Electronic smoking article

0001This application concerns an electronic smoking article. The prior art (see <patcit id="pcit0001" dnum="CN201860753U"><text>CN 201 860 753 U</text></patcit> or <patcit id="pcit0002" dnum="US2011094523A1"><text>US 2011/094523 A1</text></patcit>) describes such a device, mainly comprising an outer tube, an aerosol generator provided with a liquid supply.

Summary of Selected Features

0002An electronic cigarette or cigar (collectively "electronic smoking article") is provided which includes a heater element which vaporizes liquid material to produce an aerosol or "vapor". In an embodiment, the heater element comprises a resistive heater coil, with a wick extending therethrough. Aerosol generated by the heater coil and wick assembly is drawn down a central channel toward the mouth end portion of the smoking article.

0003The electronic article according to the invention includes a mechanical aerosol converter (MAC) insert having a face and one or more outlets. The face and outlets of the MAC insert are mutually arranged and the face is aligned with the central channel so as to cause the aerosol to strike the face prior to it being drawn out from the article. As a result, the aerosol particle size distribution is shifted to a distribution comprising a range of smaller particles, and both the vapor phase components of the aerosol and the temperature of the aerosol are reduced. These effects and possibly others are believed to contribute to sensory attributes of reduced throat irritation, even at higher levels of nicotine content in the liquid formulation, and to improved mouth feel over aerosols of electronic smoking articles lacking a MAC insert as taught herein.

Brief Description of the Drawings

0004<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">Figures 1A and 1B</figref> are cross sectional side views of an electronic smoking article according to a first embodiment;</li><li><figref idref="f0002">Figure 2</figref> is a perspective view of a mechanical aerosol converter (MAC) insert of the electronic smoking article shown in <figref idref="f0001">Figure 1A</figref>, the perspective being viewed in the general direction of arrow A in <figref idref="f0001">Figure 1A</figref>;</li><li><figref idref="f0002">Figures 3A and 3B</figref> are perspective views of MAC inserts of <figref idref="f0001">Figures 1A and 1B</figref>, the perspective being viewed in the general direction of arrow B in <figref idref="f0001">Figures 1A and 1B</figref>;</li><li><figref idref="f0002">Figure 4</figref> is a side view of the MAC insert of <figref idref="f0001">Figures 1A</figref>, <figref idref="f0002">2 and 3A</figref>, with interior features of the face shown in dashed lines;</li><li><figref idref="f0003">Figure 5A</figref> is a perspective view of an another embodiment of a MAC insert including a flange for use in the electronic smoking article shown in <figref idref="f0001">Figure 1A</figref>, the perspective being viewed in the general direction of arrow B in <figref idref="f0001">Figure 1A</figref>;</li><li><figref idref="f0003">Figure 5B</figref> is a perspective view of an another embodiment of a MAC insert excluding a flange for use in the electronic smoking article shown in <figref idref="f0001">Figure 1B</figref>, the perspective being viewed in the general direction of arrow B in <figref idref="f0001">Figure 1B</figref>;</li><li><figref idref="f0003">Figure 6</figref> is an abbreviated sectional side view of an electronic smoking article in accordance with another embodiment including a flow-centralizer disc interposed between a first MAC insert, shown in <figref idref="f0003">Figure 5A</figref>, and a second MAC insert, shown in <figref idref="f0003">Figure 5B</figref>;</li><li><figref idref="f0003">Figure 7</figref> is a perspective view of the flow-centralizing disc of <figref idref="f0003">Figure 6</figref>;</li><li><figref idref="f0003">Figure 8</figref> is a stylized representation of a possible effect of aerosol striking a MAC insert prior to exiting an electronic smoking;</li><li><figref idref="f0004">Figure 9</figref> is an abbreviated sectional side view of an electronic smoking article having a mouth end insert constructed in accordance with another embodiment, and including a flow-centralizer disc interposed between an upstream MAC insert, as shown in <figref idref="f0003">Figure 5B</figref>, and a downstream, multi-ported mouthpiece insert;</li><li><figref idref="f0004">Figures 10A and 10B</figref> are perspective views of a multi-ported mouth end insert for use in the electronic smoking article of <figref idref="f0004">Figure 9</figref>;</li><li><figref idref="f0005">Figure 11</figref> is an abbreviated sectional side view of an electronic smoking article having a MAC insert constructed in accordance with another embodiment; wherein the MAC insert is in the form of a disc.</li><li><figref idref="f0005">Figure 12</figref> is a planar view of the MAC insert as shown in <figref idref="f0005">Figure 11</figref>;</li><li><figref idref="f0005">Figure 13</figref> is sectional side view of a detail of a gasket having a convergent outlet for inclusion in any of the foregoing embodiments;</li><li><figref idref="f0005">Figure 14</figref> is a cross sectional view of a MAC insert including a plurality of partitions therein; and</li><li><figref idref="f0006">Figure 15</figref> is an abbreviated cross sectional side view of an electronic smoking article including another embodiment of a MAC insert.</li></ul>

Electronic Smoking Article Layout

0005Referring to <figref idref="f0001">Figures 1A and 1B</figref>, an electronic smoking article (cigarette) 60 comprises a replaceable cartridge (or first section) 70 and a reusable fixture (or second section) 72, which in a preferred embodiment, are coupled together at a threaded connection 205 or by other convenience such as a snug-fit, detent, snap-fit, clamp and/or clasp. Generally, the second section 72 includes a puff sensor 16 responsive to air drawn into the second section 72 via an air inlet port 45 adjacent the free end or tip of the electronic smoking article 60, a battery 1 and control circuitry. The disposable first section 70 includes a liquid supply region 22 of liquid and a heater 14 that aerosolizes liquid that is drawn from the liquid supply region 22 through a wick 28. Upon completing the threaded connection 205, the battery 1 is connectable with the electrical heater 14 of the first section 70 upon actuation of the puff sensor. Air is drawn primarily into the first section 70 through one or more air inlets 44 located in the outer tube (casing) 6.

0006In a preferred embodiment, once the liquid of the cartridge is spent, only the first section 70 is replaced. An alternate arrangement includes a layout where the entire electronic smoking article 60 is disposed once the liquid supply is depleted. In such case the battery type and other features might be engineered for simplicity and cost-effectiveness, but generally embodies the same concepts as in the preferred embodiment in which the second section is reused and/or recharged.

0007In a preferred embodiment, the electronic smoking article 60 is about the same size as a conventional cigarette. In some embodiments, the electronic smoking article 60 can be about 80 mm to about 110 mm long, preferably about 80 mm to about 100 mm long and about 7 mm to about 8 mm in diameter. For example, in a preferred embodiment, the electronic smoking article is about 84 mm long and has a diameter of about 7.8 mm.

0008Preferably, at least one adhesive-backed label is applied to the outer tube 6, preferably about the first section 70. The label preferably completely circumscribes the electronic smoking article 60 and can be colored and/or textured to provide the look and/or feel of a traditional cigarette. The label can include holes therein which are sized and positioned so as to prevent blocking of the air inlets 44 in the outer tube 6 (or casing).

0009The outer tube 6 and/or the inner tube 62 may be formed of any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK), ceramic, and polyethylene. Preferably, the material is light and non-brittle. The inner tube 62 can also include a substantially water impermeable coating.

0010Referring now to <figref idref="f0001">Figures 1A, 1B</figref>, <figref idref="f0003">6</figref> and <figref idref="f0004">9</figref>, the first section 70 includes the outer tube (or casing) 6 extending in a longitudinal direction and the inner tube (or chimney) 62 coaxially positioned within the outer tube 6. Preferably, a nose portion 61 of an upstream gasket (or seal) 15 is fitted into an upstream end portion 65 of the inner tube 62, while at the same time, an outer perimeter 67 of the upstream gasket 15 provides a liquid-tight seal with an interior surface of the outer tube 6. The upstream gasket 15 also includes a central, longitudinal air passage 20, which opens into an interior of the inner tube 62 that defines a central channel 21.

0011Referring to <figref idref="f0001">Figure 1</figref>, a transverse channel 33 can be provided across a backside potion of the upstream gasket 15, which intersects and communicates with the central channel 20 of the gasket 15. This channel 33 assures communication between the central channel 20 and a space 35 defined within a cathode connector piece 37. Optionally, the piece 37 includes a threaded section for effecting the threaded connection 205. The cathode connector piece 37 includes opposing notches about its perimeter, which, upon insertion of the cathode connector piece 37 into the outer tube 6, are aligned with the location of each of two RTD-controlling, air inlet ports 44 and 44' in the outer tube 6. Preferably, the air inlet ports 44 and 44' are precision drilled so as to provide the smoking article a predetermined, desired resistance to draw (RTD) ranging from about 60 mm H₂O to about 150 mm H₂O, more preferably about 90 mm H₂O to about 110 mm H₂O, most preferably about 100 mm H₂O to about 130 mm H₂O.

0012The space defined between the upstream gasket 15, a downstream gasket 10 and the outer tube 6 and the inner tube 62 establish the confines of the liquid supply region 22. The liquid supply region 22 comprises a liquid material and optionally a liquid storage medium 210 operable to store the liquid material therein. The liquid storage medium 210 may comprise a winding of cotton gauze or other fibrous material about the inner tube 62.

0013Optionally, the liquid supply region 22 is contained in an outer annulus 620 between inner tube 62 and outer tube 6 and between the gaskets 10 and 15. Thus, the liquid supply region 22 at least partially surrounds the central air passage 21. The heater 14 preferably extends transversely across the central channel 21 between opposing portions of the liquid supply region 22, although the teachings herein are applicable to arrangements wherein the heater 14 is oriented in the longitudinal direction instead of transversely.

0014Preferably, the liquid storage medium 210 is a fibrous material comprising cotton, polyethylene, polyester, rayon and combinations thereof. Preferably, the fibers have a diameter ranging in size from about 6 microns to about 15 microns (e.g., about 8 microns to about 12 microns or about 9 microns to about 11 microns). The liquid storage medium 210 can be a sintered, porous or foamed material. Also preferably, the fibers are sized to be irrespirable and can have a cross-section which has a y shape, cross shape, clover shape or any other suitable shape. In the alternative, the liquid supply region 22 may comprise a filled tank lacking a fibrous storage medium 21 and containing only liquid material.

0015Also preferably, the liquid material has a boiling point suitable for use in the electronic smoking article 60. If the boiling point is too high, the heater 14 will not be able to vaporize liquid in the wick 28. However, if the boiling point is too low, the liquid may vaporize even when the heater 14 is not being activated.

0016Preferably, the liquid material includes a tobacco-containing material including volatile tobacco flavor compounds which are released from the liquid upon heating. The liquid may also be a tobacco flavor containing material or a nicotine-containing material. Alternatively, or in addition, the liquid may include a non-tobacco material. For example, the liquid may include water, solvents, ethanol, plant extracts and natural or artificial flavors. Preferably, the liquid further includes an aerosol former. Examples of suitable aerosol formers are glycerine and propylene glycol.

0017In use, liquid material is transferred from the liquid supply region 22 and/or liquid storage medium 210 by capillary action at each end portion of the wick 28. In an embodiment, the heater 14 can at least partially surround a central portion of the wick 28 such that when the heater 14 is activated, the liquid in that portion of the wick 28 is vaporized by the heater 14 to form an aerosol. In other embodiments, the heater 14 can be disposed adjacent a portion of the wick without being wound about the wick. The wick 28 preferably comprises filaments having a capacity to draw a liquid, more preferably a bundle of glass (or ceramic) filaments and most preferably a bundle comprising a group of windings of glass filaments, preferably three of such windings, all which arrangements are capable of drawing liquid via capillary action via spacings between the filaments. Preferably, the wick 28 is flexible and includes three strands, each strand including a plurality of filaments. Moreover, it is noted that the end portions of the wick 28 are preferably flexible and foldable into the confines of the liquid supply region 22.

0018Preferably, a nose portion 81 of a downstream gasket 10 is fitted into a downstream end portion 83 of the inner tube 62. An outer perimeter 82 of the gasket 10 provides a substantially liquid-tight seal with an interior surface of the outer tube 6. Aerosol generated by the heater 14 travels from the central channel 21 and through a central channel 63 in the downstream gasket 10 and into a remaining downstream end portion of a mouth piece portion 99 of the smoking article 60. From the central channel 63 of the gasket 10, the aerosol, in substantial part, is drawn into contact with a face 102 of a mechanical aerosol converter (MAC) insert 104.

0019Referring now to <figref idref="f0002">Figure 2</figref>, in one embodiment, the MAC insert 104 comprises a cylindrical body portion 106 having an outer diameter that can be sized to provide a sliding fit with the interior surfaces of the outer tube 6 of the smoking article 60. As shown in <figref idref="f0001">Figure 1B</figref>, an upstream end portion 108 of the cylindrical body portion 106 of the MAC insert 104 is preferably brought into contact with adjacent portions of the gasket 10 so that the spatial relationship and orientation between the MAC insert 104 and the gasket 10 are essentially the same from one article 60 to the next. Thus, the body portion 106 is provided with a length such that a face portion 110 of the MAC insert 104 is flush with or at some other desired relation with the downstream end of the outer tube 6. The MAC insert 104 can be formed of any suitable substantially air impermeable material, such as plastic or metal foil.

0020The transverse, annular face portion 110 of the MAC insert 104 is provided with a plurality of orifices 112, which in an embodiment comprise six circular orifices 112, each orifice having a diameter ranging from about 0.015 inch to about 0.090 inch (e.g., about 0.020 inch to about 0.040 inch or about 0.028 inch to about 0.038 inch). After contacting the face 102 of the MAC insert 104, aerosol is then drawn through the orifices 112 in the MAC insert 104, which are disposed radially about the face 102.

0021Although the orifices 112 are shown as extending in a longitudinal direction, all or some of them may be directed divergently so as to impart a radially outward component to the velocity to the aerosol streams as they are drawn through the MAC insert 104. The number, size and shape of the orifices can be varied in the practice of the teachings herein.

0022Referring now to <figref idref="f0002">Figures 2 and 4</figref>, the face 102 of the MAC insert 104 is disposed within the confines of the cylindrical body portion 106 by a predetermined spacing "L" from the edge portion 108 of the cylindrical body portion 106 such that upon placement of the MAC insert 104 against the gasket 10, the face 102 is positioned a predetermined distance apart from the discharge orifice 63 of the gasket 10. In a preferred embodiment, that distance is in the range of about 1 mm to about 3 mm, more preferably in the range of about 1.5 mm to about 2.5 mm, but could be established at other values through analytic testing and/or modeling to find which distance is preferred for any particular design of the electronic smoking article 60.

0023Referring to <figref idref="f0002">Figures 3A, 3B, and 4</figref>, the MAC insert 104 can include a central recess 114 to facilitate molding operations during the manufacture of the MAC insert 104. It is envisioned that the MAC insert 104 could be formed without the recess 114 such that an external face portion 110 of the insert is generally circular and planar instead of being annular as shown in <figref idref="f0002">Figures 3A and 3B</figref>. In addition, the MAC insert 104 may be provided with a flange 116 (as shown in <figref idref="f0002">Figure 3A</figref>) which could act as a stop against the downstream edge of the outer tube 6 so as to register placement within the smoking article 60 with the flange 116 instead of abutment against the insert 10 as shown in <figref idref="f0001">Figure 1A</figref>. Such arrangement is advantageous when it is desired to locate the MAC insert 104 in spaced apart relation from the gasket 10. It is also envisioned that the MAC insert 104 and the gasket 10 can be integrally formed so as to simplify manufacture and assembly of the electronic smoking article 60.

0024Referring now to Figures land 8, as aerosol is drawn through the central channel 63 of the gasket 10, it is directed against the face 102 of the MAC insert 104, whereupon heat is exchanged such that the temperature of the aerosol is reduced. In some cases, the temperature can be reduced by 30°C or more. When the aerosol strikes the face 102, larger aerosol particles, as represented in region X of <figref idref="f0003">Figure 8</figref>, tend to break up to form several smaller particles, as represented in region Y.

0025In particular and in reference to region X of <figref idref="f0003">Figure 8</figref>, it is believed for that upon exiting the central channel 63 of the gasket 10, the aerosol comprises large particles of propylene glycol and water 510 and relatively large, separate particles of nicotine droplets 515. The relatively large, nicotine droplets 515 comprise a vapor phase component of the aerosol and are known to contribute undesirable sensory responses such as throat irritation and/or harshness when inhaled.

0026Not wishing to be bound by theory, upon striking the face 102 of the MAC insert 104, it is believed that the aerosol undergoes a transformation such as shown in region Y of <figref idref="f0003">Figure 8</figref>, whereby larger particles 510 and 515 of the aerosol as previously described become smaller particulate phase constituents 600 comprising smaller, particulate phase nicotine 615 surrounded by propylene glycol 610.

0027As a result of drawing the aerosol through the MAC insert 104, it has been found that the aerosol of the electronic smoking article 60 tends to be lower in temperature, to have a particle size distribution that has shifted toward a range of smaller particle sizes and that the vapor phase components as previously described are reduced. It is also believed that the MAC insert 104 increases production of core-shell particles comprising a nicotine particle surrounded by a shell of propylene glycol. These attributes and others are believed to contribute to a finding that the aerosol has acceptable sensory attributes including less throat irritation and improved sensory experience, even at higher nicotine levels in the liquid formulation. The reduced aerosol temperature is believed to improve mouth feel.

0028As noted, use of the MAC insert 104 tends to avoid perceived sensory deficits when elevated levels of nicotine are added to the liquid formulation of an electronic smoking article. For example, an electronic smoking article of the prior art tends to produce perceived sensations of harshness and/or irritation if the liquid formulation is modified to include nicotine at levels greater than 2% by weight. It has been found that with inclusion of a MAC insert in accordance with the teachings herein, nicotine levels in the liquid formulation can be increased up to 6% nicotine with acceptable sensory attributes. Such provides opportunity to produce an electronic smoking article 60 having high impact with little to no irritation. With inclusion of the MAC insert 104, an electronic smoking article can be constructed which provides 0.18 mg of nicotine per puff on a 10 puff basis, which provides comparable levels of nicotine when compared to traditional cigarettes, with acceptable sensory attributes.

0029With regard to particle size distribution, it has been found that particles size distribution of an aerosol from a smoking article lacking a MAC insert as taught herein has a bell-shaped distribution of sizes in the range of about 0.1 nanometer (nm) to about 0.7 nm. In contrast, the particles size distribution of an aerosol from an electronic smoking article including the MAC insert as described herein has a bell-shaped distribution of sizes in the range of about 0.1 nm to about 0.6 nm, a significant decrease in particle size distribution.

0030It has also been found that some electronic smoking articles not including a MAC insert tend to produce aerosols having temperatures at or above 110° Celsius. In contrast, an electronic smoking article 60 as described in <figref idref="f0001">Figures 1A and 1B</figref>, which include the MAC insert 104, produce an aerosol having a temperature, when measured at the exit of the mouth end of the electronic smoking article 60, of about 60° C to about 100° C.

0031Referring now to <figref idref="f0003">Figure 5A</figref>, according to another embodiment, the MAC insert 104a, 104b includes three exit orifices 112a, 112b that are elongated, generally kidney shaped and extend circumferentially about the perimeter of the face 102a, 102b of the MAC insert 104a, 104b. Being larger, the orifices 112a, 112b are less subject to risk of accumulation of material and blockage. In a preferred embodiment, each orifice 112a, 112b has a length of about 2 mm to about 5 mm, preferably about 3 mm to about 4 mm, and a width of about 0.5 mm to about 1 mm in width. The face 102a, 102b can have a diameter of about 3 mm to about 5 mm. The size, circumferential extent and the number of the orifices 112a, 112b may be varied in the practice of these teachings with respect to any particular article.

0032Referring now to <figref idref="f0003">Figure 6</figref>, another embodiment of an electronic smoking article 60 comprises many of the same components as described with reference to <figref idref="f0001">Figures 1A and 1B</figref>, but with the battery section 1 and the puff sensors/control circuitry 16 shown in block diagram. In this embodiment, a first MAC insert 104b is disposed immediately downstream of the gasket 10 as previously described with reference to <figref idref="f0001">Figure 1</figref>. A disk 120 having a central orifice 122 is positioned downstream of the first MAC insert 104b and immediately upstream of a second MAC insert 104a.

0033The disc 120 with its central orifice 122 operates to centralize the discharge of the first MAC insert 104b before it is drawn through the second MAC insert 104a. In essence the flow-centralizing disc imparts additional compaction of the aerosol while also directing the flow against the face 102a of the second MAC insert 104a. With this arrangement, additional mechanical aerosol converting events are imparted on the aerosol so as to further enhance the beneficial aspects of reduction of aerosol particle size upon the aerosol generated by the electronic smoking article 60.

0034It is envisioned that the first MAC insert 104b may have orifices of the shape such as shown in <figref idref="f0002">Figure 2</figref>, whereas the second MAC insert 104a might have the elongated orifices shown in <figref idref="f0003">Figures 5A or 5B</figref> or vise-versa. Alternatively, both the first MAC insert 104b and the second MAC insert 104a can include the round orifices shown in <figref idref="f0002">Figures 2 and 3</figref> or both can include the elongated orifices shown in <figref idref="f0003">Figures 5A and 5B</figref>. Moreover, the second MAC insert 104a can include a flange 103 as shown in <figref idref="f0003">Figure 5A</figref>, while the first MAC insert 104b may exclude a flange.

0035Referring now to <figref idref="f0004">Figure 9</figref>, another embodiment provides a smoking article as previously described including a downstream gasket 10 followed by (in the sense of direction of aerosol flow), a MAC insert 104, 104a, 104b, as shown in <figref idref="f0002">Figures 2</figref>, <figref idref="f0003">5A or 5B</figref>, which is in turn is followed by a disk 120, as previously described, which in turn is followed by a multiport mouth end insert 140 having a plurality of divergent passages 142. Referring now also to <figref idref="f0004">Figure 10A</figref>, the multi-port mouth end insert 140 is constructed in accordance with the teachings of <patcit id="pcit0003" dnum="US74121713A" dnum-type="L"><text>U.S. Application Serial Number 13/741,217 to Tucker et al. filed January 14, 2013</text></patcit> and titled "Electronic Cigarette", which has been published on August 1, 2013 with No. <patcit id="pcit0004" dnum="US20130192615A1"><text>US 2013/0192615 A1</text></patcit>, after the filing date of this application.

0036In a preferred embodiment, the multi-port mouth end insert 140 includes at least two diverging outlet passages 142 (e.g., preferably 2 to 10 outlet passages 142, more preferably 4 outlet passages or 3, 4, 5, 6, or more passages 142). Preferably, the outlet passages 142 are located off-axis and are angled outwardly in relation to the central channel 21 of the inner tube 62 (i.e., divergently). Also preferably, the outlets 142 are uni formly distributed about a perimeter of the insert 140 so as to substantially uniformly distribute aerosol in a smoker's mouth during use and create a greater perception of fullness in the mouth. Thus, as the aerosol passes into a smoker's mouth, the aerosol enters the mouth and moves in divergent directions so as to provide a full mouth feel. In contrast, electronic smoking articles having a single, on-axis orifice tend to direct its aerosol as single jet of greater velocity toward a more limited location within a smoker's mouth.

0037In addition, the multi-ported mouthpiece insert 140 and its diverging outlet passages 142 are arranged and include interior surfaces 144 such that droplets of un-aerosolized liquid material, if any, that may be entrained in the aerosol strike the interior surfaces 144 of the mouth end insert 140 and/or strike portions of walls of the diverging outlet passages 142. As a result such droplets are substantially removed or broken apart so as to enhance o\the aerosol.

0038Optionally, the diverging outlet passages 142 are angled at about 5° to about 60° with respect to the longitudinal axis of the outer tube 6 so as to more completely distribute aerosol throughout a mouth of a smoker during use and to remove droplets. In a preferred embodiment, there are four diverging outlet passages 142, each at an angle of about 40° to about 50° with respect to the longitudinal axis of the outer tube 6, more preferably about 40° to about 45° and most preferably about 42°.

0039Preferably, each of the diverging outlet passages 142 has a diameter ranging from about 0.015 inch to about 0.090 inch (e.g., about 0.020 inch to about 0.040 inch or about 0.028 inch to about 0.038 inch). The size of the diverging outlet passages 24 and the number of diverging outlet passages 24 can be selected to adjust the resistance to draw (RTD) of the electronic smoking article 60, if desired. Moreover, the mouth end insert 8 can be formed of a polymer selected from the group consisting of low density polyethylene, high density polyethylene, polypropylene, polyvinylchloride, polyetheretherketone (PEEK) and combinations thereof. The mouth end insert 8 may also be colored if desired.

0040In one embodiment, shown in <figref idref="f0004">Figure 10B</figref>, the mouth end insert 140 can include an on-axis central outlet passage 143, together with the diverging outlet passages 142.

0041As shown in <figref idref="f0004">Figure 9</figref>, an interior surface 144 of the mouth end insert 140 can comprise a generally domed surface 144. Alternatively, the interior surface 144 of the mouth end insert 140 can be generally cylindrical or frustoconical, with a planar end surface. Preferably, the interior surface 144 is substantially uniform over the surface thereof. Moreover, the interior surface 144 can be symmetrical about the longitudinal axis of the mouth end insert 140. However, in other embodiments, the interior surface 140 can be irregular and/or have other shapes.

0042In a preferred embodiment, the interior surfaces 144 of the insert 140 may include a void disposed at the convergence of the diverging outlet passages 144.

0043Referring now to <figref idref="f0005">Figure 11</figref>, in another embodiment, the electronic smoking article 60 includes a gasket 10 having a central channel 63 as previously described with the other embodiments, together with a MAC insert 104c, which functions in a manner similar to that described with respect to the MAC insert 104 of the first embodiment with reference to <figref idref="f0001">Figures 1A and 1B</figref>. However, the MAC insert 104c of embodiment in <figref idref="f0005">Figure 11</figref> is in the form of a single disc having openings 112c radially spaced outwardly of a central face 102c. In this embodiment, the openings 112c and the face 102c are coplanar, whereas in the first embodiment shown in <figref idref="f0001">Figures 1A, 1B</figref>, <figref idref="f0002">2 and 3</figref>, the face 102 is spaced upstream from the openings 112. Each opening 112c may have a diameter ranging from about 0.015 inch to about 0.090 inch (e.g., about 0.020 inch to about 0.040 inch or about 0.028 inch to about 0.038 inch).

0044Referring now to <figref idref="f0005">Figure 13</figref>, in that higher velocities may enhance the benefits of impaction, expedients may be implemented to increase the speed of the aerosol as it approaches the face 102 of the MAC insert 104. For example, the gasket 10 can include a constricted central channel 63' to produce greater velocities in the aerosol as it is drawn through the central channel 63', and acts as an aerosol stream forming element.

0045Referring now to <figref idref="f0005">Figure 14</figref>, in another embodiment, the MAC insert 104d comprises a cylindrical body 106 and a series of partitions 979 extending partially across the an interior of the cylindrical body 106 in alternating relationship. The partitions 979 are longitudinally spaced from one another and present multiple faces 102d, which aerosol may strike as aerosol passes through the MAC insert 104d. In this embodiment, the outlet orifices 112d are provided downstream of the partitions 979.

0046Optionally, the orifices 112, 112a, 112b, 112c, 112d, 112e in the embodiments of <figref idref="f0002">Figures 2, 3</figref>, <figref idref="f0003">5A, 5B</figref>, <figref idref="f0005">12, 14</figref> and <figref idref="f0006">15</figref> may be sized to provide an RTD controlling aspect.

0047Optionally, as shown in <figref idref="f0006">Figure 15</figref>, it is contemplated that the relative, radial positions of the face 102e and the exit orifices 112e can be reversed such that an aerosol may be directed instead to an outer peripheral region of the MAC insert 104e and drawn through a central orifice 112e.

0048Optionally, the face 102, 102a, 102b, 102c, 102d, 102e of the MAC insert 104, 104a, 104b, 104c, 104d, 104e may be porous such that it has the capacity to collect particles through adsorption and/or absorption and in lieu of or in addition, may be concave in the upstream direction or in the downstream direction to adjust its characteristics as a mechanical aerosol converter.

0049Although the above teachings are with reference to a particular layout of an electronic smoking article 60, the teachings are equally applicable to any electronic smoking article whatever the configuration.

0050When the word "about" is used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ± 10% around the stated numerical value. Moreover, when reference is made to percentages in this specification, it is intended that those percentages are based on weight, i.e., weight percentages.

0051Moreover, when the words "generally" and "substantially" are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. When used with geometric terms, the words "generally" and "substantially" are intended to encompass not only features which meet the strict definitions but also features which fairly approximate the strict definitions.

0052It will now be apparent that a new, improved, and nonobvious electronic smoking article has been described in this specification with sufficient particularity as to be understood by one of ordinary skill in the art. Moreover, it will be apparent to those skilled in the art that numerous modifications, variations, substitutions, and equivalents exist for features of the electronic smoking article which fall within the scope of the invention as defined by the appended claims.