Aerosol delivery device with improved atomizer

Abstract

The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides atomizers and elements thereof, such as a combined wick and heater configured to improve vaporization response time, particularly on porous, monolithic wicks. The wick can have a tapered end that engages the interior of a substantially basket-shaped wire heater coil. The heater also may be in the form of a conductive mesh that is present on a portion of the wick.

1 - 18 . (canceled) 
     
     
         19 . An aerosol delivery device comprising:
 a tank defined by an outer body;   a connector arranged at an end of the tank, the connector being configured to connect the tank to a power unit;   a mouthpiece arranged at an opposing end of the tank;   a reservoir defined within the outer body of the tank and effective for retaining an aerosol precursor composition;   an atomizer within the outer body of the tank, the atomizer comprising:   a fluid transport element in the form of a rigid, porous monolith that it at least partially hollow so as to define an open space therein; and   a heater positioned at least partially within the open space defined in the rigid, porous monolith;   wherein the atomizer is positioned relative to the reservoir so that the aerosol precursor composition retained by the reservoir contacts an outer surface of the rigid, porous monolith.   
     
     
         20 . The aerosol delivery device of  claim 19 , wherein the heater of the atomizer is positioned within the tank to be closer to the connector of the tank than to the mouthpiece of the tank. 
     
     
         21 . The aerosol delivery device of  claim 19 , wherein the rigid, porous monolith is formed of porous ceramic or porous glass. 
     
     
         22 . The aerosol delivery device of  claim 19 , wherein the fluid transport element excludes any fibrous material. 
     
     
         23 . The aerosol delivery device of  claim 19 , wherein fluid transport element comprises a porous ceramic that is formed is the presence of the heater so that the heater is integral to the rigid, porous monolith. 
     
     
         24 . The aerosol delivery device of  claim 23 , wherein at least a portion of the heater suitable for forming an electrical contact is positioned external to the rigid, porous monolith. 
     
     
         25 . The aerosol delivery device of  claim 19 , wherein the arrangement of the heater at least partially within the open space defined in the rigid, porous monolith is effective to produce a vapor that moves outward from the rigid, porous monolith. 
     
     
         26 . The aerosol delivery device of  claim 19 , wherein the heater is arranged as a wire coil. 
     
     
         27 . The aerosol delivery device of  claim 19 , wherein the heater is arranged as a wire mesh. 
     
     
         28 . The aerosol delivery device of  claim 19 , comprising a vaporization zone arranged relative to an airflow pathway through the tank so that vapor formed by heating of the aerosol precursor composition by the heater at least partially fills the vaporization zone and mixes with air passing through the airflow pathway to be passed from the vaporization zone to the mouthpiece. 
     
     
         29 . An aerosol delivery device comprising:
 an outer shell;   a reservoir defined within the outer shell and effective for retaining an aerosol precursor composition;   a heater positioned within the outer shell and arranged to vaporize the aerosol precursor composition;   a fluid transport element positioned within the outer shell and arranged to transfer the aerosol precursor composition from the reservoir to the heater to be vaporized thereby;   wherein the heater is configured as a conductive mesh formed by a network of conductive filaments and arranged to define a first end with a first clasp and a second end with a second clasp, the first clasp and the second clasp being configured to positionally secure the conductive mesh heater.   
     
     
         30 . The aerosol delivery device of  claim 29 , wherein the conductive mesh has a regular pattern of conductive filaments forming parallelograms surrounding insulating spaces. 
     
     
         31 . The aerosol delivery device of  claim 29 , wherein the insulating spaces are open. 
     
     
         32 . The aerosol delivery device of  claim 31 , wherein the insulating spaces have an average individual area of about 0.01 μm 2  to about 2 mm 2 . 
     
     
         33 . The aerosol delivery device of  claim 29 , wherein the first clasp and the second clasp are configured as electrical connections for the conductive mesh heater to receive electrical power from a power source. 
     
     
         34 . The aerosol delivery device of  claim 29 , wherein the conductive mesh heater is arranged to contact at least a portion of a surface of the fluid transport element. 
     
     
         35 . The aerosol delivery device of  claim 29 , wherein the fluid transport element is in the form of a rigid, porous monolith, the fluid transport element having a first end and a second end. 
     
     
         36 . The aerosol delivery device of  claim 35 , wherein the conductive mesh heater is circumferentially surrounding at least a portion of an outer surface of the fluid transport element. 
     
     
         37 . The aerosol delivery device of  claim 36 , wherein the fluid transport element has an overall longitudinal length, and wherein the conductive mesh is present on about 10% to about 80% of the overall longitudinal length of the fluid transport element. 
     
     
         38 . The aerosol delivery device of  claim 29 , wherein the network of conductive filaments includes one or more non-conductive filaments. 
     
     
         39 . The aerosol delivery device of  claim 38 , wherein the one or more non-conductive filaments are effective to improve direction of flow of electrical current between the first clasp and the second clasp. 
     
     
         40 . A cartridge of an aerosol delivery device, the cartridge comprising:
 an outer shell;   a reservoir defined in the outer shell, the reservoir configured to retain an aerosol precursor composition;   a mouthpiece defining a top end of the cartridge;   a connector defining a bottom end of the cartridge;   a heater positioned in the cartridge below the reservoir and proximate a vaporization zone; and   a fluid transport element positioned in the cartridge and arranged to deliver aerosol precursor composition from the reservoir to the heater;   wherein heating of the aerosol precursor composition by the heater in the vaporization zone forms a vapor that mixes with air entering the cartridge below the heater and below the vaporization zone so that the mixed vapor and air travels past the reservoir to the mouthpiece.   
     
     
         41 . The cartridge of  claim 40 , wherein the heater is configured as a conductive mesh formed by a network of conductive filaments. 
     
     
         42 . The cartridge of  claim 41 , wherein the conductive filaments are arranged to define a first end with a first clasp and a second end with a second clasp. 
     
     
         43 . The cartridge of  claim 42 , wherein the first clasp and the second clasp are configured to positionally secure the conductive mesh heater. 
     
     
         44 . The cartridge of  claim 40 , wherein the heater is positioned at an end of the fluid transport element.