1111111111111111 IIIIII IIIII 111111111111111 111111111111111 IIIII IIIII IIIII 1111111111 11111111
`US 20140261495Al
`
`c19) United States
`c12) Patent Application Publication
`Novak, III et al.
`
`c10) Pub. No.: US 2014/0261495 Al
`Sep. 18, 2014
`(43) Pub. Date:
`
`(54) CARTRIDGE AND CONTROL BODY OF AN
`AEROSOL DELIVERY DEVICE INCLUDING
`ANTI-ROTATION MECHANISM AND
`RELATED METHOD
`
`(71) Applicant: R.J. REYNOLDS TOBACCO
`COMPANY, Winston-Salem, NC (US)
`
`(72)
`
`Inventors: Charles Jacob Novak, III,
`Winston-Salem, NC (US); Michael
`Ryan Galloway, Winston-Salem, NC
`(US); John DePiano, Burlington, MA
`(US); Frank S. Silveira, Wilmington,
`MA (US); Frederic Philippe Ampolini,
`Winston-Salem, NC (US); Michael
`Laine, Newburyport, MA (US);
`Raymond Charles Henry, JR., Cary,
`NC (US)
`
`(73) Assignee: R.J. REYNOLDS TOBACCO
`COMPANY, Winston-Salem, NC (US)
`
`(21) Appl. No.: 13/840,264
`
`(22) Filed:
`
`Mar. 15, 2013
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`A24F 47100
`H0SB 3/00
`(52) U.S. Cl.
`CPC ................ A24F 471008 (2013.01); H0SB 3/00
`(2013.01)
`USPC ........................... 131/329; 392/386; 29/592.1
`
`(2006.01)
`(2006.01)
`
`(57)
`
`ABSTRACT
`
`The present disclosure relates to aerosol delivery devices
`including a cartridge and a control body. The control body
`may include a coupler and the cartridge may include a base.
`The base may be configured to releasably engage the car(cid:173)
`tridge. Further the base and the coupler may include anti(cid:173)
`rotation mechanisms configured to prevent rotation of the
`cartridge relative to the base when engaged with one another.
`The anti-rotation mechanisms may include alternating pro(cid:173)
`trusions and recesses in some embodiments. Related methods
`are also provided.
`
`1100
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`
`NJOY Exhibit 1035.001
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 1 of 18
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`US 2014/0261495 Al
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`NJOY Exhibit 1035.002
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`

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`Patent Application Publication
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`Sep. 18, 2014 Sheet 2 of 18
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`NJOY Exhibit 1035.003
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 3 of 18
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`NJOY Exhibit 1035.004
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`

`

`Patent Application Publication
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`Sep. 18, 2014 Sheet 4 of 18
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`NJOY Exhibit 1035.005
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`

`

`Patent Application Publication
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`Sep. 18, 2014 Sheet 5 of 18
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`NJOY Exhibit 1035.006
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 6 of 18
`
`US 2014/0261495 Al
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`NJOY Exhibit 1035.007
`
`

`

`US 2014/0261495 Al
`
`U S 2 0 1 4 / 0 2 6 1 4 9 5 A l
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`S e p . 1 8 , 2 0 1 4 S h e e t 7 o f 1 8
`
`Sep. 18, 2014 Sheet 7 of 18
`
`P a t e n t A p p / i c a t i o n P u b l i c a t i o n
`
`Patent Application Publication
`
`NJOY Exhibit 1035.008
`
`NJOY Exhibit 1035.008
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 8 of 18
`
`US 2014/0261495 Al
`
`FIG. 11
`
`NJOY Exhibit 1035.009
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 9 of 18
`
`US 2014/0261495 Al
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`
`NJOY Exhibit 1035.010
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 10 of 18
`
`US 2014/0261495 Al
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`NJOY Exhibit 1035.011
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 11 of 18
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`US 2014/0261495 Al
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`NJOY Exhibit 1035.012
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 12 of 18
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`NJOY Exhibit 1035.013
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 13 of 18
`
`US 2014/0261495 Al
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`NJOY Exhibit 1035.014
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 14 of 18
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`NJOY Exhibit 1035.015
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 15 of 18
`
`US 2014/0261495 Al
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`NJOY Exhibit 1035.016
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 16 of 18
`
`US 2014/0261495 Al
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`NJOY Exhibit 1035.017
`
`

`

`p blication
`t Application u
`Paten
`
`Sep.18,2014
`
`Sheet 17 of 18
`
`US 2014/0261495 Al
`
`FIG. 23
`
`FIG. 24
`
`NJOY Exhibit 1035.018
`
`

`

`Patent Application Publication
`
`Sep. 18, 2014 Sheet 18 of 18
`
`US 2014/0261495 Al
`
`PROVIDE A CONTROL BODY
`
`PROVIDE A CARTRIDGE
`
`ENGAGE THE CARTRIDGE WITH THE CONTROL BODY
`
`FIG.25
`
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`
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`
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`
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`
`NJOY Exhibit 1035.019
`
`

`

`US 2014/0261495 Al
`
`Sep. 18,2014
`
`CARTRIDGE AND CONTROL BODY OF AN
`AEROSOL DELIVERY DEVICE INCLUDING
`ANTI-ROTATION MECHANISM AND
`RELATED METHOD
`
`FIELD OF THE DISCLOSURE
`
`[0001] The present disclosure relates to a cartridge and a
`control body of an aerosol delivery device such as a smoking
`article, and more particularly to a cartridge and a control body
`of an aerosol delivery device such as a smoking article includ(cid:173)
`ing an anti-rotation mechanism. The smoking article may be
`configured to heat an aerosol precursor, which may be made
`or derived from tobacco or otherwise incorporate tobacco, to
`form an inhalable substance for human consumption.
`
`BACKGROUND
`
`[0002] Many smoking devices have been proposed through
`the years as improvements upon, or alternatives to, smoking
`products that require combusting tobacco for use. Many of
`those devices purportedly have been designed to provide the
`sensations associated with cigarette, cigar, or pipe smoking,
`but without delivering considerable quantities of incomplete
`combustion and pyrolysis products that result from the burn(cid:173)
`ing of tobacco. To this end, there have been proposed numer(cid:173)
`ous smoking products, flavor generators, and medicinal
`inhalers that utilize electrical energy to vaporize or heat a
`volatile material, or attempt to provide the sensations of ciga(cid:173)
`rette, cigar, or pipe smoking without burning tobacco to a
`significant degree. See, for example, the various alternative
`smoking articles, aerosol delivery devices and heat generat(cid:173)
`ing sources set forth in the background art described in U.S.
`Pat. No. 7,726,320 to Robinson et al., U.S. patent application
`Ser. No. 13/432,406, filed Mar. 28, 2012, U.S. patent appli(cid:173)
`cation Ser. No. 13/536,438, filed Jun. 28, 2012, U.S. patent
`application Ser. No. 13/602,871, filed Sep. 4, 2012, and U.S.
`patent application Ser. No. 13/647,000, filed Oct. 8, 2012,
`which are incorporated herein by reference.
`[0003] Certain tobacco products that have employed elec(cid:173)
`trical energy to produce heat for smoke or aerosol formation,
`and in particular, certain products that have been referred to as
`electronic cigarette products, have been commercially avail(cid:173)
`able throughout the world. Representative products that
`resemble many of the attributes of traditional types of ciga(cid:173)
`rettes, cigars or pipes have been marketed as ACCORD® by
`Philip Morris Incorporated; ALPHA™, JOYE 510™ and
`M4™ by Irmo Vapor LLC; CIRRUS™ and FLIIG™by White
`Cloud Cigarettes; COHITAT™, CO LIB RI™, ELITE CLAS(cid:173)
`SIC™, MAGNUM™, PHANTOMTM and SENSE™ by
`Epuffer® International Inc.; DUOPRO™, STORM™ and
`VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by
`Egar Australia; eGo-C™ and eGo-T™ by Joyetech; ELU(cid:173)
`SIOWM by Elusion UK Ltd; EONSMOKE® by Eonsmoke
`LLC; GREEN SMOKE® by Green Smoke Inc. USA;
`GREENARETTE™ by Greenarette LLC; HALLIGAWM,
`HENDurM, JET™, MAXXQ™, PINK™ and PITBULL™
`by Smoke Stik®; HEATBAR™ by Philip Morris Interna(cid:173)
`tional, Inc.; HYDRO IMPERIAL™ and LXE™ from
`Crown7; LOGIC™ and THE CUBAWM by LOGIC Tech(cid:173)
`nology; LUCI® by Luciano Smokes Inc.; METRO® by
`Nicotek, LLC; NJOY® and ONEJOyrM by Sottera, Inc.; NO.
`7™ by SS Choice LLC; PREMIUM ELECTRONIC CIGA(cid:173)
`RETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™
`by Ruyan America, Inc.; RED DRAGOWM by Red Dragon
`
`Products, LLC; RUYAN® by Ruyan Group (Holdings) Ltd.;
`SMART SMOKER® by The Smart Smoking Electronic
`Cigarette Company Ltd.; SMOKE ASSIST® by Coastline
`Products LLC; SMOKING EVERYWHERE® by Smoking
`Everywhere, Inc.; V2CIGS™ by VMR Products LLC;
`VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by
`Vapor 4 Life, Inc.; VEPPO™ by E-CigaretteDirect, LLC and
`VUSE® by R. J. Reynolds Vapor Company. Yet other elec(cid:173)
`trically powered aerosol delivery devices, and in particular
`those devices that have been characterized as so-called elec(cid:173)
`tronic cigarettes, have been marketed under the tradenames
`BLurM; COOLER VISIONS™; DIRECT E-CIG™; DRAG(cid:173)
`ONFLyrM; EMIST™; EVERSMOKE™; GAMUCCI®;
`HYBRID FLAME™; KNIGHT STICKS™; ROYAL
`BLUES™; SMOKETIP® and SOUTH BEACH SMOKE™.
`[0004]
`It would be desirable to provide an aerosol delivery
`device that employs heat produced by electrical energy to
`provide the sensations of cigarette, cigar, or pipe smoking,
`that does so without combusting tobacco to any significant
`degree, that does so without the need of a combustion heat
`source, and that does so without necessarily delivering con(cid:173)
`siderable quantities of incomplete combustion and pyrolysis
`products. Further, it would be desirable to provide an aerosol
`delivery device that employs convenient releasable engage(cid:173)
`ment between a control body and a cartridge thereof.
`
`BRIEF SUMMARY OF THE DISCLOSURE
`
`[0005]
`In one aspect a cartridge for an aerosol delivery
`device is provided. The cartridge may include a reservoir
`substrate configured to hold an aerosol precursor composi(cid:173)
`tion, an atomizer configured to atomize the aerosol precursor,
`and a base extending between a body end oriented toward the
`reservoir substrate and the atomizer and a connector end
`configured to releasably engage a control body. The base may
`include an anti-rotation mechanism at the connector end con(cid:173)
`figured to prevent rotation of the cartridge relative to the
`control body when engaged therewith.
`[0006]
`In some embodiments the anti-rotation mechanism
`may include a plurality of protrusions and a plurality of
`recesses alternatingly disposed about an inner periphery of
`the base. A width of each of the protrusions may increase from
`the connector end toward the body end and a width of each of
`the recesses may decrease from the connector end toward the
`body end. The cartridge may additionally include a plurality
`of ribs extending from the inner periphery of the base at the
`recesses.A radial dimension of the inner periphery of the base
`may decrease from the connector end toward the body end.
`The base may further include a groove extending at least
`partially around the inner periphery thereof.
`[0007]
`In an additional aspect a control body for an aerosol
`delivery device is provided. The control body may include a
`control component, an electrical power source, and a coupler
`extending between a body end oriented toward the control
`component and the electrical power source and a connector
`end configured to releasably engage a cartridge. The coupler
`may include an anti-rotation mechanism at the connector end
`configured to prevent rotation of the control body relative to
`the cartridge when engaged therewith.
`[0008]
`In some embodiments the anti-rotation mechanism
`may include a plurality of protrusions and a plurality of
`recesses alternatingly disposed about an outer periphery of
`the coupler. A width of each of the protrusions may increase
`from the connector end toward the body end, and a width of
`each of the recesses may decrease from the connector end
`
`NJOY Exhibit 1035.020
`
`

`

`US 2014/0261495 Al
`
`Sep. 18,2014
`
`2
`
`toward the body end. A radial dimension of the outer periph(cid:173)
`ery of the coupler may increase from the connector end
`toward the body end. The coupler may additionally include a
`circumferential protrusion extending at least partially around
`the outer periphery thereof.
`[0009]
`In a further aspect an aerosol delivery device is
`provided. The aerosol delivery device may include a control
`body. The control body may include a control component, an
`electrical power source, a coupler extending between a body
`end oriented toward the control component and the electrical
`power source and a connector end comprising an anti-rotation
`mechanism. The aerosol delivery device may additionally
`include a cartridge. The cartridge may include a reservoir
`substrate configured to hold an aerosol precursor composi(cid:173)
`tion, an atomizer configured to atomize the aerosol precursor,
`and a base extending between a body end oriented toward the
`reservoir substrate and the atomizer and a connector end
`configured to releasably engage the control body. The con(cid:173)
`nector end of the base may include an anti-rotation mecha(cid:173)
`nism configured to engage the anti-rotation mechanism of the
`coupler of the control body to prevent rotation of the cartridge
`relative to the control body when engaged therewith.
`[0010]
`In some embodiments the anti-rotation mechanism
`of the base may include a plurality of protrusions and a
`plurality of recesses alternatingly disposed about an inner
`periphery thereof and the anti-rotation mechanism of the
`coupler may include a plurality of protrusions and a plurality
`of recesses alternatingly disposed about an outer periphery
`thereof.A width of each of the protrusions of the base and the
`protrusions of the coupler may respectively increase from the
`connector end toward the body end and a width of each of the
`recesses of the base and the recesses of the coupler may
`respectively decrease from the connector end toward the body
`end. The base may further include a plurality of ribs extending
`from the inner periphery thereof at the recesses. A radial
`dimension of the inner periphery of the base may decrease
`from the connector end toward the body end and a radial
`dimension of the outer periphery of the coupler may increase
`from the connector end toward the body end. The base may
`further include a groove extending at least partially around
`the inner periphery thereof and the coupler may additionally
`include a circumferential protrusion extending at least par(cid:173)
`tially around the outer periphery thereof.
`[0011]
`In another aspect a method for forming an aerosol
`delivery device is provided. The method may include provid(cid:173)
`ing a control body and a coupler, which may respectively
`include some or all of the features described above. Further
`the method may include engaging the connector end of the
`base to the connector end of the coupler such that the cartridge
`releasably engages the control body and the anti-rotation
`mechanism of the control body engages the anti-rotation
`mechanism of the cartridge to substantially prevent rotation
`of the cartridge relative to the control body. In some embodi(cid:173)
`ments engaging the connector end of the base to the connector
`end of the coupler may include engaging a plurality of pro(cid:173)
`trusions and a plurality of recesses alternatingly disposed
`about an inner periphery of the base of the cartridge with a
`plurality of protrusions and a plurality of recesses alternat(cid:173)
`ingly disposed about an outer periphery of the control body.
`In some embodiments engaging the connector end of the base
`to the connector end of the coupler may additionally include
`engaging a plurality of ribs extending from the inner periph(cid:173)
`ery of the base at the recesses with the protrusions of the
`control body. Engaging the connector end of the base to the
`
`connector end of the coupler may further include engaging a
`circumferential protrusion extending at least partially around
`the outer periphery of the coupler with a groove extending at
`least partially around the inner periphery of the base.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`[0012] Having thus described the disclosure in the forego(cid:173)
`ing general terms, reference will now be made to the accom(cid:173)
`panying drawings, which are not necessarily drawn to scale,
`and wherein:
`[0013] FIG.1 illustrates a sectional view through an aerosol
`delivery device comprising a control body and a cartridge
`including an atomizer according to an example embodiment
`of the present disclosure;
`[0014] FIG. 2 illustrates an exploded view of a control body
`of an aerosol delivery device according to an example
`embodiment of the present disclosure;
`[0015] FIG. 3 illustrates the control body of FIG. 2 in a
`partially assembled configuration with an adhesive member
`and an outer tube removed for clarity purposes;
`[0016] FIG. 4 illustrates the control body of FIG. 2 in a
`partially assembled configuration with outer tube removed
`for clarity purposes;
`[0017] FIG. 5 illustrates the control body of FIG. 2 in an
`assembled configuration;
`[0018] FIG. 6 illustrates a partially exploded view of an
`aerosol delivery device including the control body of FIG. 2
`in the assembled configuration and a cartridge in an exploded
`configuration, the cartridge comprising a base shipping plug,
`a base, a control component terminal, an electronic control
`component, a flow tube, an atomizer, a reservoir substrate, an
`external shell, a label, a mouthpiece, and a mouthpiece ship(cid:173)
`ping plug according to an example embodiment of the present
`disclosure;
`[0019] FIG. 7 illustrates an enlarged exploded view of the
`base and the control component terminal of the cartridge of
`FIG. 6;
`[0020] FIG. 8 illustrates an enlarged perspective view of the
`base and the control component terminal of FIG. 6 in an
`assembled configuration;
`[0021] FIG. 9 illustrates an enlarged perspective view of the
`base, the control component terminal, the electronic control
`component, and heater terminals of the atomizer of FIG. 6 in
`an assembled configuration;
`[0022] FIG. 10 illustrates an enlarged perspective view of
`the base, the atomizer, and the control component of FIG. 6 in
`an assembled configuration;
`[0023] FIG. 11 illustrates an opposing perspective view of
`the assembly of FIG. 10;
`[0024] FIG. 12 illustrates an enlarged perspective view of
`the base, the atomizer, the flow tube, and the reservoir sub(cid:173)
`strate of FIG. 6 in an assembled configuration;
`[0025] FIG. 13 illustrates a perspective view of the base and
`the external shell of FIG. 6 in an assembled configuration;
`[0026] FIG. 14 illustrates a perspective view of the car(cid:173)
`tridge of FIG. 6 in an assembled configuration;
`[0027] FIG. 15 illustrates a first partial perspective view of
`the cartridge of FIG. 6 and a coupler for a control body
`according to an example embodiment of the present disclo(cid:173)
`sure;
`[0028] FIG. 16 illustrates an opposing second partial per(cid:173)
`spective view of the cartridge of FIG. 6 and the coupler of
`FIG. 15;
`
`NJOY Exhibit 1035.021
`
`

`

`US 2014/0261495 Al
`
`Sep. 18,2014
`
`3
`
`[0029] FIG. 17 illustrates a perspective view of a cartridge
`including a base with an anti-rotation mechanism according
`to an additional example embodiment of the present disclo(cid:173)
`sure;
`[0030] FIG. 18 illustrates a perspective view of a control
`body including a coupler with an anti-rotation mechanism
`according to an additional example embodiment of the
`present disclosure;
`[0031] FIG.19 illustrates alignment of the cartridge of FIG.
`17 with the control body of FIG. 18;
`[0032] FIG. 20 illustrates an aerosol delivery device com(cid:173)
`prising the cartridge of FIG. 17 and the control body of FIG.
`18 with a modified view through the aerosol delivery device
`illustrating the engagement of the anti-rotation mechanism of
`the cartridge with the anti-rotation mechanism of the connec(cid:173)
`tor body;
`[0033] FIG. 21 illustrates a perspective view of a base with
`an anti-rotation mechanism according to an additional
`example embodiment of the present disclosure;
`[0034] FIG. 22 illustrates a perspective view of a coupler
`with an anti-rotation mechanism according to an additional
`example embodiment of the present disclosure;
`[0035] FIG. 23 illustrates a sectional view through the base
`of FIG. 21 and the coupler of FIG. 22 in an engaged configu(cid:173)
`ration;
`[0036] FIG. 24 illustrates an adaptor according to an
`example embodiment of the present disclosure;
`[0037] FIG. 25 illustrates a method for forming an aerosol
`delivery device according to an example embodiment of the
`present disclosure; and
`[0038] FIG. 26 illustrates a cross-sectional view through a
`funneled mouthpiece according to an example embodiment
`of the present disclosure.
`
`DETAILED DESCRIPTION OF PREFERRED
`EMBODIMENTS
`
`[0039] The present disclosure will now be described more
`fully hereinafter with reference to exemplary embodiments
`thereof. These exemplary embodiments are described so that
`this disclosure will be thorough and complete, and will fully
`convey the scope of the disclosure to those skilled in the art.
`Indeed, the disclosure may be embodied in many different
`forms and should not be construed as limited to the embodi(cid:173)
`ments set forth herein; rather, these embodiments are pro(cid:173)
`vided so that this disclosure will satisfy applicable legal
`requirements. As used in the specification, and in the
`appended claims, the singular forms "a", "an", "the", include
`plural referents unless the context clearly dictates otherwise.
`[0040] The present disclosure provides descriptions of
`aerosol delivery devices that use electrical energy to heat a
`material (preferably without combusting the material to any
`significant degree) to form an inhalable substance; such
`articles most preferably being sufficiently compact to be con(cid:173)
`sidered "hand-held" devices. In certain highly preferred
`embodiments, the aerosol delivery devices can be character(cid:173)
`ized as smoking articles. As used herein, the term "smoking
`article" is intended to mean an article or device that provides
`some or all of the sensations (e.g., inhalation and exhalation
`rituals, types of tastes or flavors, organoleptic effects, physi(cid:173)
`cal feel, use rituals, visual cues such as those provided by
`visible aerosol, and the like) of smoking a cigarette, cigar, or
`pipe, without any substantial degree of combustion of any
`component of that article or device. As used herein, the term
`"smoking article" does not necessarily mean that, in opera-
`
`tion, the article or device produces smoke in the sense of the
`aerosol resulting from by-products of combustion or pyroly(cid:173)
`sis of tobacco, but rather, that the article or device yields
`vapors (including vapors within aerosols that can be consid(cid:173)
`ered to be visible aerosols that might be considered to be
`described as smoke-like) resulting from volatilization or
`vaporization of certain components of the article or device. In
`highly preferred embodiments, articles or devices character(cid:173)
`ized as smoking articles incorporate tobacco and/or compo(cid:173)
`nents derived from tobacco.
`[0041] Articles or devices of the present disclosure also can
`be characterized as being vapor-producing articles, aerosol
`delivery articles or medicament delivery articles. Thus, such
`articles or devices can be adapted so as to provide one or more
`substances ( e.g., flavors and/or pharmaceutical active ingre(cid:173)
`dients) in an inhalable form or state. For example, inhalable
`substances can be substantially in the form of a vapor (i.e., a
`substance that is in the gas phase at a temperature lower than
`its critical point). Alternatively, inhalable substances can be in
`the form of an aerosol (i.e., a suspension of fine solid particles
`or liquid droplets in a gas). For purposes of simplicity, the
`term "aerosol" as used herein is meant to include vapors,
`gases and aerosols of a form or type suitable for human
`inhalation, whether or not visible, and whether or not of a
`form that might be considered to be smoke-like.
`[0042]
`In use, smoking articles of the present disclosure
`may be subjected to many of the physical actions employed
`by an individual in using a traditional type of smoking article
`( e.g., a cigarette, cigar or pipe that is employed by lighting
`and inhaling tobacco). For example, the user of a smoking
`article of the present disclosure can hold that article much like
`a traditional type of smoking article, draw on one end of that
`article for inhalation of aerosol produced by that article, take
`puffs at selected intervals of time, etc.
`[0043] Smoking articles of the present disclosure generally
`include a number of components provided within an outer
`shell or body. The overall design of the outer shell or body can
`vary, and the format or configuration of the outer body that
`can define the overall size and shape of the smoking article
`can vary. Typically, an elongated body resembling the shape
`of a cigarette or cigar can be a formed from a single, unitary
`shell; or the elongated body can be formed of two or more
`separable pieces. For example, a smoking article can com(cid:173)
`prise an elongated shell or body that can be substantially
`tubular in shape and, as such, resemble the shape of a con(cid:173)
`ventional cigarette or cigar. In one embodiment, all of the
`components of the smoking article are contained within one
`outer body or shell. Alternatively, a smoking article can com(cid:173)
`prise two or more shells that are joined and are separable. For
`example, a smoking article can possess at one end a control
`body comprising a shell containing one or more reusable
`components (e.g., a rechargeable battery and various elec(cid:173)
`tronics for controlling the operation of that article), and at the
`other end and removably attached thereto a shell containing a
`disposable portion ( e.g., a disposable flavor-containing car(cid:173)
`tridge). More specific formats, configurations and arrange(cid:173)
`ments of components within the single shell type of unit or
`within a multi-piece separable shell type of unit will be evi(cid:173)
`dent in light of the further disclosure provided herein. Addi(cid:173)
`tionally, various smoking article designs and component
`arrangements can be appreciated upon consideration of the
`commercially available electronic smoking articles, such as
`those representative products listed in the background art
`section of the present disclosure.
`
`NJOY Exhibit 1035.022
`
`

`

`US 2014/0261495 Al
`
`Sep. 18,2014
`
`4
`
`[0044] Smoking articles of the present disclosure most
`preferably comprise some combination of a power source
`(i.e., an electrical power source), at least one control compo(cid:173)
`nent ( e.g., means for actuating, controlling, regulating and
`ceasing power for heat generation, such as by controlling
`electrical current flow the power source to other components
`of the article), a heater or heat generation component ( e.g., an
`electrical resistance heating element or component com(cid:173)
`monly referred to as an "atomizer"), and an aerosol precursor
`composition (e.g., commonly a liquid capable of yielding an
`aerosol upon application of sufficient heat, such as ingredi(cid:173)
`ents commonly referred to as "smoke juice," "e-liquid" and
`"e-juice"), and a mouthend region or tip for allowing draw
`upon the smoking article for aerosol inhalation ( e.g., a defined
`air flow path through the article such that aerosol generated
`can be withdrawn therefrom upon draw). Exemplary formu(cid:173)
`lations for aerosol precursor materials that may be used
`according to the present disclosure are described in U.S. Pat.
`Pub. No. 2013/0008457 to Zheng et al., the disclosure of
`which is incorporated herein by reference in its entirety.
`[0045] Alignment of the components within the article can
`vary. In specific embodiments, the aerosol precursor compo(cid:173)
`sition can be located near an end of the article ( e.g., within a
`cartridge, which in certain circumstances can be replaceable
`and disposable), which may be is proximal to the mouth of a
`user so as to maximize aerosol delivery to the user. Other
`configurations, however, are not excluded. Generally, the
`heating element can be positioned sufficiently near the aero(cid:173)
`sol precursor composition so that heat from the heating ele(cid:173)
`ment can volatilize the aerosol precursor (as well as one or
`more flavorants, medicaments, or the like that may likewise
`be provided for delivery to a user) and form an aerosol for
`delivery to the user. When the heating element heats the
`is formed,
`aerosol precursor composition, an aerosol
`released, or generated in a physical form suitable for inhala(cid:173)
`tion by a consumer. It should be noted that the foregoing terms
`are meant to be interchangeable such that reference to release,
`releasing, releases, or released includes form or generate,
`forming or generating, forms or generates, and formed or
`generated. Specifically, an inhalable substance is released in
`the form of a vapor or aerosol or mixture thereof. Addition(cid:173)
`ally, the selection of various smoking article components can
`be appreciated upon consideration of the commercially avail(cid:173)
`able electronic smoking articles, such as those representative
`products listed in the background art section of the present
`disclosure.
`[0046] A smoking article incorporates a battery or other
`electrical power source to provide current flow sufficient to
`provide various functionalities to the article, such as resistive
`heating, powering of control systems, powering ofindicators,
`and the like. The power source can take on various embodi(cid:173)
`ments. Preferably, the power source is able to deliver suffi(cid:173)
`cient power to rapidly heat the heating member to provide for
`aerosol formation and power the article through use for the
`desired duration of time. The power source preferably is sized
`to fit conveniently within the article so that the article can be
`easily handled; and additionally, a preferred power source is
`of a sufficiently light weight to not detract from a desirable
`smoking experience.
`[0047] One example embodiment of a smoking article 100
`is provided in FIG. 1. As seen in the cross-section illustrated
`therein, the smoking article 100 can comprise a control body
`102 and a cartridge 104 that can be permanently or detachably
`aligned in a functioning relationship. Although a threaded
`
`engagement is illustrated in FIG. 1, it is understood that
`further means of engagement are encompassed, such as a
`press-fit engagement, interference fit, a magnetic engage(cid:173)
`ment, or the like.
`[0048]
`In specific embodiments, one or both of the control
`body 102 and the cartridge 104 may be referred to as being
`disposable or as being reusable. For example, the control
`body may have a replaceable battery or a rechargeable battery
`and thus may be combined with any type ofrecharging tech(cid:173)
`nology, including connection to a typical electrical outlet,
`connection to a car charger (i.e., cigarette lighter receptacle),
`and connection to a computer, such as through a universal
`serial bus (USB) cable.
`[0049]
`In the exemplified embodiment, the control body
`102 includes a control component 106, a flow sensor 108, and
`a battery 110, which can be variably aligned, and can include
`a plurality of indicators 112 at a distal end 114 of an external
`shell 116. The indicators 112 can be provided in varying
`numbers and can take on different shapes and can even be an
`opening in the body (such as for release of sound when such
`indicators are present).
`[0050] An air intake 118 may be positioned in the external
`shell 116 of the control body 102. A coupler 120 also is
`included at the proximal attachment end 122 of the control
`body 102 and extends into a control body projection 124 to
`allow for ease of electrical connection with an atomizer or a
`component thereof, such as a r