Aerosol delivery devices

Abstract

The present invention relates to an aerosol delivery device. The aerosol delivery device may include a control body and a cartridge, the cartridge including an atomizer and a reservoir configured to contain an aerosol precursor composition. The control body may include a housing defining an electric power source cavity, the electric power source cavity extending along a first longitudinal axis and configured to accommodate an electric power source. The control body may additionally include a coupler configured to engage a cartridge including an aerosol precursor composition so that the cartridge extends along a second longitudinal axis. The first longitudinal axis and the second longitudinal axis may be non-coaxial and oriented substantially parallel to each other. A related assembly method is also provided.

Description

[0001] This invention application is a divisional application of the invention patent application with international application number PCT / IB2016 / 058021, international application date December 27, 2016, application number 201680082558.6 entering the Chinese national phase, and name “Aerosol delivery device comprising a shell and a coupler”. Technical Field

[0002] The present disclosure relates to an aerosol delivery device, and more specifically, to an aerosol delivery device including a housing and a coupler. The aerosol delivery device may include an atomizer, which includes a heating element configured to heat an aerosol precursor. An aerosol precursor composition that may include a component made from tobacco or derived from tobacco or otherwise incorporated into tobacco is heated by the atomizer to produce an inhalable substance for human consumption. Background Art

[0003] For several years, many smoking devices have been proposed as improvements or substitutes for smoking products that need to burn tobacco. Many of these devices are said to be designed to provide a feeling associated with cigarettes, cigars or pipes, but a large amount of incomplete combustion and pyrolysis products caused by tobacco burning will not be delivered. For this purpose, numerous smoking products, flavor generators and medicinal inhalers that utilize electric energy to atomize or heat volatile materials or attempt to provide the feeling of cigarettes, cigars or pipes to a great extent without burning tobacco have been proposed. For example, referring to various alternative smoking articles, aerosol delivery devices and heat generation sources described in the background technology described in U.S. Patent No. 7,726,320 of Robinson et al. and U.S. Patent No. 8,881,737 of Collett et al., these documents are incorporated herein by reference. See again, various types of smoking articles, aerosol delivery devices and electric heat generation sources referenced by trade names and commercial sources in U.S. Patent Publication No. 2015 / 0216232 of Bless et al., the patent is incorporated herein by reference. In addition, various types of electric aerosol and vapor delivery devices have been proposed in the following patent documents: U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al. and U.S. Patent Application Publication No. 2014 / 0283859 to Minskoff et al. and U.S. Patent Application Serial No. 14 / 282,768 filed by Sears et al. on May 20, 2014; U.S. Patent Application Serial No. 14 / 286,552 filed by Brinkley et al. on May 23, 2014; U.S. Patent Application Serial No. 14 / 327,776 filed by Ampolini et al. on July 10, 2014; and U.S. Patent Application Serial No. 14 / 465,167 filed by Worm et al. on August 21, 2014; all of which are incorporated herein by reference.

[0004] Some existing embodiments of aerosol delivery devices include a control body and a cartridge. A power source (e.g., a battery) can be positioned in the control body, and an aerosol precursor composition can be positioned in the cartridge. The cartridge and the control body can be engaged with each other to define an elongated tubular configuration. However, some other form factors may be desired for aerosol delivery devices. Summary of the invention

[0005] The present disclosure relates to an aerosol delivery device, which in certain embodiments can be characterized as an electronic cigarette. In one aspect, an aerosol delivery device is provided. The aerosol delivery device may include a housing. The housing may define: an electric power source cavity, the electric power source cavity being configured to accommodate an electric power source; and a cartridge cavity, the cartridge cavity being configured to accommodate a cartridge including an aerosol precursor composition. The electric power source cavity and the cartridge cavity may be elongated and define longitudinal axes, respectively. The longitudinal axis of the electric power source cavity and the longitudinal axis of the cartridge cavity may be non-coaxial and oriented substantially parallel to each other.

[0006] In some embodiments, the aerosol delivery device may further include an electrical power source. In addition, the aerosol delivery device may include a cartridge. In addition, the aerosol delivery device may include a coupler positioned within the housing and configured to engage the cartridge. The aerosol delivery device may additionally include an outer cover engaged with the exterior of the housing.

[0007] In some embodiments, the housing can also define an observation opening at the cartridge cavity. In addition, the aerosol delivery device can include an illumination source configured to illuminate the cartridge in the cartridge cavity. The aerosol delivery device can also include an electronic display. The housing can include a channel door configured to provide access to the electrical power source cavity. The housing can define an external opening at the cartridge cavity, the external opening being configured to accommodate the cartridge therethrough. The housing can define a partition wall that separates the electrical power source cavity from the cartridge cavity.

[0008] In an additional aspect, a method for assembling an aerosol delivery device is provided. The method may include providing a housing. The housing may define: an electrical power source cavity configured to accommodate an electrical power source; and a cartridge cavity configured to accommodate a cartridge comprising an aerosol precursor composition. The electrical power source cavity and the cartridge cavity may be elongated and define longitudinal axes, respectively. The longitudinal axis of the electrical power source cavity and the longitudinal axis of the cartridge cavity may be non-coaxial and oriented substantially parallel to each other. In addition, the method may include positioning an electrical contact in the electrical power source cavity. The electrical contact may be configured to engage the electrical power source. In addition, the method may include positioning a coupler in the cartridge cavity. The cartridge cavity may be configured to engage the cartridge.

[0009] In some embodiments, the method may further include inserting the electric power source into the electric power source cavity and engaging the electric power source with the electrical contacts. In addition, the method may include inserting the cartridge into the cartridge cavity and engaging the cartridge with the coupler. Inserting the cartridge into the cartridge cavity may include inserting the cartridge through an external opening defined by the housing.

[0010] In some embodiments, providing a housing may include defining a viewing opening at the cartridge cavity. In addition, the method may include engaging an outer cover with an exterior of the housing. The method may further include positioning an illumination source in the housing. The illumination source may be configured to illuminate the cartridge in the cartridge cavity.

[0011] In some embodiments, the method may further include engaging the electronic display with the housing. Providing the housing may include engaging the first body portion with the second body portion. Providing the housing may also include engaging an access door with at least one of the first body portion and the second body portion. The access door may be configured to selectively provide access to the electrical power source cavity.

[0012] In an additional aspect, an aerosol delivery device is provided. The aerosol delivery device may include a housing defining an electrical power source cavity configured to accommodate an electrical power source. The electrical power source cavity may define a first longitudinal axis. The aerosol delivery device may further include a coupler that engages with the housing and is configured to engage a cartridge comprising an aerosol precursor composition such that the cartridge extends along a second longitudinal axis. The first longitudinal axis and the second longitudinal axis may be non-coaxial and oriented substantially parallel to each other.

[0013] In some embodiments, the aerosol delivery device may further include an electrical power source. Additionally, the aerosol delivery device may include a controller. The controller may at least partially enclose the electrical power source.

[0014] In some embodiments, the aerosol delivery device may further include a cartridge. The cartridge may include a viewing window. The aerosol delivery device may additionally include an illumination source configured to direct illumination through the viewing window.

[0015] In some embodiments, the housing may include a coupler portion. The coupler may be at least partially positioned within the coupler portion. The housing may include a button assembly. The button assembly may be configured to control the power output level directed to the cartridge from the electrical power source. The button assembly may at least partially define a partition wall that separates the cartridge from the electrical power source cavity. In addition, the aerosol delivery device may include an illumination source. The button assembly may include an illumination source cover that is configured to direct illumination generated by the illumination source through there.

[0016] In an additional aspect, a method for assembling an aerosol delivery device is provided. The method may include providing a housing defining an electrical power source cavity configured to accommodate an electrical power source. The electrical power source cavity may define a first longitudinal axis. The method may further include engaging a coupler configured to engage a cartridge comprising an aerosol precursor composition with the housing so that the cartridge extends along a second longitudinal axis. The first longitudinal axis and the second longitudinal axis may be non-coaxial and oriented substantially parallel to each other. In addition, the method may include positioning a controller in the housing. The controller may be configured to engage the electrical power source.

[0017] In some embodiments, the method may further include engaging the electric power source with the controller. In addition, the method may include inserting the electric power source into the electric power source cavity while positioning the controller in the housing. In addition, the method may include engaging the cartridge with the coupler. The cartridge may include an observation window. In addition, the method may include positioning an illumination source in the housing. The illumination source may be configured to direct illumination through the observation window.

[0018] In some embodiments, providing the housing may include engaging the first body portion with the second body portion. In addition, providing the housing may also include engaging an access door with at least one of the first body portion and the second body portion. The access door may be configured to block access to the electrical power source cavity. Providing the housing may also include engaging a button assembly with at least one of the first body portion and the second body portion. The method may further include positioning an illumination source in the housing and engaging an illumination source cover with the button assembly. The illumination source cover may be configured to direct illumination generated by the illumination source through there.

[0019] The present invention includes but is not limited to the following examples.

[0020] Embodiment 1: An aerosol delivery device comprising:

[0021] a housing defining an electrical power source cavity configured to receive an electrical power source, the electrical power source cavity defining a first longitudinal axis; and

[0022] a coupler engaged with the housing and configured to engage a cartridge comprising an aerosol precursor composition such that the cartridge extends along a second longitudinal axis,

[0023] The first longitudinal axis and the second longitudinal axis are non-coaxial and are oriented substantially parallel to each other.

[0024] Embodiment 2: An aerosol delivery device according to any preceding or following embodiment, wherein the housing includes a coupler portion, the coupler being at least partially positioned within the coupler portion.

[0025] Embodiment 3: The aerosol delivery device according to any preceding or following embodiment, further comprising the electrical power source.

[0026] Embodiment 4: The aerosol delivery device according to any preceding or following embodiment, further comprising a controller, wherein the controller at least partially encloses the electrical power source.

[0027] Embodiment 5: The aerosol delivery device according to any preceding or following embodiment, further comprising the cartridge.

[0028] Embodiment 6: The aerosol delivery device of any preceding or following embodiment, wherein the cartridge comprises a viewing window.

[0029] Embodiment 7: The aerosol delivery device of any preceding or following embodiment, further comprising an illumination source configured to direct illumination through the viewing window.

[0030] Embodiment 8: An aerosol delivery device according to any preceding or following embodiment, wherein the housing comprises a button assembly.

[0031] Embodiment 9: The aerosol delivery device of any preceding or following embodiment, wherein the button assembly is configured to control a level of power output directed from the electrical power source to the cartridge.

[0032] Embodiment 10: The aerosol delivery device of any preceding or subsequent embodiment, wherein the button assembly at least partially defines a partition wall that separates the cartridge from the electrical power source chamber.

[0033] Embodiment 11: The aerosol delivery device of any preceding or following embodiment, further comprising an illumination source, wherein the button assembly comprises an illumination source cover configured to direct illumination generated by the illumination source therethrough.

[0034] Embodiment 12: A method for assembling an aerosol delivery device, the method comprising:

[0035] providing a housing defining an electrical power source cavity configured to receive an electrical power source, the electrical power source cavity defining a first longitudinal axis; and

[0036] engaging a coupler configured to engage a cartridge comprising an aerosol precursor composition with the housing such that the cartridge extends along a second longitudinal axis,

[0037] The first longitudinal axis and the second longitudinal axis are non-coaxial and oriented substantially parallel to each other; and

[0038] A controller is positioned in the housing, the housing being configured to engage the source of electrical power.

[0039] Embodiment 13: The method according to any preceding or following embodiment, further comprising engaging the electrical power source with the controller.

[0040] Embodiment 14: The method according to any preceding or following embodiment, further comprising inserting the electrical power source into the electrical power source cavity while positioning the controller in the housing.

[0041] Embodiment 15: The method of any preceding or following embodiment, further comprising engaging the cartridge with the coupler.

[0042] Embodiment 16: The method of any preceding or subsequent embodiment, wherein the cartridge comprises a viewing window.

[0043] Embodiment 17: The method of any preceding or subsequent embodiment, further comprising positioning an illumination source in the housing, the illumination source configured to direct illumination through the viewing window.

[0044] Embodiment 18: The method of any preceding or following embodiment, wherein providing the housing comprises joining a first body portion with a second body portion.

[0045] Embodiment 19: The method of any preceding or following embodiment, wherein providing the housing may further comprise engaging an access door with at least one of the first body portion and the second body portion, the access door being configured to block access to the electrical power source cavity.

[0046] Embodiment 20: The method of any preceding or following embodiment, wherein providing the housing may further include engaging a button assembly with at least one of the first body portion and the second body portion.

[0047] Embodiment 21: The method of any preceding or following embodiment, further comprising positioning an illumination source in the housing and engaging an illumination source cover with the button assembly, the illumination source cover configured to direct illumination generated by the illumination source therethrough.

[0048] These and other features, aspects and advantages of the present disclosure will become apparent by reading the following detailed description and the accompanying drawings briefly described below. The present invention includes any combination of two, three, four or more of the above-described embodiments, as well as any combination of two, three, four or more features or elements set forth in the present disclosure, regardless of whether these features or elements are explicitly combined in the specific embodiment description herein. The present disclosure is intended to be read as a whole, so that any separable features or elements of the disclosed invention in any of its various aspects and embodiments should be considered intended to be combinable unless the context clearly indicates otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Having thus described the present disclosure in the foregoing summary manner, reference is now made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0050] Figure 1 illustrates a side view of an aerosol delivery device including a control body and a cartridge according to an example embodiment of the present disclosure;

[0051] Figure 2 FIG. 1 shows a schematic diagram of a method for passing through an exemplary embodiment of the present disclosure. Figure 1 A cross-sectional, partially exploded view of a control body of an aerosol delivery device.

[0052] Figure 3 FIG. 1 shows a schematic diagram of a method for passing through an exemplary embodiment of the present disclosure. Figure 1 A modified cross-sectional view of an aerosol delivery device;

[0053] Figure 4 The diagram includes a reservoir substrate Figure 1 An exploded view of an example embodiment of a cartridge;

[0054] Figure 5 FIG. 1 illustrates a method of passing through a reservoir according to an example embodiment of the present disclosure. Figure 1 A cross-sectional view of an alternative example embodiment of a cartridge;

[0055] Figure 6 The present invention illustrates a method of passing through a Figure 5 The barrel Figure 1 A modified cross-sectional view of an aerosol delivery device;

[0056] Figure 7 illustrates a perspective view of a control body including a side opening configured to engage an outer cover and a relatively wide viewing opening according to another exemplary embodiment of the present disclosure;

[0057] Figure 8 FIG. 1 shows a device having an outer cover according to an exemplary embodiment of the present disclosure. Figure 7 The perspective view of the controlling subject;

[0058] Fig. 9 The present invention illustrates an exemplary embodiment of the present invention. Figure 8 An enlarged side view of the control body at the viewing opening;

[0059] Fig.10 The present invention illustrates an exemplary embodiment of the present invention. Figure 7 a cross section of a main body portion of a housing of a control body;

[0060] Fig.11 illustrates a perspective view of a control body including a plurality of side openings configured to engage an outer cover and a relatively narrow viewing opening according to another exemplary embodiment of the present disclosure;

[0061] Fig.12 The present invention illustrates an exemplary embodiment of the present invention. Fig.11 a cross section of a main body portion of a housing of a control body;

[0062] Fig.13The present invention illustrates an exemplary embodiment of the present invention. Fig.11 A bottom view of the control body;

[0063] Fig.14 FIG. 1 shows a device having an outer cover according to an exemplary embodiment of the present disclosure. Fig.11 The controlling entity;

[0064] Fig.15 The present invention illustrates an exemplary embodiment of the present invention. Fig.14 An enlarged side view of the control body at the viewing opening;

[0065] Fig.16 A method for assembling an aerosol delivery device according to an example embodiment of the present disclosure is illustrated;

[0066] Fig.17 illustrates a perspective view of an aerosol delivery device including a control body and a cartridge according to an example embodiment of the present disclosure;

[0067] Fig.18 The present invention illustrates an exemplary embodiment of the present invention. Fig.17 A partial exploded view of the control body;

[0068] Fig.19 FIG. 1 illustrates a first body portion including a housing thereof according to an exemplary embodiment of the present disclosure. Fig.17 A partial side view of a control body in a partially assembled configuration;

[0069] Fig. 20 The present invention illustrates an exemplary embodiment of the present invention. Fig.17 A perspective view of a controller and an electric power source of a control subject;

[0070] Fig.21 FIG. 1 illustrates a first body portion including a housing thereof according to an exemplary embodiment of the present disclosure. Fig.17 A perspective view of a control body in a partially assembled configuration;

[0071] Fig. 22 FIG. 1 illustrates a schematic diagram of a coupler portion of a housing including an electric power source housing portion and a housing according to an exemplary embodiment of the present disclosure. Fig.17 A perspective view of a control body in a partially assembled configuration;

[0072] Fig.23 FIG. 1 shows a schematic diagram of a method for passing through an exemplary embodiment of the present disclosure. Fig.17 A cross-sectional view of a coupler of a control body; and

[0073] Fig.24 A method for assembling an aerosol delivery device according to an example embodiment of the present disclosure is illustrated. DETAILED DESCRIPTION

[0074] The present disclosure will now be described more fully below with reference to its example embodiments. These embodiments are described so that the present disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled in the art. In fact, the present disclosure can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; on the contrary, these embodiments are provided so that the present disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms "a / an", "the" include plural references unless the context clearly indicates otherwise.

[0075] Aerosol delivery devices according to the present disclosure may use electrical energy to heat materials (preferably without burning the materials to any significant extent) to form inhalable substances; such products are most preferably compact enough to be considered as "handheld" devices. Aerosol delivery devices may provide some or all of the sensations of smoking cigarettes, cigars or pipes (e.g., inhalation and exhalation habits, taste or flavor types, sensory effects, physical sensations, usage habits, visual cues, such as those provided by visible aerosols, etc.), without any significant degree of combustion of any component of the product or device. Aerosol delivery devices may not produce smoke in the sense of aerosols produced by the combustion or pyrolysis byproducts of tobacco, but the product or device most preferably produces vapor produced by the volatilization or evaporation of certain components of the product or device (including vapor in an aerosol that can be considered as a visible aerosol, which can be considered to be described as smoke-like), although in other embodiments the aerosol may not be visible. In highly preferred embodiments, the aerosol delivery device may contain tobacco and / or components derived from tobacco. As such, an aerosol delivery device may be characterized as an electronic smoking article, such as an electronic cigarette.

[0076] Aerosol delivery equipment of the present disclosure can also be characterized as steam products or drug delivery products.Therefore, this product or equipment can be adapted to provide one or more materials (for example, flavoring agents and / or active pharmaceutical ingredients) in inhalable form or state.For example, inhalable material can be in steam form (that is, in the material of gas phase at a temperature lower than its critical point) in general.Alternately, inhalable material can be in aerosol form (that is, the suspension of fine solid particles or droplets in the gas).For simplicity, no matter whether visible and no matter whether it is a form that may be regarded as aerosol, the term "aerosol" as used herein is intended to include steam, gas and aerosol of a form or type suitable for human inhalation.

[0077] In use, the aerosol delivery device of the present disclosure can be subjected to many of the physical actions that an individual employs 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 aerosol delivery device of the present disclosure can be held by a user, the user can draw on a portion of the article to inhale the aerosol generated by the article, the user can take puffs of smoke at selected time intervals, and the like.

[0078] Aerosol delivery devices of the present disclosure generally include a housing and a plurality of additional components connected to the housing and / or positioned within the housing, and some components may be removable or replaceable. The overall design of the housing may vary, and the overall size and shape of the housing may vary. The smoking article may include a cartridge, which may be defined by an outer body or cover, the cartridge being, for example, an elongated body similar to the shape of a part of a cigarette or cigar. For example, the outer cover or body of the cartridge may be a substantially tubular shape, and therefore similar to the shape of a traditional cigarette or cigar. In some embodiments, the housing may include one or more reusable components (e.g., a rechargeable battery and various electronic devices for controlling the operation of the article), and the cartridge may be removable, refillable and / or disposable.

[0079] The aerosol delivery devices of the present disclosure most preferably include a power source (i.e., an electrical power source), at least one control component (e.g., a device for actuating, controlling, regulating, and stopping the power used for heat generation, such as by controlling the flow of electrical current from the power source to other components of the aerosol delivery device), a heater or heat generating component (e.g., a resistive heating element or component, which is often referred to as part of an "atomizer"), and an aerosol precursor composition (e.g., a liquid that is typically capable of producing an aerosol when sufficient heat is applied, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice") and a mouth end region or tip (e.g., a defined air flow path through the article so that the generated aerosol can be drawn therefrom when puffed) that allows the aerosol delivery device to be puffed to inhale the aerosol. When the heating element heats the aerosol precursor composition, the aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the aforementioned terms are meant to be interchangeable, such that references to release, releasing, releases, or released include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of vapor or aerosol or a mixture thereof.

[0080] As described above, the aerosol delivery device may include a battery and / or other electrical power source (e.g., a capacitor) to provide current sufficient to provide various functions to the aerosol delivery device, such as power supply of a heater, power supply of a control system, power supply of an indicator, etc. The power source may adopt various embodiments. Preferably, the power source is capable of delivering sufficient power to quickly heat the heating element to provide aerosol formation and to power the aerosol delivery device by using a desired duration. Preferably, the size of the power source is designed to be conveniently assembled in the aerosol delivery device so that the aerosol delivery device can be easily handled. In addition, the preferred power source has a sufficiently light weight to not detract from the desired smoking experience. The battery for this device may be a replaceable, removable and / or rechargeable battery, and therefore may be combined with any type of recharging technology, including such as being connected to a typical AC outlet, being connected to a car charger (i.e., a cigarette lighter socket) and being connected to a computer via a universal serial bus (USB) cable or connector. In a preferred embodiment, the electrical power source includes a lithium-ion battery, which may be lightweight and rechargeable, and provides a large energy storage capacity. Examples of electrical power sources are described in US Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0081] The aerosol delivery device according to the present disclosure is preferably combined with a sensor or detector for controlling the power supply to the heating element when aerosol generation is required (e.g., when inhaling during use). Thus, for example, a method or method is provided for turning off the power supply to the heating element when the aerosol generating member is not inhaled during use and for turning on the power supply to actuate or trigger the generation of heat by the heat generating element when inhaling. For example, with respect to flow sensors, representative current regulating components and other current control components including various microcontrollers, sensors, and switches for aerosol delivery devices are described in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 5,372,148 to McCafferty et al.; U.S. Pat. No. 6,040,560 to Fleischhauer et al.; U.S. Pat. No. 7,040,314 to Nguyen et al.; U.S. Pat. No. 8,205,622 to Pan; and U.S. Pat. No. 8,881,737 to Collet et al.; U.S. Pat. No. 2009 / 0230117 to Fernando et al.; and U.S. Pat. No. 2014 / 0270727 to Ampolini et al.; and U.S. Pat. No. 2015 / 0257445 to Henry et al., which are incorporated herein by reference in their entirety. Additional representative types of sensing or detection mechanisms, structures, components, configurations, and general methods of operation thereof are described in U.S. Pat. No. 5,261,424 to Sprinkel, Jr., U.S. Pat. No. 5,372,148 to McCafferty et al., and PCT WO 2010 / 003480 to Flick, which are incorporated herein by reference in their entireties.

[0082] In some embodiments, the aerosol delivery device may include an indicator, which may include one or more light emitting diodes. For example, the indicator may communicate with the control component through a connector and illuminate during the period during which the flow sensor detects the user's puffing on the mouth end.

[0083] Various elements that may be included in the housing are described in U.S. Patent Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference in its entirety. Still further components may be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device to detect user lip activity associated with puffing and then trigger heating; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow into a heating load array in response to a pressure drop across a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a socket in a smoking device, the socket including an identifier for detecting non-uniformity of infrared transmittance of an inserted component and a controller for executing a detection routine when the component is inserted into the socket; U.S. Pat. No. 6,040,5 No. 60 describes a defined executable power cycle with multiple differential phases; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic-photoelectric component; U.S. Patent No. 5,954,979 to Counts et al. discloses a device for varying the resistance to draw through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface device for a smoking device to facilitate charging and allow computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and WO 2010 / 003480 to Flick discloses a fluid flow sensing system for indicating puffs in an aerosol generating system; all of the foregoing disclosures are incorporated herein by reference in their entirety.Further examples of components related to electronic aerosol delivery articles and materials or components that can be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to Morgan 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. 7,832,410 to Hon; U.S. Pat. No. 7,513, No. 253; U.S. Patent No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; U.S. Patent No. 8,794,231 to Thorens et al.; U.S. Patent No. 8,851,083 to Oglesby et al.; U.S. Patent Nos. 8,915,254 and 8,925 to Monsees et al.; U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon; U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; WO 2009 to Foo No. 2013 / 089551; and U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al., each of which is incorporated herein by reference in its entirety.

[0084] Aerosol precursor compositions (also referred to as vapor precursor compositions) may include a variety of components, for example, the various components include any of a polyol (e.g., glycerol, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extracts, and / or flavoring agents. Various components that may be included in aerosol precursor compositions are described in U.S. Pat. No. 7,726,320 to Robinson et al., which is incorporated herein by reference in its entirety. Additional representative types of aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., PCT WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), the disclosures of which are all incorporated herein by reference in their entirety. Other aerosol precursors that may be employed in the aerosol delivery devices of the present disclosure include those described in RJ Reynolds Vapor Company's Products, BLU by Lorillard Technologies TM Aerosol precursors included in the products of , Mistic Mentho products of MisticEcigs, and Vype products of CN Creative Ltd. Also contemplated are so-called "smoke juices" for electronic cigarettes available from Johnson Creek Enterprises LLC. Additional exemplary formulations for aerosol precursor materials that may be used according to the present disclosure are described in U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Publication No. 2013 / 0213417 to Chong et al., the disclosures of which are incorporated herein by reference in their entirety.

[0085] The aerosol delivery device preferably includes a reservoir. In some embodiments, the reservoir may include a container, a fiber substrate, or a combination of a fiber substrate and a container for storing a liquid aerosol precursor. The fiber substrate suitable for use as a reservoir may include multiple layers of nonwoven fibers and may be substantially formed into a tubular shape. For example, the shape and size of the formed tube may be arranged to be conveniently placed in the outer body or cover of the cartridge for use in an aerosol delivery device. For example, the liquid component may be retained and / or retained in the reservoir container by adsorption of the fiber substrate. The reservoir is preferably fluidly connected to a liquid transport element. Therefore, the liquid transport element may be configured to transfer the liquid from the reservoir to the heating element, such as by capillary action and / or by active transmission-for example, by pumping or controlled movement of a valve. Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014 / 0261487 to Chapman et al., U.S. Patent Application Publication No. 2014 / 0004930 to Davis et al., and U.S. Patent Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference in their entirety.

[0086] The liquid transport element may be in direct contact with the heating element. Various wicking materials and the configuration and operation of those wicking materials within certain types of aerosol delivery devices are described in U.S. Pat. No. 8,910,640 to Sear et al., which is incorporated herein by reference in its entirety. Various materials disclosed by the aforementioned documents may be incorporated into the present device in various embodiments, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0087] The heating element may include a wire defining a plurality of coils wound around the liquid transport element. In some embodiments, the heating element may be formed by winding the wire around the liquid transport element, as described in U.S. Patent Application Publication No. 2014 / 0157583 to Ward et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the wire may define a variable coil spacing, as described in U.S. Patent Application Publication No. 2014 / 0270730 to DePiano et al., which is incorporated herein by reference in its entirety. Various embodiments of materials configured to generate heat when an electric current is applied therethrough may be employed to form the heating element. Example materials that may form the wire coils include titanium, platinum, silver, palladium, Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)2), graphite and graphite-based materials, and ceramics (e.g., positive or negative temperature coefficient ceramics). The heating element may include a wire defining a mesh, screen, or grid structure positioned around the liquid transport element. Example materials that can form a wire mesh, screen, or grid include titanium, platinum, silver, palladium, Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)2), graphite and graphite-based materials, and ceramics (e.g., positive or negative temperature coefficient ceramics). An example embodiment of a mesh heating element is disclosed in U.S. Patent Application Publication No. 2015 / 0034103 to Hon. In some embodiments, a stamped heating element can be employed in an atomizer, as described in U.S. Patent Publication No. 2014 / 0270729 to DePiano et al., which is incorporated herein by reference in its entirety.In addition to the above, additional representative heating elements and materials used therein are described in U.S. Pat. Nos. 5,060,671 to Counts et al.; 5,093,894 to Deevi et al.; 5,224,498 to Deevi et al.; Sprinkel et al. No. 5,228,460 to Jr. et al.; No. 5,322,075 to Deevi et al.; No. 5,353,813 to Deevi et al.; No. 5,468,936 to Deevi et al.; No. 5,498,850 to Das; No. 5,659,656 to Das; No. 5,498,855 to Deevi et al.; No. 5,530,225 to Hajaligol; No. 5,665,262 to Hajaligol; No. 5,573,692 to Das et al.; and No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties. Additionally, chemical heating may be employed in other embodiments. As described above, various additional examples of heaters and materials employed for forming the heater are described in U.S. Pat. No. 8,881,737 to Collett et al., which is incorporated herein by reference.

[0088] Various heater components may be used in the present aerosol delivery device. In various embodiments, one or more microheaters or similar solid-state heaters may be used. Embodiments of microheaters and atomizers incorporating microheaters suitable for use in the disclosed device are described in U.S. Pat. No. 8,881,737 to Collett et al., which is incorporated herein by reference in its entirety.

[0089] One or more heating terminals (e.g., a positive terminal and a negative terminal) can be connected to the heating element to form an electrical connection with a power source, and / or the terminals can be connected to one or more control elements of the aerosol delivery device. Further, various examples of electronic control components and functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference in its entirety.

[0090] The various components of the aerosol delivery device according to the present disclosure can be selected from those described in the art and commercially available. For example, reference is made to the reservoir and heater system for the controlled delivery of a plurality of aerosolizable materials in an electronic smoking article described in U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0091] In further embodiments, one or more components of the aerosol delivery device may be formed of one or more carbon materials, which may provide advantages in terms of biodegradability and the absence of wires. In this regard, the heating element may include carbon foam, the reservoir may include carbonized fabric, and graphite may be employed to form electrical connections with the battery and controller. Example embodiments of carbon-based cartridges are provided in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., which is incorporated herein by reference in its entirety.

[0092] Aerosol delivery devices are often configured in a manner that mimics aspects of certain traditional smoking devices such as cigarettes or cigars. In this regard, aerosol delivery devices typically define a generally cylindrical configuration. For example, an aerosol delivery device often includes a control body and a cartridge attached in an end-to-end relationship to define a generally cylindrical configuration. Although such a configuration can provide an appearance and feel similar to a traditional smoking article, these configurations may suffer certain impairments. For example, an aerosol delivery device of a cylindrical configuration may not define an attachment point that can be used to keep the aerosol delivery device in a desired position when not in use. In addition, when used with a reservoir having a relatively large capacity that is similar in size and shape to a cigar, this configuration may result in a relatively large device, which may not be suitable for temporary storage or for transport in a user's pocket.

[0093] So-called "mod" devices may include configurations other than parallel, coaxial alignment of the control body and cartridge. However, such devices may include exposed and / or poorly supported electrical connectors connecting the control body and cartridge that may be strained during use or storage, potentially affecting their usability. Therefore, it may be desirable to provide an aerosol delivery device that is different in configuration and shape from that associated with conventional smoking articles and conventional aerosol delivery devices.

[0094] As such, embodiments of the present disclosure provide alternative aerosol delivery devices that are configured to address the above-noted deficiencies of existing aerosol delivery device configurations and / or to provide other benefits. Figure 1 A side view of an aerosol delivery device 100 of the present disclosure is illustrated. As shown, the aerosol delivery device 100 may include a control body 101, which may include a housing 102. In some embodiments, the housing may include a plastic material, but in other embodiments a variety of other materials may be used, which are preferably substantially rigid. The housing 102 may be unitary or include multiple components. For example, the housing 102 may include a main body portion 102a and an access door 102b, and the main body portion 102a itself may include one or more components. Figure 1 As further illustrated in , the aerosol delivery device 100 may additionally include a cartridge 200 , which may be at least partially housed in the control body 101 .

[0095] Figure 2 A partially exploded cross-sectional view through a control body 101 of an aerosol delivery device 100 is illustrated. As illustrated, the housing 102 can define an electrical power source chamber 104. In particular, the electrical power source chamber 104 can be defined in a main body portion 102a of the housing 102. The electrical power source chamber 104 can be closed by an access door 102b and can be accessed via the access door 102b. As described below, the electrical power source chamber 104 can be configured to accommodate an electrical power source.

[0096] In addition, the housing 102 can define a cartridge cavity 106. As described in detail below, the cartridge cavity 106 can be configured to receive a cartridge 200 (see, e.g., Figure 3 In this regard, the housing 102 can define an exterior opening 108 at the cartridge cavity 106 that is configured to receive the cartridge 200 therethrough.

[0097] The housing 102 may include a partition wall 107 that separates the electric power source chamber 104 from the cartridge chamber 106. In some embodiments, the partition wall 107 completely separates the electric power source chamber 104 from the cartridge chamber 106. For example, the partition wall 107 may extend across the length and thickness of the control body 101 so that the electric power source chamber 104 and the cartridge chamber 106 are separate chambers. This configuration may be preferred because it can prevent fluid communication between the electric power source chamber 104 and the cartridge chamber 106. Therefore, for example, in the event of failure of the electric power source structure, chemical intrusion into the cartridge chamber 106 can be prevented. However, as can be appreciated, in other embodiments, the partition wall may be discontinuous in one or both of the length and fit. This configuration of the partition wall can still hold the electric power source in the electric power source chamber and the cartridge in the cartridge chamber, respectively, so that these components are firmly held in place.

[0098] The control body 101 may include one or more additional components. The components may be housed in the housing 102 or otherwise engaged with the housing 102. For example, the components may include an electronic circuit, the operation of which is described below. The electronic circuit may include a controller 110, a first electrical contact 112a and a second electrical contact 112b, and a coupler 114. In some embodiments, the electronic circuit may additionally include an electronic display 116 (e.g., a liquid crystal display). In addition, the electronic circuit may include a flow sensor 118, which may be positioned at the coupler 114 or be in fluid communication with the coupler 114. Wires or other electrical connectors may provide connections between the various components of the electronic circuit. In some embodiments, the electronic circuit may also include a communication module. The communication module may be configured to communicate via Bluetooth or any other communication standard. Examples of communication modules and associated antenna components that may be included in the aerosol delivery device 100 are described in U.S. patent application serial number 14 / 802,789 filed on July 17, 2015 and U.S. patent application serial number 14 / 638,562 filed on March 4, 2015 (both to Marion et al.).

[0099] Figure 3 A cross-sectional view through the aerosol delivery device 100 is illustrated. As illustrated, the cartridge 200 can be at least partially contained in the cartridge cavity 106 when engaged with the control body 101. In this regard, the cartridge 200 can be inserted into the cartridge cavity 106 through the exterior opening 108. When the cartridge 200 is inserted into the cartridge cavity 106, the cartridge 200 can engage the coupler 114. Thus, the cartridge 200 can establish an electrical connection with the control circuitry such that electrical current can be selectively directed to the cartridge by the controller 110 to generate an aerosol.

[0100] like Figure 3 As further illustrated, the aerosol delivery device 100 may additionally include an electrical power source 300. The electrical power source 300 may be housed in the electrical power source cavity 104, and the access door 102b may be secured to the main body portion 102a of the housing 102 such that the electrical power source 300 is retained in the electrical power source cavity 104. In this regard, the aerosol delivery device 100 may additionally include at least one fastener 120 (e.g., a screw) configured to retain the access door 102b in engagement with the main body portion 102a of the housing 102.

[0101] When the electric power source 300 is inserted into the electric power source cavity 104, the first electrical contact 112a can engage the first end of the electric power source, and the first terminal of the electric power source can be positioned at the first end. Thereafter, when the channel door 102b is fixed to the main body 102, the second electrical contact 112b can engage the opposite second end of the electric power source 300, and the second terminal can be positioned at the second end. Thus, power from the electric power source 300 can be provided to the controller 110. However, as can be understood, the electrical contacts 112a, 112b can be positioned and configured in other ways suitable for engaging with the terminals of the electric power source 300, so that various embodiments of the electric power source can be adopted. For example, in another embodiment, both electrical contacts can be positioned at the top or bottom of the electric power source and configured to engage the top or bottom of the electric power source.

[0102] In some embodiments, the electrical power source 300 may further include a protection circuit. Such a protection circuit can prevent overcharging of the electrical power source and / or regulate the release of current within acceptable limits. In addition, in some embodiments, the electrical power source may additionally include a shock absorbing member (e.g., a foam pad) that can protect the electrical power source from damage associated with a drop of the aerosol delivery device 100.

[0103] like Figure 2 and Figure 3 As shown, in some embodiments, the power source cavity 104 and the cartridge cavity 106 can be elongated and define longitudinal axes 104a, 106a, respectively. The longitudinal axis 104a of the power source cavity 104 and the longitudinal axis 106a of the cartridge cavity 106 can be substantially parallel to each other. Such a configuration can allow both the cartridge 200 and the power source 300 to be accommodated in a space-efficient manner within the housing 102.

[0104] As described herein, many prior art embodiments of aerosol delivery devices define a generally elongated tubular configuration in which an electrical power source and a cartridge are typically positioned end-to-end to simulate smoking articles such as cigarettes and cigars. Thus, prior art embodiments of aerosol delivery devices typically include a cartridge and an aerosol delivery device arranged with their longitudinal axes parallel to one another. However, as Figure 2 and Figure 3 As shown, the aerosol delivery device 100 of the present disclosure may be configured such that the longitudinal axis 104a of the electrical power source cavity 104 and the longitudinal axis 106a of the cartridge cavity 106 are non-coaxial.

[0105] Configuring the power source chamber 104 and the cartridge chamber 106 with parallel but non-coaxial longitudinal axes 104a, 106a can provide many benefits. In this regard, since the cartridge 200 and the power source 300 are positioned adjacent to each other rather than in an end-to-end relationship, the aerosol delivery device 100 can define a relatively short length. In addition, by configuring the power source chamber 104 and the cartridge chamber 106 to be adjacent to each other, the aerosol delivery device 100 can define an overall shape that is more suitable for transport in a user's pocket. In addition, this configuration can allow the aerosol delivery device 100 to fit more easily in the user's hand. In this regard, due to its relatively short length, the user can more easily carry and use the aerosol delivery device in a hidden manner in the palm of the user, which may be desirable in certain social environments.

[0106] The side-by-side configuration can also provide a relatively large internal volume within the housing 102, which is suitable for accommodating components of the aerosol delivery device 100 in multiple different positions. In contrast, since the reservoir in the cartridge and the electrical power source in the control body generally define a cylindrical configuration, an end-to-end arranged aerosol delivery device has limited options regarding the location of the components therein. Therefore, any remaining space in the cartridge and the control body is generally annular or cylindrical, which is not suitable for accommodating many components in a space-efficient manner. In addition, the relatively large internal volume of the aerosol delivery device 100 of the present disclosure provided by the housing 102 can accommodate a relatively large electrical power source 300 and / or a relatively large cartridge 200, so that its corresponding electronic and aerosol precursor composition storage capacity can be increased. In addition, the relatively large internal volume of the aerosol delivery device 100 can accommodate a variety of commercially available electrical power sources, not just custom electrical power sources that may be required for a cylindrical configuration, so that the costs associated with the components of the aerosol delivery device can be reduced.

[0107] The side-by-side configuration can additionally provide a relatively large external surface area. Furthermore, the side-by-side configuration can provide a relatively flat external surface (which can be slightly curved for ergonomic or aesthetic purposes), as opposed to a sharply curved surface provided by a cylindrical aerosol delivery device, which can be more suitable for display 116. In this regard, commercially available electronic displays generally define a flat display surface.

[0108] Thus, for example, the electronic display 116 can be positioned at a plurality of locations and can define a relatively larger size than an electronic display on an aerosol delivery device that defines a cylindrical configuration. In the illustrated embodiment, the electronic display 116 is positioned at the top of the main body portion 102a of the housing 102. The external opening 108 to the cartridge cavity 106 can also be positioned at the top of the main body portion 102a of the housing. This position of the electronic display 116 can allow a user to view the electronic display while holding the aerosol delivery device in the user's hand in a manner suitable for suctioning on the cartridge 200. In this regard, the user's hand can extend around the side of the aerosol delivery device so that the top surface of the aerosol delivery device (where the exposed portion of the electronic display 116 and the cartridge 200 are positioned) is exposed and not covered by the user's hand. Thus, various information about the aerosol delivery device 100 can be easily viewed during normal use. For example, data displayed by the electronic display 116 may include remaining cartridge aerosol precursor composition level, remaining electrical power source level, historical usage information, heat and aerosol output settings, charging status, communication status (e.g., when linked to another device via Bluetooth or other communication protocol), time, and / or various other data.

[0109] The side-by-side configuration of the aerosol delivery device 100 of the present disclosure can provide additional benefits. For example, the cartridge 200 can engage the control body 101 in a manner that can provide a secure connection therebetween, which can reduce stress and strain thereon, as compared to embodiments of the aerosol delivery device in which the connection between the cartridge and the control body is exposed (e.g., in embodiments in which the cartridge and the control body are arranged end-to-end). In this regard, the coupler 114 can be recessed in or proximate to the cartridge cavity 106 such that the housing 102 protects the connection between the cartridge 200 and the control body 101. In addition, a portion, and more preferably a majority, of the longitudinal length of the cartridge 200 can be retained in the cartridge cavity 106, and the size and shape of the cartridge cavity can substantially correspond to the size and shape of the cartridge, such that the housing 102 can prevent movement of the cartridge, rather than the coupler 114 being subjected to the entirety of such stress and strain associated with forces applied to one or both of the cartridge and the control body 101. In this regard, in an aerosol delivery device configured with a control body and a cartridge arranged end-to-end, the connection between the cartridge and the control body may be subject to all or substantially all of the stresses and strains associated with forces applied to one or both of the cartridge and the control body. Such stresses and strains may damage the connection therebetween, which may impede its operation, since the connection includes an electrical connection that provides electrical current to the cartridge for evaporation purposes. Furthermore, although a "mod" device may define a configuration other than the end-to-end configuration described above, such a device typically includes an exposed electrical connector that is subject to stresses and strains. Thus, the side-by-side, parallel but non-coaxial configuration of the electrical power source chamber 104 and the cartridge chamber 106 of the aerosol delivery device 100 of the present disclosure may provide various benefits.

[0110] Various embodiments of the cartridge 200 may be employed in the aerosol delivery device 100. In this regard, Figure 3 , a side view of the cartridge 200 is illustrated in view of various possible configurations of the cartridge's components, rather than a cross-sectional view therethrough. Figure 4 An example embodiment of a cartridge is illustrated in FIG.

[0111] like Figure 4As shown, according to an example embodiment of the present disclosure, a cartridge 200' may include a base shipping plug 202', a base 204', a control component terminal 206', an electronic control component 208', a flow director 210', an atomizer 212', a reservoir substrate 214', an outer body 216', a label 218', a mouthpiece 220', and a mouthpiece shipping plug 222'. The base 204' may be coupled to a first end of the outer body 216' and the mouthpiece 220' may be coupled to an opposite second end of the outer body to at least partially enclose therein the remaining components of the cartridge 200' except for the label 218', the mouthpiece shipping plug 222', and the base shipping plug 202'. The base 204' may be configured to engage the coupler 114. In some embodiments, the base 204' may include an anti-rotation feature that substantially prevents relative rotation between the cartridge and associated equipment including an electrical power source, as described in US Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0112] The base shipping plug 202' can be configured to engage and protect the base 204' prior to use of the cartridge 200'. Similarly, the mouthpiece shipping plug 222' can be configured to engage and protect the mouthpiece 200' prior to use of the cartridge 200'. The control component terminals 206', the electronic control components 208', the flow director 210', the atomizer 212', and the reservoir substrate 214' can be retained within the outer body 216'. The label 218' can at least partially surround the outer body and include information such as a product identifier thereon.

[0113] The atomizer 212' may include a first heating terminal 234a' and a second heating terminal 234b', a liquid delivery element 238' and a heating element 240'. In this regard, the reservoir substrate 214' may be configured to hold an aerosol precursor composition. The reservoir substrate 214' is fluidly connected to the liquid delivery element 238' so that the aerosol precursor composition is transported from the reservoir substrate 214' to the heating element 240' (e.g., by capillary action). Therefore, when the current is directed to the heating element 240' via the heating terminals 234a', 234b', the aerosol precursor composition can be evaporated.

[0114] Various other details regarding components that may be included in cartridge 200' are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety. Figure 7 The figure shows an enlarged exploded view of the base and control unit terminals; Figure 8 An enlarged perspective view of the base and control unit terminals in an assembled configuration is shown; Fig. 9An enlarged perspective view of the base, control component terminals, electronic control components, and heater terminals of the atomizer are illustrated in an assembled configuration; Fig.10 An enlarged perspective view of the base, atomizer, and control components in an assembled configuration is illustrated; Fig.11 Picture shows Fig.10 relative perspective views of the components of Fig.12 An enlarged perspective view of the base, atomizer, flow director, and reservoir substrate in an assembled configuration is illustrated; Fig.13 A perspective view of the base and outer body in an assembled configuration is shown; Fig.14 A perspective view of a cartridge in an assembled configuration is shown; Fig.15 The diagram shows Fig.14 A first partial perspective view of a cartridge and a coupler for controlling a body; Fig.16 The diagram shows Fig.14 The barrel and its Fig.11 A second partial perspective view of the coupler of Fig.17 A perspective view of a cartridge including a base having an anti-rotation mechanism is illustrated; Fig.18 A perspective view of a control body including a coupler with an anti-rotation mechanism is illustrated; Fig.19 Picture shows Fig.17 The barrel and Fig.18 The alignment of the control subject; Fig. 20 A modified diagram of a device comprising aerosol delivery is shown using a modified diagram of a device comprising aerosol delivery device Fig.17 The barrel and its Fig.18 The aerosol delivery device of the control body of the embodiment of the present invention is a modified diagram illustrating the engagement of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body; Fig.21 A perspective view of a base having an anti-rotation mechanism is shown; Fig. 22 A perspective view of a coupler having an anti-rotation mechanism is illustrated; and Fig.23 The diagram shows a cross section of the Fig.21 The base and its Fig. 22 Cross-sectional view of the coupler.

[0115] In another embodiment, the cartridge 200 can be substantially similar or identical to the cartridge disclosed in U.S. Patent Application Serial No. 14 / 286,552 to Brinkley et al., filed May 23, 2014, which is incorporated herein by reference in its entirety. Thus, for example, the cartridge can include a flow director defining a non-tubular configuration, an electronics compartment sealed relative to a reservoir compartment, and / or any one or more of the various other features and components disclosed therein. Accordingly, it should be understood that the specific embodiments of the cartridge 200 described herein are provided for exemplary purposes only.

[0116] in this regard, Figure 5 A cross-sectional view through an additional embodiment of the cartridge 200 is illustrated in . As illustrated, a cartridge 200" according to an example embodiment of the present disclosure may include a base 204", a control component terminal 206", an electronic control component 208", a flow guide 210", an atomizer 212", and a mouthpiece 220", and the flow guide 210" may be defined by an outer body 216" or a separate component. The atomizer 212" may include a first heating terminal 234a" and a second heating terminal 234b", a liquid delivery element 238", and a heating element 240". As described above, the cartridge 200" may additionally include a base shipping plug, a label, and a mouthpiece shipping plug.

[0117] The base 204" can be coupled to a first end of the outer body 216", and the mouthpiece 220" can be coupled to an opposite second end of the outer body so as to at least partially enclose the remaining components of the cartridge 200" therein. In some embodiments, the base 204" can include an anti-rotation feature that substantially prevents relative rotation between the cartridge and associated equipment including an electrical power source, as described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0118] The cartridge 200" may also include a sealing member 242" and an initial liquid transfer element 244". In this regard, the outer body 216" and / or additional components can be configured to retain the aerosol precursor composition 246" in the reservoir 248". In some embodiments, the reservoir 248" can be configured to be refillable, while in other embodiments, the cartridge 200" can be configured for single use. The sealing member 242" can be positioned at one end of the chamber 248" and include one or more holes 250", which allow the aerosol precursor composition 246" to contact the initial liquid transfer element 244". In addition, the liquid transfer element 238" of the nebulizer 212" can contact the initial liquid transfer element 244". Both the initial liquid transfer element 244" and the liquid transfer element 238" of the nebulizer 212" can include wicking and / or porous materials that allow the aerosol precursor composition 246" to move therethrough (e.g., by capillary action) such that when passed through the control body 101 (see, e.g. Figure 6 ) applies current to the heating element via the heating terminals 234a", 234b", the aerosol precursor composition can be drawn into the heating element 240" and heated and vaporized.

[0119] Figure 6 The diagram shows that when the power source 300 is received in the power source cavity 104 and Figure 5The aerosol delivery device 100 when the cartridge 200" is accommodated in the cartridge cavity 106. As illustrated, in some embodiments, the electronic circuit may further include an illumination source 122, such as a light emitting diode (LED). In addition, the control body 101 may include an illumination source cover 124, which may cover, protect and / or hide the illumination source 122. The illumination source cover 124 may be translucent or transparent so that light emitted by the illumination source can pass therethrough. In some embodiments, the illumination source cover 124 may be colored or diffuse so that the presence of the illumination source is hidden or concealed when not in use.

[0120] like Figure 6 As further illustrated in , in some embodiments, the cartridge 200" may include an observation window 252", which may allow a user to observe a certain amount of aerosol precursor composition 246" retained in the reservoir 248". For example, all or a portion of the outer body 216" of the cartridge 200" may include a translucent or transparent material. The illumination source 122 and the illumination source cover 124 may be positioned in the main body 102a of the shell 102 at the cartridge cavity 106 (at a position on the cartridge cavity 106 aligned with the observation window 252") so that light generated by the illumination source can be directed to the cartridge 200" to facilitate observation of the level of the aerosol precursor composition 246". In this regard, the main body 102a of the shell 102 may include a cutout or other feature that defines the observation opening 126. Thus, the user may be able to see the level of the aerosol precursor composition 246" through the observation opening 126.

[0121] The controller 110 can direct the illumination source 122 to output light under certain circumstances, such as after detecting a puff on the cartridge 200". The illumination source 122 can additionally or alternatively output light when a separate actuator (e.g., a button) is pressed or otherwise actuated. Thus, the user can be notified of the level of aerosol precursor composition in the cartridge 200".

[0122] Note that inclusion of the illumination source 122 is optional. In this regard, in some embodiments, ambient light is sufficient to observe the level of the aerosol precursor composition 246" through the viewing opening 126. However, inclusion of the illumination source 122 may be preferred due to increased usability in low light situations.

[0123] The controller 110 can be configured to control one or more operations of the aerosol delivery device 100. The controller 110 can use information provided by the control components 208', 208" to verify that the cartridge 200 is authentic. Only when it is determined that the cartridge is authentic is the cartridge 200 allowed to be used. In addition, when the user draws on the cartridge 200, the flow sensor 118 (e.g., a pressure sensor) can detect the puff. In response, the controller 110 can direct current to the cartridge 200 so that the heating element 240', 240" generates heat and evaporates the aerosol precursor composition, which can be directed to the user. In addition, the aerosol delivery device may include an actuator that can be manually actuated to trigger the controller to direct current to the cartridge 200. The actuator can be used in place of the flow sensor 118, or supplemental power can be provided to the cartridge from an electrical power source to change (e.g., increase) the aerosol output of the aerosol delivery device. In other embodiments, the actuator can be used in conjunction with the controller to adjust the amount of power directed from the electrical power source to the cartridge so that the aerosol delivery device can have various aerosol output settings (e.g., aerosol mass output settings). Thus, the actuator (e.g., a button or button assembly) can be configured to control the power output level directed from the electrical power source to the cartridge.

[0124] In some embodiments, the actuator (e.g., a button or a button assembly) may have a selection area or multiple areas, such as a lower area, a middle area, and an upper area. Each area of ​​the actuator may be configured to direct different levels of power (e.g., current and / or voltage) from an electrical power source to the cartridge. Therefore, different areas of the actuator may each correspond to different aerosol output settings. The actuator may include one or more sensors (e.g., pressure and / or force sensors) at each area, so that the force applied to the actuator by the user at one or more areas may be detected so as to control the output of the aerosol via different optional power output levels directed to the cartridge from the electrical power source. Therefore, the power output level may be controlled based on the position at which the actuator is actuated. Alternatively or additionally, the power output level may be controlled based on the magnitude of the force applied to the actuator, which may be determined by a force sensor (e.g., a stress or strain sensor).

[0125] As can be appreciated, the exact shape and size of the aerosol delivery device 100 can vary. In this regard, Figure 7-Figure 10 Alternative embodiments of control body 101 ' are illustrated wherein only those differences with respect to control body 101 described above are noted. Accordingly, unless otherwise stated, each of the aerosol delivery devices may include some or all of the components and features described herein, in any combination.

[0126] like Figure 7As shown, the control body 101' may define a more rounded profile to improve ergonomics. Figure 7 As further illustrated, the control body 101' may also include an indicator 128'. The indicator 128' may output light to indicate the operating state of the control body. In some embodiments, the indicator 128' may be used to communicate the operating state of the device without using the electronic display surface 116'. For example, when the aerosol precursor composition in the cartridge is low or indicates that the electric power source needs to be recharged or replaced, the indicator 128' may flash or change color. In addition, when the flow sensor detects a puff of smoke on the cartridge, the indicator 128' may light up.

[0127] In some embodiments, the indicator 128' can be configured to illuminate with one or more of a plurality of colors, durations, frequencies, and / or intensities to indicate to the user certain conditions of the aerosol delivery device corresponding to the output of the indicator, such as the power output level, the state of the electrical power source, and / or the activated or unactivated state of the aerosol delivery device. Thus, the indicator 128' may include an illumination source that is activated with one or more of a plurality of colors, durations, frequencies, and / or intensities to indicate to the user certain conditions of the aerosol delivery device, such as the power output level, the state of the power source, and / or the activated or unactivated state of the aerosol delivery device. The indicator 128' may be configured by the user to control the color or multiple colors of the illumination source and / or other output parameters of the illumination source. In addition, the user may be able to control which device status value is communicated to the user via the illumination signal.

[0128] like Figure 7 As shown, the main body portion 102a' of the housing 102' may include a side opening 130'. Figure 8As shown, the side opening 130' can be configured to engage the outer cover 132' (e.g., via an interference fit). Therefore, the outer cover 132' can be engaged with the outside of the housing 102'. In some embodiments, the outer cover 132' can include silicon, which can provide an enhanced grip, making it easier to keep the control body 101' in the hand without dropping it. However, various other materials (e.g., other rubbers) that may have textures or smoothness can be adopted in other embodiments. Using an elastic outer cover 132' can provide various other benefits. For example, in one embodiment, pressing the outer cover 132' at the side opening 130' can trigger the illumination source 122 (e.g., via the actuation of an actuator) to illuminate the liquid level in the cartridge 200. In another embodiment, the pressing of the outer cover 132' at the side opening 130' can trigger the illumination source 122, wherein the pressing duration of the outer cover corresponds to the activation duration of the illumination source, so that during the filling or refilling of the cartridge or when the user-selected time period is otherwise desired, the user can continuously illuminate the cartridge 200 for the desired duration.

[0129] Fig. 9 A partial side view of the control body 101' is illustrated. As illustrated, the illumination source cover 124' can be aligned with the viewing opening 126', as described above. In the illustrated embodiment, the viewing opening 126' can be relatively wide to facilitate viewing the level of the aerosol precursor composition in the cartridge. For example, in some embodiments, the viewing opening 126' can define an opening having a width perpendicular to the longitudinal axis 106a' of the cartridge cavity 106' and equal to at least half of the diameter of the cartridge.

[0130] As described above, in some embodiments, the main body portion of the housing of the control body may include multiple components. In this regard, Fig.10 The first portion 102a1' of the main body portion 102a' of the housing 102' is shown in FIG. Figure 7 ). The second part 102a2' and the third part 102a3' of the main body 102a' of the housing 102' are Figure 7 The third portion 102a3' may be integral with the portion 102a2' or a separate component. The first portion 102a1' and the second portion 102a2' of the main body portion 102' of the housing 102' may be configured to engage the access door 102b' (see Fig.10). The electronic display 116' can be positioned at (e.g., below) a third portion 102a3' of the main body portion 102a' of the housing 102'. In this regard, in some embodiments, all or a portion of the housing 102' can be translucent or transparent. The housing 102' can additionally include an illumination source or have an illumination source proximate to the housing. For example, the housing 102' can include the illumination source 122 described above, which can be configured to emit direct or indirect illumination through the housing 102', wherein the housing can be translucent or transparent.

[0131] like Fig.10 As shown, the first portion 102a1' of the main body portion 102a' of the housing 102' may further include a side opening 134' configured to engage the outer cover 132' (see, e.g. Figure 8 ). Thus, the outer cover 132' can be securely held in place via the opposing side openings 130', 134'. Although the outer body 132' can provide an enhanced grip, the third portion 102a' can include a metal such as aluminum for enhanced strength and / or improved appearance, or a separate outer body defining such features may be attached to the third portion.

[0132] Fig.10 The interior of the first portion 102a1' of the main body portion 102a' of the housing 102' is also illustrated. As illustrated, the housing 102' can define one or more ribs 136', which can be configured to connect the electrical power source 300 (see, e.g., Figure 3 ) is held in the electrical power source chamber 104' and / or the cartridge 200 (see e.g. Figure 3 ) is retained in the cartridge cavity 106'. In this regard, the rib 136' can be bent or otherwise customized to match the size and shape of the electrical power source 300 and / or the cartridge 200. The rib 136' can extend to an end 138'. The end 138' of the rib 136' at the first portion 102a1' of the main body portion 102a' of the housing 102' can be configured to engage a corresponding end of the rib at the second portion 102a2' of the main body portion of the housing (see Figure 7 ), thereby separating the power source chamber 104' from the cartridge chamber 106', so as to separate the power source 300 and the cartridge 200 (see Figure 3) retained therein. In this regard, the ends 138' of the ribs 136' can collectively define a partition wall 107' that is segmented along its length. Using ribs 136' rather than a solid structure can reduce the amount of material required to form the housing 102', thereby additionally reducing the weight of the housing, while still maintaining components of the control body 101' in desired locations and providing additional rigidity. The ribs 136' may include a non-rigid material, such as a foam or thermoplastic polymer, or include an element containing foam, thermoplastic polymers or other non-rigid materials, which allows the ribs 136' to compress or shift in the event that the electrical power source 300 experiences a change in diameter that may occur during diameter expansion common in lithium-type batteries. In this regard, the ribs 136' can at least partially surround the electrical power source 300 (see, e.g. Figure 3 ).

[0133] like Fig.10 As additionally illustrated in FIG. 1 , the first portion 102a1′ of the body portion 102a′ of the housing 102′ may include a protrusion and / or a socket 140′, which may be configured to engage a corresponding socket / protrusion at the second portion 102a2′ (see Figure 7 ). Thus, the parts 102a1', 102a2' of the housing 102' may interlock with each other when assembled.

[0134] like Fig.10 As shown, portion 102b' may include an aperture 137' or a plurality of apertures in fluid communication with electrical power source cavity 104' and the atmosphere outside housing 102' to allow for the possibility of electrical power source 300 (see, e.g., Figure 3 ) to escape any one or more gases generated by the housing 102' so as to prevent the one or more gases from creating an area of ​​increased pressure within the housing 102'. The orifice 137' may include one or more openings of sufficient cross-sectional area to prevent a pressure differential between the interior area of ​​the housing 102' and the external atmosphere. In one embodiment, the orifice 137' may include a permeable membrane or porous material that allows the electrical power source 300 (see, e.g., Figure 3 ) to escape to the outside atmosphere while preventing liquid from entering the housing 102' due to the selective permeability of the membrane or porous material.

[0135] Figure 11-Figure 15 An additional embodiment of a control body 101" is shown. The control body 10" may be substantially similar in one or more aspects to Figure 7-Figure 10 In this regard, if Fig.11 and Fig.12 As shown, the control body 101" may include a housing 102", the housing 102" includes a main body portion 102a" and a channel door 102b", which may be fixed to the main body portion by screws 120" (see Fig.13 ). The body portion 102a" may include a plurality of portions, including a first portion 102a1" and a second portion 102a2". The first portion 102a1" may define a protrusion and / or a socket 140" configured to engage a corresponding socket / protrusion at the second portion 102a2' (see Figure 7 ). The main body portion 102a" can define one or more ribs 136", which extend to the end 138" respectively to define the partition wall 107". As shown, in some embodiments, the ribs 136" can extend in both the power source cavity 104" and the cartridge cavity 106", thereby helping to retain the power source and the cartridge respectively therein. In addition, the control body 101" can include an indicator 128" and an outer cover 132" (see Fig.14 ). The electronic display 116" may be positioned at the top of the housing 102", proximate the opening of the exterior opening 108" to the cartridge cavity 106", which extends along the longitudinal axis 106a".

[0136] However, the control body 101" may differ from the control bodies described above in one or more aspects. In this regard, in addition to the end 138" of the rib 136", the partition wall 107" may further include a partial wall 109", which further helps to retain the cartridge in the cartridge chamber 106". In addition, as Fig.11 and Fig.12 As shown, in some embodiments, the main body portion 102a" of the housing 102" may include a first side opening 130a" and a second side opening 130b" at the first portion 102a1" thereof and a first side opening 134a" and a second side opening 134b" at the second portion 102a2" thereof (see Fig.11 and Fig.13 ).like Fig.12 As illustrated, the use of a plurality of side openings 130a", 130b", 134a", 134b" at each portion 102a1", 102a2" of the body portion 102a" of the housing 102" may provide for improved engagement of the outer cover 132".

[0137] In addition, if Fig.15 As shown, in some embodiments, the viewing opening 126" can be relatively wide (see, e.g. Fig. 9 ). However, if Fig.13 As illustrated, in other embodiments, the width of the viewing opening 126" can be relatively small. For example, in some embodiments, the viewing opening can define a width equal to or less than half of the diameter configured to be accommodated in the cartridge compartment 106". Although a wide viewing opening can facilitate viewing the level of the aerosol precursor composition, a relatively smaller width viewing opening can provide more protection for the cartridge while still allowing the user to view the level of the aerosol precursor composition.

[0138] In additional embodiments, Fig.16 A method for assembling aerosol delivery is illustrated. As illustrated, the method may include providing a housing at operation 402. The housing may define: an electric power source cavity configured to accommodate an electric power source; and a cartridge cavity configured to accommodate a cartridge comprising an aerosol precursor composition. The electric power source cavity and the cartridge cavity may be elongated and define longitudinal axes, respectively. The longitudinal axis of the electric power source cavity and the longitudinal axis of the cartridge cavity may be non-coaxial and oriented substantially parallel to each other. In addition, the method may include positioning an electrical contact in the electric power source cavity at operation 404, the electrical contact being configured to engage the electric power source. In addition, the method may include positioning a coupler in the cartridge cavity at operation 406, the coupler being configured to engage the cartridge.

[0139] In some embodiments, the method may further include inserting the electric power source into the electric power source cavity and engaging the electric power source with the electrical contact. The method may additionally include inserting the cartridge into the cartridge cavity and engaging the cartridge with the coupler. Inserting the cartridge into the cartridge cavity may include inserting the cartridge through an external opening defined by the housing.

[0140] Providing a housing at operation 402 may include defining an observation opening at the cartridge cavity. In addition, the method may include engaging an outer cover with an exterior of the housing. The method may additionally include positioning an illumination source in the housing. The illumination source may be configured to illuminate the cartridge in the cartridge cavity. The method may also include engaging an electronic display with the housing. Providing a housing at operation 402 may include engaging a first body portion with a second body portion. Providing a housing at operation 402 may also include engaging a channel door with at least one of the first body portion and the second body portion, the channel door being configured to selectively provide access to the electrical power source cavity.

[0141] Fig.17 An additional embodiment of an aerosol delivery device 500 is illustrated. As illustrated, the aerosol delivery device 500 may include a control body 501 and a cartridge. In the illustrated embodiment, the aerosol delivery device 500 may include a control body 501 and a cartridge. Figure 5 A cartridge 200" may be included in the aerosol delivery device 500. However, as may be appreciated, other cartridges may be employed in other embodiments.

[0142] The control body 501 may include a housing 502. The housing 502 may be integral or include multiple components. For example, the housing 502 may include an electric power source portion 502a, a channel door 502b, and a coupler portion 502c. Fig.10 As described above with respect to orifice 137 in FIG. 1 , access door 502b may include an orifice or multiple orifices in fluid communication with the atmosphere outside housing 502b to allow for the passage of fluids that may be supplied by electrical power source 504 (see FIG. 1 ). Fig.18 ) to prevent the one or more gases generated by the one or more gases from escaping so as to prevent the one or more gases from creating an area of ​​increased pressure within the housing 502. In this regard, each housing of the aerosol delivery device of the present disclosure may include such an orifice. The orifice may preferably be located at the access door to hide the orifice and position the orifice at the electrical power source cavity, but in other embodiments, the orifice may be located at other locations.

[0143] in this regard, Fig.18 A partial exploded view of the control body 501 is illustrated. As illustrated, the electrical power source portion 502a of the housing 502 may include a first body portion 502a1 and a second body portion 502a2. The first body portion 502a1 and the second body portion 502a2 may be configured to engage with each other and define an electrical power source cavity 504. The electrical power source cavity 504 may be configured to accommodate an electrical power source 600 (e.g., a battery and / or a capacitor). The electrical power source cavity 504 may define a first longitudinal axis 504a.

[0144] Additionally, the coupler portion 502c of the housing 502 can be configured to engage the electrical power source portion 502a of the housing. The coupler 514 can engage the coupler portion 502c of the housing 502. For example, the coupler 514 can be at least partially positioned within the coupler portion 502c of the housing 502.

[0145] The coupler 514 can be configured to engage the cartridge 200 (see Fig.17 ), the cartridge 200" may include an aerosol precursor composition. Fig.17 As shown, when engaged with the coupler 514, the cartridge 200" can extend along the second longitudinal axis 200a". The first longitudinal axis 504a defined by the electrical power source cavity 504 and the second longitudinal axis 200a" defined by the cartridge 200" can be non-coaxial and oriented substantially parallel to each other. This configuration can provide the various benefits described above with respect to the embodiment of the control body in which the longitudinal axis of the electrical power source cavity and the longitudinal axis of the cartridge cavity are non-coaxial but substantially parallel.

[0146] In some embodiments, the cartridge 200" can be at least partially housed in a coupler cavity 506 defined by the coupler portion 502c of the housing 502. In this regard, as described above, the coupler 514 can be at least partially housed in the coupler cavity 506. Thus, the depth of the coupler cavity 506 and the position of the coupler 514 therein (see Fig.18) can determine whether the cartridge 200" is at least partially contained in the coupler cavity 506. Partially containing the cartridge 200" in the coupler cavity 506 can provide improved engagement of the cartridge with the control body 501 and / or reduce sensitivity to damage or contamination of the coupler 514. However, in other embodiments, the cartridge 200" may not extend into the coupler portion 502c of the housing 502. This configuration can facilitate engagement of the cartridge 200" with the coupler 514 and allow cartridges of a wider variety of shapes and sizes to be used with the control body 501.

[0147] The control body 501 may further include a controller 510 (see, for example, Fig. 20 ), which is not included in the Fig.18 As shown in the figure. In some embodiments, the controller 510 may include a control board. The controller 510 may be configured to control some or all of the functions of the control body 501, including directing current from the electrical power source 600 to the barrel 200. In this regard, the controller 510 may be electrically coupled to the electrical power source 600.

[0148] like Fig.18 As shown, the control body 501 may further include one or more button components. In particular, the control body 501 may include a first button component 542 and a second button component 544. Fig.19 As shown, the first button assembly 542 can be configured to actuate a first switch 546 on the controller 510. Similarly, the second button assembly 544 can be configured to actuate a second switch 548 on the controller 510. In this regard, the button assemblies 542, 544 can be configured to bend or otherwise move to actuate the switches 546, 548. For example, the first button assembly 542 and the second button assembly 544 can be hingedly coupled to the first body portion 502a1 and the second body portion 502a2 of the electrical power source portion 502a of the housing 502 (see, e.g., Fig.18 ) or both.

[0149] Thus, actuation of switches 546, 548 may control one or more functions of control body 501. For example, actuation of first switch 546 may direct current from electrical power source 600 to cartridge 200 (see Fig.17 ) so as to heat the aerosol precursor composition therein and generate an aerosol. In addition, the actuation of the second switch 548 can control other functions.

[0150] For example, the control body 501 may also include an illumination source 522, such as a light emitting diode (LED). The illumination source 522 may be configured to output illumination. In this regard, the control body 501 may include an illumination source cover 524 that may cover, protect, and / or hide the illumination source 522. The illumination source cover 524 may be translucent or transparent so that light emitted by the illumination source may pass therethrough. In some embodiments, the illumination source cover 524 may be colored or diffuse so that the presence of the illumination source 522 is hidden or concealed when not in use.

[0151] The illumination source 522 can be configured to illuminate the cartridge 200". In particular, Fig.17 As schematically illustrated in , the cartridge 200" may include an observation window 252" so that the level of aerosol precursor therein can be observed, as described above. Thus, a second button assembly 544 may be employed to turn on the illumination source 522 such that illumination is directed through the observation window 252" of the cartridge 200" so that a user may more easily observe the level of aerosol precursor composition therein, and / or the second switch may perform other functions. For example, in another embodiment, depression of the second button assembly 544 and the resulting actuation of the second switch 548 may cause the controller 510 to provide supplemental power to the cartridge from an electrical power source to increase the aerosol output of the aerosol delivery device, or to direct power to the cartridge regardless of whether a draw on the cartridge is detected. In this regard, in some embodiments, the aerosol delivery device may not include a flow sensor. In other embodiments, the second button assembly 544 may be used to actuate the second switch 548 to cycle through various adjustable controller power levels such that the device may have various aerosol mass output settings, or various other functions may be controlled. Thus, any one or more of the second button assembly 544 and / or other actuators discussed herein may be configured to control the level of power output directed from the electrical power source to the cartridge and / or otherwise control the amount (e.g., mass) of aerosol output.

[0152] In some embodiments, the second button assembly 544 can at least partially define a partition wall 550 that separates the cartridge 200" from the electrical power source chamber 504 (see Fig.18 ). In addition, as described below, the controller 510 can be housed in the power source cavity 504. Therefore, the second button assembly 544 can include an illumination source cover 524 at the partition wall 550 so that illumination can be directed therethrough to the cartridge 200".

[0153] The assembly of the control body 501 can be performed in various ways. In one embodiment, Fig. 20As shown, the controller 510 can at least partially encase the electrical power source 600. For example, the controller 510 can be bent or configured so that the electrical power source 600 is accommodated between the opposing substantially parallel walls of the controller. At this time, the controller 510 can also be electrically connected to the electrical power source 600. In this regard, for example, the electrical power source can include wires or other electrical leads that are welded or otherwise connected to the controller 510.

[0154] like Fig.21 As shown, the controller 510 and the electrical power source 600 can be inserted into the housing 502. More specifically, the controller 510 and the electrical power source can be housed in the electrical power source cavity 504. In some embodiments, the housing 500 can include features configured to engage the controller 510. For example, as shown, the controller 510 can be housed in a slot 552, which can be defined by an extension 554 formed by a first body portion 502a1 of the electrical power source portion 502a of the housing 502. Thus, the extension 554 can support the controller 510 so as to allow the switches 546, 548 to be actuated in the manner described above.

[0155] In one embodiment, the first button assembly 542 can be engaged with the first body portion 502a1 of the power source portion 502a of the housing 502 before the controller 510 and the power source 600 are inserted into the power source cavity 504. For example, a portion of the first button assembly 542 can be welded (e.g., ultrasonically welded), adhered, engaged via an interference fit, or mechanically coupled to the first body portion 502a1 of the power source portion 502a of the housing 502. Thus, the first button assembly 542 can be engaged with the first body portion 502a1, but still be able to move as described above to actuate the first switch 546. In addition, as Fig.21 As further illustrated in FIG. 5 , in some embodiments, the second button assembly 544 can be engaged with the first body portion 502a1 of the power source portion 502a of the housing 502 before the controller 510 and the power source 600 are inserted into the power source cavity 504. For example, a portion of the second button assembly 544 can be welded (e.g., ultrasonically welded), adhered, engaged via an interference fit, or mechanically coupled to the first body portion 502a1 of the power source portion 502a of the housing 502. Thus, the second button assembly 544 can be engaged with the first body portion 502a1, but still be able to move in order to actuate the second switch 546, as described above.

[0156] Back to Fig. 20, the controller 510 may include a connector 556. The connector 556 may include an electrical connector and / or a data connector. Thus, the connector 556 may be used to recharge the electrical power source 600 and / or to send data to or from the controller 510. Fig.21 As illustrated, the housing 502 can include a recess 558 configured to receive the connector 556. For example, the recess 558 can be defined by one or both of the first body portion 502a1 and the second body portion 502a2 of the electrical power source portion 502a of the housing 502.

[0157] like Fig. 22 As shown, after the controller 510 and the electric power source 600 are inserted into the electric power source cavity 504, the second body portion 502a2 of the electric power source portion 502a of the housing 502 can be engaged with the first body portion 502a1. For example, the second body portion 502a2 can be welded (e.g., ultrasonic welding), adhered, engaged via interference fit, or mechanically coupled to the first body portion 502a1 of the electric power source portion 502a of the housing 502. In addition, the coupler portion 502c of the housing 502 can be engaged with the electric power source portion 502a of the housing 502. For example, the coupler portion 502c can be welded (e.g., ultrasonic welding), adhered, engaged via interference fit, or mechanically coupled to the electric power source portion 502a of the housing 502.

[0158] Fig. 22 Further illustrated is a coupler 514 engaged with the housing 502. In particular, the coupler 514 can be received in the coupler cavity 506. Fig.23 As shown, additional components can be inserted into the coupler cavity 506. In particular, a seal 560 can be inserted through the coupler 514. In addition, an electrical contact 562 can extend through the seal 560. The seal 560 can be configured to electrically insulate the coupler 514 from the electrical contact 562. In this regard, the electrical contact 562 can include a conductive material such as brass, and the seal 560 can include an electrically insulating material such as silicone. The electrical contact 562 can be connected to a first terminal 564 of the controller 510 (see, e.g., Fig. 22 For example, after the first terminal is bent into contact with the electrical contact 562, the electrical contact 562 may be welded to the first terminal 564.

[0159] In addition, the tab 566 can be engaged with the coupler 514 and received in the coupler cavity 506 defined by the coupler portion 502c of the housing 502. A fastener 568 (e.g., a nut) can be secured to the coupler 514 to retain the tab 566 engaged therewith. The tab 566 can be coupled to a second terminal 570 of the controller 510 (see, e.g., Fig. 22). For example, after the second terminal is bent to engage with the tab 566, the second terminal 570 can be welded to the tab 566. Thus, the coupler 514 can be electrically coupled to the controller 510. In another embodiment, the second terminal 570 can directly engage the coupler 514. In any case, when the cartridge is engaged with the coupler 514 (via the electrical contact 562) and the control body 501, it can be connected to the cartridge 200 (see, for example Fig.17 ) establishes positive and negative connections. Thus, when the user presses the first button assembly 542 (see, e.g. Fig.18 ), an electric current may be directed to the cartridge 200″ so as to be instructed by the controller 510 to vaporize the aerosol precursor composition therein.

[0160] After the various components are inserted into the coupler cavity 506, the access door 502b (see Fig.18 ) can be engaged with the power source portion 502a and the coupler portion 502c of the housing 502. Therefore, the control body 501 can define Fig.17 The completed configuration is shown in .

[0161] Note that although the control body of the present disclosure is described herein as being usable with a cartridge, it should be understood that the term "cartridge" is intended to include embodiments referred to as "boxes" or "box-type cartridges." Boxes differ from other embodiments of cartridges of aerosol delivery devices in that they may not include a reservoir substrate, at least a portion of which may be transparent or translucent so that the level of aerosol precursor composition can be observed, and the amount of aerosol precursor composition that can be contained therein may be relatively large. Embodiments of box-type cartridges are described in U.S. Patent Application Serial No. 14 / 802,667, filed by O'Brien on July 17, 2015, which is incorporated herein by reference in its entirety.

[0162] In additional embodiments, methods for assembling an aerosol delivery device are provided. Fig.24 As shown, the method may include providing a housing defining an electrical power source cavity at operation 702, the electrical power source cavity being configured to accommodate an electrical power source, the electrical power source cavity defining a first longitudinal axis. In addition, the method may include engaging a coupler at operation 704, the coupler being configured to engage a cartridge comprising an aerosol precursor composition with the housing so that the cartridge extends along a second longitudinal axis, the first longitudinal axis and the second longitudinal axis being non-coaxial and oriented substantially parallel to each other. In addition, the method may include positioning a controller in the housing at operation 706, the controller being configured to engage the electrical power source.

[0163] In some embodiments, the method may further include engaging the electric power source with the controller. In addition, the method may include inserting the electric power source into the electric power source cavity at operation 706, while positioning the controller in the housing. In addition, the method may include engaging the cartridge with the coupler. The cartridge may include an observation window. The method may additionally include positioning an illumination source in the housing, the illumination source being configured to direct illumination through the observation window.

[0164] In some embodiments, providing the housing at operation 702 may include engaging the first body portion with the second body portion. Providing the housing at operation 702 may also include engaging an access door with at least one of the first body portion and the second body portion, the access door being configured to block access to the electrical power source cavity. Providing the housing at operation 702 may also include engaging a button assembly with at least one of the first body portion and the second body portion. In addition, the method may include positioning an illumination source in the housing and engaging an illumination source cover with the button assembly, the illumination source cover being configured to direct illumination generated by the illumination source therethrough.

[0165] Many modifications and other embodiments of the present disclosure will occur to those skilled in the art to which the present disclosure belongs, having the benefit of the teachings presented in the preceding description and the associated drawings. It is therefore understood that the present invention is not limited to the specific embodiments disclosed herein, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, the terms are used only in a generic and descriptive sense and not for purposes of limitation.

Claims

1. An aerosol delivery device comprising: Nebulizer; an electrical power source cavity configured to receive an electrical power source, the electrical power source cavity extending along a first longitudinal axis; a coupler for coupling a reservoir with the aerosol delivery device, the reservoir being retained in an outer body of a cartridge including the reservoir such that the outer body extends along a second longitudinal axis, the reservoir including an aerosol precursor composition, wherein the coupler is configured to deliver power for generating heat to the cartridge; as well as a liquid transport element configured to transport liquid from the reservoir to the atomizer; The first longitudinal axis and the second longitudinal axis are non-coaxial and oriented parallel to each other, and The electrical power source is disposed within the electrical power source cavity and is configured to deliver power for generating heat to the reservoir.

2. An aerosol delivery device as described in claim 1, further comprising the reservoir.

3. An aerosol delivery device as described in claim 1, wherein the reservoir comprises a fibrous substrate configured to hold the aerosol precursor composition.

4. An aerosol delivery device as described in claim 1, wherein the reservoir is substantially formed into a tube.

5. An aerosol delivery device as described in claim 1, wherein the aerosol delivery device further includes a coupler portion, the coupler portion includes a coupler cavity, and the coupler cavity is configured to at least partially accommodate the reservoir when engaged with the coupler.

6. An aerosol delivery device as described in claim 5, further comprising a housing in which the electronic circuit is housed, wherein the housing includes walls that help retain the reservoir in the coupler cavity.

7. The aerosol delivery device of claim 1, further comprising a button assembly, wherein the button assembly is configured to control a power output level from the electrical power source for heating the aerosol precursor composition.

8. An aerosol delivery device as described in claim 1, wherein the coupler is electrically coupled to a controller, and the controller is configured to adjust the amount of power from the electrical power source so that the aerosol delivery device has various aerosol output settings.

9. The aerosol delivery device of claim 1, further comprising an illumination source and a button assembly, wherein the button assembly comprises an illumination source cover configured to direct illumination generated by the illumination source through the illumination source cover.

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