RU2835129C1 - Aerosol delivery device with reservoir housing and evaporator unit - Google Patents

Abstract

FIELD: aerosol delivery systems.

SUBSTANCE: present invention relates to an aerosol delivery device comprising a reservoir housing forming a mouthpiece channel. The aerosol delivery device includes a sealing component configured to be placed within a reservoir casing to form a reservoir chamber configured to hold the aerosol precursor composition. The aerosol delivery device also includes a base configured to be placed in the reservoir casing and to interact directly with the evaporation unit to generate an aerosol.

EFFECT: reservoir casing, sealing component, base and/or evaporator assembly can be used to produce aerosols with precise and reproducible compositions.

20 cl, 15 dwg

Description

AREA OF TECHNOLOGY

[0001] The present invention relates to aerosol delivery devices and, in particular, to aerosol delivery devices comprising a reservoir housing and an evaporation unit that can use electrical energy to heat an aerosol precursor composition to generate an aerosol. The aerosol precursor composition, which may contain materials and/or components made or obtained from tobacco, or otherwise include tobacco, is heated by the evaporation unit to produce an inhalable substance for human consumption.

LEVEL OF TECHNOLOGY

[0002] Over the years, a variety of smoking devices have been proposed as improvements to smoking products or alternatives to smoking products that require the combustion of tobacco. Many of these devices are specifically designed to provide the sensations associated with smoking a cigarette, cigar, or pipe, but without delivering a significant amount of the incomplete combustion and pyrolysis products formed by burning tobacco. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a volatile substance or attempt to provide the sensations of smoking a cigarette, cigar, or pipe without substantially burning tobacco. For example, various known alternative smoking articles, aerosol delivery devices, and heat generating sources are described in U.S. Patent Nos. 7,726,320 (Robinson et al.) and 8,881,737 (Collett et al.), which are incorporated herein by reference. In addition, for example, various types of smoking articles, aerosol delivery devices, and electrical heat-generating sources referenced by trademark or trade name are disclosed in U.S. Patent Application Publication No. 2015/0216232 (Bless et al.), which is incorporated herein by reference. In addition, various types of electrically powered aerosol and vapor delivery devices are also disclosed in U.S. Patent Application Publication Nos. 2014/0096781 (Sears et al.), 2014/0283859 (Minskoff et al.), 2015/0335070 (Sears et al.), 2015/0335071 (Brinkley et al.), 2016/0007651 (Ampolini et al.), and U.S. Patent Application Ser. No. 14/465,167 (Worm et al.), filed August 21, 2014, which are incorporated herein by reference.

[0003] Certain existing embodiments of aerosol delivery devices include a control housing (i.e., a power source assembly) and a cartridge (i.e., a reservoir housing). The power source (e.g., a battery) can be located in the control housing, and the aerosol precursor composition can be retained and/or stored in the cartridge. The cartridge and the control housing can cooperate with each other to form an elongated tubular configuration. However, other specific structural features for aerosol delivery devices and other configurations for storing the aerosol precursor composition can be desirable.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

[0004] The present invention relates to aerosol delivery devices that can be used to generate vapor. The aerosol delivery device described herein may be advantageous in providing precise control of the aerosol composition and/or in providing reliable storage of any aerosol precursor composition.

[0005] In some aspects, the present invention provides an aerosol delivery device comprising a reservoir housing having a mouthpiece end and a connecting end and defined by an outer wall. The aerosol delivery device also comprises a mouthpiece channel in the reservoir housing defined by the outer wall. The mouthpiece channel extends at least partially along the length of the reservoir housing from the mouthpiece end of the reservoir housing to the outlet end. In addition, the mouthpiece channel may have an opening at the mouthpiece end of the reservoir housing and another opening at the outlet end of the mouthpiece channel.

[0006] According to some aspects, the aerosol delivery device may comprise a sealing component that forms a seal with the outer wall of the reservoir housing and the outer wall of the mouthpiece channel to form a reservoir chamber configured to retain the aerosol precursor composition. The sealing component may comprise at least one opening for the aerosol precursor composition configured to allow the aerosol precursor composition to flow therethrough, and may also comprise an opening of the sealing component for vapor that communicates with the opening at the outlet end of the mouthpiece channel.

[0007] In some aspects, the aerosol delivery device comprises a base located adjacent to the sealing component for fluid communication with the reservoir chamber through the sealing component. The base may also comprise a vapor opening communicating with the vapor opening of the sealing component.

[0008] According to some aspects, an aerosol delivery device may comprise a vaporizer assembly that comprises a liquid transfer element in fluid communication with a base. The vaporizer assembly may also comprise a heating element that forms a heating structure with the liquid transfer element.

[0009] The evaporation unit may also comprise at least one power connector that is operatively coupled with the heating element. In addition, the aerosol delivery device may comprise a connector housing configured to operatively couple with the power source. In some aspects, the evaporation unit may be located at least partially within the connector housing. According to some aspects, the aerosol delivery device may also comprise an atomizer housing that comprises a evaporation chamber. In some aspects, the liquid transfer element and the heating element may be located within the evaporation chamber. In addition, the evaporation chamber may be in fluid communication with the base opening for vapor. Additionally, the atomizer housing may be brought into operative communication with the connector housing. In some aspects, the opening of the sealing component for vapor may be configured to provide fluid communication between the mouthpiece passage and the evaporation unit. Additionally, the opening of the sealing component for vapor may be configured to receive at least a portion of the mouthpiece passage therein.

[0010] In some aspects, the sealing component may comprise a sealing element configured to operatively engage with the outer wall of the tank housing. For example, the sealing element may comprise a protruding portion configured to operatively engage with the outer wall of the tank housing. According to some aspects, the sealing element may comprise a protruding portion configured to operatively engage with the outer wall of the mouthpiece channel. The mouthpiece channel and the tank housing may be substantially coaxial with respect to each other.

[0011] According to some aspects, the tank housing may also comprise at least one support for a sealing component that extends along a direction substantially parallel to the longitudinal axis of the tank housing. In addition, said at least one support for a sealing component may have an outlet end. In some aspects, the outlet end of the mouthpiece channel may extend beyond the outlet end of the support for the sealing component from the mouthpiece end of the tank housing. The outlet end of the support for the sealing component may directly interact with the sealing component.

[0012] In some aspects, the present invention may provide a liquid storage container for an aerosol delivery device. The liquid storage container may comprise an outer casing defined by a wall. The outer casing may have a closed mouthpiece end and an opposite end. According to some aspects, the liquid storage container comprises a central tube located inside the outer casing and defined by the wall. The central tube may also have a first end opening passing through the closed mouthpiece end of the outer casing and a second opposite open end. In some aspects, the liquid storage container comprises a sealing component that engages in a seal with the wall of the outer casing and has a central opening aligned with the second open end of the central tube to form a seal with the wall of the central tube. Additionally, the liquid storage container may comprise a base located adjacent to the sealing component. In addition, the wall of the outer casing, the wall of the central tube and the sealing component may form a reservoir chamber configured to store the aerosol precursor composition. The sealing component may also contain at least one opening configured to allow the aerosol precursor composition to pass between the reservoir chamber and the base.

[0013] According to some aspects, the present invention may provide a method for producing a liquid storage container for an aerosol delivery device. The method may include providing a reservoir chamber that may be formed in part by an outer casing defined by a wall and a central tube located inside the outer casing and defined by the wall. The outer casing may comprise a closed mouthpiece end and an opposite connecting end. In addition, the central tube may have a first end opening passing through the closed mouthpiece end of the outer casing. Additionally, the central tube may have a second opposite open end. The method may also include dispensing an aerosol precursor composition into the reservoir chamber. In particular, the method may include dispensing an aerosol precursor composition between the wall of the outer casing and the wall of the central tube from the connecting end of the outer casing. In some aspects, the method may include inserting a sealing component into the outer casing from the connecting end of the outer casing. The sealing component has a sealing component opening for steam, and inserting the sealing component into the outer casing may include introducing the peripheral portion of the sealing component into interaction with the wall of the outer casing and introducing the sealing component opening for steam into interaction with the second open end of the central tube to form a seal. According to some aspects, the method may include inserting the base adjacent to the sealing component into the outer casing from the connecting end of the outer casing. Additionally, the base may have a base opening for steam.

[0014] According to some aspects, the method may also include inserting at least a portion of the evaporation unit into the outer casing from the connecting end of the outer casing. The evaporation unit may comprise a liquid transfer element. Additionally, inserting at least a portion of the evaporation unit into the outer casing may ensure that the liquid transfer element cooperates with a base located in the outer casing. In some aspects, the evaporation unit comprises a heating element that forms a heating structure with the liquid transfer element.

[0015] In some aspects, the sealing component also comprises a base interaction element that extends from the sealing component along a direction substantially parallel to the longitudinal axis of the outer casing. According to some aspects, inserting the base adjacent to the sealing component into the outer casing includes inserting the base interaction element through at least a portion of the base opening for steam to provide fluid communication between the first end opening of the central tube and the base opening for steam. In addition, the outer casing also comprises at least one support for the sealing component that extends along a direction substantially parallel to the longitudinal axis of the outer casing and has an outlet end. According to some aspects, inserting the sealing component into the outer casing from the connecting end of the outer casing also includes inserting the sealing component for a portion of the sealing component with the outlet end of the support for the sealing component. Additionally, the second opposite open end of the central tube extends beyond the outlet end of the support for the sealing component from the closed mouth end of the outer casing.

[0016] The present invention includes, without limitation, the following embodiments:

[0017] Embodiment 1: An aerosol delivery device comprising: a reservoir housing having a mouthpiece end and a connecting end and defined by an outer wall; a mouthpiece channel in the reservoir housing defined by the outer wall and extending at least partially along the length of the reservoir housing from the mouthpiece end of the reservoir housing to the outlet end, wherein the mouthpiece channel has an opening at the mouthpiece end of the reservoir housing and at the outlet end of the mouthpiece channel; a sealing component that forms a seal with the outer wall of the reservoir housing and the outer wall of the mouthpiece channel to form a reservoir chamber configured to retain an aerosol precursor composition, wherein the sealing component comprises at least one opening for the aerosol precursor composition configured to allow the aerosol precursor composition to flow through it, and an opening of the sealing component for vapor that communicates with an opening at the outlet end of the mouthpiece channel; a base located adjacent to the sealing component for fluid communication with the reservoir chamber through the sealing component and comprising an opening of the base for vapor that communicates with the opening of the sealing component for vapor; and an evaporation unit that comprises a liquid transfer element that communicates in fluid communication with the base, and a heating element that forms a heating structure with the liquid transfer element.

[0018] Embodiment 2: An aerosol delivery device according to any preceding or following embodiment, further comprising a connector housing configured to operably interact with a power source.

[0019] Embodiment 3: An aerosol delivery device according to any preceding or following embodiment, wherein the evaporative unit is located at least partially within the connector housing.

[0020] Embodiment 4: An aerosol delivery device according to any preceding or following embodiment, further comprising an atomizer housing, wherein the atomizer housing comprises a vapor chamber in which a liquid transfer element and a heating element are located, wherein the vapor chamber is in fluid communication with the base opening for vapor, and the atomizer housing is brought into operative interaction with the connector housing.

[0021] Embodiment 5: An aerosol delivery device according to any preceding or following embodiment, wherein the opening of the vapor sealing component is configured to provide fluid communication between the mouthpiece channel and the vaporizer assembly.

[0022] Embodiment 6: An aerosol delivery device according to any preceding or following embodiment, wherein the opening of the vapor sealing component is configured to receive at least a portion of the mouthpiece passage therein.

[0023] Embodiment 7: An aerosol delivery device according to any preceding or following embodiment, wherein the sealing component comprises a sealing element configured to operatively engage an outer wall of the reservoir housing.

[0024] Embodiment 8: An aerosol delivery device according to any preceding or following embodiment, wherein the sealing element comprises a protruding portion configured to operatively engage with an outer wall of the mouthpiece channel.

[0025] Embodiment 9: An aerosol delivery device according to any preceding or following embodiment, wherein the mouthpiece channel and the reservoir housing are substantially coaxial.

[0026] Embodiment 10: An aerosol delivery device according to any preceding or following embodiment, wherein the reservoir housing also comprises at least one support for a sealing component extending along a direction substantially parallel to the longitudinal axis of the reservoir housing and having an outlet end.

[0027] Embodiment 11: An aerosol delivery device according to any preceding or following embodiment, wherein the outlet end of the mouthpiece passage extends beyond the outlet end of the support for the sealing component from the mouthpiece end of the reservoir housing.

[0028] Embodiment 12: An aerosol delivery device according to any preceding or following embodiment, wherein the outlet end of the support for the sealing component directly engages the sealing component.

[0029] Embodiment 13: An aerosol delivery device according to any preceding or following embodiment, wherein the evaporative assembly further comprises at least one power connector operatively engaged with the heating element.

[0030] Embodiment 14: A liquid storage container for an aerosol delivery device, comprising: an outer casing defined by a wall and having a closed mouthpiece end and an opposite end; a central tube located inside the outer casing and defined by the wall, wherein the central tube has a first end opening passing through the closed mouthpiece end of the outer casing and a second opposite open end; a sealing component engaged in a seal with the wall of the outer casing and having a central opening aligned with a second open end of the central tube to form a seal with the wall of the central tube; and a base located adjacent to the sealing component; wherein the wall of the outer casing, the wall of the central tube and the sealing component form a reservoir chamber configured to store an aerosol precursor composition, and the sealing component comprises at least one opening configured to allow the aerosol precursor composition to pass between the reservoir chamber and the base.

[0031] Embodiment 15: A method of manufacturing a liquid storage container for an aerosol delivery device, comprising: providing a reservoir chamber defined in part by an outer casing defined by a wall and a central tube positioned within the outer casing and defined by the wall; wherein the outer casing has a closed mouthpiece end and an opposite connecting end, and the central tube has a first end opening passing through the closed mouthpiece end of the outer casing and a second opposite open end; dispensing an aerosol precursor composition into the reservoir chamber and between the wall of the outer casing and the wall of the central tube from the connecting end of the outer casing; inserting a sealing component having an opening of the sealing component for vapor into the outer casing from the connecting end of the outer casing with introducing a peripheral portion of the sealing component into engagement with the wall of the outer casing and introducing the opening of the sealing component for vapor into engagement with the second open end of the central tube to form a seal; and inserting a base adjacent to the sealing component into the outer casing from the connecting end of the outer casing, wherein the base has a base opening for steam.

[0032] Embodiment 16: The method according to any preceding or following embodiment, further comprising inserting at least a portion of the evaporation unit comprising the liquid transfer element into the outer casing from a connecting end of the outer casing to bring the liquid transfer element into engagement with a base located in the outer casing.

[0033] Embodiment 17: The method according to any preceding or following embodiment, wherein the evaporation unit comprises a heating element that forms a heating structure with a liquid transfer element.

[0034] Embodiment 18: The method according to any preceding or following embodiment, wherein the sealing component also comprises a base engagement element extending from the sealing component along a direction substantially parallel to the longitudinal axis of the outer casing, wherein inserting the base adjacent to the sealing component into the outer casing includes inserting the base engagement element through at least a portion of the base steam opening to provide fluid communication between the first end opening of the central tube and the base steam opening.

[0035] Embodiment 19: The method according to any preceding or following embodiment, wherein the outer casing also comprises at least one support for a sealing component extending along a direction substantially parallel to the longitudinal axis of the outer casing and having a terminal end, wherein inserting the sealing component into the outer casing from the connecting end of the outer casing also includes inserting the sealing component to directly engage a portion of the sealing component with the terminal end of the support for the sealing component.

[0036] Embodiment 20: The method of any preceding or following embodiment, wherein the second opposite open end of the central tube extends beyond the terminal end of the support for the sealing component from the closed mouth end of the outer casing.

[0037] These and other features, aspects and advantages of the present disclosure will become apparent from reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more of the above embodiments, as well as combinations of any two, three, four or more features or elements set forth in this description, regardless of whether such features or elements are explicitly combined in a specific description of an embodiment presented herein. This description is intended to be read taking into account all elements, such that any separable features or elements of the disclosed invention in any of its various aspects and embodiments are to be considered as combinable unless the context clearly indicates otherwise.

[0038] It should be understood that the above "Summary of the Invention" section is presented only for the purpose of briefly describing some exemplary aspects in order to provide a basic understanding of some aspects of the present invention. Thus, it should be understood that the above-described exemplary aspects are only examples of some aspects and should not be construed as limiting the scope or spirit of the invention in any way. It should be understood that the scope of the present invention covers many potential aspects, some of which will be further described below in addition to those generally set forth herein. Additionally, these and other features, aspects and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, which show, by way of example, the principles of the described aspects.

BRIEF DESCRIPTION OF DRAWINGS

[0039] To facilitate understanding of aspects of the present invention, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale and in which like reference numerals refer to like elements. The drawings are examples only and should not be construed as limiting the present invention.

[0040] FIG. 1 is a perspective view of an aerosol delivery device according to an exemplary aspect of the disclosure of the present invention.

[0041] FIG. 2 is a perspective view of an aerosol delivery device according to another example aspect of the disclosure of the present invention.

[0042] FIG. 3 is a partially exploded view of an aerosol delivery device with a reservoir housing shown transparent for convenience, according to an example aspect of the disclosure of the present invention.

[0043] FIG. 4 is a perspective view of a tank housing according to an example aspect of the disclosure of the present invention.

[0044] FIG. 5 is a perspective view of a tank housing and a tank chamber formed in part by the tank housing, according to an example aspect of the disclosure of the present invention.

[0045] FIG. 6 is a perspective view of a sealing component, a base, and an evaporator assembly according to an example aspect of the disclosure of the present invention.

[0046] FIG. 7A is a perspective view from above of a sealing component and base according to an exemplary aspect of the disclosure of the present invention.

[0047] FIG. 7B is a perspective view from below of a sealing component and base according to an exemplary aspect of the disclosure of the present invention.

[0048] FIG. 8 is a perspective view of a near end of an evaporator assembly according to an example aspect of the disclosure of the present invention.

[0049] FIG. 9 is a perspective view of a distal end of an evaporator assembly according to an example aspect of the disclosure of the present invention.

[0050] FIG. 10 is a perspective view of an evaporator assembly having a connector housing (shown removed from the evaporator assembly for clarity of view) according to an example aspect of the disclosure of the present invention.

[0051] FIG. 11 is a perspective view of an evaporator assembly having a connector housing (shown removed from the evaporator assembly for clarity of view) according to an example aspect of the disclosure of the present invention.

[0052] FIG. 12 is a perspective view of an evaporator assembly operatively engaged with a base and a sealing component according to an exemplary aspect of the disclosure of the present invention.

[0053] FIG. 13 is a schematic block diagram of a method for assembling an aerosol delivery device according to an example aspect of the disclosure of the present invention.

[0054] FIG. 14A is a sectional view of a portion of a tank housing according to an exemplary aspect of the disclosure of the present invention.

[0055] FIG. 14B is a sectional view of a portion of a tank housing according to an exemplary aspect of the disclosure of the present invention.

[0056] FIG. 14C is a sectional view of a portion of a tank housing according to an exemplary aspect of the disclosure of the present invention.

[0057] FIG. 14D is a sectional view of a portion of a tank housing according to an exemplary aspect of the disclosure of the present invention.

[0058] FIG. 15 is a bottom view of the tank housing shown in FIG. 14C, according to an example aspect of the disclosure of the present invention.

IMPLEMENTATION OF THE INVENTION

[0059] The present invention will now be described in more 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 a full disclosure of its scope 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 herein; rather, these embodiments are presented in such a way that the present invention satisfies the relevant requirements of law. As used in the description and in the appended claims, the singular forms "a" and "an" include plural forms unless the context clearly dictates otherwise.

[0060] As described further, embodiments of the disclosure of the present invention relate to aerosol delivery systems. Aerosol delivery systems according to the disclosure of the present invention use electrical energy to heat a material (preferably without burning the material to any significant extent and/or without substantially chemically changing the material) to form a respirable substance; wherein components of such systems are in the form of articles that are most preferably sufficiently compact to be considered "portable" devices. In other words, use of components of the preferred aerosol delivery systems does not result in the generation of smoke - i.e., by-products of combustion or pyrolysis of tobacco, but rather use of these preferred systems results in the generation of vapors/aerosols resulting from the volatilization or evaporation of certain components included therein. In preferred embodiments, the components of the aerosol delivery systems may be characterized as electronic cigarettes, wherein such electronic cigarettes most preferably contain tobacco and/or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0061] Aerosol-generating articles of certain preferred aerosol delivery systems may create a variety of sensations (e.g., inhalation and exhalation rituals, flavor or aroma types, organoleptic effects, physical sensation, rituals of use, visual stimuli such as those created by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe that are achieved by lighting and burning tobacco (and thus inhaling tobacco smoke) without actually burning any of its components to any significant degree. For example, a user of an aerosol-generating article according to the disclosure of the present invention may hold and use this article in a manner very similar to how a smoker uses a smoking article of a traditional type (e.g., a cigarette, cigar or pipe used by lighting a flame and inhaling tobacco, which is then burned and/or combusted), draw on one end of such an article to inhale the aerosol generated by this article, puff at selected time intervals, and the like. However, the devices described herein are not limited to devices that are substantially the shape and size of a traditional cigarette. Rather, the devices according to the disclosure of the present invention may have any shape and may be substantially larger than a traditional cigarette. In certain preferred aspects, the devices may be compact enough to be considered "portable" devices.

[0062] Aerosol delivery devices according to the disclosure of the present invention may also be characterized as vapor-generating articles or drug delivery articles. Thus, such articles or devices may be adapted to deliver one or more substances (e.g., flavoring agents 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 lower than its critical point). According to an alternative embodiment, 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 that are suitable for inhalation by a person, regardless of whether they are visible or not and whether they have a form that can be considered "smoke-like" or not.

[0063] Aerosol delivery devices according to the disclosure of the present invention generally comprise a number of components located within an outer housing or casing, which may be referred to as a housing. The overall design of the outer housing or casing may vary, and the configuration and format of the outer housing, which may define the overall size and shape of the aerosol delivery device, may also vary. In exemplary embodiments, an elongated housing resembling a cigarette or cigar in shape may be formed from a single integral housing, or the elongated housing may be formed from two or more separable housings. For example, the aerosol delivery device may comprise an elongated casing or body, which may be substantially tubular in shape and accordingly resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are located within a single housing. In an alternative embodiment, the aerosol delivery device may comprise two or more housings that are removably connected to each other. For example, an aerosol delivery device may have two housings that are substantially aligned in an axial direction when connected and may contain at one end a control housing that includes a housing that encloses one or more components (e.g., a battery and various electronics for controlling the operation of the article), and at the other end of the device an outer housing or shell that encloses aerosol-forming components (e.g., one or more aerosol precursor components, such as flavors and aerosol-forming substances, one or more heaters, and/or one or more wicks) may be detachably attached thereto. However, the aerosol delivery devices described herein are not limited to devices that include two housings that are substantially aligned in an axial direction when connected to each other.

[0064] Aerosol delivery devices according to the disclosure of the present invention may be formed by an outer housing or shell that is not substantially tubular in shape, but may be configured to be substantially larger in size - i.e., substantially "palm-sized" for holding in the palm of a user. The housing or shell may be configured to contain a mouthpiece and/or may be configured to receive a separate shell (e.g., a cartridge) that may contain consumable elements, such as a liquid aerosol-forming substance, and may contain a vaporizer or atomizer.

[0065] Aerosol delivery devices according to the disclosure of 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 electrical power, controlling the electrical power, regulating and stopping the electrical 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 microcontroller or a microprocessor), a heater or heat generating member (e.g., an electrical resistive heating element or other component that, alone 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 upon the application of sufficient heat, such as ingredients commonly referred to as “smoking juice,” “e-liquid,” and “e-juice”), and a mouthpiece or mouthpiece region for allowing a puff from the aerosol delivery device to be drawn into the aerosol (e.g., a given air flow path through the product so that the generated aerosol can be drawn through it when inhaled).

[0066] More specific structures, configurations, and arrangements of components in aerosol delivery systems according to the disclosure of the present invention will become apparent in light of the further description provided below. In addition, the selection and arrangement of various components of the aerosol delivery system may become apparent upon review of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of the present disclosure. One example of an aspect of an aerosol delivery device 10 according to the disclosure of the present invention is shown in FIG. 1. The aerosol delivery device 10 may comprise a reservoir housing 200, a vaporizer assembly 300, and a power supply assembly 600 that may be operatively engaged with one another. In one aspect, the reservoir housing 200 and the vaporizer assembly 300 may be permanently or detachably engaged to form an operative relationship. The functional interaction between the reservoir housing 200 and the evaporative assembly 300 may be accomplished by a press fit, a threaded interaction, an interference fit, a magnetic interaction, ultrasonic welding, and/or the like. In some aspects, the evaporative assembly 300 and the power source assembly 600 may directly and operatively interact with each other. For example, the evaporative assembly 300 and the power source assembly 600 may be configured to be detachable from each other and may be mechanically engaged to form a functional connection. In some aspects, the evaporative assembly 300 and the power source assembly 600 may be engaged with each other to form a functional connection such that the power source assembly 600 supplies electrical power to the evaporative assembly 300 and/or provides additional functional controls, as described in more detail herein. According to another aspect, as shown in FIG. 2, the reservoir housing 200 may be operatively coupled with the power source assembly 600 and may comprise therein an evaporative assembly configured to operatively couple with a power source located within the power source assembly 600. Alternatively, the evaporative assembly may be located within the power source assembly 600 and may be configured to operatively couple with the reservoir housing, which is removably coupled with the power source assembly 600 to form an operative connection. Additional aspects of such devices are described in U.S. Patent Application Ser. No. 14/465,167 (Worm et al.), filed August 21, 2014, and U.S. Patent Application Ser. No. 14/981,051 (Phillips et al.), filed December 28, 2015, the disclosures of which are incorporated herein by reference.

[0067] According to some aspects, one or any of the reservoir housing 200, the evaporation assembly 300, and/or the power source assembly 600 may be referred to as disposable or as reusable. For example, the power source assembly 600 may comprise a replaceable power source, such as a replaceable battery. In another aspect, the power source assembly may comprise a rechargeable battery and thus may be combined with any type of charger, including a connection to a conventional electrical network, a connection to a vehicle charger (e.g., a cigarette lighter receptacle), and/or a connection to a computer, such as via a universal serial bus (USB) cable. For example, an adapter including a USB connector at one end and a control housing connector at the opposite end is disclosed in U.S. Patent Application Publication No. 2014/0261495 (Novak et al.), which is incorporated herein by reference in its entirety. Examples of suitable rechargeable power sources include lithium-ion batteries and, more particularly, lithium-polymer batteries. Additional examples of batteries that can be used according to the present invention are described in U.S. Patent Application Publication No. 2010/0028766 (Peckerar et al.), the disclosure of which is incorporated herein by reference in its entirety.

[0068] In another aspect, the reservoir housing 200 and the vaporizer assembly 300 may be securely connected and/or attached to each other to form a disposable, single-use cartridge. For example, the reservoir housing 200 may contain a limited amount of an aerosol precursor composition to create a variety of sensations (e.g., inhalation and exhalation rituals, types of tastes or aromas, organoleptic effects, etc.) of smoking a certain number of traditional-type smoking articles (e.g., cigarettes, cigars, pipes, etc.). In some aspects, the reservoir housing 200 may contain a specific amount of an aerosol precursor composition equivalent to the number of traditional-type smoking articles that someone might consume to obtain the sensations of smoking a typical number of traditional-type smoking articles (e.g., a typical pack of cigarettes - i.e., twenty (20) cigarettes). According to an additional or alternative embodiment, the reservoir housing 200 and the evaporation unit 300 can be securely engaged with each other to prevent damage and/or alteration of the aerosol precursor composition stored in the reservoir chamber 210.

[0069] As shown in FIG. 1, the aerosol delivery device 10 defines a longitudinal axis Y that extends from the first end 12 to the opposite second end 14 of the aerosol delivery device 10. The aerosol delivery device 10 may be substantially rod-shaped or have a substantially tubular or cylindrical shape in some aspects. Although the aerosol delivery device 10 is shown as having a substantially tubular and cylindrical shape in FIG. 1, other suitable shapes and sizes (e.g., rectangular or triangular in cross-section, or the like) are also encompassed by the present invention.

[0070] Referring to FIG. 3, the reservoir housing 200 comprises a first closed mouthpiece end 202 and an opposite second connecting end 204. In addition, the reservoir housing 200 comprises an outer wall 201 that extends from the mouthpiece end 202 to the connecting end 204 along a direction parallel to the longitudinal axis Y of the aerosol delivery device 10. In some aspects, the reservoir housing 200 may comprise a mouthpiece portion 206 located in close proximity to the mouthpiece end 202 of the reservoir housing 200, and a storage portion 208 that extends from the mouthpiece portion 206 to the connecting end 204 of the reservoir housing 200. In addition, the storage portion 208 may extend from the mouthpiece portion 206 to the connecting end 204 along a direction parallel to the longitudinal axis Y of the aerosol delivery device 10. According to some aspects, the storage portion 208 may be configured to accommodate various components of the aerosol delivery device 10 within the outer wall 201 of the housing 200 of the reservoir, as described in more detail below.

[0071] In some aspects, the mouthpiece portion 206 located in close proximity to the mouthpiece end 202 of the reservoir housing 200 may comprise a conical portion of a smaller diameter than other portions (for example, the storage portion 208) of the reservoir housing 200. According to some aspects, the aerosol delivery device 10 may comprise a mouthpiece passage 216 formed by an outer wall 217 located inside the reservoir housing 200. For example, the mouthpiece passage 216 may be formed by an outer wall 217 that has the shape of a substantially cylindrical tube and is located inside with respect to the outer wall 201 of the reservoir housing 200. In addition, the mouthpiece passage 216 may comprise an opening 214 located in close proximity to the mouthpiece end 202 of the reservoir housing 200. The opening 214 can provide an outlet of the generated aerosol from the aerosol delivery device 10. In particular, the mouthpiece channel 216 can be configured to communicate via a fluid medium with the opening 214. In addition, the mouthpiece channel 216 can comprise a second opening 215 located in close proximity to the outlet end 219 of the mouthpiece channel 216. The second opening 215 can also communicate via a fluid medium with the mouthpiece channel 216 and also provide an outlet of the generated aerosol from the aerosol delivery device 10.

[0072] As shown in FIGS. 3 and 5, the mouthpiece passage 216 may have a substantially tubular and cylindrical shape. In addition, the mouthpiece passage 216 may extend from the mouthpiece end 202 to the outlet end 219 of the mouthpiece passage 216. In some aspects, the mouthpiece passage 216 may extend from the mouthpiece end 202 toward the connection end 204 of the reservoir housing 200 along a direction parallel to the longitudinal axis Y of the aerosol delivery device 10. In some aspects, the mouthpiece bore 216 may taper as it extends from the first end to the second end of the mouthpiece bore 216. According to some aspects, the mouthpiece bore 216 may be shaped and/or positioned so as to prevent the likelihood of a meniscus forming within the mouthpiece bore 216. For example, as shown in FIG. 14A, the shape of the mouthpiece bore 216 may include a first portion 230, a second portion 232, and a transition therebetween that includes an oval opening 234. According to another aspect, as shown in FIG. 14B, the shape of the mouthpiece channel 216 may include a first portion 230, a second portion 232, and a projecting portion 236 located in close proximity therebetween that provides a seal for the fluid configured to minimize the formation of a thickening within the mouthpiece channel 216. In some aspects, as shown in FIGS. 14C and 14D, the mouthpiece channel 216 may comprise corrugated elements 238 extending radially inward from the outer wall 217 that defines the mouthpiece channel 216. According to some aspects, as shown in FIG. 15, the corrugated elements 238 may extend radially inward from the outer wall 217 so as to define a radial cross-section of the mouthpiece channel 216 in the shape of a star configured to prevent the formation of a meniscus therein. In addition, the mouthpiece channel 216 may pass through the reservoir chamber 210 formed by the reservoir housing 200 and may be in fluid communication with the evaporator unit 300, as described in more detail herein.

[0073] Referring to FIGS. 3 and 5, the storage portion 208 may partially form a reservoir chamber 210 configured to store the aerosol precursor composition. As noted above, the reservoir housing 200 may have a substantially tubular shape and, more particularly, the storage portion 208 may have a substantially tubular and/or cylindrical shape. As shown in FIG. 5, the outer wall 201, which forms the casing 200 of the reservoir of a substantially cylindrical tubular shape, can comprise an inner surface 212. In addition, the outer wall 217, which forms the mouthpiece channel 216, can comprise an outer surface 218. The inner surface 212 of the outer wall 201, which forms the casing 200 of the reservoir, and the outer surface 218 of the outer wall 217, which forms the mouthpiece channel 216, can partially form a chamber 210 of the reservoir, adapted to retain a certain amount of the aerosol precursor composition.

[0074] In some aspects, the reservoir housing 200 may also comprise at least one support 220 for a sealing component. According to one aspect, and as particularly shown in FIGS. 3 and 5, the reservoir housing 200 may comprise four supports 220 for a sealing component located around the inner surface 212 of the outer wall 201 of the reservoir housing 200 at substantially equal angular intervals around the longitudinal Y-axis of the aerosol delivery device 10. Although the reservoir housing 200 is shown as having four supports 220 for a sealing component, one skilled in the art will understand that any number of supports for a sealing component are encompassed by the present invention. In some aspects, at least one support 220 for the sealing component may be formed integrally with the inner surface 212 of the outer wall 201. In another aspect, the support 220 for the sealing component may be securely attached to the inner surface 212 of the tank housing 200.

[0075] Referring to FIGS. 3 and 5, the supports 220 for the sealing component may extend in close proximity to the mouth end 202 of the reservoir housing to the outlet end 221 along a direction substantially parallel to the longitudinal axis Y of the aerosol delivery device 10. In some aspects, the supports 220 for the sealing component may extend in a longitudinal direction along the inner surface 212 of the outer wall 201 of the reservoir housing 200. In addition, the supports 220 for the sealing component can extend along a direction substantially parallel to the mouthpiece channel 216. According to some aspects, the mouthpiece channel 216 extends a greater distance along a direction substantially parallel to the longitudinal axis Y of the aerosol delivery device 10 10 than the distance that any support 220 for the sealing component extends along a direction substantially parallel to the longitudinal axis Y of the aerosol delivery device 10, as shown in FIG. 3. In particular, the outlet end 219 of the mouthpiece channel 216 extends beyond the outlet end 221 of the support 220 for the sealing component from the mouthpiece end 202 of the reservoir housing 200.

[0076] As shown in FIGS. 3 and 5, the connecting end 204 of the reservoir housing 200 may be configured to receive a sealing component 500 therein. The sealing component 500 may be configured to directly interact with the reservoir housing 200 so as to form a reservoir chamber 210 configured to retain the aerosol precursor composition. In addition, the sealing component 500 may form a seal with the outer wall 201 of the reservoir housing 200 and the outer wall 217 of the mouthpiece channel 216 so as to form the reservoir chamber 210. In particular, the sealing component 500 can be configured to directly interact with the inner surface 212 of the storage portion 208 and the outer surface 218 of the mouthpiece channel 216 to form a seal in such a way that the sealing component 500, the inner surface 212 of the storage portion 208 and the outer surface 218 of the mouthpiece channel 216 form a chamber 210 of the reservoir. In addition, the support 220 for the sealing component can be configured to directly interact with the sealing component 500 when the sealing component 500 is located and/or accommodated in the casing 200 of the reservoir.

[0077] According to one aspect, the sealing component 500 can be configured to directly interact with the inner surface 212 of the storage portion 208 so as to substantially prevent the aerosol precursor composition from passing through the circumferential surface 502 of the sealing component 500, which directly interacts with the inner surface 212 of the storage portion 208 to form a seal. For example, the circumferential surface 502 of the sealing component 500 can further comprise at least one sealing element 504 that extends in a radial direction from it, as particularly shown in FIGS. 7A and 7B. The sealing element 504 can be configured to directly interact with the inner surface 212 of the storage portion 208. In some aspects, the sealing element 504 may comprise a plurality of ridges, projections and/or the like that extend radially from and along the peripheral surface 502 of the sealing component 500 and are configured to directly and operatively engage with the inner surface 212 of the reservoir housing 200. When directly engaging with the inner surface 212, the sealing element 504 may be configured to substantially limit and/or prevent the passage of the aerosol precursor composition located in the reservoir chamber 210 through the peripheral surface 502 of the sealing component 500 when the sealing component 500 is brought into operative and direct engagement with and positioned in the reservoir housing 200.

[0078] In addition, the mouthpiece channel 216 can be configured to directly interact with the sealing component 500 when the sealing component 500 is located and/or accommodated in the housing 200 of the reservoir. Referring to FIG. 7A, the sealing component 500 can form an opening 506 of the sealing component for steam that passes through it. In addition, the sealing component 500 can also include a protruding portion 508 that can partially form a part of the opening 506 of the sealing component for steam. For example, as shown in FIG. 12, the protruding portion 508 can have the form of an annular element that forms a medial portion of the opening 506 of the sealing component for steam. According to another aspect, the protruding portion 508 can form a distant or proximal portion of the opening 506 of the sealing component for steam. Additionally, the portion of the opening 506 of the sealing component for steam formed by the protruding portion 508 of the annular shape may have a smaller diameter than the diameter of at least another portion of the opening 506 of the sealing component for steam. Furthermore, when the sealing component 500 is brought into functional interaction with the casing 200 of the tank (for example, the circumferential peripheral surface 502 directly interacts with the inner surface 212 of the casing of the tank to form a seal, etc.), the protruding portion 508 of the annular shape may be configured to directly interact with the mouthpiece channel 216 to form a seal. In particular, the projecting portion 508 provides a seat for the mouthpiece channel 216 in a substantially abutting manner such that the sealing component 500, the inner surface 212 of the casing 200 of the reservoir and the outer surface 218 of the mouthpiece channel 216 enclose a volume that forms the chamber 210 of the reservoir.

[0079] In some aspects, the opening 506 of the steam sealing component may be configured to provide fluid communication between the mouthpiece passage 216 and the evaporator assembly 300 when the mouthpiece passage 216 is located within the opening 506 of the steam sealing component and/or substantially abuts against the protruding portion 508 of the opening 506 of the steam sealing component. For example, when the mouthpiece channel 216 substantially abuts against the protruding portion 508, the opening 506 of the sealing component for the vapor can provide fluid communication between the mouthpiece channel 216 and the evaporator unit 300 such that the aerosol, vapor and/or the like generated by the evaporator unit 300, which heats the aerosol precursor composition, can exit the aerosol delivery device 10 through the opening 215 located in close proximity to the outlet end 219 of the mouthpiece channel 216, through the mouthpiece channel 216 and through the opening 214 located in close proximity to the mouthpiece end 202 of the reservoir housing 200. According to some aspects, when the mouthpiece channel 216 substantially abuts the projecting portion 508 and/or is located within the opening 506 of the sealing component for steam, the functional interaction between the mouthpiece channel 216 and the opening 506 of the sealing component for steam and/or the projecting portion 508 can provide an airtight seal or a fluid-tight seal therebetween. The functional interaction between the mouthpiece channel 216 and the opening 506 of the sealing component for steam and/or the projecting portion 508 can advantageously prevent and/or substantially limit the entry of an aerosol, steam and/or the like, formed by the evaporative unit 300, into the chamber 210 of the reservoir. In a further or alternative embodiment, the functional interaction between the mouthpiece channel 216 and the opening 506 of the sealing component for the vapor and/or the protruding portion 508 may advantageously prevent and/or substantially limit the entry of the aerosol precursor composition retained in the reservoir chamber 210 into the mouthpiece channel 216, the opening 506 of the sealing component for the vapor and/or the evaporator assembly 300.

[0080] According to some aspects, the sealing component 500 may also be configured to directly engage the at least one sealing component support 220 when the circumferential peripheral surface 502 of the sealing component 500 is directly engaged with the inner surface 212 of the tank housing 200 and/or when the steam opening 506 of the sealing component and/or the protruding portion 508 of the sealing component 500 is directly engaged with the mouthpiece channel 216. In this regard, the first flat surface 510 of the sealing component 500 may be oriented, directed, facing, and/or the like toward the tank chamber 210 when the sealing component 500 is operatively engaged with the tank housing 200. In addition, when the sealing component 500 is brought into operative interaction with the tank casing 200 and/or when the mouthpiece channel 210 is located in the opening 506 of the sealing component for steam and/or substantially abuts the projecting portion 508, the support 220 for the sealing component can substantially abut the first flat surface 510. In particular, the terminal end 221 of the support 220 for the sealing component can substantially abut the first flat surface 510 of the sealing component 500 so as to prevent the peripheral portions of the sealing component 500 from being shifted in the longitudinal direction toward the mouthpiece end 202 of the tank casing 200. As shown in FIG. 7A, the longitudinal distance A is located between the projecting portion 508 and the first flat surface 510 of the sealing component 500 such that the length of the distance A between the projecting portion 508 and the first flat surface 510 of the sealing component 500 corresponds to the difference in length between the length of the mouthpiece channel 210 and the length of the support 220 for the sealing component, as described earlier in this document.

[0081] As shown in FIG. 7B, the sealing component 500 may also define a base engaging element 514 that extends along a direction parallel to the longitudinal axis Y of the aerosol delivery device 10. In particular, the base engaging element 514 may extend from a second flat surface 512 that is located opposite the first flat surface 510 relative to the longitudinal axis Y of the sealing element 500. In some aspects, and as particularly shown in FIG. 6 and 12, the sealing component 500 can be configured to operatively interact with the base 400. For example, the base interaction element 514 can be configured to directly interact with the base 400 so as to limit the radial displacement of the base 400 from the longitudinal Y axis of the aerosol delivery device 10 relative to the sealing component 500. In particular, the base interaction element 514 can be located inside the base opening 402 for vapor, which is formed by the base 400. In some aspects, the base opening 402 for vapor of the base 400 can completely pass through the base 400, and the diameter of the base opening 402 for vapor can be substantially consistent along the entire length of the base opening 402 for vapor. According to some aspects, the largest diameter of the base engaging element 514 may be substantially equal to the diameter of the base opening 402 for steam such that when the base engaging element 514 is inserted therein, the base 400 is prevented from radially shifting from the longitudinal axis Y relative to the sealing component 500. The functional interaction between the base engaging element 514 of the sealing component 500 and the base opening 402 for steam may include a friction fit, a press fit, an interference fit, and/or the like such that the radial shift between the sealing component 500 and the base 400 is substantially limited.

[0082] Furthermore, the base opening 402 for vapor may be configured to provide fluid communication between any of the opening 214 of the mouthpiece passage 210 of the reservoir housing 200, the opening 506 for vapor of the sealing component 500 and the evaporator assembly 300 such that the aerosol, vapor and/or the like generated by the evaporator assembly 300, which heats the aerosol precursor composition, can exit the aerosol delivery device 10 through the base opening 402 for vapor, the opening 506 of the sealing component for vapor, the second opening 215 of the mouthpiece passage 216, the mouthpiece passage 216 and the opening 214 of the mouthpiece passage 216 located in close proximity to the mouthpiece end 202 of the reservoir housing 200.

[0083] As shown in FIG. 6-7B, the sealing component 500 may also define at least one opening 516 for the aerosol precursor composition that passes therethrough. In some aspects, the sealing component 500 may comprise four openings 516 for the aerosol precursor composition that are arranged about the longitudinal axis Y of the aerosol delivery device 10 at substantially equal angular intervals. The at least one opening 516 for the aerosol precursor composition is configured to provide fluid communication between the reservoir chamber 210 and the base 400. In particular, the base 400 may have a first flat surface 404 that substantially abuts a second flat surface 512 of the sealing component 500 when the base engaging member 514 is directly engaged with the opening 402 of the base for vapor. In addition, portions of the first flat surface 404 of the base 400 may be open to corresponding openings 516 for the aerosol precursor composition when the first flat surface 404 of the base 400 substantially abuts the second flat surface 512 of the sealing component 500.

[0084] According to some aspects, the sealing component 500 may comprise any suitable number of aerosol precursor composition openings 516 so as to ensure accurate transfer of a desired amount of the aerosol precursor composition from the reservoir chamber 210 to the base 400. The aerosol precursor composition openings 516 may be shaped and/or configured to ensure transfer of small volumes of liquid (i.e., aerosol precursor composition and/or components thereof), such as a milliliter or less, a microliter or less, from the reservoir chamber 210 to the base 400. In a further and/or alternative embodiment, the aerosol precursor composition openings 516 may be shaped and/or configured to substantially limit and/or prevent premature evaporation of any amount of the aerosol precursor composition retained in the reservoir chamber 210 (i.e., evaporation prior to delivery to the evaporation unit 300). For example, the opening 516 for the aerosol precursor composition may be shaped and/or configured so that the pressure inside the reservoir chamber 210 does not decrease below the operating threshold during use of the aerosol delivery device 10. In some aspects, the opening 516 for the aerosol precursor composition may be approximately 0.047 mm. According to another aspect, the opening 516 for the aerosol precursor composition may be approximately 0.065 mm. According to yet another example of an aspect, the opening 516 for the aerosol precursor composition may be approximately 0.080 mm. In addition, the size of the opening 516 for the aerosol precursor composition may be set in response to the surface energy of the aerosol precursor composition retained in the reservoir chamber 210. Such sizing may be particularly suitable for substantially limiting the mass flow of liquid from the reservoir chamber 210 until a negative pressure is applied (i.e., by performing a puff on the mouth end 202 of the device), when the desired volume of liquid can be released through the openings 516 for the aerosol precursor composition. Accordingly, the opening(s) for the aerosol precursor composition may have a size in the range of about 0.02 mm to about 0.11 mm, from about 0.03 mm to about 0.1 mm, or from about 0.04 mm to about 0.09 mm. When a plurality of openings for the aerosol precursor composition are provided, each opening may have substantially the same size, or two or more openings may have different sizes. In an additional or alternative embodiment, another approach, when determining the dimensions of the opening(s) 516 for the aerosol precursor composition, may include the density of the base, the amount of negative pressure inside the aerosol delivery device during use by the user and/or the selection of materials of the sealing component 500. Thus, the sealing component 500 can ensure the transfer of the aerosol precursor composition from the reservoir chamber 210 to the base 400 in small, precise volumes and can provide improved aerosol formation and/or a reduction in unnecessary power consumption.

[0085] Although FIGS. 3 and 5 show the reservoir housing 200 defining a single reservoir chamber 210 when the sealing component 500 is positioned within and operatively interacts with the reservoir housing 200, one skilled in the art will appreciate that the aerosol delivery device 10 may comprise a reservoir housing 200 that defines any number of reservoir chambers 210. For example, in some aspects, the sealing component 500 that defines four openings 516 for the aerosol precursor composition may be brought into operative interaction with the reservoir housing 200 that defines four separate reservoir chambers 210, each of which has its own compartment and is separate from another chamber. More particularly, each of the separate reservoir chambers will be configured to be in fluid communication with a corresponding opening for the aerosol precursor composition and will not be in fluid communication with any other reservoir chamber. In some aspects, the components of the aerosol precursor composition may be separated and distributed into chambers in separate chambers of the reservoir and may be supplied to the base 400 in specific amounts based at least in part on the shape, configuration and/or size of a particular aerosol precursor composition opening 516 that is in fluid communication with the corresponding chamber of the reservoir.

[0086] Although the base 400 is shown as having a substantially annular shape in FIGS. 7A and 7B, other suitable shapes and sizes (e.g., a rectangular ring, a triangular ring, etc.) are also encompassed by the present invention. In some aspects, the base 400 may have a relatively small thickness (e.g., from about 1 mm to about 20 mm, from about 1.5 mm to about 15 mm, or from about 2 mm to about 10 mm). Furthermore, FIGS. 7A and 7B show that the first flat surface 404 of the base 400 defines a surface area that is substantially equal to the surface area opposite the second flat surface 406 of the base 400. Although in FIG. 7A and 7B show that the surface area of the first flat surface 404 and the surface area of the second flat surface 406 of the base 400 are substantially equal to each other, it will be understood by one skilled in the art that the corresponding surface areas of the first and second flat surfaces 404, 406 may differ in magnitude from each other. According to some aspects, the base 400 defines a surface area of the first and second flat surfaces 404, 406 that is from about 0.5 cm ² to about 50 cm ² , from about 1 cm ² to about 45 cm ² , from about 2 cm ² to about 40 cm ² , or from about 3 cm ² to about 30 cm ² .

[0087] The base 400 can be made of any material that is sufficiently and/or substantially inert with respect to the aerosol precursor composition and with respect to the degree of heating required to evaporate the aerosol precursor composition. In particular, the base 400 does not chemically react with the components of the aerosol precursor composition (including aerosol-forming materials, flavoring materials, etc.). In addition, the base 400 is preferably thermally and mechanically stable under the conditions of use. For example, the base 400 can be made of a material that is thermally stable at a temperature of from about 100°C or more, from about 150°C or more, from about 200°C or more, from about 300°C or more, from about 400°C or more, or from about 500°C or more. In some aspects, the base 400 can comprise a plurality of layers of nonwoven fibers. For example, the base 400 may comprise cellulose acetate (CA) fibers, bicomponent polyethylene terephthalate (PET) fibers, polyvinyl alcohol (PVA) fibers, and/or the like. Other materials, such as glass fiber fibers, are also encompassed by the present invention. In a further or alternative embodiment, the base 400 may comprise glass fiber fibers, a porous ceramic material, in particular a silicon-based material, a silicon nitride material, and/or a porous glass or quartz material. Additionally, certain thermoplastic materials, such as a cycloolefin copolymer (COC), may be included in the base 400. In a further and/or alternative embodiment, the base 400 may comprise wicks and/or porous materials that allow the aerosol precursor composition to move therethrough (e.g., by capillary action) such that the aerosol precursor composition can be drawn into the liquid transfer element 314, as described in more detail below. The base 400 may comprise any combination of materials to provide capillary action so as to provide the liquid transfer element 314 with an amount of an aerosol precursor composition, as described in U.S. Patent Application Ser. No. 14/989,109, filed January 5, 2016, which is incorporated herein by reference in its entirety.

[0088] Referring to FIG. 8, the evaporative assembly 300 configured to be at least partially received in the reservoir housing 200 may comprise an atomizer housing 306 and a connector housing 330 operatively engaged therewith. In particular, the atomizer housing 306 may be located in close proximity to the evaporative end 302 of the evaporative assembly 300, and the connector housing 300 may be located in close proximity to the opposite connecting end 304 of the evaporative assembly 300. According to some aspects, the atomizer housing 306 may be operatively engaged with the connector housing 330 by means of a friction fit, an interference fit, a magnetic interaction, a lock fit, and/or the like. In some aspects, the atomizer housing 306 and the connector housing 330 may be securely attached and/or connected to each other by ultrasonic welding and/or the like. Although the atomizer housing 306 and the connector housing 330 are shown as separate elements, the atomizer housing 306 and the connector housing 330 may be formed integrally with each other.

[0089] The atomizer housing 306 and/or the connector housing 330 may have such a size and/or shape that the atomizer housing 306 and/or at least a portion of the connector housing 330 are located in the reservoir housing 200, as shown in FIG. 1. In some aspects, the atomizer housing 306 may comprise a plurality of sealing elements 308 configured to directly engage the inner surface 212 of the reservoir housing 200. In some aspects, the sealing element 308 may comprise a plurality of ridges, projections, and/or the like that extend in a circumferential direction along a peripheral surface of the atomizer housing 306. In particular, the sealing elements 308 can be configured to substantially limit and/or prevent the passage of the aerosol precursor composition and/or the aerosol formed in the evaporation chamber 310 through the sealing elements 308 located on the peripheral surface of the atomizer housing 306 and exiting the aerosol delivery device 10 by means other than the mouthpiece channel 216 and/or the openings 214, 215 of the mouthpiece channel 216.

[0090] In addition, the aerosol delivery device 10 comprises an atomizer 312 located in the evaporation chamber 310. The atomizer 312 comprises a liquid transfer element 314 that comprises a first end 314a and a second end 314b. When the evaporation unit 300 is brought into operative engagement with the base 400 and, more particularly, when the evaporation end 302 of the evaporation unit 300 substantially abuts the base 400, as shown in FIG. 6, 9 and 12, each end of the first and second ends 314a, 314b of the liquid transfer element 314 directly interacts with the base 400. For example, the first and second ends 314a, 314b of the liquid transfer element 314 can substantially abut a portion of the second flat surface 406 of the base 400 such that the liquid transfer element 314 is in fluid communication with the base 400. In addition, a medial portion of the liquid transfer element 314 extends between the first end 314a and the second end 314b and can comprise wick and/or porous materials that provide movement of the aerosol precursor composition therethrough (e.g., by capillary action) such that the aerosol precursor composition can be drawn into the immediate vicinity of the heating element 316.

[0091] In an additional or alternative embodiment, the base 400 may define at least one opening configured to receive at least a portion of the fluid transfer element 314 in close proximity to the first and second ends 314a, 314b therethrough. For example, the base 400 can define an opening that has a size similar to the opening 516 for the aerosol precursor composition formed by the sealing component 500, and the opening formed by the base 400 can be aligned with the opening 516 for the aerosol precursor composition of the sealing component 500. In some aspects, a portion of the fluid transfer element 314 in close proximity to the first and second ends 314a, 314b can pass through the opening formed by the base 400 and aligned with the opening 516 for the aerosol precursor composition of the sealing component 500 so as to be in direct fluid communication with the aerosol precursor composition located in the reservoir chamber 210. According to some aspects, the first and second ends 314a, 314b passing through the openings 516 for the aerosol precursor composition can ensure the movement of the aerosol precursor composition in the reservoir chamber 210 (for example, by capillary action) such that the aerosol precursor composition is drawn in close proximity to the heating element 316. According to another aspect, the remaining openings 516 for the aerosol precursor composition that are not engaged with the first and second ends 314a, 314b of the liquid transfer element 314 can be engaged with the base 400 so as to retain the aerosol precursor composition in the reservoir chamber 210 and/or ensure the accurate transfer of the desired amount of the aerosol precursor composition from the reservoir chamber 210 to the base 400. As shown in FIG. 8, the heating element 316 can form a heating structure with the liquid transfer element 314. In particular, the heating element 316 can extend at least partially around the medial portion of the liquid transfer element 314 and, more particularly, can extend at least partially around the liquid transfer element 314 in a position between the first end 314a and the second end 314b of the liquid transfer element 314. In some aspects, the heating element 316 can be configured to heat the aerosol precursor composition located in the medial portion of the liquid transfer element 314 to form an aerosol for inhalation by the user. In particular, the heating element 316 can be formed from a material that provides resistive heating when an electric current is applied to it.

[0092] As shown in FIGS. 8 and 11, the resistive heating element 316 may comprise a wire that forms a plurality of turns wound around a medial portion of the fluid transfer element 314. In addition, as shown in FIGS. 8-11, the heating element 316 may comprise a wire material that provides resistive heating and may extend between the first electrical terminal 318a and the second electrical terminal 318b. For example, in some aspects, the wire material may include kanthal (FeCrAl); nichrome; molybdenum disilicide (MoSi ₂ ); molybdenum disilicide doped with aluminum (Mo(Si,Al) ₂ ); ceramics (e.g., ceramics with a positive coefficient of thermal expansion), titanium and/or corresponding alloys, although in other aspects various other materials may be used. According to some aspects, the heating element 316 may be formed by wrapping a wire around the liquid transfer element 314 as described in U.S. Patent No. 9,210,738 (Ward et al.), which is incorporated herein by reference in its entirety. However, various other aspects of methods may be used to form the heating element 316, and various other aspects of the heating element may be used in the atomizer 312. For example, the heating element 316 may be configured to heat an aerosol precursor composition located in the liquid transfer element 314 using radiant heating as described in U.S. Patent Applications Ser. No. 14/808,405, filed July 24, 2015, and Ser. No. 14/958,651, filed December 3, 2015, the contents of which are incorporated herein by reference in their entireties. In another aspect, the heating element 316 may be configured to heat the aerosol precursor composition using induction heating as described in U.S. Patent Applications Ser. No. 14/958,651, filed December 3, 2015, and Ser. No. 14/934,763, filed November 6, 2015, the entire contents of which are incorporated herein by reference.

[0093] In some aspects, the first electrical terminal 318a and the second electrical terminal 318b may be configured to supply electrical current to the resistive heating element 316 when the evaporator assembly 300 is brought into operative interaction with the power source assembly 600. In some aspects, the heating element 316 may be formed integrally with the first and second electrical terminals 318a, 318b. In another aspect, the heating element 316 may be brought into operative interaction with the first and second electrical terminals 318a, 318b to form an electrical connection. For example, portions of the heating element 316 may be welded, soldered, fused, and/or the like to the corresponding first and second electrical terminals 318a, 318b. In some aspects, the first and second electrical terminals 318a, 318b may be brought into operative interaction with a power source located in the power source assembly 600 with the tabs 319a, 319b of the first and second electrical terminals. For example, in some aspects, the circuit may be closed when the tabs 319a, 319b of the first and second electrical terminals are brought into operative interaction with a power source located in the power source assembly 600. The power source may supply an electric current through the heating element 316 when the first and second electrical tabs 319a, 319b close the electrical circuit and are brought into interaction with the first and second electrical terminals 318a, 318b. The aerosol precursor composition located in the medial portion of the liquid transfer element 314 is heated by the coils of the wire of the heating element 316 wound around the medial portion of the transfer element 314. Although the heating element 316 is shown as a wire having a plurality of turns wound around the aerosol precursor carrying element 314, additional forms of the heating element 316 are also encompassed by the present invention, such as a heating element in the form of foil, foam, discs, coils, fibers, wires, films, threads, strips, tapes and/or cylinders.

[0094] In addition, the first and second electrical terminals 318a, 318b may be configured to supply an electrical current to the heating element 316 when the control component of the aerosol delivery device 10, which may be located in the evaporation unit 300, the reservoir housing 200 and/or the power source unit 600, activates the flow of electrical current from the power source to the heating element 316 via the first and second electrical terminals 318a, 318b. In particular, the aerosol delivery device 10 may comprise a control component (e.g., a controller) 322 configured to at least control the heating of the heating element 316 and/or other operations of the aerosol delivery device 10 (e.g., power and/or actuation of various visual indicators and/or the like).

[0095] For example, the evaporation assembly 300 may comprise a control component 322 and at least one control component terminal 320. In some aspects, the aerosol delivery device 10 may comprise a control component 322 as described in U.S. Patent Application Publication No. 2015/0245658 (Worm et al.), which is incorporated herein by reference in its entirety. The control component terminal 320 may be configured to operably interact with a power source (not shown) located in the power source assembly 600 when the connector housing 330 is directly and/or mechanically engaged with the power source assembly 600. In particular, the control component terminal 320 may be operably engaged with the power source so as to supply electrical current to power the control component 322 to control various operations of the aerosol delivery device 10. According to some aspects, the control component terminal 320 may be configured to receive electrical signals from additional and/or alternative control components (e.g., a separate control component, etc.) located in the power source assembly 600. Furthermore, the control component terminal 320 may be configured to provide electrical communication (i.e., electrical current, data signals, and/or the like) between the control component located in the power source assembly 600 and the control component 322 located in the evaporation assembly 300. In a further or alternative embodiment, the power source assembly 600 may comprise a single control component therein (not shown) configured to control various operations of the aerosol delivery device 10, as previously described herein. For example, the power supply assembly 600 may comprise a housing configured to store therein a control component and/or a terminal of the control component, as described in U.S. Patent Application Publication No. 2015/0335071 (Brinkley et al.), which is incorporated herein by reference in its entirety.

[0096] Referring to FIG. 9, the connector housing 330 of the evaporative assembly 300 may be configured to functionally and/or mechanically engage with the power source assembly 600. In some aspects, the connector housing 330 may be configured to receive at least a portion of the power source assembly 600 therein. In addition, the connector housing 330 may be configured to provide access to at least one of the first electrical terminal 318a, the second electrical terminal 318b, and/or the terminal 320 of the control component. For example, the connector housing 330 may comprise a connector device 332 configured to directly and mechanically engage with at least a portion of the power source assembly 600.

[0097] In addition, the connecting device 332 can form a plurality of openings 340a, 340b, 340c configured to receive therein the first electrical terminal 318a, the second electrical terminal 318b and the terminal 320 of the control component, respectively. Additionally, the connecting device 332 can in particular have a shape and/or be made in such a way that the connector housing 330 can only mechanically interact with the original power source assembly 600. In particular, the original power source assembly 600 can have a mutually corresponding shape with respect to the connecting component 332 in such a way that a suitable interaction between the power source assembly 600 and the connector housing 330 can be performed only when the original power source assemblies 600 are brought into interaction with the original connector housings 330. For example, the actual connector housing 330 may comprise a connector device 332 located in close proximity to the connecting end 304 of the evaporative assembly 300.

[0098] According to some aspects, the coupling device 332 may provide advantages in terms of ease of assembly and ease of attachment of the power source assembly 600. In some aspects, the coupling device 332 may in particular have such a shape that the power source assembly 600 of a mutually corresponding shape can only mechanically interact with the coupling device 332 when the components are aligned with each other in a certain way (i.e., aligned in an axial or circumferential direction with each other). For example, the coupling device 332 may comprise an anti-rotation mechanism 334 configured to prevent the evaporator assembly 300 from rotating relative to the power source assembly 600 when interacting with it. In some aspects, in which the reservoir housing 200 is securely connected and/or attached to the evaporator assembly 300 (e.g., ultrasonic welding), the anti-rotation mechanism 334 can be configured to prevent rotation of the reservoir housing 200 relative to the power source assembly 600 when the connector housing 330 is mechanically engaged with the power source assembly 600. Such anti-rotation mechanisms are described in more detail in U.S. Patent Application Publication No. 2014/0261495 (Novak III et al.), which is incorporated herein by reference in its entirety.

[0099] In some aspects, the anti-rotation mechanism 334 may comprise a plurality of projections 336a, 336b, 336c, 336d, 336e, 336f and a plurality of recesses 338a, 338b, 338c, 338d, 338e, 338f located along the outer periphery of the coupling device 332 in an alternating arrangement. The power source assembly 600 may include a corresponding arrangement (not shown) of a plurality of recesses and a plurality of projections configured to directly interact with a plurality of projections 336a, 336b, 336c, 336d, 336e, 336f and a plurality of recesses 338a, 338b, 338c, 338d, 338e, 338f alternately arranged along the outer periphery of the coupling device 332. According to some aspects, the anti-rotation mechanism 334 of the connector housing 330 may advantageously provide simple alignment and reliable interaction with the power source assembly 600 when brought into functional and direct interaction with it. For example, the anti-rotation mechanism 334 can ensure the alignment of the connector housing 330 with the power source assembly 600 such that the first and second heating terminals 318a, 318b and/or the terminal 320 of the control component are aligned with the corresponding terminals, connectors and/or the like located inside the power source assembly 600 when the connector housing 330 is brought into engagement with it. Additionally, the anti-rotation mechanism 334 can substantially limit any rotation of the connector housing 330 relative to the power source assembly 600 when the connector housing 330 is mechanically brought into engagement with the power source assembly 600. In some embodiments, the connector housing 330 can comprise additional engagement assemblies that provide a threaded engagement, a friction fit, an interference fit, a magnetic engagement and/or the like with the power source assembly 600.

[0100] Additionally, other features, controls, or components that may be included in aerosol delivery systems according to the present disclosure 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.); 9,220,302 (DePiano et al.); U.S. Patent Application Publication Nos. 2010/0163063 (Fernando et al.); 2013/0192623 (Tucker et al.); No. 2013/0298905 (Leven et al.); No. 2013/0180553 (Kim et al.); No. 2014/0000638 (Sebastian et al.); and No. 2014/0261495 (Novak et al.), which are incorporated herein by reference in their entireties.

[00101] Referring to FIG. 13, aspects of the present invention may provide a method 1300 for producing a liquid storage container for an aerosol delivery device. The method 1300 may include providing a reservoir chamber 1302 formed in part by an outer casing formed by a wall, and a central tube located inside the outer casing and formed by the wall. The chamber 210 of the reservoir can be formed partially by the inner surface 212 of the outer wall 201, which forms the casing 200 of the reservoir, and the outer surface 218 of the outer wall 217, which forms the mouthpiece channel 216. The outer casing (for example, the casing 200 of the reservoir) can contain a closed mouthpiece end and an opposite connecting end, and the central tube (for example, the mouthpiece channel 216) can contain a first end opening passing through the closed mouthpiece end of the outer casing, and a second opposite open end.

[00102] The method 1300 may also include dispensing a certain amount of the aerosol precursor composition into the reservoir chamber 1304. In particular, the method may include dispensing the aerosol precursor composition into the reservoir chamber from the connecting end of the outer casing and between the outer surface of the outer wall of the central tube and the inner surface of the outer wall of the outer casing.

[00103] According to some aspects, the method 1300 may also include inserting a sealing component into the outer casing 1306. For example, the method may include inserting a sealing component, such as the sealing component 500 shown in FIGS. 7A and 7B, into the outer casing from a connecting end of the outer casing. In addition, the sealing component may comprise a central opening (for example, an opening 506 of the sealing component for steam) configured to provide fluid communication between any of the openings of the central tube (for example, an opening 215 located at the outlet end 219 of the mouthpiece channel 216 and/or an opening 214 of the mouthpiece channel 216 located in close proximity to the mouthpiece end 202 of the reservoir housing 200), the central tube (for example, the mouthpiece channel 216) and/or the vapor chamber (for example, the vapor chamber 310). In particular, the method may include inserting the sealing component into the outer housing so as to bring a peripheral portion of the sealing component into engagement with a wall of the outer housing and to bring the central opening of the sealing component into engagement with a second open end of the central tube to form a seal. As described herein, the sealing component may comprise a sealing element that surrounds the circumferential periphery of the sealing component. Additionally, the central bore of the sealing component may comprise an annular projection that provides a seat for the central tube, against which the central tube may substantially abut when the central tube forms a seal with the sealing component, as described previously herein.

[00104] The method 1300 may also include inserting a base adjacent to the sealing component 1308. In particular, the base may be inserted into the outer casing from a connecting end of the outer casing and may be located in the outer casing and substantially abuts the sealing component when inserted into the outer casing. In some aspects, the method may include inserting the base adjacent to the sealing component such that the base interaction component is inserted into the central opening of the base, as described earlier in this document.

[00105] The foregoing description of the use of the article may be applied to the various embodiments described herein with minor modifications that may be apparent to one skilled in the art in light of the additional disclosure provided herein. The foregoing description of the use, however, is not intended to limit the use of the article, but is provided to meet all necessary requirements of the disclosure of the present invention.

[00106] Many modifications and other embodiments of the invention will become apparent to those skilled in the art to which this disclosure pertains, which has the benefit of the explanations provided in the foregoing descriptions and the accompanying drawings. It is therefore to be understood that the present invention should not 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 used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (31)

1. A cartridge for an aerosol delivery device comprising: an outer wall that extends from the mouthpiece end to the connecting end; a storage portion formed within the outer wall and extending from the mouthpiece end to the connecting end of the outer wall, wherein the storage portion at least partially forms a reservoir configured to store the aerosol precursor composition; a mouthpiece channel formed inside relative to the outer wall and extending from the mouthpiece end towards the connecting end of the outer wall, wherein the mouthpiece channel is designed to ensure the passage of steam through it; a base located inside the outer wall between the tank and the connecting end of the outer wall; a sealing component located with the storage portion and the mouthpiece channel for separating the base from the reservoir, wherein the sealing component comprises at least one opening for the aerosol precursor composition passing through it and configured to allow the aerosol precursor composition to pass from the reservoir to the base; and an evaporator unit located at least partially within the outer wall for fluid communication with the base. 2. The cartridge of claim 1, wherein the sealing component is located at least partially within the storage portion. 3. The cartridge of claim 1, wherein the base is located at least partially within the storage portion. 4. The cartridge of claim 1, wherein the base is configured to allow the aerosol precursor composition to move through it by capillary action. 5. The cartridge according to claim 1, wherein the base is a fibrous material or a porous ceramic material. 6. The cartridge of claim 1, wherein the sealing component is located with the storage portion and the mouthpiece channel for sealing interaction with the inner surface of the storage portion and the outer surface of the mouthpiece channel. 7. The cartridge according to claim 1, wherein the sealing component is designed to form a sealing interaction with the inner surface of the storage portion and comprises a seat that substantially abuts the mouthpiece channel. 8. The cartridge of claim 1, wherein the sealing component comprises a plurality of openings passing therethrough for the aerosol precursor composition. 9. The cartridge according to claim 1, wherein the atomizer comprises an element for transferring liquid in a heating structure with a heating element. 10. The cartridge of claim 9, wherein the fluid transfer element is in fluid communication with the base. 11. The cartridge according to claim 10, wherein the liquid transfer element is made in the form of a wick with multiple ends that are located in physical contact with the base. 12. The cartridge according to claim 9, wherein the atomizer comprises an atomizer casing forming an evaporation chamber, wherein the liquid transfer element and the heating element are designed to be located at least partially inside the evaporation chamber. 13. A cartridge according to claim 1, comprising a mouthpiece located near the mouthpiece end of the outer wall. 14. A cartridge for an aerosol delivery device comprising an outer wall that extends from a mouthpiece end to a connection end, the outer wall comprising: storage part; a sealing component located with the storage portion to form a reservoir configured to store the aerosol precursor composition, wherein the sealing component comprises at least one opening passing therethrough for the aerosol precursor composition; a base located relative to the sealing component for receiving the aerosol precursor composition through the sealing component; a liquid transfer element configured to receive the aerosol precursor composition from the base; and heating element in a heating structure with a liquid transfer element. 15. The cartridge of claim 14, wherein the base is configured to allow the aerosol precursor composition to move through it by capillary action. 16. The cartridge of claim 14, wherein the base is a fibrous material or a porous ceramic material. 17. The cartridge of claim 14, wherein the sealing component is configured to form a sealing interaction with the inner surface of the storage portion. 18. The cartridge according to claim 14, also comprising an atomizer casing located at least partially inside the outer wall, wherein the atomizer casing forms an evaporation chamber, wherein the liquid transfer element and the heating element are designed to be located at least partially inside the evaporation chamber. 19. The cartridge according to claim 14, also comprising a mouthpiece channel formed inside relative to the outer wall and extending from the mouthpiece end towards the connecting end of the outer wall, wherein the mouthpiece channel is designed to ensure the passage of steam through it. 20. The cartridge of claim 19, wherein the mouthpiece channel extends at least partially along the storage portion.