ELECTRONIC SMOKING ARTICLE

• US 20190082742A1
• Filed: 11/21/2018
• Published: 03/21/2019
• Est. Priority Date: 02/22/2013
• Status: Active Grant

• Current Assignee: Altria Client Services LLC (Altria Group, Inc.)
• Original Assignee: Altria Client Services LLC (Altria Group, Inc.)
• Inventors: PLUNKETT, Susan E., KANE, David B.
• Granted Patent: US 10,561,177 B2
• Time in Patent Office: Days
• CPC Class Codes: A24F 40/10 Devices using liquid inhalable precursors
• CPC Class Codes: A24F 40/40 Constructional details, e.g. connection of cartridges and battery parts
• CPC Class Codes: A24F 40/44 Wicks
• CPC Class Codes: A24F 40/46 Shape or structure of electric heating means
• CPC Class Codes: A24F 40/50 Control or monitoring

Abstract

An electronic smoking article includes a liquid supply region including liquid material and a heater-wick element operable to wick liquid material and heat the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol. The heater-wick element is formed of a carbon or graphite foam.

Claims

1-20. -20. (canceled)

21. An electronic vaping device comprising:

an integral heater-wick element configured to draw a pre-vapor formulation from a supply region and to heat the pre-vapor formulation, the integral heater-wick element including a foamed carbon, the foamed carbon having a density of about 0.1 to 1.0 g/cc and an open porosity of at least about 90%.

22. The electronic vaping device of claim 21, wherein the foamed carbon has an electrical resistance ranging from about 0.3 to about 10 ohms.

23. The electronic vaping device of claim 21, wherein the foamed carbon has an electrical resistance ranging from about 0.8 to about 5 ohms.

24. The electronic vaping device of claim 21, wherein the foamed carbon has impurities of less than about 100 ppm.

25. The electronic vaping device of claim 21, wherein the foamed carbon has impurities of less than about 10 ppm.

26. The electronic vaping device of claim 21, wherein the foamed carbon is resistant to oxidation up to at least about 400°

C. in an oxygen atmosphere.

27. The electronic vaping device of claim 21, wherein the foamed carbon has a heat capacity of about 0.5 to 1.0 J/g-K.

28. The electronic vaping device of claim 21, wherein the foamed carbon has an open porosity of at least about 95%.

29. The electronic vaping device of claim 21, wherein the foamed carbon has a total porosity of at least about 70%.

30. The electronic vaping device of claim 21, wherein the foamed carbon has a total porosity of at least about 75%.

31. The electronic vaping device of claim 21, wherein the foamed carbon is a non-ceramic.

32. The electronic vaping device of claim 21, wherein the foamed carbon is a graphite foam or a carbon foam.

33. The electronic vaping device of claim 21, wherein the integral heater-wick element is structured to protect the pre-vapor formulation in the supply region from degradation by inhibiting an ingress of ambient oxygen into the supply region.

34. The electronic vaping device of claim 21, wherein the integral heater-wick element has a length ranging from about 10 to 15 mm.

35. The electronic vaping device of claim 21, wherein the integral heater-wick element has a width ranging from about 0.5 to 2.0 mm.

36. The electronic vaping device of claim 21, further comprising:

an electrical lead that is directly inserted into the integral heater-wick element to establish an electrical connection without soldering or brazing.

37. The electronic vaping device of claim 21, further comprising:

control circuitry electrically connected to the integral heater-wick element, the control circuitry configured to apply a voltage to the integral heater-wick element in response to a pressure drop.

38. The electronic vaping device of claim 21, further comprising:

control circuitry electrically connected to the integral heater-wick element, the control circuitry configured to apply a voltage to the integral heater-wick element in response to a manually-operable switch.

39. A method of producing a vapor in an electronic vaping device, comprising:

drawing a pre-vapor formulation from a supply region with an integral heater-wick element, the integral heater-wick element including a foamed carbon, the foamed carbon having a density of about 0.1 to 1.0 g/cc and an open porosity of at least about 90%; and

heating the pre-vapor formulation from the supply region with the integral heater-wick element to produce a vapor.

40. The method of claim 39, wherein the heating includes applying a voltage to the integral heater-wick element in response to a pressure drop.

41. The method of claim 39, wherein the heating includes applying a voltage to the integral heater-wick element in response to a manually-operable switch.