Atomizer for an aerosol delivery device formed from a continuously extending wire and related input, cartridge, and method

• US 9,277,770 B2
• Filed: 03/14/2013
• Issued: 03/08/2016
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: RAI STRATEGIC HOLDINGS, INC. (British American Tobacco PLC)
• Original Assignee: R J Reynolds Tobacco Company (R. J. Reynolds Tobacco)
• Inventors: DePiano, John, Smith, David, Coppola, Patsy, Novak, Charles Jacob III, Alderman, Steven Lee, McClellan, James William, Wolber, John William, Silveira, Frank S., Laine, Michael, Brinkley, Paul A., Dooly, Grady Lance
• Primary Examiner(s): CAMPBELL, THOR S
• Application Number:
  US13/827,994
• Publication Number:
  US 20140270730A1
• Time in Patent Office: 1,090 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: A24F 40/10 Devices using liquid inhalable precursors
• CPC Class Codes: A24F 40/46 Shape or structure of electric heating means
• CPC Class Codes: A24F 40/70 Manufacture
• CPC Class Codes: H05B 3/03 Electrodes
• CPC Class Codes: Y10T 29/49083 Heater type

Abstract

The present disclosure relates to atomizers for an aerosol delivery device such as a smoking article. The atomizer may include a liquid transport element and a wire continuously extending along a longitudinal length thereof. The wire may define end portions, contact portions, and a heating portion. The wire may be continuously wound about the liquid transport element such that each of the portions of the wire defines coils. A related input, cartridge, and method of forming atomizers also provided.

Claims

1. An input for production of a plurality of atomizers, the input comprising:

a liquid transport element; and

a wire continuously extending along a longitudinal length of the liquid transport element and defining a plurality of heating elements, the heating elements respectively comprising a plurality of coils of the wire,

wherein each of the heating elements is spaced apart along the longitudinal length of the liquid transport element.

2. The input of claim 1, wherein the wire is continuously wound about the liquid transport element.

3. The input of claim 2, wherein the wire further defines a plurality of end portions defining a first pitch, and each of the heating elements comprises a plurality of contact portions positioned between the end portions and defining a second pitch and a heating portion positioned between the contact portions and defining a third pitch,

wherein the second pitch is less than the first pitch, and the third pitch is less than the first pitch and greater than the second pitch.

4. The input of claim 3, wherein the second pitch is substantially equal to a diameter of the wire.

26. The input of claim 1, wherein the wire further defines a plurality of end portions positioned between each of the heating elements,

the end portions extending substantially parallel to the longitudinal length of the liquid transport element or defining a greater pitch than that of the heating elements.

5. An atomizer for an aerosol delivery device, the atomizer comprising:

a liquid transport element extending between a first liquid transport element end and a second liquid transport element end; and

a wire continuously extending along the liquid transport element from the first liquid transport element end to the second liquid transport element end and defining a heating element comprising a plurality of coils of the wire.

6. The atomizer of claim 5, wherein the wire is continuously wound about the liquid transport element.

7. The atomizer of claim 6, wherein the wire further defines a plurality of end portions defining a first pitch, and the heating element comprises a plurality of contact portions positioned between the end portions and defining a second pitch and a heating portion positioned between the contact portions and defining a third pitch,

wherein the second pitch is less than the first pitch, and the third pitch is less than the first pitch and greater than the second pitch.

8. The atomizer of claim 7, wherein the second pitch is substantially equal to a diameter of the wire.

9. The atomizer of claim 7, further comprising a first heater terminal and a second heater terminal, wherein the contact portions of the heating element respectively contact one of the first heater terminal and the second heater terminal.

10. The atomizer of claim 9, wherein the end portions respectively contact one of the first heater terminal and the second heater terminal.

11. A cartridge for an aerosol delivery device, the cartridge comprising:

a base defining a connector end configured to engage a control body;

a reservoir substrate configured to hold an aerosol precursor composition, the reservoir substrate defining a cavity extending therethrough from a first reservoir end to a second reservoir end, wherein the first reservoir end is positioned proximate the base; and

an atomizer extending through the cavity of the reservoir substrate, the atomizer comprising;

a liquid transport element extending between a first liquid transport element end and a second liquid transport element end; and

a wire continuously extending along the liquid transport element from the first liquid transport element end to the second liquid transport element end and defining a heating element comprising a plurality of coils of the wire.

12. The cartridge of claim 11, wherein the wire is continuously wound about the liquid transport element.

13. The cartridge of claim 12, wherein the wire further defines a plurality of end portions defining a first pitch, and the heating element comprises a plurality of contact portions positioned between the end portions and defining a second pitch and a heating portion positioned between the contact portions and defining a third pitch,

wherein the second pitch is less than the first pitch, and the third pitch is less than the first pitch and greater than the second pitch.

14. The cartridge of claim 13, wherein the second pitch is substantially equal to a diameter of the wire.

15. The cartridge of claim 13, wherein the atomizer further comprises a first heater terminal and a second heater terminal, and

wherein the contact portions of the heating element respectively contact one of the first heater terminal and the second heater terminal.

16. The cartridge of claim 15, wherein the end portions respectively contact one of the first heater terminal and the second heater terminal.

17. The cartridge of claim 13, wherein the reservoir substrate defines a plurality of grooves at the cavity extending between the first reservoir end and the second reservoir end and configured to receive the liquid transport element and the end portions.

18. A method of forming atomizers, the method comprising:

providing a liquid transport element;

providing a wire; and

coupling the wire to the liquid transport element such that the wire extends continuously along a longitudinal length of the liquid transport element and defines a plurality of heating elements, the heating elements respectively comprising a plurality of coils of the wire,

wherein each of the heating elements is spaced apart along the longitudinal length of the liquid transport element.

19. The method of claim 18, wherein coupling the wire to the liquid transport element comprises continuously winding the wire about the liquid transport element.

20. The method of claim 19, wherein winding the wire about the liquid transport element comprises:

winding the wire to define a plurality of end portions defining a first pitch; and

winding the wire such that each of the heating elements comprises a plurality of contact portions positioned between the end portions and defining a second pitch and a heating portion positioned between the contact portions and defining a third pitch,

wherein the second pitch is less than the first pitch, and the third pitch is less than the first pitch and greater than the second pitch.

21. The method of claim 20, wherein the second pitch is substantially equal to a diameter of the wire.

22. The method of claim 20, further comprising cutting the liquid transport element and the wire at one of the end portions to separate one of the heating elements and a segment of the liquid transport element therefrom.

23. The method of claim 22, further comprising providing a first heater terminal and a second heater terminal;

and

respectively engaging the contact portions of the one of the heating elements with the first heater terminal and the second heater terminal.

24. The method of claim 23, further comprising bending the one of the heating elements and the segment of the liquid transport element about the first heater terminal and the second heater terminal.

25. The method of claim 24, further comprising respectively engaging the end portions with one of the first heater terminal and the second heater terminal.

27. The method of claim 18, wherein coupling the wire to the liquid transport element comprises defining a plurality of end portions positioned between each of the heating elements,

the end portions extending substantially parallel to the longitudinal length of the liquid transport element or defining a greater pitch than that of the heating elements.