Heater for an aerosol delivery device and methods of formation thereof

Patent metadata

Field	Value
Publication number	US-2016007652-A1
Application number	US-201414329334-A
Country	US
Kind code	A1
Filing date	Jul 11, 2014
Priority date	Jul 11, 2014
Publication date	Jan 14, 2016
Grant date	—

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 a heating member that can be formed of a heating element conformed to a heater substrate configured as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size. In some embodiments, the disclosure provides methods of forming an aerosol delivery device, which can include providing a shell, providing a heating member formed of a heating element conformed to a substrate, configuring the heating member as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size, and inserting the heating member within the shell.

First claim

1 . An aerosol delivery device comprising a heating member formed of a heating element conformed to a heater substrate configured as a truncated cone having a first end of a first size and a second end of greater size.

2 . The aerosol delivery device according to claim 1 , wherein the heater substrate comprises a film or membrane underlying the heating element.

3 . The aerosol delivery device according to claim 2 , wherein the heater substrate further comprises a film or membrane overlying the heating element.

4 . The aerosol delivery device according to claim 3 , wherein one or both of the heater substrate and the film or membrane overlying the heating member comprises a textured surface.

5 . The aerosol delivery device according to claim 4 , wherein the texturing is configured to provide for capillary flow across the textured surface.

6 . The aerosol delivery device according to claim 1 , further comprising a porous transport element configured for passage of an aerosol precursor composition along a length thereof, the porous transport element having a first end in a heating arrangement with the heating member.

7 . The aerosol delivery device according to claim 6 , wherein the truncated cone includes an interior passage therethrough, and wherein the first end of the porous transport element in the heating arrangement with the heating member is positioned at least partially within the interior passage of the truncated cone.

8 . The aerosol delivery device according to claim 6 , wherein the first end of the porous transport element in the heating arrangement with the heating member is positioned so as to at least partially surround the first end of the truncated cone.

9 . The aerosol delivery device according to claim 6 , wherein the porous transport element is a fibrous mat.

10 . The aerosol delivery device according to claim 9 , wherein the fibrous mat comprises a plurality of layers.

11 . The aerosol delivery device according to claim 10 , wherein the first end of the fibrous mat comprises fewer layers than the remainder of the fibrous mat.

12 . The aerosol delivery device according to claim 6 , wherein the porous transport element comprises a central passage through the length thereof.

13 . The aerosol delivery device according to claim 1 , further comprising an airflow path entering the lesser sized first end of the truncated cone, passing through an interior passage therethrough, and exiting past the greater sized second end of the truncated cone.

14 . The aerosol delivery device according to claim 1 , further comprising an airflow path exterior to the heating member passing around the truncated cone from the first end thereof past the greater sized second end thereof.

15 . The aerosol delivery device according to claim 1 , wherein the heating member is mounted inside a support frame.

16 . The aerosol delivery device according to claim 1 , wherein the heater substrate is configured as a frustum.

17 . The aerosol delivery device according to claim 1 , wherein the heating element comprises an electrically conductive ink.

18 . An aerosol delivery device comprising:
a shell having an air inlet and a mouthpiece configured for exit of a formed aerosol; a heating member positioned within the shell and being formed of a heating element conformed to a heater substrate configured as a frustum with an interior passage therethrough and having a first end of a first size and a second end of greater size; a porous transport element configured for passage of an aerosol precursor composition along a length thereof, the porous transport element having a first end in a heating arrangement with the heating member; and an airflow path through the shell from the air inlet to the mouthpiece past the first end of the frustum and then past the second, greater sized end of the frustum.

19 . A method of forming an aerosol delivery device comprising:
providing a shell; providing a heating member formed of a heating element conformed to a substrate; configuring the heating member as a truncated cone having a first end of a first size and a second end of greater size; and inserting the heating member within the shell.

20 . The method according to claim 19 , further comprising providing a porous transport element configured for passage of an aerosol precursor composition along a length thereof, the porous transport element having a first end and a second opposing end, and configuring the first end thereof in a heating arrangement with the heating member.

21 . The method according to claim 20 , further comprising contacting the second end of the porous transport element with the aerosol precursor composition.

22 . The method according to claim 20 , wherein the truncated cone includes a central passage therethrough, and wherein configuring the first end of the porous transport element in a heating arrangement with the heating member comprises inserting the first end of the porous transport element into the central passage at the second, greater sized end of the heating member.

23 . The method according to claim 20 , wherein the first end of the porous transport element comprises a central opening therein, and wherein configuring the first end of the porous transport element in a heating arrangement with the heating member comprises inserting the first, lesser sized end of the heating member into the central opening in the first end of the porous transport element.

24 . The method according to claim 19 , wherein providing the heating member comprises forming the heating member on the substrate by printing an electrically conductive ink thereon.

Assignees

• Reynolds Tobacco Co R

Inventors

• Taluskie Karen V
• Sears Stephen Benson
• Hunt Eric Taylor
• Collett William Robert
• Chang Yi-Ping
• Weight Kristen Dodds
• Karg Jeffrey A
• Eacock Graham P
• Ebbs Matthew C
• Uschold Robert C
• Sloan Iii Walker Maclaughlin

Classifications

• A61M16/1045

  Devices for humidifying or heating the inspired gas by using recovered moisture or heat from the expired gas · CPC title

• A61M11/041

  using heaters · CPC title

• A61M15/06

  Inhaling appliances shaped like cigars, cigarettes or pipes · CPC title

• A61M2205/36

  related to heating or cooling · CPC title

• A24F47/008 Primary

  Human Necessities · mapped topic