Cartridge for an aerosol delivery device and method for assembling a cartridge for a smoking article

• US 10,143,236 B2
• Filed: 11/18/2015
• Issued: 12/04/2018
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: R J Reynolds Tobacco Company (R. J. Reynolds Tobacco)
• Original Assignee: RAI STRATEGIC HOLDINGS, INC. (British American Tobacco PLC)
• Inventors: DePiano, John, Smith, David, Novak, III, Charles Jacob, Silveira, Frank S., Alderman, Steven Lee, Dooly, Grady Lance, Ampolini, Frederic Philippe, Nestor, Timothy Brian, Guenther, Jr., Quentin Paul, Sears, Stephen Benson, Wolber, John William, Laine, Michael
• Primary Examiner(s): Yaary, Eric
• Application Number:
  US14/944,434
• Publication Number:
  US 20160066621A1
• Time in Patent Office: 1,112 Days
• CPC Class Codes: A24F 40/10 Devices using liquid inhalable precursors
• CPC Class Codes: A24F 40/42 Cartridges or containers for 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 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/016 Heaters using particular connecting means
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/021 Heaters specially adapted for heating liquids
• CPC Class Codes: H05B 2203/022 Heaters specially adapted for heating gaseous material
• CPC Class Codes: H05B 3/04 Waterproof or air-tight seals for heaters
• CPC Class Codes: H05B 3/44 heating conductor arranged within rods or tubes of insulating material
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

The present disclosure relates to a cartridge for an aerosol delivery device such as a smoking article. The cartridge may include a base, a reservoir substrate, and an atomizer. The reservoir substrate may define a cavity therethrough. The atomizer may comprise a liquid transport element and a heating element extending at least partially about the liquid transport element. The atomizer may extend through the cavity through the reservoir substrate such that the heating element is positioned proximate an end of the reservoir substrate. Ends of the liquid transport element may extend to an opposing end of the reservoir substrate. A related method for assembling a cartridge for a smoking article is also provided.

Claims

1. 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 comprising a liquid transport element extending between a first liquid transport element end and a second liquid transport element end and a heating element extending at least partially about the liquid transport element at a position between the first liquid transport element end and the second liquid transport element end, the atomizer extending through the cavity of the reservoir substrate such that the heating element is positioned past the second reservoir end and the first liquid transport element end and the second liquid transport element end are positioned proximate the first reservoir end.

2. The cartridge of claim 1, wherein the atomizer further comprises a plurality of heater terminals connected to the base and the heating element.

3. The cartridge of claim 2, 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.

4. The cartridge of claim 2, wherein the heater terminals extend through the reservoir substrate.

5. The cartridge of claim 2, further comprising an electronic control component and a control component terminal coupled thereto, wherein the electronic control component is received in the cavity of the reservoir substrate and the control component terminal is connected to the base.

6. The cartridge of claim 5, wherein the control component terminal and the heater terminals extend to a plurality of different depths within the base.

7. The cartridge of claim 2, wherein the heating element comprises a wire defining a plurality of coils wound about the liquid transport element extending between a first wire end and a second wire end.

8. The cartridge of claim 7, wherein the atomizer further comprises a plurality of connector rings surrounding the heating element at the first wire end and the second wire end, wherein the heater terminals engage the connector rings.

9. The cartridge of claim 7, wherein the heater terminals directly contact the wire proximate the first wire end and the second wire end.

10. The cartridge of claim 9, wherein a spacing of the coils of the wire is less proximate the first wire end and the second wire end.

11. The cartridge of claim 1, further comprising a mouthpiece and an external shell.

12. A method for assembling a cartridge for an aerosol delivery device, the method comprising:

providing a base defining a connector end configured to engage a control body, an atomizer, and a reservoir substrate configured to hold an aerosol precursor composition and defining a cavity extending therethrough from a first reservoir end to a second reservoir end;

connecting the atomizer to the base;

inserting the atomizer through the cavity through the reservoir substrate; and

positioning the atomizer such that a heating element thereof is past the second reservoir end;

wherein the first reservoir end is positioned proximate the base.

13. The method of claim 12, further comprising assembling the atomizer, wherein assembling the atomizer comprises:

providing a plurality of heater terminals, a liquid transport element extending between a first liquid transport element end and a second liquid transport element end, and a heating element;

wrapping the heating element at least partially about the liquid transport element; and

connecting the heating element to the heater terminals such that the heating element extends therebetween and a first distal arm of the liquid transport element and a second distal arm of the liquid transport element extend along the heater terminals.

14. The method of claim 13, wherein connecting the atomizer to the base comprises connecting the heater terminals to the base, and

wherein positioning the atomizer comprises positioning the atomizer such that the second distal arm of the liquid transport element and the heater terminals are at least partially received in the cavity, the first liquid transport element end and the second liquid transport element end are proximate the first reservoir end.

15. The method of claim 14, wherein positioning the atomizer comprises inserting the first distal arm and the second distal arm of the liquid transport element in a plurality of grooves extending between the first reservoir end and the second reservoir end of the reservoir substrate at the cavity.

16. The method of claim 14, further comprising providing an electronic control component and a control component terminal;

connecting the control component terminal to the base;

coupling the electronic control component to the control component terminal; and

inserting the electronic control component into the cavity of the reservoir substrate.

17. The method of claim 16, wherein connecting the control component terminal to the base and connecting the heater terminals to the base comprise inserting the control component terminal and the heater terminals to a plurality of different heights within the base.

18. The method of claim 16, wherein connecting the control component terminal to the base and coupling the electronic control component to the control component terminal are conducted before connecting the heater terminals to the base.

19. The method of claim 14 wherein wrapping the heating element at least partially about the liquid transport element comprises winding a wire about the liquid transport element to define a plurality of coils wound about the liquid transport element extending between a first wire end and a second wire end.

20. The method of claim 19, further comprising coupling a plurality of connector rings to the heating element at the first wire end and the second wire end, wherein connecting the heating element to the heater terminals comprises connecting the heater terminals to the connector rings.

21. The method of claim 19, wherein connecting the heating element to the heater terminals comprises connecting the heating element to the heater terminals directly.

22. The method of claim 19, wherein winding the wire about the liquid transport element to define the coils comprises winding the wire such that a spacing of the coils of the wire is less proximate the first wire end and the second wire end.

23. The method of claim 14, further comprising providing an external shell and a mouthpiece;

and

coupling the external shell to the base and coupling the mouthpiece to the external shell.