Aerosol delivery device with alternative consumable loading and ejection configurations

Abstract

Disclosed is an aerosol delivery device for use with removable and replaceable cartridges that may be loaded into and ejected from the devices in different orientations and via different access points. The device includes a holder defining a proximal end and a distal end and a receiving chamber configured to receive the removable cartridge. The holder defines a first aerosol passageway extending therethrough. The device may include a mouthpiece coupled to the holder and defining a second aerosol passageway extending therethrough. The device may further include an access point (e.g., a door) movably coupled to the holder. In an open configuration, the access point provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway.

What is claimed is: 
     
         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, the main body further defining a first aerosol passageway that extends through at least a portion of the main body;   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; and   an access door movably coupled to the distal end of the main body and defining a third aerosol passageway, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the third aerosol passageway.   
     
     
         2 . The aerosol delivery device of  claim 1 , wherein a sidewall of the holder defines an opening therethrough, the opening in fluid communication with the receiving chamber and disposed proximate the ignitable heat source when the removable cartridge is loaded within the receiving chamber 
     
     
         3 . The aerosol delivery device of  claim 2  further comprising:
 a power source disposed within the main body; and 
 a pair of ignitor contacts in electrical communication with the power supply and disposed proximate the opening and configured to engage the ignitable heat source when the removable cartridge is loaded within the receiving chamber. 
 
     
     
         4 . The aerosol delivery device of  claim 3  further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated. 
     
     
         5 . The aerosol delivery device of  claim 1 , 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. 
     
     
         6 . The aerosol delivery device of  claim 1 , wherein the access door sealingly engages the distal end of the main body in the closed configuration. 
     
     
         7 . The aerosol delivery device of  claim 1 , wherein the third aerosol passageway is configured to redirect a vapor path extending through the main body about 180°. 
     
     
         8 . The aerosol delivery device of  claim 1  further comprising an actuator assembly coupled to the holder and configured to eject the removable cartridge therefrom. 
     
     
         9 . The aerosol delivery device of  claim 8 , wherein the actuator assembly comprises:
 a slider body slidably disposed within the main body of the holder and configured to slide along a length of the main body in a first direction and a second direction;   a slider button disposed on a surface of the slider body and configured to be accessible to a user; and   a stem extending beyond a distal end of the slider body and configured to engage with the ignitable heat source of the removable cartridge to drive the cartridge at least partially out of the receiving cavity.   
     
     
         10 . The aerosol delivery device of  claim 2 , wherein the opening is configured to provide air intake therethrough for mixing with an aerosol generated by the removable cartridge and deliverable to a user via the mouthpiece. 
     
     
         11 . An aerosol delivery device having different consumable loading and ejecting paths comprising:
 a holder comprising an upper body portion and a lower body portion, each defining a proximal end and a distal end, wherein:   the lower body portion further defines a receiving chamber disposed in the proximal end thereof and configured to receive a removable cartridge therein, and   the upper body portion comprises an actuator assembly slidably disposed within the upper body portion and configured to eject the removable cartridge from the lower body portion via the distal end thereof and defining a first aerosol passageway, wherein the upper body portion and the lower body portion are coupled together and configured to be rotatable relative to one another between an open configuration exposing the receiving chamber for loading the removable cartridge and closed configuration where the cartridge may be ejected from the distal end of the lower body portion.   
     
     
         12 . The aerosol delivery device of  claim 11 , wherein the actuator assembly comprises:
 a tubular body defining a portion of the first aerosol passageway and configured to slide along a portion of the upper body portion 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 upper body portion 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 lower body portion when the tubular body is moved in the first or second direction.   
     
     
         13 . The aerosol delivery device of  claim 11  further comprising a pair of ignitor contacts coupled to the lower body portion and disposed proximate the distal end thereof, wherein the ignitor contacts are configured to engage with an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber. 
     
     
         14 . The aerosol delivery device of  claim 11  further comprising a locking mechanism disposed on at least one of the lower body portion or the upper body portion and configured to maintain the device in the closed configuration. 
     
     
         15 . An aerosol delivery device having different consumable loading and ejecting paths 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, the main body further defining a first aerosol passageway that extends through at least a portion of the main body, wherein a sidewall of the holder defines an opening therethrough and in communication with the receiving chamber;   an access door sealingly coupled to the main body and disposed proximate the opening, wherein, in an open configuration, the access door is positioned so as to expose the opening to provide access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, the access door is positioned to cover the opening so as to secure the cartridge in fluid communication with first aerosol passageway; and   an actuator assembly coupled to the main body and configured to eject the removable cartridge through the distal end thereof.   
     
     
         16 . The aerosol delivery device of  claim 15  further comprising:
 a power source disposed within the main body; and 
 a pair of ignitor contacts in electrical communication with the power supply and disposed proximate the distal end of the main body and configured to engage an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber. 
 
     
     
         17 . The aerosol delivery device of  claim 15 , wherein the access door is slidably coupled to the main body and configured to be slid distally into the open configuration. 
     
     
         18 . The aerosol delivery device of  claim 17  further comprising a latching mechanism configured to secure the access door in the closed configuration. 
     
     
         19 . 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 a receptacle that extends along at least a portion of the main body; and   a mouthpiece movably coupled to the main body and including a first end and a longitudinally opposed second end with a first 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 holder; and   wherein the mouthpiece is configured to translate between an open configuration where the receiving chamber is exposed for loading of the removable cartridge and a closed configuration where the first aerosol passageway is generally aligned with the receiving chamber.   
     
     
         20 . The aerosol delivery device of  claim 19  further comprising a translating mechanism movably coupled to the main body and at least partially disposed within the receptacle, wherein the translating mechanism is configured to couple the mouthpiece to the holder and bias the mouthpiece into the closed configuration. 
     
     
         21 . The aerosol delivery device of  claim 20 , wherein the main body receptacle is configured to at least partially receive the translating mechanism and the mouthpiece in the open configuration. 
     
     
         22 . The aerosol delivery device of  claim 21 , wherein the mouthpiece is translated into the receptacle upon application of a force to the translating mechanism. 
     
     
         23 . The aerosol delivery device of  claim 20 , wherein a distal end of the translating mechanism or the second end of the mouthpiece is configured to sealingly engage the receiving chamber in the closed configuration. 
     
     
         24 . The aerosol delivery device of  claim 19 , wherein the mouthpiece is slidably disposed within the main body and configured to eject the removable cartridge from the distal end of the main body. 
     
     
         25 . The aerosol delivery device of  claim 20 , wherein the mouthpiece comprises a first enlarged portion disposed at the first end of the mouthpiece and a second elongate portion extending from the enlarged portion to the second end of the mouthpiece. 
     
     
         26 . The aerosol delivery device of  claim 25 , wherein the translating mechanism comprises:
 a channel extending therethrough and configured to allow the elongate portion of the mouthpiece to slidably move in a first direction and a second direction therein; and   a stop disposed within the channel configured to engage the enlarged portion of the mouthpiece to limit travel of the mouthpiece in the first direction.   
     
     
         27 . The aerosol delivery device of  claim 26 , wherein the stop is configured to prevent the mouthpiece from exiting the distal end of the main body. 
     
     
         28 . The aerosol delivery device of  claim 26  further comprising a biasing mechanism disposed within the holder or the translating mechanism and configured to bias the mouthpiece in the second direction. 
     
     
         29 . 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   a mouthpiece movably coupled to the main body and including a first end and a longitudinally opposed second end with a first 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 holder so as to provide fluid communication between the receiving chamber and the first aerosol passageway; and   a biasing mechanism disposed within the main body and operatively coupled to the mouthpiece, wherein the biasing mechanism is configured to maintain the mouthpiece in a neutral orientation and the mouthpiece is actuatable to eject the removable cartridge from the receiving chamber.   
     
     
         30 . The aerosol delivery device of  claim 29 , wherein the mouthpiece is actuated via application of a force to the first end of the mouthpiece that is greater than a resistance of the biasing mechanism. 
     
     
         31 . The aerosol delivery device of  claim 29 , wherein the second end of the mouthpiece is configured to sealingly engage with the receiving chamber or the removable cartridge. 
     
     
         32 . The aerosol delivery device of  claim 29  further comprising:
 a receptacle defined by the holder and extending along at least a portion of the main body; and 
 a translating mechanism movably coupled to the main body and at least partially disposed within the receptacle, wherein the translating mechanism is configured to couple the mouthpiece to the holder and move the mouthpiece between an open configuration where the receiving chamber is exposed for loading of the removable cartridge and a closed configuration where the first aerosol passageway is generally aligned with the receiving chamber. 
 
     
     
         33 . 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, the main body further defining a first aerosol passageway that extends through at least a portion of the main body;   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; and   an access door pivotably coupled to the distal end of the main body and defining an opening therein, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, secures the removable cartridge in the receiving chamber for ignition thereof.   
     
     
         34 . The aerosol delivery device of  claim 33  further comprising:
 a power source disposed within the main body; and 
 a pair of ignitor contacts disposed within the access door and in electrical communication with the power source when the access door is in the closed configuration. 
 
     
     
         35 . The aerosol delivery device of  claim 34 , wherein the ignitor contacts are partially disposed within the opening in the access door and configured to engage the ignitable heat source when a cartridge is disposed within the receiving chamber and the access door is in the closed configuration. 
     
     
         36 . The aerosol delivery device of  claim 34  further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated. 
     
     
         37 . The aerosol delivery device of  claim 34 , wherein the distal end of the main body and the access door each comprise a mating half of an electrical coupling. 
     
     
         38 . The aerosol delivery device of  37 , wherein the distal end of the main body comprises at least one electrical contact in electrical communication with the power source and the access door comprises at least one mating electrical contact in electrical communication with the ignitor contacts, wherein the electrical contacts complete an electrical circuit when the access door is in the closed configuration. 
     
     
         39 . The aerosol delivery device of  38 , wherein the electrical circuit is disrupted when the access door is in the open configuration. 
     
     
         40 . The aerosol delivery device of  claim 33 , wherein the device further comprises a biasing mechanism disposed within the main body and configured to bias the access door into the closed configuration. 
     
     
         41 . The aerosol delivery device of  claim 33 , wherein the receiving chamber comprises a biasing mechanism disposed therein, the biasing member configured to maintain the removable cartridge in contact with the ignitor contacts in the closed configuration. 
     
     
         42 . 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; and   a removable mouthpiece comprising:
 an elongate body portion defined by a first end and a longitudinally opposed second end and defining an aerosol passageway extending therethrough; 
 a first retention mechanism disposed about an exterior surface of the elongate body portion, the first retention mechanism configured to removably secure the second end of the mouthpiece within the holder; and 
 a second retention mechanism disposed within a receptacle defined by the second end of the elongate body member, the second retention mechanism configured to removably secure a portion of the cartridge therein, wherein the first end of the mouthpiece is configured to engage with a user's mouth. 
   
     
     
         43 . The aerosol delivery device of  claim 42  further comprising an inner housing disposed within the main body of the holder and defining a passageway therethrough configured to receive a portion of the mouthpiece therein. 
     
     
         44 . The aerosol delivery device of  claim 43 , wherein the first retention mechanism is configured to sealingly engage with the passageway in the inner housing. 
     
     
         45 . The aerosol delivery device of  claim 44 , wherein the first retention mechanism includes an elastomeric seal disposed about an exterior surface thereof and configured to frictionally engage with the inner housing passageway. 
     
     
         46 . The aerosol delivery device of  claim 42 , wherein the second retention mechanism includes an elastomeric seal disposed about an interior surface thereof and configured to frictionally engage with the cartridge. 
     
     
         47 . 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; and   a removable mouthpiece configured to engage the proximal end of the holder and comprising:
 a first portion comprising an elongate body defined by a first end and a longitudinally opposed second end and defining a passageway extending therethrough; 
 a second portion defined by a first end and a longitudinally opposed second end and defining a first aerosol passageway therethrough, wherein the first end of the second portion is configured to engage with a user's mouth and the second end is partially disposed within the passageway of the first portion of the mouthpiece proximate the first end of the first portion; 
 a slider body defined by a first end and a longitudinally opposed second end and defining a second aerosol passageway therethrough, wherein the slider body is slidably disposed within the first portion of the mouthpiece and the first end of the slider body is coupled to the second end of the second portion of the mouthpiece and the second end of the slider body is configured to engage the removable cartridge; 
 an inner tubular body defined by a first end and a longitudinally opposed second end and defining a receptacle comprising a first biasing mechanism disposed therein, the receptacle configured to at least partially receive the slider body, the slider body slidably coupled to the inner tubular body, wherein the second end of the inner tubular body is configured to engage the first portion of the mouthpiece proximate the second end of the first portion and the biasing mechanism is configured to maintain the slider body in a loading configuration; and 
 an outlet guide coupled to the second end of the first portion of the mouthpiece and partially received within the second end of the inner tubular body, wherein the outlet guide defines a cavity configured to sealingly engage and removably secure the removable cartridge therein. 
   
     
     
         48 . The aerosol delivery device of  claim 47 , wherein the holder further comprises:
 a pair of ignitor contacts disposed within the receiving chamber proximate the distal end of the holder; and   a second biasing mechanism disposed within the main body and configured to engage a distal end of the mouthpiece, wherein the mouthpiece is slidably disposed within the main body and the second biasing mechanism is configured to position an ignitable heat source portion of the cartridge away from the ignitor contacts.   
     
     
         49 . The aerosol delivery device of  claim 48 , wherein the holder further comprises:
 an inner housing disposed within the main body of the holder and defining one or more receptacles therein;   an outer tubular body disposed within a first one of the receptacles and defining an interior cavity configured to slidably receive the mouthpiece therein;   a first end cap coupled to proximal end of the holder and defining a first opening in communication with the interior cavity of the outer tubular body, the first end cap configured to secure at least one of the inner housing or the outer tubular body within the holder; and   a second end cap coupled to the distal end of the holder and defining a second opening in communication with the interior cavity of the outer tubular body, the second end cap configured to secure at least one of the inner housing or the outer tubular body within the holder.   
     
     
         50 . The aerosol delivery device of  claim 49 , wherein the second biasing mechanism comprises:
 a return spring; and   a collar slidably disposed within the outer tubular body, a distal end of the collar configured to engage the return spring.   
     
     
         51 . The aerosol delivery device of  claim 50 , wherein the first biasing mechanism comprises an ejection spring and the ejection spring has a greater spring force than the return spring. 
     
     
         52 . The aerosol delivery device of  claim 47 , wherein the second end cap further comprises a standoff extending into the inner housing and partially defining the receiving chamber. 
     
     
         53 . The aerosol delivery device of  claim 52 , wherein the standoff comprises a pair of opposing slots configured to secure the ignitor contacts therein. 
     
     
         54 . The aerosol delivery device of  claim 47 , wherein the holder comprises a retention mechanism configured to movably couple the mouthpiece to the holder. 
     
     
         55 . The aerosol delivery device of  claim 47  further comprising:
 a power source disposed within the inner housing; 
 a printed circuit board disposed within the inner housing and in electrical communication with the ignitor contacts; and 
 a switch in electrical communication with the power source and the printed circuit board and configured to electrically couple the power source to the ignitor contacts. 
 
     
     
         56 . The aerosol delivery device of  claim 1  further comprising the removable cartridge, wherein the cartridge includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto. 
     
     
         57 . The aerosol delivery device of  claim 11  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. 
     
     
         58 . The aerosol delivery device of  claim 1 , wherein the mouthpiece is removable.