Aerosol delivery device with radiant heating

• US 10,206,429 B2
• Filed: 12/03/2015
• Issued: 02/19/2019
• Est. Priority Date: 07/24/2015
• Status: Active Grant

• Current Assignee: RAI STRATEGIC HOLDINGS, INC. (British American Tobacco PLC)
• Original Assignee: RAI STRATEGIC HOLDINGS, INC. (British American Tobacco PLC)
• Inventors: Davis, Michael F., Chang, Yi-ping, Sears, Stephen Benson, Taluskie, Karen V., Pike, Susan K., Watson, Nicholas Harrison, Reynolds, Stephen C.
• Primary Examiner(s): Campbell, Thor
• Application Number:
  US14/958,651
• Publication Number:
  US 20170020193A1
• Time in Patent Office: 1,174 Days
• Field of Search: None
• 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: A61M 11/041 using heaters
• CPC Class Codes: A61M 11/042 electrical
• CPC Class Codes: A61M 15/06 Inhaling appliances shaped like cigars, cigarettes or pipes
• CPC Class Codes: A61M 2016/0021 with a proportional output signal, e.g. from a thermistor
• CPC Class Codes: A61M 2205/3653 by Joule effect, i.e. electric resistance
• CPC Class Codes: A61M 2205/368 by electromagnetic radiation, e.g. IR waves
• CPC Class Codes: A61M 2205/8206 battery-operated
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/018 Heaters using heating elements comprising mosi2
• CPC Class Codes: H05B 2203/019 Heaters using heating elements having a negative temperature coefficient
• CPC Class Codes: H05B 2203/02 Heaters using heating elements having a positive temperature coefficient
• 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 2203/032 Heaters specially adapted for heating by radiation heating
• CPC Class Codes: H05B 3/04 Waterproof or air-tight seals for heaters
• CPC Class Codes: H05B 3/145 Carbon only, e.g. carbon black, graphite
• CPC Class Codes: H05B 3/44 heating conductor arranged within rods or tubes of insulating material

Abstract

The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides devices configured for vaporization of an aerosol precursor composition through radiant heating. The radiant heat source may be a laser diode or further element suitable for providing electromagnetic radiation, and heating may be carried out within an optional chamber, which can be a radiation-trapping chamber. In some embodiments, an interior of such chamber may be configured as a black body or as a white body.

Claims

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

a first heater having a heating surface;

a second heater having a heating surface; and

a liquid transport element;

wherein the first heater and the second heater are spaced apart with the respective heating surfaces facing each other and aligned in a substantially parallel arrangement with the fluid transport element positioned therebetween and not in direct contact with either of the first heater and the second heater such that the heating surface of the first heater and the heating surface of the second heater are each in a direct radiant heating relationship with the liquid transport element; and

wherein the liquid transport element is substantially flattened having a top surface and a bottom surface and is positioned so as to form a heating space between the top surface of the substantially flattened liquid transport element and the heating surface of the first heater and to form a heating space between the bottom surface of the substantially flattened liquid transport element and the heating surface of the second heater.

2. The atomizer of claim 1, wherein the first heater and the second heater are substantially flattened.

3. The atomizer of claim 1, wherein the first heater and the second heater each comprise a substrate with a heating trace on a surface so as to define the heating surface.

4. The atomizer of claim 3, wherein the heating surface of each of the first heater and the second heater further comprises a passivating layer over the heater trace.

5. The atomizer of claim 1, wherein the liquid transport element comprises a material containing an open pore network.

6. The atomizer of claim 1, wherein the liquid transport element comprises opposing ends, and at least one of the opposing ends of the liquid transport element extends so as to not be in a heating arrangement with the first heater and the second heater.

7. The atomizer of claim 1, further comprising an atomizer housing formed of at least one wall enclosing the first heater element and the second heater element.

8. The atomizer of claim 7, wherein the atomizer housing comprises at least one aperture through which the liquid transport element extends.

9. The atomizer of claim 8, wherein the atomizer housing includes a leak resistive gasket at the at least one aperture.

10. The atomizer of claim 8, wherein the atomizer housing comprises an air inlet and an aerosol outlet.

11. An aerosol delivery device comprising:

a housing having a mouthend;

a mouthpiece at the mouthend of the housing

an aerosol precursor liquid;

a first heater having a heating surface;

a second heater having a heating surface; and

a liquid transport element having at least one end in a wicking arrangement with the aerosol precursor liquid;

wherein the first heater and the second heater are aligned in a substantially parallel arrangement with a portion of the fluid transport element positioned therebetween such that the heating surface of the first heater and the heating surface of the second heater are each in a direct radiant heating relationship with the liquid transport element; and

wherein the device includes and airflow path through the housing, said airflow path extending through a space defined between the first heater and the second heater and to the mouthpiece at the mouthend of the housing.

12. The aerosol delivery device of claim 11, wherein the aerosol precursor liquid is physically separated from the first heater and the second heater by at least one wall.

13. The aerosol delivery device of claim 12, wherein the at least one wall at least partially defines a chamber storing the aerosol precursor liquid.

14. The aerosol delivery device of claim 13, wherein the chamber storing the aerosol precursor liquid is substantially annularly arranged relative to the housing.

15. The aerosol delivery device of claim 13, wherein the chamber storing the aerosol precursor liquid is refillable.

16. The aerosol delivery device of claim 12, wherein the at least one wall physically separating the aerosol precursor liquid from the first heater and the second heater includes at least one aperture through which the at least one end of the liquid transport element extends.

17. The aerosol delivery device of claim 16, wherein the at least one aperture includes a leak resistive gasket.

18. The aerosol delivery device of claim 11, wherein the first heater and the second heater are arranged apart so as to define an aerosol forming space therebetween.

19. The aerosol delivery device of claim 18, wherein the first heater and the second heater are arranged such that the aerosol forming space is substantially parallel to a longitudinal axis of the housing.

20. The aerosol delivery device of claim 11, wherein the device further comprises one or more of a controller, a power source, and a flow sensor.

21. The aerosol delivery device of claim 20, wherein the device further comprises a second housing that is connectable with the housing, and wherein one or more of the controller, power source, and flow sensor is positioned in the second housing.

22. A method of forming a vapor for inhalation, the method comprising:

supplying an aerosol precursor liquid along a liquid transport element that is substantially flattened having a top surface and a bottom surface, a portion of the liquid transport element being positioned between a heating surface of a first heater and a heating surface of a second heater that are aligned in a substantially parallel arrangement such that the heating surface of the first heater and the heating surface of the second heater are each in a direct radiant heating relationship with the liquid transport element; and

providing power to the first heating element and the second heating element sufficient to cause the first heater and the second heater to heat and vaporize at least a portion of the aerosol precursor liquid supplied along the liquid transport element by direct radiant heating; and

wherein the first heater and the second heater are spaced apart so as to define an aerosolization space therebetween, the liquid transport element being positioned within the aerosolization space, and wherein the liquid transport element is not in physical contact with either of the first heater and the second heater.

23. The method of claim 22, wherein heating of the aerosol precursor liquid supplied along the liquid transport element is substantially only by radiant heating from the first heater and the second heater.