Aerosol delivery device with a unitary reservoir and liquid transport element comprising a porous monolith and related method

• US 10,602,775 B2
• Filed: 07/21/2016
• Issued: 03/31/2020
• Est. Priority Date: 07/21/2016
• 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., Phillips, Percy D., Rogers, James W., Ampolini, Frederic P., Clemens, David A., Carpenter, William K., Joyce, Owen L., King, Michael L., Ahr, Sean M.
• Primary Examiner(s): Paik, Sang Y
• Application Number:
  US15/216,590
• Publication Number:
  US 20180020723A1
• Time in Patent Office: 1,349 Days
• Field of Search: 392386-406
• 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 40/44 Wicks
• 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 2016/0027 pressure meter
• CPC Class Codes: A61M 2016/0039 in the inspiratory circuit
• CPC Class Codes: A61M 2205/3653 by Joule effect, i.e. electric resistance
• CPC Class Codes: A61M 2205/50 with microprocessors or computers
• CPC Class Codes: A61M 2205/8206 battery-operated
• CPC Class Codes: B65D 83/265 by fall or rise in pressure or temperature
• CPC Class Codes: B65D 83/72 with heating or cooling devices , e.g. heat-exchangers
• CPC Class Codes: B65D 83/753 characterised by details or accessories associated with outlets
• CPC Class Codes: F22B 1/284 with water in reservoirs
• CPC Class Codes: H05B 1/0297 Heating of fluids for non specified applications
• 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, elements of such devices, and methods for producing vapor. In some embodiments, the present disclosure provides devices configured for vaporization of an aerosol precursor composition that is contained in and transported to a heating element by a unitary reservoir and liquid transport element. The unitary reservoir and liquid transport element may include a porous monolith.

Claims

1. An aerosol delivery device, comprising:

an outer body extending along an axis from a first end to a second end, the second end defining a mouthpiece;

a heating element having a heating portion;

a unitary reservoir and liquid transport element disposed within the outer body and comprising an integral porous monolith and storing an aerosol precursor composition, wherein the unitary reservoir and liquid transport element has the heating element engaged therewith, with the heating portion extending along the axis, and wherein the unitary reservoir and liquid transport element defines one or more channels extending at least partially therethrough and into communication with the heating element; and

a first heating terminal and a second heating terminal each extending from the first end of the outer body toward the second end of the outer body, at least partially through the one or more channels defined by the unitary reservoir and liquid transport element and into electrical communication with the heating element such that the heating portion extends parallel to the first and second heating terminals, the first heating terminal and the second heating terminal being arranged to direct electrical current from the first end of the outer body to the heating element, the heating portion of the heating element producing heat in response to the electrical current to vaporize at least a portion of the aerosol precursor composition stored in the unitary reservoir and liquid transport element, the vaporized aerosol precursor composition being directed through the mouthpiece defined by the second end of the outer body.

2. The aerosol delivery device of claim 1, wherein a longitudinal axis of the heating element is substantially parallel to the axis of the outer body.

3. The aerosol delivery device of claim 1, wherein the integral porous monolith comprises at least one of a porous ceramic and a porous glass.

4. The aerosol delivery device of claim 1, wherein the heating element is at least partially received in the one or more channels.

5. The aerosol delivery device of claim 1, further comprising an electronic component at least partially received in the one or more channels.

6. The aerosol delivery device of claim 5, wherein the electronic component is positioned between the first heating terminal and the second heating terminal.

7. The aerosol delivery device of claim 5, wherein a longitudinal axis of the electronic component extends substantially parallel to the axis of the outer body.

8. The aerosol delivery device of claim 1, wherein the heating element extends at least partially about the unitary reservoir and liquid transport element.

9. The aerosol delivery device of claim 8, wherein the unitary reservoir and liquid transport element defines a protrusion and the heating element extends at least partially about the protrusion.

10. The aerosol delivery device of claim 1, further comprising a base engaged with the outer body and an electronic component positioned between the base and the unitary reservoir and liquid transport element.

11. The aerosol delivery device of claim 10, wherein a longitudinal axis of the electronic component extends substantially perpendicular to the axis of the outer body.

12. The aerosol delivery device of claim 11,

wherein the first heating terminal and the second heating terminal extend substantially perpendicular to the longitudinal axis of the electronic component.

13. The aerosol delivery device of claim 1, wherein the unitary reservoir and liquid transport element defines a variable porosity.

14. The aerosol delivery device of claim 1, wherein the integral porous monolith stores a substantial entirety of the aerosol precursor composition.

15. A method for producing a vapor, the method comprising:

receiving a unitary reservoir and liquid transport element comprising an integral porous monolith and storing an aerosol precursor composition therein within an outer body extending along an axis from a first end to a second end, the second end defining a mouthpiece and the unitary reservoir;

engaging a heating element having a heating portion with the unitary reservoir and liquid transport element, the heating portion extending along the axis and the unitary reservoir and liquid transport element defining one or more channels extending at least partially therethrough and into communication with the heating element;

coupling a first heating terminal and a second heating terminal, each heating terminal extending from the first end of the outer body toward the second end of the outer body, into electrical communication with the heating element at least partially through the one or more channels defined by the unitary reservoir and liquid transport element, such that the heating portion extends parallel to the first and second heating terminals; and

directing an electrical current through the first heating terminal and the second heating terminal, from the first end of the outer body to the heating element, the heating element producing heat in response to the electrical current to vaporize

at least a portion of the aerosol precursor composition stored in the unitary reservoir and liquid transport element, the vaporized aerosol precursor composition being directed through the mouthpiece defined by the second end of the outer body.

16. The method of claim 15, wherein directing the electrical current to the heating element comprises directing the electrical current to the heating element substantially surrounded by the unitary reservoir and liquid transport element.

17. The method of claim 15, wherein directing the electrical current to the heating element comprises directing the electrical current to the heating element extending around at least a portion of the unitary reservoir and liquid transport element.

18. The method of claim 15, further comprising directing an airflow through the one or more channels extending at least partially through the unitary reservoir and liquid transport element.