the Mistic Menthol product by Mistic Ecigs, and the
Vype product by CN Creative Ltd. Also desirable are the so-called
"Smoke Juices" for electronic cigarettes that have been available
from Johnson Creek Enterprises LLC.
[0067] The reservoir substrate 126 may comprise one layer or a
plurality of layers of woven or nonwoven fibers (e.g., C-glass,
E-glass) formed into the shape of a tube encircling the interior of
the second outer body 104. Thus, liquid components, for example,
can be sorptively retained by the reservoir substrate 126. The
reservoir substrate 126 is in fluid connection with the liquid
transport element 132. In this regard, the opposing arms 178A, 178B
may be positioned between the flow director 130 and the reservoir
substrate 126. Accordingly, contact between the liquid transport
element 132 and the reservoir substrate 126 may allow for fluid
transfer therebetween. Thus, the liquid transport element 132 may
be configured to transport liquid from the reservoir substrate 126
to the heating element 134 (e.g., via wicking or capillary action).
In FIG. 9, a space is present between the reservoir substrate 126
and the flow director 130 for accommodating the opposing arms 178A,
178B. In other embodiments, the reservoir substrate 126 may be in
substantial contact with the flow director 130 around at least a
portion of the circumference of the flow director. As such, at
least a portion of the opposing arms 178A, 178B may be
substantially flattened between the reservoir substrate and the
flow director. Exemplary reservoirs formed of cellulose acetate
fibers and liquid transport elements that may be used herein as
described in U.S. patent application Ser. No. 13/802,950 to Chapman
et al., filed Mar. 14, 2013, which is incorporated herein by
reference in its entirety.
[0068] As illustrated in FIG. 9, the liquid transport element 132
may be in direct contact with the heating element 134. As further
illustrated in FIG. 9, the heating element 134 may comprise a wire
defining a plurality of coils (e.g., from about 4 coils to about 12
coils) wound about the liquid transport element 132. In some
embodiments the heating element 134 may be formed by winding the
wire about the liquid transport element 132 as described in U.S.
patent application Ser. No. 13/708,381 to Ward et al., filed Dec.
7, 2012, which is incorporated herein by reference in its entirety.
Further, in some embodiments the wire may define a variable coil
spacing, as described in U.S. patent application Ser. No.
13/827,994 to DePiano et al., filed Mar. 14, 2013, which is
incorporated herein by reference in its entirety. Various
embodiments of materials configured to produce heat when electrical
current is applied therethrough may be employed to form the heating
element 134. Example materials from which the wire coil may be
formed include Kanthal (FeCrAl), Nichrome, Molybdenum disilicide
(MoSi.sub.2), molybdenum silicide (MoSi), Molybdenum disilicide
doped with Aluminum (Mo(Si,Al).sub.2), graphite and graphite-based
materials; and ceramic (e.g., a positive or negative temperature
coefficient ceramic).
[0069] However, various other embodiments of methods may be
employed to form the heating element 134, and various other
embodiments of heating elements may be employed in the atomizer
128. For example, a stamped heating element may be employed in the
atomizer, as described in U.S. patent application Ser. No.
13/842,125 to DePiano et al., filed Mar. 15, 2013, which is
incorporated herein by reference in its entirety. Further to the
above, additional representative heating elements and materials for
use therein are described in U.S. Pat. No. 5,060,671 to Counts et
al.; U.S. Pat. No. 5,093,894 to Deevi et al.; U.S. Pat. No.
5,224,498 to Deevi et al.; U.S. Pat. No. 5,228,460 to Sprinkel Jr.,
et al.; U.S. Pat. No. 5,322,075 to Deevi et al.; U.S. Pat. No.
5,353,813 to Deevi et al.; U.S. Pat. No. 5,468,936 to Deevi et al.;
U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 to Das;
U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to
Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No.
5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to
Fleischhauer et al., and U.S. Pat. Pub. No. 2013/0192618 to Li et
al., the disclosures of which are incorporated herein by reference
in their entireties. Further, chemical heating may be employed in
other embodiments. Various additional examples of heaters and
materials employed to form heaters are described in U.S. patent
application Ser. No. 13/602,871 to Collett et al., filed Sep. 4,
2012, which is incorporated herein by reference, as noted above.
Additionally, in various embodiments, one or more microheaters or
like solid state heaters may be used.
[0070] Note that, as illustrated in FIG. 7, the heating element 134
may be positioned relatively closer to the coupler 106 than the
mouthpiece 120. This configuration may be preferable in that it
provides a separation between a user's mouth and the heating
element 134, which produces heat during use. Accordingly, as a
result of the heating element 134 being positioned proximate the
coupler 106, the opposing arms 178A, 178B may be folded away from
the coupler 106 in order for the liquid transport element 132 to
remain in contact with a significant portion of the reservoir
substrate 126. This configuration may also result in the one or
more electrical connectors 146 extending in an opposite direction
as compared to the opposing arms 178A, 178B of the liquid transport
element 132, toward the coupler 106, with the electrical couplers
148 connecting the heating element 134 to the electrical connectors
146.
[0071] In this regard, FIG. 10 illustrates a view of the coupler
106 at an end configured to engage the first outer body 102. As
illustrated, one or more connector apertures 180 may extend through
a longitudinal length of the coupler 106. Accordingly, the
electrical connectors 146 may extend from the first outer body 102
through the connector apertures 180 to the second outer body 104 in
order to connect the atomizer 128 to the power source 136.
[0072] Still further components can be utilized in the aerosol
delivery device 100 of the present disclosure. For example, U.S.
Pat. No. 5,154,192 to Sprinkel et al. and U.S. Pat. No. 8,539,959
to Scatterday disclose indicators and LEDs for smoking articles;
U.S. Pat. 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 draw and then
trigger heating; U.S. Pat. No. 5,372,148 to McCafferty et al.
discloses a puff sensor for controlling energy flow into a heating
load array in response to pressure drop through a mouthpiece; U.S.
Pat. No. 5,967,148 to Harris et al. discloses receptacles in a
smoking device that include an identifier that detects a
non-uniformity in infrared transmissivity of an inserted component
and a controller that executes a detection routine as the component
is inserted into the receptacle; U.S. Pat. No. 6,040,560 to
Fleischhauer et al. describes a defined executable power cycle with
multiple differential phases; U.S. Pat. No. 5,934,289 to Watkins et
al. discloses photonic-optronic components; U.S. Pat. No. 5,954,979
to Counts et al. discloses means for altering draw resistance
through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.
discloses specific battery configurations for use in smoking
devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses
various charging systems for use with smoking devices; U.S. Pat.
No. 8,402,976 to Fernando et al. discloses computer interfacing
means for smoking devices to facilitate charging and allow computer
control of the device; U.S. Pat. App. Pub. No. 2010/0163063 by
Fernando et al. discloses identification systems for smoking
devices; and WO 2010/003480 by Flick discloses a fluid flow sensing
system indicative of a puff in an aerosol generating system; all of
the foregoing disclosures being incorporated herein by reference in
their entireties. Further examples of components related to
electronic aerosol delivery articles and disclosing materials or
components that may be used in the present article include U.S.
Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to
Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat.
No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White;
U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter
et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410
to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.
7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat.
Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. App. Pub. Nos.
2006/0196518 and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.
2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos.
2009/0260641 and 2009/0260642 to Monsees et al.; U.S. Pat. App.
Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.; U.S.
Pat. App. Pub. No. 2010/0307518 to Wang; WO 2010/091593 to Hon; WO
2013/089551 to Foo; and U.S. patent application Ser. No. 13/841,233
to DePiano et al., filed Mar. 15, 2013, each of which is
incorporated herein by reference in its entirety. A variety of the
materials disclosed by the foregoing documents may be incorporated
into the present devices in various embodiments, and all of the
foregoing disclosures are incorporated herein by reference in their
entireties.
[0073] Various other details with respect to the components that
may be included in the aerosol delivery device, are provided, for
example, in U.S. patent application Ser. No. 13/840,264 to Novak et
al., filed Mar. 15, 2013, U.S. Pat. No. 8,365,742 to Hon; U.S. Pat.
Pub. Nos. 2013/0192623 to Tucker et al., 2013/0298905 to Leven et
al., and 2013/0180553 to Kim et al., each of which is incorporated
herein by reference in its entirety. Reference is also made, for
example, to the reservoir and heater system for controllable
delivery of multiple aerosolizable materials in an electronic
smoking article disclosed in U.S. Pat. App. Pub. No. 2014/0000638
to Sebastian et al., which is incorporated herein by reference in
its entirety.
[0074] Additionally, various components of an aerosol delivery
device according to the present disclosure can be chosen from
components described in the art and that have been commercially
available. In this regard, representative products that resemble
many of the attributes of traditional types of cigarettes, cigars
or pipes have been marketed as ACCORD.RTM. by Philip Morris
Incorporated; ALPHA.TM., JOYE 510.TM. and M4.TM. by InnoVapor LLC;
CIRRUS.TM. and FLING.TM. by White Cloud Cigarettes; BLU.TM. by
Lorillard Technologies, Inc.; COHITA.TM., COLIBRI.TM., ELITE
CLASSIC.TM., MAGNUM.TM., PHANTOM.TM. and SENSE.TM. by Epuffer.RTM.
International Inc.; DUOPRO.TM., STORM.TM. and VAPORKING.RTM. by
Electronic Cigarettes, Inc.; EGAR.TM. by Egar Australia; eGo-C.TM.
and eGo-T.TM. by Joyetech; ELUSION.TM. by Elusion UK Ltd;
EONSMOKE.RTM. by Eonsmoke LLC; FIN.TM. by FIN Branding Group, LLC;
SMOKE.RTM. by Green Smoke Inc. USA; GREENARETTE.TM. by Greenarette
LLC; HALLIGAN.TM., HENDU.TM., JET.TM., MAXXQ.TM., PINK.TM. and
PITBULL.TM. by Smoke Stik.RTM.; HEATBAR.TM. by Philip Morris
International, Inc.; HYDRO IMPERIAL.TM. and LXE.TM. from Crown7;
LOGIC.TM. and THE CUBAN.TM. by LOGIC Technology; LUCI.RTM. by
Luciano Smokes Inc.; METRO.RTM. by Nicotek, LLC; NJOY.RTM. and
ONEJOY.TM. by Sottera, Inc.; NO. 7.TM. by SS Choice LLC; PREMIUM
ELECTRONIC CIGARETTE.TM. by PremiumEstore LLC; RAPP E-MYSTICK.TM.
by Ruyan America, Inc.; RED DRAGON.TM. by Red Dragon Products, LLC;
RUYAN.RTM. by Ruyan Group (Holdings) Ltd.; SF.RTM. by Smoker
Friendly International, LLC; GREEN SMART SMOKER.RTM. by The Smart
Smoking Electronic Cigarette Company Ltd.; SMOKE ASSIST.RTM. by
Coastline Products LLC; SMOKING EVERYWHERE.RTM. by Smoking
Everywhere, Inc.; V2CIGS.TM. by VMR Products LLC; VAPOR NINE.TM. by
VaporNine LLC; VAPOR4LIFE.RTM. by Vapor 4 Life, Inc.; VEPPO.TM. by
E-CigaretteDirect, LLC; VUSE.RTM. by R. J. Reynolds Vapor Company;
Mistic Menthol product by Mistic Ecigs; and the Vype product by CN
Creative Ltd. Yet other electrically powered aerosol delivery
devices, and in particular those devices that have been
characterized as so-called electronic cigarettes, have been
marketed under the tradenames COOLER VISIONS.TM.; DIRECT E-CIG.TM.;
DRAGONFLY.TM.; EMIST.TM.; EVERSMOKE.TM.; GAMUCCI.RTM.; HYBRID
FLAME.TM.; KNIGHT STICKS.TM.; ROYAL BLUES.TM.; SMOKETIP.RTM.; SOUTH
BEACH SMOKE.TM..
[0075] Additional manufacturers, designers, and/or assignees of
components and related technologies that may be employed in the
aerosol delivery device of the present disclosure include Shenzhen
Jieshibo Technology of Shenzhen, China; Shenzhen First Union
Technology of Shenzhen City, China; Safe Cig of Los Angeles,
Calif.; Janty Asia Company of the Philippines; Joyetech Changzhou
Electronics of Shenzhen, China; SIS Resources; B2B International
Holdings of Dover, Del.; Evolv LLC of OH; Montrade of Bologna,
Italy; Shenzhen Bauway Technology of Shenzhen, China; Global Vapor
Trademarks Inc. of Pompano Beach, Fla.; Vapor Corp. of Fort
Lauderdale, Fla.; Nemtra GMBH of Raschau-Markersbach, Germany,
Perrigo L. Co. of Allegan, Mich.; Needs Co., Ltd.; Smokefree
Innotec of Las Vegas, Nev.; McNeil AB of Helsingborg, Sweden; Chong
Corp; Alexza Pharmaceuticals of Mountain View, Calif.; BLEC, LLC of
Charlotte, N.C.; Gaitrend Sarl of Rohrbach-les-Bitche, France;
FeelLife Bioscience International of Shenzhen, China; Vishay
Electronic BMGH of Selb, Germany; Shenzhen Smaco Technology Ltd. of
Shenzhen, China; Vapor Systems International of Boca Raton, Fla.;
Exonoid Medical Devices of Israel; Shenzhen Nowotech Electronic of
Shenzhen, China; Minilogic Device Corporation of Hong Kong, China;
Shenzhen Kontle Electronics of Shenzhen, China, and Fuma
International, LLC of Medina, Ohio, and 21st Century Smoke of
Beloit, Wis.
[0076] In another embodiment, part or substantially all of the
aerosol delivery device may be formed from one or more carbon
materials, which may provide advantages in terms of
biodegradability and absence of wires. In this regard, the heating
element may comprise carbon foam, the reservoir may comprise
carbonized fabric, and graphite may be employed to form an
electrical connection with the battery and controller. An example
embodiment of a carbon-based cartridge is provided in U.S. Pat.
App. Pub. No. 2013/0255702 to Griffith et al., which is
incorporated herein by reference in its entirety.
[0077] Note that in the embodiment of the aerosol delivery device
100 described above, first and second outer bodies 102, 104 are
employed. Use of two or more outer bodies may be advantageous in a
number of respects. For example, the components may be assembled in
each of the outer bodies 102, 104 separately. Thus, for example,
components may be assembled in the first outer body 102 at a
separate time and/or location as compared to assembly of the
components in the second outer body 104. Thus, for example, the
outer bodies 102, 104 may be assembled with their respective
components under different conditions in some embodiments. For
example, it may be desirable to assemble components in the second
outer body 104 under controlled conditions to avoid contamination
of the flow path or undesirable absorption of moisture in the
reservoir substrate 126, which may cause leaks or affect the
resulting aerosol.
[0078] Further, separate assembly of the components in the outer
bodies 102, 104 may additionally allow for final assembly of the
aerosol delivery device 100 at an alternate location and/or time,
if desirable. For example, a consumer may be provided with the
outer bodies 102, 104 respectively having the components assembled
therein, and final assembly may be completed by the consumer.
Further, enhanced customization of the aerosol delivery device 100
and/or supply chain management may be provided by use of separate
outer bodies 102, 104. In this regard, for example, multiple
embodiments of components may be received in one or both of the
outer bodies 102, 104. Thus for example, the first outer body 102
may be provided with either regular or extended capacity power
sources 136, which may be employed irrespective of the components
received in the second outer body 104. Conversely, the second outer
body 104 may include reservoir substrates 126 having any of varying
capacities and/or types of aerosol precursor compositions received
therein. Thus, various embodiments of aerosol delivery devices 100
may be formed simply by selecting the appropriate desired
embodiment of outer bodies 102, 104, which may be respectively
assembled in advance, rather than specifically assembled to suit
demand. As may be understood, the coupler 106 may additionally
provide and/or facilitate the above-noted benefits by allowing for
coupling of the outer bodies 102, 104. Further, the coupler 106 may
be coupled to one of the outer bodies 102, 104 in advance of
completion of the aerosol delivery device 100 in order to complete
a section of the aerosol delivery device. Accordingly, the
embodiments of aerosol delivery devices including multiple outer
bodies as provided herein may provide benefits over existing
embodiments of aerosol delivery devices that include a single,
unitary housing, such as those embodiments of aerosol delivery
devices disclosed in U.S. Pat. Nos. 8,364,742 and 8,393,331 to Hon,
which are incorporated herein by reference in their entireties.
Additional examples of aerosol delivery devices including a single,
unitary housing are commercially available Vype.TM. by CN Creative,
LTD and NJOY.RTM. by Sottera, Inc.
[0079] A method for assembling an aerosol delivery device is also
provided. As illustrated in FIG. 11, the method may include
positioning a power source in a first outer body defining an inlet
aperture at operation 202. Further, the method may include
positioning an atomizer in a second outer body at operation 204.
The method may additionally include engaging a coupler defining a
coupler inlet and a longitudinal channel with the first outer body
and the second outer body such that the coupler is positioned to
receive air from the inlet aperture defined in the first outer body
through the coupler inlet and to direct the air through the
longitudinal channel to the second outer body at operation 206.
[0080] In some embodiments the method may further comprise
substantially irreversibly securing the first outer body to the
second outer body with a securing mechanism. Substantially
irreversibly securing the first outer body to the second outer body
with the securing mechanism may comprise wrapping a wrapper at
least partially around the first outer body, the second outer body,
and the coupler. The method may additionally include positioning a
reservoir substrate and a flow director in the second outer body
such that the flow director extends at least partially through the
reservoir substrate. Positioning the atomizer in the second outer
body may comprise inserting the atomizer through a transverse
aperture extending through the flow director.
[0081] The method may further comprise inserting a plurality of
electrical connectors through the coupler and connecting the
electrical connectors to the power source and the atomizer. The
method may additionally include coupling a heating element to a
center portion of a liquid transport element to form the atomizer
and folding first and second opposing arms of the liquid transport
element extending from the center section away from the
coupler.
[0082] In some embodiments the method may further comprise coupling
the flow director to a nipple of the coupler. The method may also
include coupling the flow director to a nipple of a mouthpiece.
Further, engaging the coupler with the first outer body and the
second outer body at operation 206 may comprise engaging a rib of
the coupler with the first outer body and the second outer
body.
[0083] In an additional embodiment a controller configured to
assemble the aerosol delivery device 100 of the present disclosure
is provided. The controller may be configured to execute computer
code for performing the operations described herein. In this
regard, as illustrated in FIG. 12, the controller 300 may comprise
a processor 302 that may be a microprocessor or a controller for
controlling the overall operation thereof. In one embodiment the
processor 302 may be particularly configured to perform the
functions described herein, including the operations for assembling
the aerosol delivery device 100 of the present disclosure. The
controller 300 may also include a memory device 304. The memory
device 304 may include non-transitory and tangible memory that may
be, for example, volatile and/or non-volatile memory. The memory
device 304 may be configured to store information, data, files,
applications, instructions or the like. For example, the memory
device 304 could be configured to buffer input data for processing
by the processor 302. Additionally or alternatively, the memory
device 304 may be configured to store instructions for execution by
the processor 302.
[0084] The controller 300 may also include a user interface 306
that allows a user to interact therewith. For example, the user
interface 306 can take a variety of forms, such as a button,
keypad, dial, touch screen, audio input interface, visual/image
capture input interface, input in the form of sensor data, etc.
Still further, the user interface 306 may be configured to output
information to the user through a display, speaker, or other output
device. A communication interface 308 may provide for transmitting
and receiving data through, for example, a wired or wireless
network 310 such as a local area network (LAN), a metropolitan area
network (MAN), and/or a wide area network (WAN), for example, the
Internet.
[0085] The various aspects, embodiments, implementations or
features of the described embodiments can be used separately or in
any combination. Various aspects of the described embodiments can
be implemented by software, hardware or a combination of hardware
and software. The described embodiments can also be embodied as
computer readable code on a computer readable medium for
controlling the above-described operations. In particular, computer
readable code may be configured to perform each of the operations
of the methods described herein and embodied as computer readable
code on a computer readable medium for controlling the
above-described operations. In this regard, a computer readable
storage medium, as used herein, refers to a non-transitory,
physical storage medium (e.g., a volatile or non-volatile memory
device, which can be read by a computer system. Examples of the
computer readable medium include read-only memory, random-access
memory, CD-ROMs, DVDs, magnetic tape, and optical data storage
devices. The computer readable medium can also be distributed over
network-coupled computer systems so that the computer readable code
is stored and executed in a distributed fashion.
[0086] As noted above, the controller 300 may be configured to
execute computer code for performing the above-described assembly
operations. In this regard, an embodiment of a non-transitory
computer readable medium for storing computer instructions executed
by a processor in a controller (e.g. controller 300) configured to
assemble an aerosol delivery device is provided. The non-transitory
computer readable medium may comprise program code instructions for
positioning a power source in a first outer body defining an inlet
aperture, program code instructions for positioning an atomizer in
a second outer body, and program code instructions for engaging a
coupler defining a coupler inlet and a longitudinal channel with
the first outer body and the second outer body such that the
coupler is positioned to receive air from the inlet aperture
defined in the first outer body through the coupler inlet and to
direct the air through the longitudinal channel to the second outer
body.
[0087] In some embodiments the computer readable medium may further
comprise program code instructions for substantially irreversibly
securing the first outer body to the second outer body with a
securing mechanism. The program code instructions for substantially
irreversibly securing the first outer body to the second outer body
with the securing mechanism may comprise program code instructions
for wrapping a wrapper at least partially around the first outer
body, the second outer body, and the coupler. The computer readable
medium may further comprise program code instructions for
positioning a reservoir substrate and a flow director in the second
outer body such that the flow director extends at least partially
through the reservoir substrate. The program code instructions for
positioning the atomizer in the second outer body may comprise
program code instructions for inserting the atomizer through a
transverse aperture extending through the flow director.
[0088] The computer readable medium may further comprise program
code instructions for inserting a plurality of electrical
connectors through the coupler program code instructions for
connecting the electrical connectors to the power source and the
atomizer. The computer readable medium may further comprise program
code instructions for coupling a heating element to a center
portion of a liquid transport element to form the atomizer and
program code instructions for folding first and second opposing
arms of the liquid transport element extending from the center
section away from the coupler. The computer readable medium may
further comprise program code instructions for coupling the flow
director to a nipple of the coupler. The computer readable medium
may further comprise program code instructions for coupling the
flow director to a nipple of a mouthpiece. The program code
instructions for engaging the coupler with the first outer body and
the second outer body may comprise program code instructions for
engaging a rib of the coupler with the first outer body and the
second outer body.
[0089] Many modifications and other embodiments of the disclosure
will come to mind to one skilled in the art to which this
disclosure pertains having the benefit of the teachings presented
in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the disclosure is not to be
limited to the specific embodiments disclosed herein and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *