Aerosol Delivery Device with Static Ignitor Contacts

This application is a divisional application of U.S. patent application Ser. No. 17/899,026, filed on Aug. 30, 2022, which is incorporated herein in its entirety by reference.

The present disclosure relates to aerosol delivery devices and systems, such as smoking articles; and more particularly, to aerosol delivery devices and systems that utilize heat sources, such as combustible carbon-based ignition sources, for the production of an aerosol (e.g., smoking articles for purposes of yielding components of tobacco, tobacco extracts, nicotine, synthetic nicotine, non-nicotine flavoring, and other materials in an inhalable form, commonly referred to as heat-not-burn systems or electronic cigarettes). Components of such articles may be made or derived from tobacco, or those articles may be characterized as otherwise incorporating tobacco for human consumption, and which may be capable of vaporizing components of tobacco and/or other tobacco related materials to form an inhalable aerosol for human consumption.

Many smoking articles have been proposed through the years as improvements upon, or alternatives to, smoking products based upon combusting tobacco. Example alternatives have included devices wherein a solid or liquid fuel is combusted to transfer heat to tobacco or wherein a chemical reaction is used to provide such heat source. Examples include the smoking articles described in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

The point of the improvements or alternatives to smoking articles typically has been to provide the sensations associated with cigarette, cigar, or pipe smoking, without delivering considerable quantities of incomplete combustion and pyrolysis products. To this end, there have been proposed numerous smoking products, flavor generators, and medicinal inhalers which utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant degree.

See, for example, the various alternative smoking articles, aerosol delivery devices and heat generating sources set forth in the background art described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S. Pat. App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; and 2014/0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices and electrically powered heat generating sources referenced by brand name and commercial source in U.S. Pat. App. Pub. No. 2015/0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices and electrically powered heat generating sources referenced by brand name and commercial source are listed in U.S. Pat. App. Pub. No. 2015/0245659 to DePiano et al., which is also incorporated herein by reference in its entirety. Other representative cigarettes or smoking articles that have been described and, in some instances, been made commercially available include those described in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,388,594 to Counts et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,476 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. App. Pub. No. 2009/0095311 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518, 2009/0126745, and 2009/0188490 to Hon; U.S. Pat. App. Pub. No. 2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641 and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; and WO 2010/091593 to Hon, which are incorporated herein by reference.

Various manners and methods for assembling smoking articles that possess a plurality of sequentially arranged segmented components have been proposed. See, for example, the various types of assembly techniques and methodologies set forth in U.S. Pat. No. 5,469,871 to Barnes et al. and U.S. Pat. No. 7,647,932 to Crooks et al.; and U.S. Pat. App. Pub. Nos. 2010/0186757 to Crooks et al.; 2012/0042885 to Stone et al., and 2012/00673620 to Conner et al.; each of which is incorporated by reference herein in its entirety.

Certain types of cigarettes that employ carbonaceous fuel elements have been commercially marketed under the brand names “Premier,” “Eclipse” and “Revo” by R. J. Reynolds Tobacco Company. See, for example, those types of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, p. 1-58 (2000). Additionally, a similar type of cigarette has been marketed in Japan by Japan Tobacco Inc. under the brand name “Steam Hot One.”

In some instances, some smoking articles, particularly those that employ a traditional paper wrapping material, are also prone to scorching of the paper wrapping material overlying an ignitable fuel source, due to the high temperature attained by the fuel source in proximity to the paper wrapping material. This can reduce enjoyment of the smoking experience for some consumers and can mask or undesirably alter the flavors delivered to the consumer by the aerosol delivery components of the smoking articles. In further instances, traditional types of smoking articles can produce relatively significant levels of gasses, such as carbon monoxide and/or carbon dioxide, during use (e.g., as products of carbon combustion). In still further instances, traditional types of smoking articles may suffer from poor performance with respect to aerosolizing the aerosol forming component(s).

As such, it would be desirable to provide smoking articles that address one or more of the technical problems sometimes associated with traditional types of smoking articles. In particular, it would be desirable to provide a smoking article that is easy to use and that provides reusable and/or replaceable components.

In various implementations, the present disclosure relates to aerosol delivery devices for use with removable and replaceable cartridges that may be loaded into the devices via an access door and positioned relative to a pair of static ignition contacts. The present disclosure includes, without limitation, the following example implementations.

Embodiment 1: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and further defining a first aerosol passageway that extends through at least a portion of the main body; an access door coupled to the holder and configured to be movable between an open configuration and a closed configuration, where in the open configuration, the receiving chamber is at least partially exposed for loading of the removable cartridge; and a static ignitor contact disposed on or in the access door and oriented to contact the ignitable heat source when the removable cartridge is secured within the receiving chamber and the access door is in the closed configuration.

Embodiment 2: The aerosol delivery device of the preceding Embodiment, further comprising a power source disposed within the main body, wherein the static ignitor contact is in electrical communication with the power source when the door is in the closed configuration.

Embodiment 3: The aerosol delivery device of any one of Embodiment 1 or 2, or any combination thereof, wherein the static ignitor contact comprises a pair of static ignitor contacts oriented so as to contact the ignitable heat source at, at least two points when the removable cartridge is secured within the receiving chamber and the access door is in the closed configuration

Embodiment 4: The aerosol delivery device of any of Embodiments 1 to 3, or any combination thereof, wherein the pair of static ignitor contacts are disposed on an inner surface of the access door.

Embodiment 5: The aerosol delivery device of any of Embodiments 1 to 4, or any combination thereof, wherein the holder comprises at least one electrical contact in electrical communication with the power source and configured to mate with the static ignitor contact when the access door is in the closed configuration to complete an electrical circuit.

Embodiment 6: The aerosol delivery device of any of Embodiments 1 to 5, or any combination thereof, wherein at least one of the electrical contact comprises a pogo pin.

Embodiment 7: The aerosol delivery device of any of Embodiments 1 to 6, or any combination thereof, wherein the static ignitor contact comprises an elongate body with a first contact portion disposed at a distal end thereof and configured to engage the ignitable heat source and a second contact portion disposed at a proximal end of the elongate body and configured to engage the at least one electrical contact.

Embodiment 8: The aerosol delivery device of any of Embodiments 1 to 7, or any combination thereof, further comprising an ignition switch disposed on the holder and in electrical communication with the power source and the static ignitor contact(s) when the access door is in the closed configuration, the ignition switch configured to deliver electrical current (i.e., power) to the static ignitor contacts when actuated.

Embodiment 9: The aerosol delivery device of any of Embodiments 1 to 8, or any combination thereof, further comprising a printed circuit board disposed within the holder and in electrical communication with the power source and comprising a controller.

Embodiment 10: The aerosol delivery device of any of Embodiments 1 to 9, or any combination thereof, wherein the electrical circuit is disrupted when the access door is in the open configuration (e.g., the static ignitor contacts are no longer in electrical communication with the power source).

Embodiment 11: The aerosol delivery device of any of Embodiments 1 to 10, or any combination thereof, wherein the access door is pivotably coupled to the main body.

Embodiment 12: The aerosol delivery device of any of Embodiments 1 to 11, or any combination thereof, wherein the access door is hingedly coupled to the main body.

Embodiment 13: The aerosol delivery device of any of Embodiments 1 to 12, or any combination thereof, wherein the access door is coupled to the main body via a detent hinge configured maintain the access door in at least one of the open configuration or the closed configuration.

Embodiment 14: The aerosol delivery device of any of Embodiments 1 to 13, or any combination thereof, wherein the access door sealingly engages the main body in the closed configuration.

Embodiment 15: The aerosol delivery device of any of Embodiments 1 to 14, or any combination thereof, wherein the access door further comprises an inner housing defining the receiving chamber, wherein the access door is configured to at least one of secure the cartridge within the chamber and/or orient the receiving chamber in fluid communication with the first aerosol passageway when in the closed configuration.

Embodiment 16: The aerosol delivery device of any of Embodiments 1 to 15, or any combination thereof, further comprising a latching mechanism (e.g., magnetic engagement or a snap-fit) configured to secure the access door in the closed configuration.

Embodiment 17: The aerosol delivery device of any of Embodiments 1 to 16, or any combination thereof, wherein the access door is substantially flush with an outer surface of the holder when in the closed configuration.

Embodiment 18: The aerosol delivery device of any of Embodiments 1 to 17, or any combination thereof, further comprising an actuator assembly configured to release the access door from the closed configuration.

Embodiment 19: The aerosol delivery device of any of Embodiments 1 to 18, or any combination thereof, wherein the access door includes an insert disposed therein and configured to receive the cartridge and provide thermal insulation thereto.

Embodiment 20: The aerosol delivery device of any of Embodiments 1 to 19, or any combination thereof, further comprising a biasing mechanism disposed within the holder and oriented to engage a removable cartridge secured within the receiving chamber, wherein the biasing mechanism urges the ignitable heat source portion of the cartridge into contact with the static ignitor contact when the access door is in the closed configuration.

Embodiment 21: The aerosol delivery device of any of Embodiments 1 to 20, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein. In some implementations, the seal assembly is configured to guide the cartridge into its proper orientation, with or without sealing.

Embodiment 22: The aerosol delivery device of any of Embodiments 1 to 21, or any combination thereof, further comprising a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder, thereby providing fluid communication between the first and second aerosol passageways for delivery of the aerosol generated in the receiving chamber to the user.

Embodiment 23: The aerosol delivery device of any of Embodiments 1 to 22, or any combination thereof, wherein the access door defines an opening in a distal end thereof, the opening may be configured to provide air/oxygen to the ignited heat source. In some implementations, the air/oxygen may travel through the heat source and/or the air/oxygen may mix with an aerosol generated by the removable cartridge and deliverable to a user via the mouthpiece.

Embodiment 24: The aerosol delivery device of any of Embodiments 1 to 23, or any combination thereof, further comprising a sliding actuator assembly coupled to the holder and configured to eject the removable cartridge.

Embodiment 25: The aerosol delivery device of any of Embodiments 1 to 24, or any combination thereof, wherein the sliding actuator assembly comprises a tubular body defining a portion of the first aerosol passageway and configured to slide along a portion of the main body in a first direction and a second direction, a first protrusion extending from an outer surface of the tubular body and configured to extend through an opening in a wall of the main body to provide for moving the tubular body in the first and second directions, and a second protrusion extending from a distal end of the tubular body and configured to engage the removable cartridge so as to advance the removable cartridge through the distal end of the main body when the tubular body is moved in the first or second direction.

Embodiment 26: The aerosol delivery device of any of Embodiments 1 to 25, or any combination thereof, wherein the actuator further comprises a sealing arrangement for sealingly engaging an internal surface of the main body.

Embodiment 27: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end; a receiving compartment coupled to the holder and configured to be movable between an open configuration and a closed configuration, the receiving compartment defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source, where in the open configuration, the receiving chamber is at least partially exposed; and a pair of static ignitor contacts disposed within the receiving compartment and oriented to contact the ignitable heat source when the removable cartridge is secured within the receiving chamber and the receiving compartment is in the closed configuration. In some implementations, the ignitable heat source may be in contact with the ignitor contacts in the open configuration prior to closing the receiving compartment. Typically, in the closed configuration, the ignitable heat source will be in optimal contact with the ignitor contacts.

Embodiment 28: The aerosol delivery device of the preceding Embodiment, further comprising a power source disposed within the main body, wherein the static ignitor contact is in electrical communication with the power source when the door is in the closed configuration.

Embodiment 29: The aerosol delivery device of any one of Embodiment 27 or 28, or any combination thereof, wherein the holder comprises at least one electrical contact in electrical communication with the power source and configured to mate with the static ignitor contacts when the receiving compartment is in the closed configuration to complete an electrical circuit.

Embodiment 30: The aerosol delivery device of any of Embodiments 27 to 29, or any combination thereof, further comprising an ignition switch disposed on the holder and in electrical communication with the power source and the static ignitor contacts, the ignition switch configured to deliver electrical current (i.e., power) to the static ignitor contacts when actuated.

Embodiment 31: The aerosol delivery device of any of Embodiments 27 to 30, or any combination thereof, further comprising a printed circuit board disposed within the holder and in electrical communication with the power source and comprising a controller.

Embodiment 32: The aerosol delivery device of any of Embodiments 27 to 31, or any combination thereof, wherein the electrical circuit is disrupted when the receiving compartment is in the open configuration.

Embodiment 33: The aerosol delivery device of any of Embodiments 27 to 32, or any combination thereof, wherein the receiving compartment is pivotably coupled to the main body.

Embodiment 34: The aerosol delivery device of any of Embodiments 27 to 33, or any combination thereof, wherein the receiving compartment sealingly engages the main body in the closed configuration.

Embodiment 35: The aerosol delivery device of any of Embodiments 27 to 34, or any combination thereof, wherein the main body further defines a first aerosol passageway that extends through at least a portion of the main body.

Embodiment 36: The aerosol delivery device of any of Embodiments 27 to 35, or any combination thereof, wherein the receiving compartment further comprises an inner housing defining the receiving chamber, wherein the receiving compartment is configured to secure the cartridge and/or orient the receiving chamber in fluid communication with first aerosol passageway when in the closed configuration.

Embodiment 37: The aerosol delivery device of any of Embodiments 27 to 36, or any combination thereof, further comprising a latching mechanism configured to secure the receiving compartment in the closed configuration.

Embodiment 38: The aerosol delivery device of any of Embodiments 27 to 37, or any combination thereof, wherein the receiving compartment (e.g., at least a portion of an outer surface thereof) is substantially flush with an outer surface of the holder when in the closed configuration.

Embodiment 39: The aerosol delivery device of any of Embodiments 27 to 38, or any combination thereof, wherein the receiving compartment includes an insert disposed therein and configured to receive the cartridge and provide thermal insulation thereto.

Embodiment 40: The aerosol delivery device of any of Embodiments 27 to 39, or any combination thereof, further comprising a biasing mechanism disposed within the holder and oriented to engage a removable cartridge secured within the receiving chamber, wherein the biasing mechanism urges the ignitable heat source of the cartridge into contact with the static ignitor contacts when the receiving compartment is in the closed configuration.