RU2847191C1 - Aerosol delivery device cartridge including proximity recognition - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: invention relates to a cartridge for an aerosol delivery device. Cartridge is connected or is configured to be connected to a control housing equipped with a control component, wherein the control housing is connected or is configured to be connected to the cartridge to form an aerosol delivery device. Cartridge comprises: a shell defining a reservoir configured to hold the aerosol precursor composition; a heating element configured to operate in an active mode, in which the cartridge is connected to the control housing, wherein in active mode, the control component is configured to control the heating element for activation and evaporation of components of the aerosol precursor composition; and a proximity sensor configured to detect the level of the aerosol precursor composition in the reservoir without the need for any physical contact with the aerosol precursor composition, wherein the proximity sensor is selected from a group comprising a capacitive, ultrasonic, Hall effect, photoelectric or non-mechanical magnetic proximity sensor, and wherein the proximity sensor is configured to transmit to the control component a signal indicating the level of the aerosol precursor composition, to enable the control component to control the operation of at least one functional element of the aerosol delivery device in response to the thus detected level of the aerosol precursor composition, wherein, when the proximity sensor is a capacitive proximity sensor, the proximity sensor comprises first and second capacitive proximity sensors configured to measure a first and a second capacitance, respectively, which indicate a level and a reference signal, wherein the proximity sensor design with the possibility of detecting the level of the aerosol precursor composition includes its design with the possibility of calculating the level of the aerosol precursor composition depending on the first and second capacitances or outputting signals corresponding to the first and second capacitances to a control component for calculating the level of the aerosol precursor composition depending on the first and second capacitances.

EFFECT: accurate control of the level of the aerosol precursor composition in the cartridge reservoir.

4 cl, 4 dwg

Description

AREA OF TECHNOLOGY

The present invention relates to aerosol delivery devices, such as smoking articles, and more particularly to aerosol delivery devices that can utilize electrically generated heat to generate an aerosol (e.g., smoking articles commonly referred to as electronic cigarettes). Smoking articles can be configured to heat an aerosol precursor, which may comprise tobacco-based or derived materials, or otherwise contain tobacco, wherein the precursor is capable of forming an inhalable substance for human consumption.

LEVEL OF TECHNOLOGY

Over the years, numerous smoking articles have been proposed as improvements to smoking products or alternatives to smoking products that require the 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 delivering significant amounts of the incomplete combustion and pyrolysis products that result from burning tobacco. To this end, numerous smoking articles, aroma generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a volatile material, or in an attempt to create the sensation of smoking a cigarette, cigar, or pipe without substantially burning tobacco. See, for example, the various prior art alternative smoking articles, aerosol delivery devices, and heat sources described in U.S. Patent No. 7,726,320 (Robinson et al.) and U.S. Patent No. 8,881,737 (Collett et al.), which are incorporated herein by reference. Also see, for example, the various types of smoking articles, aerosol delivery devices, and electric heat sources cited by trademark and trade information in U.S. Patent Publication No. 2015/0216232 (Bless et al.), which is incorporated herein by reference. In addition, various types of electric aerosol and vapor delivery devices have also been proposed in U.S. Patent Publication Nos. 2014/0096781 (Sears et al.) and 2014/0283859 (Minskoff et al.), as well as in U.S. Patent Applications Nos. 14/282,768 (Sears et al.), filed May 20, 2014; No. 14/286,552 (Brinkley et al.), filed May 23, 2014; No. 14/327,776 (Ampolini et al.), filed July 10, 2014, and No. 14/465,167 (Worm et al.), filed August 21, 2014; each of which is incorporated herein by reference.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

The present invention relates to aerosol delivery devices, methods for creating such devices, and components of such devices. The present invention includes, but is not limited to, the following exemplary embodiments.

An exemplary embodiment 1: A control body connected to or configured to be connected to a cartridge that is equipped with a heating element and contains an aerosol precursor composition, wherein the control body is connected to or configured to be connected to the cartridge to form an aerosol delivery device in which the heating element is configured to activate and vaporize components of the aerosol precursor composition, wherein the control body comprises: a shell; and inside the shell, a control component configured to operate in an active mode, in which the control body is connected to the cartridge, wherein the control component in the active mode is configured to control the heating element to activate and vaporize components of the aerosol precursor composition; and a proximity sensor configured to detect the presence of an object near the control body without the need for any physical contact with the object, wherein the proximity sensor or the control component are further configured to control the operation of at least one functional element of the aerosol delivery device in response to the presence of the object thus detected.

Exemplary embodiment 2: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the proximity sensor is an inductive, capacitive, ultrasonic, Hall effect, photoelectric, or non-mechanical magnetic proximity sensor.

Exemplary embodiment 3: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the proximity sensor is configured to detect the presence of an object within a user-programmable range.

Exemplary embodiment 4: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of a proximity sensor capable of detecting the presence of an object includes provision of the proximity sensor capable of receiving a measured value and detecting the presence of the object in the case in which the measured value satisfies a threshold value, wherein the threshold value is programmable by the user to be dependent on a specific user such that the proximity sensor is configured to detect the presence of a specific user.

Exemplary embodiment 5: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the operation of at least one functional element is programmable by the user.

Exemplary embodiment 6: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of the proximity sensor or control component to control at least one functional element includes its provision to control a sensory feedback element to provide user-perceivable feedback.

Exemplary embodiment 7: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of the proximity sensor or control component to control at least one functional element includes provision thereof to change the power state of the at least one functional element.

Exemplary embodiment 8: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of a proximity sensor or control component with the ability to change the power state includes provision thereof with the ability to change the power state of a communication interface connected to the control component and configured to provide wireless communication.

Exemplary embodiment 9: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of the proximity sensor or control component to control at least one functional element includes its provision to control at least one functional element to change a locked state of the aerosol delivery device.

An exemplary embodiment 10: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the proximity sensor is further configured to output a proximity detection signal in response to the presence of an object thus detected, wherein the control housing further comprises a flow sensor configured to detect an air flow through at least a portion of the enclosure and to output an air flow detection signal in response to the air flow thus detected, wherein the provision of the proximity sensor or the control component with the capability of controlling the operation of at least one functional element includes its provision for the control component to initiate operation in an active mode in response to both the proximity detection signal and the air flow detection signal, and thereby control the heating element for activating and evaporating the components of the aerosol precursor composition.

An exemplary embodiment 11: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the proximity sensor comprises first and second capacitive proximity sensors configured to measure, respectively, first and second electrical capacitances that respectively indicate the presence of a user and a reference signal, wherein the proximity sensor is further configured to calculate the user's sweating level depending on the first and second electrical capacitances or to output output signals corresponding to the first and second electrical capacitances to a control component for calculating the user's sweating level depending on the first and second electrical capacitances, wherein the further implementation of the proximity sensor or the control component with the capability of controlling the operation of at least one functional element includes its further implementation with the capability of controlling the operation of at least one functional element in response to the presence and the sweating level of the user.

Exemplary embodiment 12: A control housing according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of the proximity sensor or control component to control at least one functional element includes provision thereof to upload to a service platform data related to the presence of an object detected by the proximity sensor.

An exemplary embodiment 13: A cartridge connected or configured to be connected to a control housing provided with a control component, wherein the control housing is connected or configured to be connected to the cartridge to form an aerosol delivery device, wherein the cartridge comprises a shell defining a reservoir configured to hold an aerosol precursor composition, a heating element configured to operate in an active mode in which the cartridge is connected to the control housing, wherein in the active mode the control component is configured to control the heating element to activate and vaporize components of the aerosol precursor composition; and a proximity sensor configured to detect the level of the aerosol precursor composition in the reservoir without the need for any physical contact with the aerosol precursor composition, wherein the proximity sensor or the control component are configured to control the operation of at least one functional element of the aerosol delivery device in response to the thus detected level of the aerosol precursor composition.

Exemplary embodiment 14: A cartridge according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the proximity sensor is an inductive, capacitive, ultrasonic, Hall effect, photoelectric, or non-mechanical magnetic proximity sensor.

An exemplary embodiment 15: A cartridge according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the proximity sensor comprises first and second capacitive proximity sensors configured to measure, respectively, first and second electrical capacitances that indicate, respectively, a level and a reference signal, wherein the configuration of the proximity sensor with the capability of detecting the level of the aerosol precursor composition includes its configuration with the capability of calculating the level of the aerosol precursor composition depending on the first and second electrical capacitances, or outputting output signals corresponding to the first and second electrical capacitances to a control component for calculating the level of the aerosol precursor composition depending on the first and second electrical capacitances.

Exemplary embodiment 16: A cartridge according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of the proximity sensor or control component to control at least one functional element includes its provision to control a sensory feedback element to provide user-perceived feedback.

Exemplary embodiment 17: A cartridge according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of the proximity sensor or control component to control at least one functional element includes its provision to control at least one functional element to change a locked state of the aerosol delivery device.

Exemplary embodiment 18: A cartridge according to the preceding or any subsequent exemplary embodiment, or any combination thereof, wherein the provision of a proximity sensor or control component capable of controlling at least one functional element includes provision thereof for uploading to a service platform data related to the level of the aerosol precursor composition detected by the proximity sensor.

These and other features, aspects, and advantages of the present invention will become apparent upon reading the following detailed description together with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more features or elements set forth in the present invention, regardless of whether such features or elements are explicitly combined or otherwise set forth in the description of a particular exemplary embodiment of the present application. The present description is intended to be read taking into account all elements, such that any individual features or elements of the invention in any of its aspects and exemplary embodiments should be considered, in particular, mutually combinable, unless the context clearly indicates otherwise.

It should therefore be understood that the "Summary of the Invention" section is provided merely to summarize certain exemplary embodiments in order to provide a basic understanding of certain aspects of the invention. Accordingly, it should be understood that the exemplary embodiments described above are merely examples and should in no way be considered as narrowing the scope and spirit of the invention. Other exemplary embodiments, aspects, and advantages will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of some of the described exemplary embodiments.

BRIEF DESCRIPTION OF DRAWINGS

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

FIG. 1 is a side view of an aerosol delivery device comprising a cartridge coupled to a control housing, according to an exemplary embodiment of the present invention.

FIG. 2 is a partial cross-sectional view of an aerosol delivery device according to various exemplary embodiments.

FIGS. 3 and 4 illustrate proximity sensors according to various exemplary embodiments.

IMPLEMENTATION OF THE INVENTION

The present invention will now be described in detail with reference to exemplary embodiments thereof. These exemplary embodiments are described in such a way that the present invention will be presented comprehensively and in a complete form, with its scope fully disclosed to a person skilled in the art. Of course, the present invention can be implemented in many different forms and should not be considered as limited to the embodiments described in this application; rather, these embodiments are presented in such a way that the present invention satisfies the relevant legal requirements. As used in the description and in the appended claims, the singular forms "a", "an", and "the" include plural forms unless the context clearly dictates otherwise.

As described below, exemplary embodiments of the present invention relate to aerosol delivery systems. Aerosol delivery systems according to the present invention use electrical energy to heat a material (preferably without burning the material to any significant extent) to form an inhalable substance; wherein the components of such systems are in the form of articles that are most preferably compact enough to be considered "portable" devices. In other words, use of the components of the preferred aerosol delivery systems does not result in the formation of smoke in the sense that the aerosol is primarily the result of by-products of combustion or pyrolysis of tobacco, but rather use of these preferred systems results in the formation of vapors resulting from the volatilization or evaporation of certain components included therein. In some exemplary embodiments, the components of the aerosol delivery systems may be characterized as electronic cigarettes, wherein such electronic cigarettes most preferably contain tobacco and/or components derived from tobacco, and thus deliver components derived from tobacco in aerosol form.

Aerosol-generating articles of certain preferred aerosol delivery systems may create a variety of sensations (e.g., inhalation and exhalation rituals, flavor or aroma patterns, organoleptic effects, physical sensations, rituals of use, visual stimuli such as those created by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe, which are achieved by lighting and burning tobacco (and thus inhaling tobacco smoke), without substantially burning any of its components. For example, a user of an aerosol-generating article according to the present invention may hold and use the article in a manner very similar to how a smoker uses a traditional smoking article, puffing on one end of such an article to inhale the aerosol generated by the article, puffing at selected time intervals, etc.

The aerosol delivery systems of the present invention may also be characterized as vapor-forming articles or drug delivery articles. Such articles or devices may thus be adapted to deliver one or more substances (e.g., flavorings and/or pharmaceutical active ingredients) in a respirable form or state. For example, the respirable substances may be substantially in the form of a vapor (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the respirable substances may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is intended to refer to vapors, gases, and aerosols of a form or type suitable for human inhalation, whether or not they are visible and whether or not they have a shape that can be considered "smoke-like."

Aerosol delivery systems according to the present invention generally comprise a number of components located within an outer housing or sleeve, which may be referred to as a casing. The overall design of the outer housing or sleeve may vary, and the format or configuration of the outer housing, which may determine the overall size and overall shape of the aerosol delivery device, may vary. Typically, an elongated housing, shaped like a cigarette or cigar, may be formed from a single, single casing, or the elongated casing may be formed from two or more separable casings. For example, an aerosol delivery device may comprise an elongated sleeve or housing, which may be substantially tubular in shape and thus resemble the shape of a conventional cigarette or cigar. In one example, all components of the aerosol delivery device are contained within a single casing. According to an alternative embodiment, the aerosol delivery device may comprise two or more casings that are connected and separable. For example, an aerosol delivery device may comprise at one end a control housing that is a shell containing one or more reusable components (e.g., a battery, such as a rechargeable battery and/or a supercapacitor, and various electronics for controlling the operation of the product), and at the other end an outer housing or sleeve configured to be removably attached thereto, containing a disposable portion (e.g., a disposable flavoring cartridge).

Aerosol delivery systems according to the present invention most preferably comprise some combination of a power source (i.e., an electrical power source), at least one control component (e.g., means for activating the power, controlling the power, regulating and terminating the power for heat generation, such as by controlling an electrical current flowing from the power source to other components of the article, such as a microprocessor, implemented separately or as part of a microcontroller), a heater or heat-generating element (e.g., an electrical resistive heating element or other component that, by itself or in combination with one or more additional elements, may be generally referred to as an "atomizer"), an aerosol precursor composition (e.g., typically a liquid capable of generating an aerosol when sufficient heat is applied thereto, such as ingredients commonly referred to as "smoking juice," "e-liquid," and "e-juice"), and a mouth end or tip region for enabling drawing from the aerosol delivery device for inhalation of the aerosol (e.g., a predetermined airflow path through the article such that the aerosol formed can be drawn through it when inhaled).

More specific formats, configurations, and component arrangements in the aerosol delivery systems of the present invention will become apparent in light of the further description provided below. Furthermore, the selection and arrangement of the various components of the aerosol delivery system may become clear upon consideration of commercially available electronic aerosol delivery devices, such as the representative products referenced in the "Background of the Invention" section of this specification.

In various examples, an aerosol delivery device may comprise a reservoir configured to hold an aerosol precursor composition. The reservoir may, in particular, be made of a porous material (e.g., a fibrous material) and thus may be referred to as a porous support (e.g., a fibrous support).

A fibrous support suitable as a reservoir in an aerosol delivery device may be a woven or non-woven material formed from a plurality of fibers or filaments, and may be made from natural fibers and/or synthetic fibers. For example, the fibrous support may comprise a fiberglass material. In specific examples, a cellulose acetate material may be used. In other exemplary embodiments, a carbon material may be used. The reservoir may be substantially container-shaped and may comprise a fibrous material.

FIG. 1 shows a side view of an aerosol delivery device 100 comprising a control body 102 and a cartridge 104 , according to various exemplary embodiments of the present invention. In particular, FIG. 1 shows a control body and a cartridge connected to each other. The control body and the cartridge may be removably coupled to form a functional connection. The cartridge may be connected to the control body using various mechanisms, including a threaded engagement, an engagement as a result of a press fit, an interference fit, a magnetic engagement, or the like. In some exemplary embodiments, the aerosol delivery device may be substantially rod-shaped or have a substantially tubular shape, or have a substantially cylindrical shape when the cartridge and the control body are in an assembled configuration. The aerosol delivery device may also have a substantially triangular or rhomboidal cross-section, which makes it more compatible with a substantially flat or thin-film power source, such as a flat-panel battery. The cartridge and control housing may comprise separate, corresponding shells or outer housings, which may be constructed of any number of different materials. The shell may be constructed of any suitable, structurally sound material. In some examples, the shell may be constructed of a metal or alloy, such as stainless steel, aluminum, etc. Other suitable materials include various plastics (e.g., polycarbonate), metal electrodeposition on plastic, ceramics, etc.

In some exemplary embodiments, the control body 102 and/or the cartridge 104 of the aerosol delivery device 100 may be designated as disposable or reusable. For example, the control body may have a replaceable battery or a rechargeable battery and, thus, may be combined with any type of charging device, including a connection to a typical wall charger, a connection to a car charger (i.e., a cigarette lighter receptacle), a connection to a computer, such as via a universal serial bus (USB) cable or connector, or a connection to a photovoltaic cell (sometimes called a solar cell), or a solar array of solar cells, or a connection to a radio frequency to direct current (RF-to-DC) converter. Additionally, in some exemplary embodiments, the cartridge may comprise a disposable cartridge as described in U.S. Patent No. 8,910,639 (Chang et al.), which is incorporated herein by reference in its entirety.

FIG. 2 shows in more detail an aerosol delivery device 100 in accordance with some exemplary embodiments. As shown again in the illustrated sectional view, the aerosol delivery device may comprise a control body 102 and a cartridge 104 , each of which includes a number of corresponding components. The components shown in FIG. 2 are a typical example of components that may be present in the control body and the cartridge and are not intended to limit the scope of components covered by the present invention. As shown, for example, the control body may be formed by a control body sleeve 206 , which may include a control component 208 (e.g., a microprocessor, implemented separately or as part of a microcontroller), a flow sensor 210 , a power source 212 and one or more light-emitting diodes (LEDs) 214 , and such components may be combined in various ways. The power source may include, for example, a battery (disposable or rechargeable), a solid-state battery, a thin-film solid-state battery, a supercapacitor, or the like, or some combination thereof. Some examples of suitable power sources are disclosed in U.S. Patent Application No. 14/918,926 (Sur et al.), filed October 21, 2015, which is incorporated by reference. An LED may be one example of a suitable visual indicator that may be equipped with the aerosol delivery device 100. In addition to or as an alternative to visual indicators such as LEDs, other indicators may be included, such as audio indicators (e.g., an acoustic device), haptic indicators (e.g., vibration motors), or the like.

Cartridge 104 may be formed by a cartridge sleeve 216 that encloses a reservoir 218 configured to hold an aerosol precursor composition and contains a heater 222 (sometimes referred to as a heating element). In various configurations, this structure may be referred to as a container; and accordingly, the terms "cartridge,""container," and the like may be used interchangeably to refer to a sleeve or other enclosure that encloses a reservoir for an aerosol precursor composition and contains a heater.

As shown, according to some examples, the reservoir 218 may be in fluid communication with a liquid transfer element 220 configured to wick or otherwise transport the aerosol precursor composition stored in the reservoir shell to the heater 222. According to some examples, a valve may be located between the reservoir and the heater, configured to control the amount of the aerosol precursor composition passing or delivered from the reservoir to the heater.

Various examples of materials capable of producing heat when an electric current is passed through them may be used to form the heater 222. The heater in these examples may be a resistive heating element, such as a winding wire, a microheater, and the like. Examples of materials from which the heating element may be formed include kanthal (FeCrAl), nichrome, stainless steel, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), graphite and graphite-based materials (e.g., carbon-based foam and yarn), and ceramics (e.g., ceramics with a positive or negative coefficient of thermal expansion). Exemplary embodiments of heaters or heating elements suitable for use in aerosol delivery devices according to the present invention are further described below and may be included in devices as shown in FIG. 2, described in this application.

An opening 224 may be provided in the cartridge barrel 216 (e.g., at the mouthpiece end) to allow the generated aerosol to exit the cartridge 104 .

The cartridge 104 may also include one or more electronic components 226 , which may include an integrated circuit, a memory element, a sensor, or the like. The electronic components may be configured to communicate with the control component 208 and/or with an external device via wired or wireless means. The electronic components may be located anywhere within the cartridge or its base 228 .

Although the control component 208 and the flow sensor 210 are shown separately, it should be understood that the control component and the flow sensor can be combined in the form of an electronic circuit board, wherein the air flow sensor is attached directly to it. Additionally, the electronic circuit board can be positioned horizontally relative to the image in FIG. 1, namely, the electronic circuit board can be positioned longitudinally, parallel to the central axis of the control housing. According to some examples, the air flow sensor can comprise its own circuit board or another base element to which it can be attached. According to some examples, a flexible circuit board can be used. The flexible circuit board can have a variety of shapes, including substantially tubular shapes. According to some examples, the flexible circuit board can be combined with, layered on, or form part or all of the heater substrate, as further described below.

The control body 102 and the cartridge 104 may include components adapted to facilitate interaction with the possibility of transferring a fluid between them. As shown in FIG. 2, the control body may include a connector 230 having a cavity 232 therein. The base 228 of the cartridge may be configured to interact with the connector and may include a projection 234 configured to be embedded in the cavity. Such interaction may facilitate a stable connection between the control body and the cartridge and the establishment of an electrical connection between the power source 212 and the control component 208 in the control body and the heater 222 in the cartridge. Additionally, the sleeve 206 of the control body may include an air inlet 236 , which may be a cutout in the sleeve at the place where it connects to the connector, allowing ambient air to pass around the connector into the sleeve, from where it then passes through the cavity 232 of the connector into the cartridge through the projection 234 .

A connector and base suitable for use in accordance with the present invention are described in U.S. Patent Application Publication No. 2014/0261495 (Novak et al.), which is incorporated herein by reference in its entirety. For example, connector 230 , as shown in FIG. 2, may define an outer periphery 238 configured to mate with an inner periphery 240 of base 228. In one example, the inner periphery of the base may have a radius substantially equal to or slightly greater than the radius of the outer periphery of the connector. Additionally, the connector may define one or more projections 242 on the outer periphery configured to interact with one or more recesses 244 formed in the inner periphery of the base. However, various other examples of designs, shapes and components may be used to connect the base to the connector. According to some examples, the connection between the base of the cartridge 104 and the connector of the control body 102 may be substantially non-detachable, while in other examples, the connection between them may be detachable, so that, for example, the control body can be reused with one or more additional cartridges, which may be disposable and/or refillable.

According to some examples, the aerosol delivery device 100 may be substantially rod-shaped, substantially tubular, or substantially cylindrical. According to other examples, other shapes and sizes are encompassed—for example, rectangular or triangular cross-sections, polygonal shapes, and the like.

The reservoir 218 shown in FIG. 2 may be a container or may be a fibrous reservoir as described herein. For example, in this example, the reservoir may comprise one or more layers of non-woven fibers, substantially formed in the form of a tube enclosing the interior of the cartridge barrel 216. The aerosol precursor composition may be retained in the reservoir. Liquid components, for example, may be retained by the reservoir with the ability to be adsorbed. The reservoir may be fluidly connected to the liquid transfer element 220. The liquid transfer element may transfer the aerosol precursor composition stored in the reservoir by capillary action to the heater 222 , which in this example is formed as a coil of metal wire. Thus, the heater together with the liquid transfer element form a heating circuit. Exemplary embodiments of reservoirs and transfer elements suitable for use in aerosol delivery devices according to the present invention are further described below, and such reservoirs and/or transfer elements may be included in devices as shown in FIG. 2 described in this application. In particular, specific combinations of heating elements and transfer elements, as further described below, may be included in devices as shown in FIG. 2 described in this application.

In use, when a user draws on the aerosol delivery device 100 , an air flow is detected by the flow sensor 210 , and the heater 222 is activated to vaporize the components of the aerosol precursor composition. Drawing through the mouthpiece end of the aerosol delivery device causes ambient air to enter the air intake 236 and pass through the cavity 232 in the connector 230 and the central opening in the projection 234 of the base 228. In the cartridge 104, the drawn air combines with the generated vapor to form an aerosol. The aerosol is entrained, aspirated, or otherwise diverted from the heater and then from the opening 224 at the mouthpiece end of the aerosol delivery device.

According to some examples, the aerosol delivery device 100 may include a number of additional software-controlled functions. For example, the aerosol delivery device may include a power supply protection circuit configured to detect the power supply input, the load on the power supply terminals, and the charging input. The power supply protection circuit may include short-circuit protection, undervoltage power blocking, and overvoltage charging protection. The aerosol delivery device may also include components for measuring the ambient air temperature, and its control component 208 may be configured to control at least one functional element to prevent charging of the power supply, in particular any battery, if the ambient air temperature is below a certain temperature (e.g., 0°C) or above a certain temperature (e.g., 45°C) before or during charging.

Power delivery from power source 212 may vary during each puff on device 100 in accordance with a power management mechanism. The device may include a "long puff" safety timer such that, if a user or component failure (e.g., flow sensor 210 ) causes the device to perform continuous puffs, control component 208 may control at least one functional element to automatically prevent the puff from being performed after a certain period of time (e.g., four seconds). Additionally, the time between puffs on the device may be limited to less than a period of time (e.g., 100 seconds). The watchdog safety timer may automatically reset the aerosol delivery device if its control component or the software running on it becomes unstable and does not service the timer within a suitable time interval (e.g., eight seconds). Additionally, in the event of a faulty or otherwise disabled flow sensor 210 , for example, by permanently disabling the aerosol delivery device to prevent unintentional heating, safety protection may be implemented. The puff limit switch can deactivate the device if the pressure sensor fails, causing the device to continuously activate without stopping after four seconds of maximum puff time.

The aerosol delivery device 100 may include a puff tracking algorithm designed to disable the heater after a predetermined number of puffs have been delivered for the attached cartridge (based on the number of available puffs calculated based on the charge of the e-liquid in the cartridge). The aerosol delivery device may have a sleep mode, a standby mode, or a low-power mode, wherein power delivery may be automatically terminated after a specified period of non-use. Additional safety protection may be implemented in which all charge/discharge cycles of the power source 212 may be monitored by the control component 208 during its service life. After the power source has reached the equivalent of a predetermined number (e.g., 200) of full discharge or recharge cycles, it may be considered depleted, and the control component may control at least one functional element to prevent further charging of the power source.

The various components of the aerosol delivery device of the present invention can be selected from commercially available components described in the prior art. Examples of batteries that can be used in accordance with the present invention are described in U.S. Patent Application Publication No. 2010/0028766 (Peckerar et al.), which is incorporated herein by reference in its entirety.

The aerosol delivery device 100 may include a sensor 210 or other sensor or detector for controlling the supply of electrical power to the heater 222 when an aerosol is required to be generated (e.g., during a puff during use). Thus, for example, a procedure or method is provided for turning off the supply of electrical power to the heater when a puff is not required to be performed on the aerosol delivery device during use, and for turning on the supply of electrical power to activate or start the generation of heat by the heater during a puff. Additional representative types of recognition or detection mechanisms, their design and configuration, their components and general methods of controlling them are described in U.S. Patent Nos. 5,261,424 (Sprinkel, Jr.), 5,372,148 (McCafferty et al.) and PCT Patent Application Publication WO 2010/003480 (Flick), which are fully incorporated herein by reference.

The aerosol delivery device 100 may most preferably include a control component 208 or other control mechanism for controlling the amount of electrical power supplied to the heater 222 during the puffing process. Representative types of electronic components, their design and configuration, their features, and general methods of controlling them are described in U.S. Patent Nos. 4,735,217 (Gerth et al.), 4,947,874 (Brooks et al.), 5,372,148 (McCafferty et al.), 6,040,560 (Fleischhauer et al.), 7,040,314 (Nguyen et al.), and 8,205,622 (Pan), U.S. Patent Application Publication Nos. 2009/0230117 (Fernando et al.), 2014/0060554 (Collet et al.), and 2014/0270727 (Ampolini et al.), and U.S. Patent Application Ser. No. 14/209 191, filed March 13, 2014 (Henry et al.), which are incorporated herein by reference in their entirety.

Representative types of substrates, reservoirs, or other components for serving an aerosol precursor are described in U.S. Patent No. 8,528,569 (Newton), U.S. Patent Application Publication No. 2014/0261487 (Chapman et al.), U.S. Patent Application No. 14/011,992 (Davis et al.), filed August 28, 2013, and U.S. Patent Application No. 14/170,838 (Bless et al.), filed February 3, 2014, which are incorporated herein by reference in their entirety. Additionally, various wicking materials and the configuration and operation of these wicking materials in certain types of electronic cigarettes are set forth in U.S. Patent Application Publication No. 2014/0209105 (Sears et al.), which is incorporated herein by reference in its entirety.

The aerosol precursor composition, also referred to as a vapor precursor composition, may contain a plurality of components, including, for example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, and/or flavoring agents. Representative types of aerosol precursor components and formulations are also set forth and characterized in U.S. Patent No. 7,217,320 (Robinson et al.) and U.S. Patent Publication Nos. 2013/0008457 (Zheng et al.), 2013/0213417 (Chong et al.), 2014/0060554 (Collett et al.), 2015/0020823 (Lipowicz et al.), 2015/0020830 (Koller), and WO 2014/182736 (Bowen et al.), the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those included in the VUSE® product from RJ Reynolds Vapor Company, the BLU™ product from Imperial Tobacco Group PLC, the MISTIC MENTHOL product from Mistic Ecigs, and the VYPE product from CN Creative Ltd. Also desirable are the so-called "smoking juices" for electronic cigarettes, which are available from Johnson Creek Enterprises LLC.

Additional representative types of components providing visual information or indicators may be used in the aerosol delivery device 100 , such as visual indicators and related components, audio indicators, haptic indicators, and the like. Examples of suitable LED components and their configurations and methods of use are described in U.S. Patents 5,154,192 (Sprinkel et al.), 8,499,766 (Newton), and 8,539,959 (Scatterday), and U.S. Patent Application No. 14/173,266 (Sears et al.), filed February 5, 2014, which are herein incorporated by reference in their entirety.

Additional features, controls, or components that may be included in the aerosol delivery devices of the present invention are described in U.S. Patent Nos. 5,967,148 (Harris et al.), 5,934,289 (Watkins et al.), 5,954,979 (Counts et al.), 6,040,560 (Fleischhauer et al.), 8,365,742 (Hon.), 8,402,976 (Fernando et al.), U.S. Patent Application Publication Nos. 2005/0016550 (Katase), 2010/0163063 (Fernando et al.), 2013/0192623 (Tucker et al.), 2013/0298905 (Leven et al.), 2013/0180553 (Kim et al.), 2014/0000638 (Sebastian et al.), 2014/0261495 (Novak et al.), and 2014/0261408 (DePiano et al.), which are incorporated herein by reference in their entirety.

The control component 208 includes a number of electronic components and, in some examples, may be formed from a printed circuit board that supports and electrically connects the electronic components. The electronic components may include a microprocessor or a processor core and memory. According to some examples, the control component may include a microcontroller with an integrated processor core and memory and may further include one or more input/output peripherals. According to some examples, the control component may be connected to a communication interface 246 to provide wireless communication with one or more electrical networks, computing devices, or other appropriately provided devices. Examples of suitable communication interfaces are disclosed in U.S. Patent Application No. 14/638,562, filed March 4, 2015 (Marion et al.), the contents of which are incorporated herein by reference in their entirety. Examples of suitable arrangements by which an aerosol delivery device may be configured to communicate wirelessly are disclosed in U.S. Patent Application Nos. 14/327,776, filed July 10, 2014 (Ampolini et al.) and 14/609,032, filed January 29, 2015 (Henry, Jr. et al.), each of which is incorporated herein by reference.

According to some exemplary embodiments, control housing 102 may comprise a proximity sensor 248 configured to detect the presence of an object near the control housing without requiring any physical contact with the object. Examples of suitable proximity sensors include inductive, capacitive, ultrasonic, Hall-effect, photoelectric, or non-mechanical magnetic proximity sensors. One specific example of a suitable proximity sensor includes a capacitive proximity sensor and the AD7150 or AD7151 capacitive transducer from Analog Devices, Norwood, Massachusetts.

The proximity sensor 248 or the control component 208 may be configured to control the operation of at least one functional element of the aerosol delivery device 100 in response to the presence of an object detected in this manner. The aerosol delivery device may be implemented in any of a number of different ways for any of a number of different applications, and, according to some examples, may be programmable by the user for various applications. More specifically, according to some examples, this user programmability may extend to the range of the proximity sensor, the operation of the functional element(s), or the like. In yet another example, the proximity sensor may receive a measured value and detect the presence of an object in the case in which the measured value satisfies a threshold value, wherein this threshold value may be programmable by the user, ensuring that it is dependent on a specific user, such that the proximity sensor is configured to detect the presence of a specific user.

The functional element(s) of the aerosol delivery device 100 can be controlled in any of a number of different ways in response to the presence of an object thus detected. For example, the sensory feedback element 250 (e.g., an LED, an acoustic element, a vibration element) can be controlled to provide user-perceived feedback. According to an additional or alternative embodiment, the proximity sensor 248 or the control component 208 can change the power state of at least one functional element, such as the communication interface 246. This may include, for example, activating the communication interface and possibly other functional elements from a low-power state.

In yet another example, the functional element(s) can be controlled to change the locked state of the aerosol delivery device 100. This may include, for example, ensuring the operation of one or more components of the aerosol delivery device when the presence of a user is detected. Similar functionality can also be used to limit the active operation of the aerosol delivery device only to those cases when both the flow sensor 210 detects an air flow through the aerosol delivery device and the proximity sensor 248 detects the presence of a user. More specifically, for example, the proximity sensor can output a proximity detection signal in response to the presence of an object detected in this way, and the flow sensor can output an air flow detection signal in response to the detection of an air flow through at least a portion of the aerosol delivery device. Thus, the control component 208 can be configured to initiate the active operation in response to both the proximity detection signal and the air flow detection signal, and thus control the heating element to activate and vaporize the components of the aerosol precursor composition.

In addition to or instead of applications including activating the functional element(s) from a low power state or unlocking the aerosol delivery device 100 for operation in an active mode, the proximity sensor 248 can provide an even greater number of applications. According to some examples, the range of the proximity sensor can be set to enable the use of the aerosol delivery device as a warning system. The aerosol delivery device and its proximity sensor can be used to detect the presence of an unfamiliar object or wild animal in the vicinity of the user of the aerosol delivery device and control the sensory feedback element 250 to provide user-perceived feedback to warn the user. According to another example, the aerosol delivery device and its proximity sensor can be used to detect the presence of a vehicle, a person, or another object approaching a moving vehicle carrying the user of the aerosol delivery device and control the sensory feedback element to provide user-perceived feedback to warn the user.

According to some examples, aerosol delivery device 100 with proximity sensor 248 can also be used as a sweat detector to detect user perspiration. In the case of a capacitive proximity sensor, the capacitor's electrical capacitance may depend on the relative static permittivity. This relative static permittivity may depend on humidity, which, for a capacitor located near the user, may depend on the user's perspiration. Thus, the proximity sensor may comprise a capacitive proximity sensor for measuring the electrical capacitance, which depends on the user's perspiration, and another proximity sensor for measuring the relative electrical capacitance, which depends on the ambient atmospheric pressure and humidity. A comparison of the two electrical capacitances can yield a measurement of the user's perspiration.

More specifically, the proximity sensor 248 may comprise first and second capacitive proximity sensors configured to measure first and second electrical capacitances, respectively, which respectively indicate the presence of the user and the reference signal. The proximity sensor may further calculate the user's sweating level depending on the first and second electrical capacitances or output output signals corresponding to the first and second electrical capacitances to the control component 208 for calculating the user's sweating level depending on the first and second electrical capacitances (e.g., the difference between the first electrical capacitance and the second electrical capacitance). Thus, the proximity sensor or the control component may control the operation of at least one functional element in response to the presence and sweating level of the user. Furthermore, this may include controlling the sensory feedback element 250 to provide user-perceived feedback to warn the user, for example, in cases where the user's dehydration may be above a threshold level (e.g., the difference between the electrical capacitances exceeds a threshold level).

As further shown in FIG. 2, in addition to or instead of the control housing 102 , the cartridge may comprise a proximity sensor 252 and possibly also a sensory feedback element 254. Examples of suitable proximity sensors in the present application include a capacitive, ultrasonic, Hall effect-based, photoelectric, or non-mechanical magnetic proximity sensor. According to some examples, this proximity sensor may be configured to detect the level of the aerosol precursor composition in the reservoir 218 without the need for any physical contact with the aerosol precursor composition. Thus, the proximity sensor or control component 208 may be configured to control the operation of the functional element(s) of the aerosol delivery device 100 in response to the thus detected level of the aerosol precursor composition.

As noted above with respect to the presence of the object, the functional element(s) of the aerosol delivery device 100 can be controlled in any of a number of different ways in response to the thus detected level of the aerosol precursor composition. For example, the sensory feedback element 250 , 254 can be controlled to provide user-perceived feedback. According to an additional or alternative embodiment, for example, the functional element(s) can be controlled to change the blocked state of the aerosol delivery device, for example by activating one or more components of the aerosol delivery device to operate when at least a threshold level of the aerosol precursor composition is detected.

In any of the above examples, as well as in other examples, the proximity sensor 248 , 252 , or the control component 208 may be configured to upload data related to the presence of the detected object to a service platform for storage, display, analysis, etc. This service platform may comprise one or more computing devices (e.g., servers), and according to some examples, the service platform may provide an infrastructure for cloud computing. The aerosol delivery device 100 may be in communication with the service platform via its communication interface 246 and possibly one or more electrical networks. This communication may even be indirect, when the aerosol delivery device is in communication with the computing device (directly or via one or more electrical networks), which in turn is in communication with the service platform (directly or via one or more electrical networks).

FIG. 3 shows a proximity sensor 300 , which, according to some examples, may correspond to the proximity sensor 248 shown in FIG. 2. As shown, the proximity sensor may comprise an excitation source 302 configured to trigger a capacitive proximity sensor 304 configured to measure a change in electrical capacitance in the presence of a nearby object. The measured electrical capacitance may be transmitted to a capacitance-to-digital converter (CDC) 306 configured to convert the electrical capacitance into a corresponding digital signal. This digital signal may be transmitted to a microprocessor 308 or other digital processing logic circuit, which may be located on the board of the proximity sensor or, according to some examples, be part of the control component 208. In turn, the microprocessor may be configured to control the operation of at least one functional element in response to the digital signal and the thus detected nearby object. This may include, for example, controlling the touch feedback element 310 , which may also be located on the proximity sensor board or separately but in communication with it (e.g., the touch feedback element 250 ).

FIG. 4 shows a proximity sensor 400 , which, according to some examples, may correspond to the proximity sensor 252 shown in FIG. 2. As shown, the proximity sensor may comprise an excitation source 402 configured to trigger first and second capacitive proximity sensors 404a , 404b configured to measure first and second electrical capacitances that respectively indicate a level and a reference signal with respect to the aerosol precursor composition in a reservoir 406 (for example, a reservoir 218 ). The measured electrical capacitance may be transmitted to a capacitance-to-digital converter (CDC) 408 configured to convert the electrical capacitance into corresponding digital signals. The excitation source and the CDC are shown supporting both capacitive proximity sensors via a multiplexer 410. According to another example, the proximity sensor may comprise an excitation source and a CDC for each of the capacitive proximity sensors.

The digital signals from the CDC 408 can be transmitted to the microprocessor 412 or other digital processing logic circuit, which can be located on the board of the proximity sensor 400 or, according to some examples, be part of the control component 208. In turn, the microprocessor can be configured to calculate the level of the aerosol precursor composition from the digital signals and, thus, the first and second electrical capacitances, and to control the operation of at least one functional element in response to the level of the aerosol precursor composition. This can include, for example, controlling the sensory feedback element 414 , which can also be located on the board of the proximity sensor or separately, but in communication with it (for example, the sensory feedback element 250 , 254 ).

The above description of the use of the article(s) may be extended to various exemplary embodiments described in the present application by minor modifications that may be obvious to one skilled in the art in light of the additional disclosure provided in the present application. The above description of the use, however, is not intended to limit the use of the article, but is offered to meet all the necessary requirements of the disclosure of the present invention. Any of the elements presented in the article(s) illustrated in FIGS. 1-4, or otherwise described above, may be included in the aerosol delivery device according to the present invention.

Numerous modifications and other embodiments of the invention described in the present application will become apparent to those skilled in the art to which the present disclosure pertains, which has the benefit of the explanations provided in the above descriptions and the associated drawings. Accordingly, it should be understood that the invention should not be limited to the specific embodiments disclosed in the present description, and that modifications and other embodiments should be included within the scope of the appended claims. Moreover, although the above descriptions and the associated drawings describe exemplary embodiments in the context of specific combinations of elements and/or functions, it should be understood that various combinations of elements and/or functions may be represented by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, various combinations of elements and/or functions than those expressly described above, which may be set forth in some of the claims of the appended claims, are also contemplated. Although specific terms are used in this application, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (4)

1. A cartridge connected or configured to be connected to a control housing equipped with a control component, wherein the control housing is connected or configured to be connected to the cartridge to form an aerosol delivery device, wherein the cartridge comprises: a shell forming a reservoir configured to hold an aerosol precursor composition; a heating element configured to operate in an active mode, in which the cartridge is connected to the control housing, wherein in the active mode the control component is configured to control the heating element to activate and evaporate components of the aerosol precursor composition; and a proximity sensor configured to detect a level of an aerosol precursor composition in a reservoir without requiring any physical contact with the aerosol precursor composition, wherein the proximity sensor is selected from the group consisting of a capacitive, ultrasonic, Hall effect, photoelectric or non-mechanical magnetic proximity sensor, and wherein the proximity sensor is configured to transmit to a control component a signal indicative of a level of an aerosol precursor composition to enable the control component to control the operation of at least one functional element of the aerosol delivery device in response to the thus detected level of the aerosol precursor composition, wherein when the proximity sensor is a capacitive proximity sensor, the proximity sensor comprises first and second capacitive proximity sensors configured to measure first and second electrical capacitances, respectively, that indicate a level and a reference signal, wherein the implementation of the proximity sensor with the ability to detect a level of an aerosol precursor composition includes its implementation with the ability to calculate the level of the aerosol precursor composition depending on the first and second electrical capacitances or output signals corresponding to the first and second electrical capacitances to the control component to calculate the level of the aerosol precursor composition depending on the first and second electrical capacities. 2. The cartridge of claim 1, wherein the signal indicative of the level of the aerosol precursor composition transmitted by the proximity sensor to the control component causes the control component to control the sensory feedback element to provide user-perceived feedback. 3. The cartridge of claim 1, wherein the signal indicative of the level of the aerosol precursor composition transmitted by the proximity sensor to the control component causes the control component to control at least one functional element to change the blocked state of the aerosol delivery device. 4. The cartridge of claim 1, wherein the signal indicating the level of the aerosol precursor composition transmitted by the proximity sensor to the control component causes the control component to upload to the service platform data associated with the level of the aerosol precursor composition detected by the proximity sensor.