Electronic cigarette.

(54) Title: ELECTRONIC CIGARETTE. (54) Title: ELECTRONIC CIGARETTE.

(57) Summary

An electronic smoking article includes an outer tube that extends in a longitudinal direction, an inner tube inside the outer tube and includes a pair of opposite grooves, a liquid supply including a liquid material, a coil heater, a wick, and insert end of mouth. The coil heater is located in the inner tube. The coil heater is formed of a nickel-chromium alloy, iron free and has substantially evenly spaced windings. The wick is surrounded by the coil heater such that the wick delivers liquid material to the coil heater and the coil heater heats the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol in the inner tube.

(57) Abstract

An electronic smoking article ineludes an outer tube extending in a longitudinal direction, an inner tube within the outer tube and including a pair of opposing slots, a liquid supply comprising a liquid material, a coil heater, a wick and a mouth end insert. The coil heater is located in the inner tube. The coil heater is formed of an iron-free, nickel-chromium alloy and has substantially uniformly spaced windings. The wick is surrounded by the coil heater such that the wick delivers liquid material to the coil heater and the coil heater heats the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol in the inner tube.

ELECTRONIC CIGARETTE

Selected Features Compendium

An electronic cigarette or cigar (collectively a smoking article) is provided, which includes a heating element that vaporizes liquid material to produce an aerosol or vapor. The heating element preferably comprises a resistance heating coil, with a wick extending therethrough. The heating coil is constructed in a manner and formed of a material such that the production of hot spots and excessive temperatures is avoided during a smoke.

The preferred electronic article includes a mouth end insert that includes at least two diverging outlets to impart a more complete mouth feel from the steam outlet. Preferably, the aforementioned multi-gate mouth end insert cooperates with a packing. As aspirated through the gasket, the steam outlet enters a space just upstream of the manhole piece that allows the air stream to expand and decelerate before entering the passageways of the manhole end insert to avoid substantially perceptions of hot on or around the smoker's lips.

The preferred electronic item includes a

-2 portion of metal box and a precisely formed primary air inlet gate at a location along the metal box portion, preferably along a metal side wall portion of the article. The air inlet gate is precisely formed within tight tolerances and the air inlet gate is dimensioned to be the predominant source of pressure drop along an air communication path between the air inlet and the steam source (the heater). Such an arrangement ensures that the resistance to aspiration (RTD) remains essentially the same from one puff to the next and from one item to the next. To further enhance consistent performance, the RTD of an item is verified in the course of its manufacture and corrective action is taken if necessary.

Brief Description of Drawings

Figure 1 is a flattened top view of an electronic cigarette according to a first embodiment;

Figure 2 is a cross sectional side view of the electronic cigarette shown in Figure 1;

Figure 3A is an exploded perspective view of the elements comprising the cartridge section of the electronic cigarette shown in Figure 1;

Figure 3B is a detailed view of an air inlet flap of the cigarette cartridge section

-3 electronic I shown in figure 1;

Figure 4 is a perspective view of the mouth end insert of the electronic cigarette shown in Figure

1;

Figure 5 is a cross-sectional view along line AA of the mouth end insert of Figure

4;

Figure 6 is a perspective view of an alternative embodiment of the mouth end insert of the electronic cigarette shown in Figure 1;

Figure 7 is a cross-sectional view along line BB of the mouth end insert of Figure 6;

Figure 8 is an enlarged view in detail of the heater assembly of the electronic cigarette for smoking shown in Figure 1;

Figure 9A is an enlarged view of the inner tube with a heater coil and a wick assembly in place before placing a seal ring;

Figure 9B is an enlarged view of the inner tube with a heater coil and a wick assembly in place after a closure ring is placed;

Figure 10 is a cross sectional view of a third embodiment of a mouth end insert for use with the electronic cigarette of Figure 1;

Figure 11 is an exploded view of the mouth end insert of Figure 10;

Figure 12 is a detailed view of an alternative connection arrangement assembly for use with the electronic cigarette of Figure 1;

Figure 13 is a second embodiment of a connector cathode including a notch;

Figures 14A, 14B and 14C illustrate a third embodiment of a connector cathode including angled holes;

Figure 15 is an illustration of a connecting cathode and anode in which the anode is shortened to allow communication with air inlets;

Figure 16 is a top view of an electronic cigarette including an aroma strip on an external surface thereof;

Figure 17 is a perspective view of a fourth embodiment of a mouth end insert for use with the electronic cigarette;

Figure 18 is a cross sectional view of an electronic cigarette according to the first embodiment and further including a sleeve assembly;

Figure 19 is a side view of an electronic cigarette according to another embodiment.

Detailed description

-5 General Plan of the Electronic Cigarette

Referring to Figures 1 and 2, an electronic cigarette (article) 60 is provided and comprises a replaceable cartridge (or first section) 70 and a reusable attachment (or second section) 72, which in the preferred embodiment are coupled together in a threaded connection 205 or by another device such as loose fit, stop, clip and / or fastener. Generally, the second section 72 includes a smoke sensor 16 that responds to the air drawn into the second section 72 via an air inlet gate 45 adjacent to the free end or tip of the electronic cigarette 60, a battery 1, and control circuits. The first disposable section 70 includes a liquid supply region 22 for liquid and a heater 14 that converts the liquid into an aerosol, which is taken from the liquid supply region 22 through a wick 28. Upon completion of the threaded connection 205, the battery 1 can be connected to the electric heater 14 of the first section 70 upon actuation of the smoke sensor. Air is drawn primarily to the first section 70 through one or more air inlets 44.

In the preferred embodiment, once the liquid in the cartridge is used up, only the first section 70 is replaced. An alternate arrangement includes an arrangement in which all of the article 60 is disposed of once the liquid supply is exhausted. In such a case, the battery type and

-6other features can be designed for simplicity and cost effectiveness, but it generally embodies the same concepts as in the preferred embodiment, in which the second section is reused and / or recharged.

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

Preferably, at least one adhesive backing label is applied to outer tube 6. The label completely circumscribes electronic cigarette 60 and can be colored and / or textured to provide the impression and / or feel of a traditional cigarette. The tag may include holes in it that are sized and positioned to prevent blocking of air inlets 44.

The outer tube 6 and / or the inner tube 62 can be formed of any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites that contain one or more of those materials, or thermoplastics that are suitable.

-7for food or pharmaceutical applications, for example polypropylene, polyether ether ketone (PEEK), ceramic, and polyethylene. Preferably, the material is light and not brittle.

Cartridge Structure

Referring now to Figures 1, 2 and 3, the first section 70 includes an outer tube (or housing) 6 extending in a longitudinal direction and an inner tube (or chimney) 62 positioned coaxially with the outer tube 6. Preferably, a nose portion 61 (see Figure 3A) of an upstream packing (or seal) 15 fits into an upstream end portion 65 of inner tube 62, while at the same time an outer perimeter 67 of packing 15 Provides a liquid proof seal with an inner surface of the outer housing 6. Upstream gasket 15 also includes a central longitudinal air passage 20, which opens into an inner tube 62 defining a central channel.

twenty-one. A transverse channel 33 in a rear side portion of the package 15 forms an intersection and communicates with the central channel 20 of the package 15. This channel 33 ensures communication between the central channel 20 and a space 35 (see figure 2) defined between the gasket 15 and a cathode connector piece 37. In the preferred embodiment, part 37 includes a threaded section for effecting threaded connection 205.

The cathode connector piece 37 includes opposite notches 38, 38 'around its perimeter 39, which, at

-8 occur the insertion of the cathode connector piece 37 in housing 6, are aligned with the location of each of two air inlet gates, which control RTD 44 and 44 'in external housing 6. In a manner embodiment, such alignment may appear as shown in Figure 3B (detail). Such an arrangement allows gates 44, 44 'to be placed near threaded connection 205 without occlusion by the presence of cathode connector piece 37. The arrangement also reinforces the area of ​​gates 44, 44 'to facilitate accurate drilling of holes 44, 44'.

Air Inlets and Resistance to Aspiration Control

In the preferred embodiment, at least one air inlet 44 is formed in the outer tube 6, preferably adjacent to the threaded connection 205 to minimize the possibility that a smoker's fingers occlude one of the gates and control the Aspiration resistance (RTD) during smoking. Preferably, each of the air inlets controlling the RTD 44 and 44 'is machined in housing 6 with precision tooling such that their diameters are closely controlled and replicated from one electronic cigarette 60 to the next during manufacture. Preferably, the air inlets 44 and 44 'are drilled with carbide drill bits or other high precision tools and / or techniques. Also preferably, the outer tube 6 is formed of metal or metal alloys such that the size and shape of

-9 the air inlets 44, 44 'are not altered during manufacturing, packing and smoking operations. In this way, the air inlets 44, 44 'provide a constant RTD. In the preferred embodiment, the air inlets 44, 44 'are dimensioned and configured such that the electronic cigarette 60 has an RTD in the range of about 60 to about 150mmH₂Or, more preferably about 90 to about 110 mm H₂Or, most preferably around 100 to around 130mm H₂OR.

The air inlets that control the RTDs 44 and 44 'are the critical holes (i.e. the smallest hole along the path of the air inlets 44 and 44' and the inner passage of passage 21 of inner tube 62 ), where the heater 14 forms the liquid into an aerosol. Accordingly, the air inlets 44 and 44 'control the level of resistance to inhaling of the electronic cigarette 60, which can be set at a level that contributes to a similar vacuuming experience to that of inhaling a conventional lighted cigarette.

With specific reference to Figure 1, another aspect of maintaining a precise and reproducible suction resistance is the use of a metallic material in housing 6, which is conducive to tooling and precision techniques. If another material for the housing 6 is desired (such as plastic for a softer feel), the air inlets 44, 44 'can instead be formed into a metal plate attachment (or

-10insert) 43 provided at the location of the air inlets 44, 44 'so as to maintain the accuracy of the air inlets 44,'.

It is contemplated that the metal plate insert 43 can be included even in cases where the housing 6 is metal, as such an arrangement allows air inlets 44, 44 'to be produced and tested separately (offline) in a collection of metal plate inserts 43. Advantageously, if any metal terminal plate insert 43 cannot meet the standards or specifications for air inlet diameter (and RTD), the failed inserts can be discarded instead of all complete cartridge assemblies (first section) 70.

Referring back to Figure 1, the metal plate insert 43 may comprise a separate part that becomes attached to an external surface of the housing 6 or entirely within the housing 6, in which case the external housing 6 is preferably provided with an oversized hole, which may be superimposed over the area of ​​the air inlet 44. It is also contemplated that the insert can be configured and adjusted flush with the contour of the housing 6, using press fit and / or adhesive between the insert and housing 6 or entirely inside (internal to external housing 6). Preferably, the shape and placement of the air inlet 44 of the insert 43 have a symmetry such that the air inlet 44 remains fully operational with the insert 43 positioned as

-11 shown in figure 1 or flipped 180 degrees. Furthermore, the metal plate insert 43 can be provided on an inner surface or an outer surface of the outer housing 6. The metal plate insert 43 can extend in whole or in part around a circumference of the electronic cigarette 60. When the metal plate insert 43 partially extends around the circumference, multiple metal plate inserts 43 can be used, each metal plate insert 43 corresponding to a single air inlet 44, 44 '.

In the preferred embodiment, the second section 72 includes an air inlet 45 at an upstream end 5 of the electronic cigarette 60, which is dimensioned just enough to ensure proper operation of the smoke sensor 16, placed nearby. The action of sucking in the mouth end insert 8 is communicated to the air inlet gate 45 through central channels provided in the anode post 47c of the first section 70 and the anode connection post 47b of the second section 72 and along the space 13 between the battery 1 and the housing of the second section 72. These channels and the gate 45 itself are dimensioned such that the air flow rate therethrough is much less than that through the air inlets 44, 44 ', so that the impact on the RTD is minimized and the consistency in RTD. For example, each air inlet may be less than about 2.0mm wide and less than about

-121.5 mm depth. For example, each air intake can be from about 0.7 to about 0.8 mm in width and from about 0.7 to about 0.8 mm in depth. In a preferred embodiment, 95% of the air introduced into the electronic cigarette 60 is through the air inlets 44, 44 ', while only 5% of the total air flow enters through the inlet 45 at the end upstream 5 of the electronic cigarette 60. Preferably, the ratio is determined by making a center channel 34 of the anode post 47b of the second section 72 sufficiently small to impart a much greater pressure drop than that of the air inlets 44, 44 '. For example, the center channel 34 of the anode pole 47b can be sized to impart a pressure drop of approximately 2,000 mm of water (in contrast to a nominal pressure drop of 100 mm of water from the air inlets 44, 44 'combined).

Referring to Figure 19, in order to maintain a consistent RTD in the product, a removable protective covering 601 can be applied to the air inlets 44, 44 ', to prevent degradation by debris and foreign materials during manufacturing, the packaging, shipping and handling at retail and thereafter, as shown in Figure 18. To maintain a consistent RTD until consumption, a wrap or tape 601 can be wrapped around the outer housing 6 at the locations of the air inlets 44,

-1344 '. Alternatively or in addition, the electronic cigarette 60 may be accompanied by a protective cover capable of being reused to provide the same or additional protections.

In addition, current manufacturing techniques for electronic smoking articles can be modified to include testing for a consistent RTD. In other words, there is a need to couple an understanding of how to achieve consistent RTD in the product (as noted earlier) with an understanding of how to test it in the course of product manufacturing (as noted below). Achieving a consistent RTD from one e-cigarette to the next promotes consistent performance and levels of delivery, and enhances the smoking experience by satisfying the smoker's expectations that inhaling an e-cigarette will be similar to inhaling an extreme cigarette or cigar switched on. The latter may include testing the metal plate inserts 43 prior to installation, as previously described; or instead, or in addition, test the finished first sections 70 by clamping a nominal but inactivated second section 72 to a newly produced first section 70 to create a benign, inactive test configuration that accurately reproduces a flow event. air, but without the risk of heater activation and applying a predetermined suction action when setting up while measuring the pressure drop. As a non-limiting example, an electronic cigarette

-14 Fully assembled can be aspirated through the test setup while measuring the pressure drop using a PV10 pressure drop instrument manufactured by Borgwaldt KC of Chesterfield, Virginia, United States. A suitable pressure drop test method for electronic smoking articles can be adopted from the standardized ISO 6565: 2011 method, entitled Tobacco and tobacco products - resistance to cigarette sniffing and pressure drop of filter bars - standard conditions and measurement, and applied with instrumentation capable of measuring pressure drop over a working range of 50 mm WG (mm of water, gauge) to 1,900 mm WG and a diameter range of 5.0 to 9.0 mm. The test can be completed in a matter of seconds and the instrumentation can be calibrated to a range of 50 to 300 mm WG.

Rather than using a second inactivated section 72, it is contemplated that a releasable test body can be employed to serve the same purpose in a benign (inactive) test configuration. The test body can be configured to reduce the nominal impact of a real second portion, capable of reusing 72 on the RTD, but can be optimized and machine driven and automated at high speed by coupling to and removing first 70 sections just produced that they are being tested.

The inclusion of a 205 threaded connection does not facilitate automated, high-speed handling and execution of

-15 RTD tests. Referring now to Figure 12, an alternate coupling 205 'may include connections comprising pins 501 and releasable stops 503 and / or electrical bearing surfaces 505 with releasable stops, rotatable locking devices, or the like. In the illustrated embodiment, the stop 503 cooperates with a raised ring 509. In an alternative, one or more installed spheres can be used in place of or in addition to the raised ring 509. Such arrangements facilitate automated machine handling, provide greater capacity for fast but accurate RTD testing, and facilitate automated machine execution of RTD tests. It is envisaged that quality control during hole drilling may include a feedback loop such that RTD test results are monitored for trends away from specifications so that corrective action can be taken, such as replacement of a worn drill bit.

Referring now to Figures 3A and 3B, preferably, the cathode connector part 37 includes opposite notches 38, 38 'around its perimeter 39, which, when the cathode connector part 37 is inserted into the outer housing 6, are aligned with the location of each of the two or more air inlets 44 and 44 'that control the RTD in the outer housing 6. In some embodiments, more than two air inlets 44, 44' may be included (see. gr., three,

-16four, five, six, seven, eight, nine, ten or more). Alternatively, a single air inlet 44 may be included. In one embodiment, such an alignment may appear as shown in Figure 3B. Such an arrangement allows the placement of the air inlets 44, 44 'near the threaded connection 205 without occlusion due to the presence of the cathode connector piece 37. The arrangement also reinforces the area of ​​the air inlets 44, 44 ', which can serve to facilitate precise drilling of the air inlets 44, 44'. Other arrangements can also be used as discussed below.

In another embodiment, as shown in Figure 13, the cathode connector part 37 may include one or more slits 300 formed in the perimeter 39 of the cathode connector part 37. The outer housing 6 of the cartridge portion 70 it is slid over the unthreaded end of connecting piece 37 until it reaches stop (or edge) 307, leaving a predetermined portion of slit 300 open to the outside of cartridge portion 70 for air intake. The admitted air can move along the slit 300 and into the cartridge portion 70. The slit 300 can be used as the critical hole and can be used in place of the air inlets 44 and 44 '. In another embodiment, the slit 300 can be used in addition to the air inlets 44 and 44 '.

In yet another embodiment, as shown

- In Figures 14A, 14B and 14C, the cathode connector piece 37 may include one or more angled holes 301 formed therein, communicating with the one or more grooves 302 in a cathode connecting fitting 49b. Preferably, the cathode connecting fitting 49b may include a void annular space 303 in its internal portion that communicates with one or more grooves 302. Air is drawn through slot 302 and travels into annular space 303 and thence into angled holes 307. Thus, there is no need to align slot 302 with angled hole 301 because air will travel around the annular space 303 and towards the angled holes 301 even if the holes 301 and the grooves 302 are not aligned. This arrangement provides advantages during manufacturing since angled holes 301 need not be aligned with grooves 302.

As shown in Figure 15, in yet another embodiment, the anode pole 47c can be shortened compared to the anode pole 47c in Figure 2, so as to provide a larger air gap behind the connector piece. cathode 37. Air enters via slot 302 '(not shown in Figure 15 except for its relative position) and is exhaled through an internal air inlet 44 via annular space 303 and then flows straight into the air space, through from the central channel 34 of the anode pole 47c and towards the central channel 20 leading to the heater 14.

Liquid, Heater and Wick Supply Region

-18 Preferably, a nose portion 93 of a downstream gasket 10 is fitted into a downstream end portion 81 of inner tube 62. An outer perimeter 82 of gasket 10 provides a substantially liquid-proof seal with an inner surface 97 external housing 6. The downstream packing 10 includes a center channel 84 disposed between the center passage 21 of the inner tube 62 and the interior of the mouth end insert 8 and which communicates aerosol from the center passage 21 to the mouth end insert 8.

The defined space between gaskets 10 and 15 and outer tube 6 and inner tube 62 establishes the confines of a liquid supply region 22. Liquid supply region 22 comprises a liquid material and optionally a liquid storage medium 210 operative to store the liquid material in it. Liquid storage medium 210 may comprise a wrap of cotton gauze or other fibrous material around inner tube 62.

In the preferred embodiment, the liquid supply region 22 is contained in an outer ring 60 between the inner tube 62 and the outer tube 6 and between the gaskets 10 and 15. Thus, the liquid supply region 22 At least partially surrounds central air passage 21. Heater 14 extends transversely through central channel 21 between opposite portions of liquid supply region 22.

-19 Preferably, liquid storage medium 210 is a fibrous material comprising cotton, polyethylene, polyester, rayon, and combinations thereof. Preferably, the fibers have a diameter ranging from about 6 to about 15 microns (eg, about 8 to about 12 microns, or about 9 to about 11 microns). Liquid storage medium 210 can be a sintered, porous, or foamed material. Also preferably, the fibers are dimensioned to be non-breathable and may have a cross section having a y-shape, a cross shape, a trefoil shape or any other suitable shape. In the alternative, the liquid supply region 22 may comprise a full tank that lacks a fibrous storage medium 21 and contains only liquid material.

Also preferably, the liquid material has a boiling point suitable for use in the electronic cigarette 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 point boiling is too low, the liquid can vaporize even when heater 14 is not being activated.

Preferably, the liquid material includes a tobacco-containing material that includes volatile tobacco flavor compounds, which are released from the liquid upon heating and may contain nicotine. Liquid can also be a material that

-20 contains tobacco flavor or a nicotine-containing material that is tasteless. Alternatively or in addition, the liquid may include a non-tobacco material, other flavoring materials, and may be free of nicotine. For example, the liquid can 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 glycerin and propylene glycol.

Referring now also to Figure 8, in use, the liquid material is transferred from the liquid supply region 22 and / or the liquid storage medium 210 in proximity to the heater 14 by the capillary action of the wick 28. In a In an embodiment, the wick 28 has a first end portion 29 and a second end portion 31, as shown in Figure 8. The first end 29 and the second end 31 extend to opposite sides of the liquid storage medium 21 for contact with the liquid material contained therein. Also preferably, heater 14 at least partially surrounds a central portion 113 of wick 28 such that when heater 14 is activated, the liquid in central portion 113 of wick 28 is vaporized by heater 14 to form an aerosol . The wick 28 preferably comprises filaments having a capacity to suck a liquid, more preferably a bundle of glass (or ceramic) filaments and, most preferably, a bundle comprising a

-21 group of glass filament windings, preferably three of such windings, all of which arrays are capable of aspirating liquid via capillary action through interstitial spacings between the filaments. Preferably, the wick 28 is flexible and includes three strands, each strand including a plurality of strands. Furthermore, it is observed that the end portions 29 and 31 of the wick 28 are flexible and capable of bending towards the confines of the liquid supply region 22.

Advantageously, the liquid material in the liquid supply region 22 is protected from oxygen (because oxygen generally cannot enter the liquid supply region 22 via the wick 28). In some embodiments, the liquid material is also protected from light so that the risk of degradation of the liquid material is significantly reduced. In this way, a high standard of shelf life and cleanliness can be maintained.

In the preferred embodiment, the liquid supply region 22 is dimensioned and configured to contain enough liquid material such that the electronic cigarette 60 is operable to smoke for at least about 200 seconds, preferably at least about 250 seconds , most preferably at least about 300 seconds, and most preferably at least about 350 seconds. In this way, the liquid supply region

-2222 is equivalent to about a pack of traditional cigarettes. Furthermore, the electronic cigarette 60 can be configured to allow each puff to last a maximum of about 5 seconds.

Mouth End Insert

Referring to Figures 2, 3A, 4, 5, 6, 7, and 17, the first section 70 includes a mouth end insert 8 having at least two divergent outlet passages 24 (e.g., 3, 4 , 5 or more, preferably 2 to 10 exits or more, preferably 2 to 6 passages 24, even more preferably 4 exit passages 24). Preferably, the outlet passages 24 are positioned off-axis and angled outward relative to the center channel 21 of the inner tube 62 (ie, divergently). Also preferably, the mouth end insert (or flow guide) 8 includes outlets 24 evenly distributed around the perimeter of the mouth end insert 8 so as to substantially uniformly distribute aerosol into the mouth of a smoker during use and create a greater perception of fullness in the mouth. In this way, as the aerosol passes into a smoker's mouth, the aerosol enters the mouth and moves in different directions so as to provide a full mouthfeel. In contrast, electronic smoking articles that have a single hole in the shaft tend to direct their aerosol as a single jet of higher velocity towards a more limited location within the mouth of

-23 a smoker.

In addition, the divergent outlet passages 24 are arranged and include interior surfaces 83 such that droplets of non-aerosolized liquid material, if any, that may be trapped in the aerosol, impact the interior surfaces 83 of the mouth end insert 8 and / or impact portions of the walls 305 defining the divergent outlet passages 24. As a result, such droplets are substantially removed or disintegrated, to increase the aerosol.

In the preferred embodiment, the diverging outlet passages 24 are angled at about 5 to about 60 ° from the longitudinal axis of the outer tube 6 so as to more fully distribute the aerosol through a user's mouth during use and remove droplets. In a preferred embodiment, there are four divergent outlet passages 24, each at an angle of about 40 to about 50 ° to the longitudinal axis of the outer tube 6, more preferably about 40 to about 45 ° and most preferably around 42 °.

Preferably, each of the diverging outlet passages 24 has a diameter ranging from about 0.015 to about 0.090 inches (e.g., about 0.020 to about 0.040 inches, or about 0.028 to about 0.038 inches ). The size of the divergent exit passages 24 and the number of the divergent exit passages 24 can be

-24 selected to adjust the resistance to aspirate (RTD) of the electronic cigarette 60, if desired.

In one embodiment shown in FIG. 17, the mouth end insert 8 may include divergent exit passages 24 and an exit passage on shaft 26.

As shown in Figure 2, an inner surface 83 of the mouth end insert 8 may comprise a generally domed surface 83. Alternatively, as shown in Figure 7, the annular inner surface 83 'of the end insert Mouth 8 can be generally cylindrical or frusto-conical, with a flattened end surface. Preferably, the inner surface 83 is substantially uniform over its surface. Furthermore, the inner surface 83 may be asymmetric about the longitudinal axis of the mouth end insert 8. However, in other embodiments, the inner surface 83 may be irregular and / or have other shapes.

In a preferred embodiment, a gap 911 is provided at the convergence of the divergent outlet passages 24 within the mouth end insert 8.

The mouth end insert 8 can be integrally fixed within the outer tube 6 of the cartridge 70. Furthermore, the mouth end insert 8 can be formed of a polymer selected from the group consisting of low-density polyethylene, high-polyethylene density, polypropylene,

-25 polyvinylchloride, polyether ether ketone (PEEK), and combinations thereof. The mouth end insert 8 may also be colored, if desired.

As previously mentioned, the multi-gate mouth end insert 8 disperses and changes the direction of the aerosol as it is drawn from the electronic cigarette 60 so as to provide a fuller mouth feel. As the aerosol forms, it passes through center channel 21 in inner tube 62 and through center channel 84 in downstream gasket 10. In a previous prototype test panel, panelists reported a hot lip sensation when smoking an electronic cigarette constructed to include a mouth end insert that includes a plurality of divergent outlet passages 24 and a center channel 84 having a diameter about 1.3 mm. However, in electronic smoking articles in which the internal diameter of the central channel 84 was increased to about 2.6 mm, reports of hot sensations essentially ceased.

Dynamic modeling of the area in and around downstream packing 10 and mouth end insert 8 has indicated that a small 1mm wide center channel 84 in packing 10 tends to create peak speeds of approximately 12 meters per second ( m / sec) in the aerosol that comes out of the mouth end insert. In contrast, modeling a system that includes a 5mm wide center channel 8 indicates speeds

-26 peak of only 2.5 m / sec achieved at the exits of the diverging exit passages 24 of the mouth end insert 8, which is an approximately five-fold reduction in air velocity. From the aforementioned testing and modeling, it is believed that a further improvement in the organoleptic experience is achieved with an electronic cigarette by preventing acceleration of the aerosol flow stream by increasing the diameter of the central channel 84 before aspirating through the outlets of the diverging outlet passages 24 of the multi-gate mouth end insert 8.

Accordingly, it is advantageous to provide an electronic cigarette having a downstream gasket 10 having a central channel 84, which is of sufficient diameter to prevent acceleration of the aerosol flow stream prior to reaching the mouth end insert 8 Preferably, the diameter of the central channel 84 is from about 2.0 to about 3.0 mm, more preferably from about 2.4 to about

2.8 mm. The mouth end insert 8 then divides the outlet of the center channel 84 into multiple divergent streams of reduced speed so as to provide a full mouthfeel and avoid hot sensations.

Where a central channel 84 of appropriate dimensions of packing 10 serves to substantially prevent acceleration of the aerosol, such functionality can be further enhanced by providing the outlet port with a beveled ring (not

-27 shown) in its outlet plane to further reduce the speed of the spray before it reaches the mouth end insert 8.

In an alternative embodiment, the mouth end insert 8 and the downstream packing 10 can be integrally formed as a single piece so as to enhance consistent performance and facilitate manufacturing.

As shown in Figures 10 and 11, in an alternative embodiment, the electronic cigarette 60 of Figure 1 may include a mouth end insert 8 having a stationary part 27 and a part capable of rotating 25. The outlets 24 , 24 'are located in each of the pieces 27 stationary and rotatable 25. The outlets 24, 24' are combined, as shown, to allow the aerosol to enter a smoker's mouth. However, the rotatable part 25 can be rotated within the mouth end insert 8 so as to at least partially block one or more of the outlets 24 in the stationary mouth end insert 28. That is, the consumer can adjust the amount of aerosol aspirated with each puff. The outlets 24, 24 'can be formed in the mouth end insert 8 such that the outlets 24, 24' diverge to provide a fuller mouthfeel during inhalation of the aerosol.

Circuits, Alloys that Improve Consistent Heater Performance, Hot Spots and Carbonyl Abatement

-28 In the preferred embodiment, the power source 1 includes a battery arranged in the smoking electronics 60 such that anode 47a is downstream of cathode 49a. A battery anode pole 47b of the second section 72 preferably makes contact with the anode 47a of the battery.

More specifically, the electrical connection between the anode 47a of the battery 1 and the heating coil 14 in the first section 70 is established through a battery anode connection post 47b in the second section 72 of the electronic cigarette 60, an anode pole 47c of cartridge 70 and an electrical terminal 47d connecting a ring portion of anode pole 47c with an electrical terminal 109 of heater element 14 (see figure 8). Similarly, the electrical connection between cathode 49a of battery 1 and the other terminal

109 'of heater coil 14 is established through threaded connection 205 between a cathode connection fitting

49b of the second portion 72 and the cathode connector piece 37 of the first section 70 and thence through the electrical terminal 49c which electrically connects the attachment 37 to the opposite terminal 109 'of the heater coil 14.

Preferably, the electrical terminals 47d, 49c and heater terminals 109, 109 'are highly conductive and temperature resistant while the coil section of heater 14 is highly resistive so that heat generation occurs primarily at length of heater coils 110 14. Also preferably, the electrical terminal

47d is connected to terminal 109 of the heater by crimping. Similarly, electrical terminal 49c is connected to terminal 109 'of the heater by crimp. In an alternate embodiment, electrical terminals 47d, 49c may be attached to heater terminals 109, 109 'via solder. Crimp is preferred because it makes manufacturing faster.

The battery can be a lithium ion battery or one of its variants, for example a lithium ion polymer battery. Alternatively, the battery may be a metal-nickel hydride battery, a nickel-cadmium battery, a lithium-manganese battery, a lithium-cobalt battery, or a fuel cell. In that case, preferably, the electronic cigarette 60 is capable of being used by a smoker until the energy in the power source is exhausted or in the case of the lithium polymer battery, until a level is reached. minimum voltage cut-off.

Alternatively, the power source 1 can be rechargeable and includes circuits that allow the battery to be charged by an external charging device. In that case, preferably the circuits, when charged, provide power for a predetermined number of puffs, after which the circuits must be re-connected to an external device.

-30load. To recharge the electronic cigarette 60, a USB charger or other suitable charger assembly can be used.

Preferably, the electronic cigarette 60 also includes control circuits including a smoke sensor 16. The smoke sensor 16 is capable of operating to detect a drop in air pressure and initiate the application of voltage from power source 1 to the heater 14. As shown in Figure 2, the control circuits may also include an operable heater trigger light 48 to glow when heater 14 is activated. Preferably, the heater activation light 48 comprises an LED and is at an upstream end of the electronic cigarette 60 so that the heater activation light 48 takes on the appearance of a burning charcoal during a smoke. Furthermore, the heater activation light 48 may be arranged to be visible to the smoker. Furthermore, the heater activation light 48 can be used to diagnose the electronic cigarette system or to indicate that the recharging action is proceeding. Light 48 can also be configured such that the smoker can activate and / or deactivate light 48 for privacy, such that light 48 is not activated during the smoking action, if desired.

Preferably, the at least one air inlet 45 (Figure 1) is located adjacent to the smoke sensor 16, such that the smoke sensor 16 detects air flow indicative of a smoker who is smoking and activates the source of energy z

-31 1 and heater activation light 48 to indicate that heater 14 is operating.

A control circuit is preferably integrated with a smoke sensor 16 and supplies power to heater 14 in response to smoke sensor 16, preferably with a maximum time period limiter.

Alternatively, control circuits may include a manually operated switch for a smoker to start a smoke. The period of time for supplying electrical power to the heater can be pre-set, depending on the amount of liquid to be vaporized. Alternatively, the circuits can supply power to the heater 14 as long as the smoke sensor 16 detects a pressure drop.

Preferably, when activated, heater 14 heats a portion of wick 28 surrounded by heater for less than about 10 seconds, more preferably less than about 7 seconds. In this way, the energy cycle (or maximum smoking length) can vary over a period of from about 2 to about 10 seconds (e.g., about 3 to about 9 seconds, about 4 to about 8 seconds, or about 5 to about 7 seconds).

Preferably heater 14 is a coil of wire surrounding the wick 28. Examples of electrically resistive materials include titanium, zirconium, tantalum, and metals.

-32 from the platinum group. Examples of suitable metal alloys include stainless steel, alloys containing nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, and iron, and nickel-based super-alloys. , iron, cobalt, stainless steel. For example, the heater may be formed of nickel aluminum oxide, a material with a layer of alumina on the surface, iron aluminum oxide and other composite materials; the electrically resistive material can optionally be attached to, encapsulated in or coated with an insulating material or vice versa, depending on the energy transfer kinetics and the required external physicochemical properties. Preferably, heater 14 comprises at least one material selected from the group consisting of stainless steel, copper, copper alloys, nickel-chromium alloys, super-alloys, and combinations thereof. In a preferred embodiment, heater 14 is formed of nickel-chromium alloys or iron-chrome alloys, although the latter are not preferred for reasons noted below. In another embodiment, heater 14 may be a ceramic heater having an electrically resistive layer on an external surface thereof.

In another embodiment, heater 14 can be constructed of an iron aluminoid (eg, FeAl or Fe₃Al), such as those described in US Patent 5, 595,706 to Sikka and

-33 collaborators, filed on December 29, 1994, or nickel aluminoid (e.g., Ni₃Al). The use of iron aluminoid is advantageous in that the iron aluminoid exhibits high resistivity. FeAl exhibits a resistivity of approximately 180 micro-ohms, while stainless steel exhibits approximately 50 to 91 micro-ohms. Higher resistivity reduces current draw or load on the power source (battery) 1.

In the preferred embodiment, the heater coil 14 is formed from a nickel-chrome alloy that is essentially free of iron content. Experience has indicated that heater coils constructed of an alloy of iron and chromium undergo oxidation of their iron content if the alloys come into contact with water during manufacturing operations, during shelf life and / or device operation.

Heating glycerin and / or propylene glycol beyond certain temperatures is known to produce carbonyls (including formaldehyde). Iron oxide tends to catalyze these reactions such that carbonyls are produced at lower temperatures. By using alloys essentially free of iron content, such catalysis is avoided and the possibility of producing carbonyls and other constituents is minimized.

Furthermore, in manufacturing and design of the preferred embodiment, certain aspects and measures are employed.

-34 to prevent accidental hot spots from occurring on heater coil 14 during its heating cycle. Hot spots can contribute to excessive peak temperatures that can produce unwanted constituents that would otherwise be avoided in the absence of a hot spot.

While not wishing to be bound by theory, it is believed that if a coil heater coil 14 is altered such that the coil spacing of coil 14 is locally reduced, the reduced spacing will create hot spots that are believed to drive higher peak temperatures. beyond desirable levels. It is also believed that establishing a uniform spacing along the coils of the heater 14 and taking steps to preserve the original, uniform spacing in the winding of the coil heater 14 will avoid the consequence of hot spots.

In particular and referring to Figure 8, it is contemplated that the production of a consistent coil spacing 111 across the entire coil section 110 of a given heater coil 14 can be accomplished in ways that include using automated coilers to wind the coil. around the wick 28 and use the wick 28 as an axis for the winding step. In the preferred embodiment, 3 to 8 windings are preferred, more preferably 3 to 5 windings.

Once established, the uniformity of the spacing

-35111 coil is preserved in the course of manufacturing and in the design of the preferred embodiment.

Referring also to Figure 9A, in particular, the provision of opposing grooves 63 in inner tube 62 facilitates the placement of heater 14 and wick 28 in position within inner tube 62 without impacting between edges of grooves 63 and section coil 110 (shown in Figure 8) of heater 14. Consequently, the edges of the grooves 63 are not allowed to impact and alter the coil spacing 111 of the heater 14, which would otherwise create potential sources of hot spots.

Referring now to FIG. 9B, care is taken to position a closure ring 69 such that it is close to or touches but does not press against the wick 28. Such placement avoids imposing bending moments on the heater coil 14 and avoiding buckling of coil 14 that could otherwise produce hot spots along one side of coil 14 where spacing 111 thereof would become compressed and reduced. In this way, the upstream edge 114 of the sealing ring 69 is brought into proximity of the wick 28, but is not placed on the wick 28 so as to avoid the possibility of the aforementioned buckling effect. Seal ring 69, when positioned as shown in Figure 9B, closes a remainder of open space provided between heater coil assembly and slot 63.

-36 In the preferred embodiment, inner tube 62 and sealing ring 69 are constructed of woven fiberglass.

In the preferred embodiment, inner tube 62 has a diameter of about 4mm and each of opposite grooves 63 has larger and smaller dimensions of about 2 by about 4mm.

In one embodiment, the heater 14 comprises a coil of wire that at least partially surrounds the wick 28. In that embodiment, preferably the wire is a metal wire and / or the heater coil can be fully or partially extended along the length of the wick 28. The heating coil 14 may extend in whole or in part around the circumference of the wick 28. In another embodiment, the heating coil is not in contact with the wick 28.

Preferably, the heater 14 heats the liquid in the wick 28 by thermal conduction. Alternatively, the heat from the heater 14 can be conveyed to the liquid by means of a thermo-conductive element or the heater 14 can transfer heat to the entering ambient air that is drawn through the electronic cigarette 60 during use, which in turn Once the liquid is heated by convection.

In one embodiment, the wick 28 comprises a ceramic ceramic filament wick having a capacity

-37to suck up a liquid. As noted above, wick 28 is at least partially surrounded by heater 14. Furthermore, in the preferred embodiment, wick 28 extends through opposing grooves 63 in inner tube 62 such that each end of the wick 28 is in contact with the liquid supply region 22 (shown in Figure 2).

In the preferred embodiment, the wick 28 comprises filaments and comprises a bundle of glass filaments.

<td>For example,</td><td>the</td><td>wick 28</td><td>can include</td><td>a plurality</td><td>of</td>

<td>filaments.</td><td>The</td><td>filaments</td><td>or threads can</td><td colspan="2">be generally</td>

<td>aligned in</td><td>a</td><td>direction</td><td>perpendicular</td><td>(cross) to</td><td>the</td>

longitudinal direction of the electronic cigarette. Preferably, the wick 28 includes one to eight filaments, more preferably two to six filaments. In the preferred embodiment, the wick 28 includes three strands, each strand comprising a plurality of glass strands braided together.

In the preferred embodiment, the wick structure 28 is formed of filaments through which liquid can be transported to heater 14 by capillary action. The wick 28 may include filaments having a cross section that is generally cross-shaped, clover-shaped, Y-shaped, or any other suitable shape.

Preferably, wick 28 includes any suitable material or combination of materials. Examples of suitable materials are glass, ceramic or graphite based materials.

Furthermore, the wick 28 may have any suitable capillary suction action to accommodate aerosol generating liquids having different physical properties, such as density, viscosity, surface tension, and vapor pressure. The capillary properties of the wick 28, combined with the properties of the liquid, ensure that the wick 28 is always wet in the area of ​​heater 14 to avoid overheating heater 14.

Instead of using a wick 28, heater 14 may be a porous material that incorporates a resistance heater formed from a material having a high electrical resistance capable of rapidly generating heat.

Preferably, the wick 28 and the fibrous medium of the liquid supply region 22 are constructed of fiberglass.

Sleeve Assembly

As shown in FIG. 18, the electronic smoking article 60 may also include a sleeve assembly 87 removably and / or rotatably positioned around a first section 70 of the electronic cigarette 60. Furthermore, the sleeve assembly 87 isolates at least a portion of the first section 70 so as to maintain the temperature of the aerosol before delivery to the smoker. In the preferred embodiment, sleeve assembly 87 is capable of rotating around electronic cigarette 60 and includes grooves

-39 spaced 88 arranged transversely around the sleeve assembly such that grooves 88 align with air inlets 44, 44 'in first section 70 to allow air to pass into electronic cigarette 60 when a smoker puffs. Before or during the smoking action, the smoker can rotate the sleeve assembly 87 to adjust the resistance to aspirate and / or the ventilation of the electronic cigarette 60, if desired.

Preferably, the sleeve assembly 87 is made of Silicon or other deformable material so as to provide a smooth mouthfeel to the smoker. However, sleeve assembly 87 can be formed in one or more pieces and can be formed from a variety of materials, including plastics, metals, and combinations thereof. In a preferred embodiment, sleeve assembly 87 is a single piece formed from Silicon. Sleeve assembly 87 can be removed and reused with other electronic smoking items or it can be discarded along with first section 70. Sleeve assembly 87 can be of any suitable color and / or can include graphics or other indices.

Aroma Delivery

As shown in Figure 11, the electronic cigarette 60 may also include an aroma strip 89 located on an external surface 91 of at least one of the first 70 and second 72 sections. Alternatively, the aroma strip

-4089 may be located in a portion of the sleeve assembly 87. Preferably, the aroma strip 89 is located between the device battery and the heater 14 such that the aroma strip 8 9 is adjacent to a smoker's nose during the action of smoking. The aroma strip 89 can include a gel, a film or a solution including a fragrance or flavor material that is released before and / or during the action of smoking. In one embodiment, the flavor or aroma of the gel, fluid, and / or solution can be released through the action of a puff, which can open a vent over the aroma strip when placed within the first section 70 (not shown). Alternatively, the heat generated by heater 14 can cause aroma release.

In one embodiment, aroma strip 89 may include tobacco flavor extracts. Such extracts can be obtained by grinding tobacco material into small pieces and extracting with an organic solvent. The extract can then be filtered, dried (eg, with sodium sulfate) and concentrated. Alternatively, the extracts can be obtained using techniques known in the field of flavor chemistry, such as the solvent-assisted flavor extraction distillation (SAFE) technique (Engel et al., 1999), which allows separation of the volatile fraction of the non-volatile fraction. Additionally, pH fractionation and chromatography methods can be used for separation and / or

-41 additional isolation of specific compounds. The intensity of the extract can be adjusted by diluting with an organic solvent or water.

The aroma strip 89 may be a paper or polymeric strip to which the extract or flavoring material can be applied, for example using a brush or by impregnation. The flavor material can be natural or artificial. Alternatively, the extract or flavoring material can be encapsulated in a paper ring and / or strip and manually released by the smoker, for example by squeezing the aroma strip during the smoking action.

In one embodiment, the electronic cigarette 60 of Figures 2, 5, 7, and 9 may also include a filter segment upstream of the heater 14 and capable of operating to restrict air flow through the electronic cigarette 60. The Adding a filter segment can also help adjust the resistance to aspiration.

When the word around is used in this description in relation to a numerical value, the associated numerical value is intended to include a tolerance of ± 10% around the expressed numerical value. Furthermore, when referring to percentages in the description, those percentages are intended to be based on weight, ie percentages by weight.

Furthermore, when the words are used generally and substantially in relation to geometric shapes, it is intended that such precision of the geometric shape is not required but rather

-42 laxity for the form within the scope of disclosure. When used with geometric terms, the words generally and substantially are intended to encompass not only features that satisfy strict definitions but also features that closely approximate strict definitions.

It will now be apparent that a new, improved and inventive electronic cigarette has been described in this description, with sufficient particularity as would be understood by one skilled in the art. Furthermore, it will be evident to those skilled in the art that there are numerous modifications, variations, substitutions and equivalents for characteristics of the electronic cigarette that do not materially depart from the spirit and scope of the invention. Accordingly, it is expressly intended that all such equivalents, modifications, variations, and substitutions fall within the spirit and scope of the invention, as defined in the appended claims, to be embodied in the appended claims.