Aerosol delivery devices with liquid delivery units including porous monolith and related methods

Abstract

The present disclosure relates to aerosol delivery devices, methods of making such devices, and elements of such devices. In one embodiment, the disclosure provides an aerosol delivery device (204) comprising an outer body (216), a heating element (254) received in the outer body, a reservoir received in the outer body, and a liquid delivery element (254) received at least partially within the reservoir and in engagement with the heating element, the liquid delivery element includes a porous monolith.

Description

[0001] This invention patent application is a divisional application of the invention patent application with international application number PCT / IB2017 / 054380, international application date July 19, 2017, application number 201780058347.3 entering the Chinese national phase, and name “Aerosol delivery device having a liquid delivery unit including a porous integral part and related methods”. Technical Field

[0002] The present disclosure relates to aerosol delivery devices, and more particularly to aerosol delivery devices (e.g., smoking articles commonly referred to as electronic cigarettes) that can utilize electrically generated heat to generate an aerosol. The aerosol delivery device can be configured to heat an aerosol precursor, which can include a material that can be made or derived from tobacco or can otherwise include tobacco, which precursor can form an inhalable substance for human ingestion. Background Art

[0003] In recent years, many devices have been proposed as improvements or substitutes for smoking products that need to burn tobacco to use. It is said that many of the above-mentioned devices have been designed to provide the sensation associated with smoking cigarettes, cigars or pipes without delivering a large amount of incomplete combustion products and pyrolysis products produced due to the burning of tobacco. For this reason, it has been proposed to adopt electric energy vaporization or heating volatile materials or attempt to provide the sensation of smoking cigarettes, cigars or pipes without burning tobacco to a significant degree of many products, flavor generators and medicated inhalers. For example, referring to the various alternative articles, aerosol delivery devices and heating sources described in the background technology described in the U.S. Patent No. 7,726,320 of Robinson et al., the U.S. Patent No. 2013 / 0255702 of Griffith Jr. et al. and the U.S. Patent No. 2014 / 0096781 of Sears et al., the above-mentioned document is incorporated herein by reference. For example, see also U.S. Patent Publication No. 2015 / 0216236 to Bless et al., which references trade names and commercial sources for various types of articles, aerosol delivery devices, and electrically powered heat sources, the contents of which are incorporated herein by reference.

[0004] It may be desirable to provide a reservoir and a liquid delivery element for an aerosol precursor composition used in an aerosol delivery device, the reservoir and the liquid delivery element being provided to improve the formation of the aerosol delivery device. It may also be desirable to provide an aerosol delivery device that is prepared to utilize such a reservoir and a liquid delivery element. Summary of the invention

[0005] The present disclosure relates to an aerosol delivery device that is configured to generate an aerosol, and in some embodiments, the aerosol delivery device may be referred to as an electronic cigarette. In one aspect, an aerosol delivery device is provided. The aerosol delivery device may include an outer body. A heating element and a reservoir may be received in the outer body. A liquid delivery element may be at least partially received in the reservoir and may be engaged with the heating element. The liquid delivery element may include a porous monolith.

[0006] In some embodiments, the longitudinal axis of the heating element may be substantially parallel to the longitudinal axis of the outer body. The porous monolith may include at least one of a porous ceramic and a porous glass. The aerosol delivery device may also include a first heating terminal and a second heating terminal coupled to the heating element. The first heating terminal and the second heating terminal may be positioned between the liquid delivery element and the reservoir.

[0007] In some embodiments, the liquid delivery element may be defined with one or more channels that extend at least partially through the liquid delivery element. The heating element may be at least partially received in the one or more channels. The aerosol delivery device may also include a first heating terminal and a second heating terminal, which are connected to the heating element and are at least partially received in the one or more channels. In addition, the aerosol delivery device may include an electronic component that is at least partially received in the one or more channels. The electronic component may be positioned between the first heating terminal and the second heating terminal. The longitudinal axis of the electronic component may extend substantially parallel to the longitudinal axis of the outer body.

[0008] In some embodiments, the liquid transport element may extend at least partially around the liquid transport element.The aerosol delivery device may further comprise a flow director.The flow director may define a longitudinal axis extending substantially parallel to the longitudinal axis of the liquid transport element.

[0009] In some embodiments, the aerosol delivery device may further include a base engaged with the outer body, and an electronic component positioned between the base and the reservoir. The longitudinal axis of the electronic component may extend substantially perpendicular to the longitudinal axis of the outer body. In addition, the aerosol delivery device may include a first heating terminal and a second heating terminal coupled to the heating element. The first heating terminal and the second heating terminal may extend substantially perpendicular to the longitudinal axis of the electronic component.

[0010] In an additional aspect, a method for manufacturing an aerosol delivery device is provided. The method may include positioning a heating element, a reservoir, and a liquid delivery element in an outer body so that the liquid delivery element contacts the reservoir and the heating element. Positioning the heating element, the reservoir, and the liquid delivery element in the outer body may include aligning the respective longitudinal axes of the heating element, the reservoir, and the liquid delivery element.

[0011] In some embodiments, the method may further include positioning the liquid delivery element at least partially within the reservoir. Positioning the liquid delivery element at least partially within the reservoir may include wrapping the liquid delivery element with the reservoir. In addition, the method may include inserting a heating element into a channel extending at least partially through the liquid delivery element. The method may further include coupling the heating element to an outer surface of the liquid delivery element.

[0012] Therefore, the present disclosure includes but is not limited to the following embodiments:

[0013] Embodiment 1: An aerosol delivery device comprises: an outer body; a heating element received in the outer body; a reservoir received in the outer body; and a liquid delivery element, which is at least partially received in the reservoir and engaged with the heating element, and the liquid delivery element comprises a porous integral piece.

[0014] Embodiment 2: The device according to any preceding or following embodiment or a combination thereof, wherein the longitudinal axis of the heating element is substantially parallel to the longitudinal axis of the outer body.

[0015] Embodiment 3: The device according to any preceding or following embodiment or a combination thereof, wherein the porous monolith comprises at least one of porous ceramic and porous glass.

[0016] Embodiment 4: The device according to any preceding or following embodiment or a combination thereof, further comprising a first heating terminal and a second heating terminal coupled to the heating element, wherein the first heating terminal and the second heating terminal are located between the liquid delivery element and the reservoir.

[0017] Embodiment 5: The device according to any preceding or following embodiment or a combination thereof, wherein the liquid delivery element defines one or more channels extending at least partially therethrough.

[0018] Embodiment 6: The device according to any preceding or following embodiment or a combination thereof, wherein the heating element is at least partially received in one or more channels.

[0019] Embodiment 7: The device according to any preceding or following embodiment or a combination thereof, further comprising a first heating terminal and a second heating terminal coupled to the heating element, wherein the first heating terminal and the second heating terminal are coupled to the heating element and at least partially received in one or more channels.

[0020] Embodiment 8: The device according to any preceding or following embodiment or a combination thereof, further comprising an electronic component at least partially received in the one or more channels.

[0021] Embodiment 9: The device according to any preceding or following embodiment or a combination thereof, wherein the electronic component is positioned between the first heating terminal and the second heating terminal.

[0022] Embodiment 10: The device according to any preceding or following embodiment or a combination thereof, wherein a longitudinal axis of the electronic component extends substantially parallel to a longitudinal axis of the outer body.

[0023] Embodiment 11: The device according to any preceding or following embodiment or a combination thereof, wherein the liquid delivery element extends at least partially around the liquid delivery element.

[0024] Embodiment 12: The device according to any preceding or following embodiment or a combination thereof, further comprising a flow director defining a longitudinal axis extending substantially parallel to the longitudinal axis of the liquid transport element.

[0025] Embodiment 13: The device according to any preceding or following embodiment or a combination thereof, further comprising a base engaged with the outer body, and an electronic component positioned between the reservoir and the base.

[0026] Embodiment 14: The device according to any preceding or following embodiment or a combination thereof, wherein a longitudinal axis of the electronic component extends substantially perpendicular to a longitudinal axis of the outer body.

[0027] Embodiment 15: The device according to any preceding or following embodiment or a combination thereof, further comprising a first heating terminal and a second heating terminal coupled to the heating element, wherein the first heating terminal and the second heating terminal extend substantially perpendicular to a longitudinal axis of the electronic component.

[0028] Example 16: A method for manufacturing an aerosol delivery device, the method comprising: positioning a heating element, a reservoir, and a liquid delivery element in an outer body so that the liquid delivery element is in contact with the reservoir and the heating element, wherein positioning the heating element, the reservoir, and the liquid delivery element in the outer body comprises aligning respective longitudinal axes of the heating element, the reservoir, and the liquid delivery element.

[0029] Embodiment 17: The method according to any preceding or following embodiment or a combination thereof, further comprising positioning a fluid delivery element at least partially within the reservoir.

[0030] Embodiment 18: The method according to any preceding or following embodiment or combination thereof, wherein positioning the liquid delivery element at least partially within the reservoir comprises wrapping the liquid delivery element with the reservoir.

[0031] Embodiment 19: The method according to any preceding or following embodiment or combination thereof, further comprising inserting a heating element into a channel extending at least partially through the liquid transport element.

[0032] Embodiment 20: The method according to any preceding or following embodiment or a combination thereof, further comprising coupling a heating element to an outer surface of the liquid transport element.

[0033] These and other features, aspects and advantages of the present disclosure will be clear from reading the following detailed description and the accompanying drawings briefly described below. The present disclosure includes any combination of two, three, four or more features or elements set forth in the disclosure or recorded in any one or more claims, whether or not such features or elements are clearly combined or otherwise described in the specific embodiments described herein or recorded in the claims. Unless otherwise expressly provided in the context of the present disclosure, the present disclosure is intended to be read as a whole, so that any separable features or elements of the present disclosure in any of its aspects and embodiments should be considered to be intended to be combined. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Having generally described the present disclosure in the foregoing, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0035] Figure 1 shows a longitudinal cross-sectional view of an aerosol delivery device including a control body and a cartridge including a reservoir and a liquid transport element according to an exemplary embodiment of the present disclosure;

[0036] Figure 2 A longitudinal cross-sectional view showing a perspective view of a cartridge for an aerosol delivery device including an integral reservoir and liquid transport element surrounding a heating element according to an exemplary embodiment of the present disclosure;

[0037] Figure 3 According to the exemplary embodiment of the present disclosure Figure 2 A perspective view of an integrated reservoir and liquid delivery element is shown in side section;

[0038] Figure 4 shows a modified perspective view of a cartridge for an aerosol delivery device including an integral reservoir and liquid delivery element including a protrusion proximate to a mouthpiece and around which a heating element extends, according to an exemplary embodiment of the present disclosure;

[0039] Figure 5 The exemplary embodiment according to the present disclosure is shown Figure 4 A perspective view of an integrated reservoir and liquid delivery element;

[0040] Figure 6shows a modified perspective view of a cartridge for an aerosol delivery device including an integral reservoir and liquid delivery element including a protrusion proximate a base and around which a heating element extends, according to an exemplary embodiment of the present disclosure;

[0041] Figure 7 According to the exemplary embodiment of the present disclosure Figure 6 A perspective view of the barrel showing a modified side section;

[0042] Figure 8 The exemplary embodiment according to the present disclosure is shown Figure 6 a partial end view of an integrated reservoir and liquid delivery element;

[0043] Fig. 9 It is an exemplary embodiment according to the present disclosure. Figure 6 A perspective view of the terminals, electronic components and base of the cartridge;

[0044] Fig.10 shows a modified perspective view of a cartridge for an aerosol delivery device including an integral reservoir and liquid delivery element and laterally extending electronic components according to an exemplary embodiment of the present disclosure;

[0045] Fig.11 The exemplary embodiment according to the present disclosure is shown Fig.10 A perspective view of the integral reservoir and liquid delivery element of the cartridge;

[0046] Fig.12 It is an exemplary embodiment according to the present disclosure. Fig.10 A perspective view of the terminals, electronic components and the base of the cartridge;

[0047] Fig.13 Schematically illustrates a method for generating steam according to an exemplary embodiment of the present disclosure;

[0048] Fig.14 A longitudinal cross-sectional view showing a perspective view of a cartridge for an aerosol delivery device according to an exemplary embodiment of the present disclosure, the cartridge including a heating element and electronic components received in a liquid delivery element received in a reservoir;

[0049] Fig.15 Shows Fig.14 A perspective view of a liquid delivery element;

[0050] Fig.16shows a modified perspective view of a cartridge for an aerosol delivery device according to an exemplary embodiment of the present disclosure, the cartridge including a liquid delivery element defining a protrusion at which a heating element is positioned, the liquid delivery element being received in a reservoir;

[0051] Fig.17 Shows Fig.16 A side cross-sectional view of a perspective view of a barrel;

[0052] Fig.18 The exemplary embodiment according to the present disclosure is shown Fig.16 A perspective view of the liquid delivery element and electronic components of the cartridge;

[0053] Fig.19 a modified longitudinal cross-sectional view of a perspective view of a cartridge for an aerosol delivery device according to an exemplary embodiment of the present disclosure, the cartridge including a liquid delivery element defining a protrusion at which a heating element is positioned and laterally extending electronic components, the liquid delivery element being received in a reservoir;

[0054] Fig. 20 Shows Fig.19 A side cross-sectional view of a perspective view of a barrel;

[0055] Fig.21 shows a modified perspective view of a cartridge for an aerosol delivery device according to an exemplary embodiment of the present disclosure, the cartridge including a liquid delivery element defining a protrusion at which a heating element is positioned and laterally extending electronic components, the liquid delivery element and flow director being received in a reservoir;

[0056] Fig. 22 pass Fig.21 A perspective view of the barrel of FIG. 1 is shown in side cross-section; and

[0057] Fig.23 A method for manufacturing an aerosol delivery device according to an exemplary embodiment of the present disclosure is schematically illustrated. DETAILED DESCRIPTION

[0058] The present disclosure will now be more fully described below with reference to exemplary embodiments. These embodiments are described so that the present disclosure will be exhaustive and complete, and will fully convey the scope of the present disclosure to those skilled in the art. Indeed, the present disclosure may be implemented in many forms and should not be construed as being limited to the embodiments set forth herein; on the contrary, these embodiments are presented so that the disclosure will satisfy applicable legal requirements. Unless otherwise clearly stated herein, the singular forms "a", "an", and "the" used in this specification and the appended claims include plural variations.

[0059] As described below, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat materials (preferably, without burning the materials to any significant extent and / or without significant chemical changes in the materials) to form inhalable substances; and components of such systems are in the form of articles, most preferably articles that are compact enough to be considered as handheld devices. That is, the use of the components of the preferred aerosol delivery system does not result in the generation of smoke, i.e., the generation of smoke from byproducts of the combustion or pyrolysis of tobacco, while the use of those preferred systems results in the generation of vapor / aerosols, which are caused by the volatilization or evaporation of certain components therein. In preferred embodiments, the components of the aerosol delivery system can be characterized as electronic cigarettes, and those electronic cigarettes most preferably contain tobacco and / or components derived from tobacco, and thus deliver tobacco-derived components in the form of aerosols.

[0060] The aerosol generating member of certain preferred aerosol delivery systems can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the habit of inhaling and exhaling, the type of taste or aroma, the sensory effects, the physical sensation, the habit of use, the visual cue provided by the visible aerosol, etc.) without burning any of the components therein to a significant degree. These cigarettes, cigars, or pipes are used by lighting and burning tobacco (and thus inhaling tobacco smoke). For example, a user of the aerosol generating member of the present disclosure can hold and use the article as a smoker would use a conventional type of smoking article, inhale on one end of the article to inhale the aerosol generated by the article, and take puffs or inhales at selected time intervals, etc. However, the devices described herein are not limited to devices that are substantially designed in shape and size as conventional cigarettes. Rather, the present device can take any shape and can be substantially larger than a conventional cigarette.

[0061] Aerosol delivery device of the present disclosure can also be characterized as the article or medicament delivery article that produces steam.Therefore, this article or device can be adapted, thereby one or more materials (for example, fragrance and / or pharmaceutically active ingredients) are provided in a form or state that can be inhaled.For example, inhalable material can be the form of steam (that is, the material in gas phase at a temperature lower than the critical point) basically.As an alternative, inhalable material can be the form of aerosol (that is, the suspension of fine solid particles or droplets in the gas).For the purpose of simplification, the term "aerosol" used herein is intended to include steam, gas or aerosol of a form or type that is suitable for human body inhalation, whether visible or not, whether or not it can be considered as a smoke-like form.

[0062] The aerosol delivery device of the present disclosure generally includes a plurality of components disposed within an outer body or shell, which may be referred to as a shell. The overall design of the outer body or shell can vary, and the form or construction of the outer body, which can define the overall size and shape of the aerosol delivery device, can vary. In an exemplary embodiment, an elongated body resembling a cigarette or cigar shape can be formed by a single integral shell, or the elongated shell can be formed by two or more separable bodies. For example, the aerosol delivery device can include an elongated shell or body, which can be generally tubular in shape and thereby resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are contained within a shell. Alternatively, the aerosol delivery device may include two or more shells that are connected and separable. For example, an aerosol delivery device may have a control body at one end, which includes a housing that houses one or more components (e.g., batteries and / or capacitors and various electronic components for controlling the operation of the item), and an outer body or shell at the other end of the aerosol delivery device, which is removably attached to the other end and contains aerosol-forming components (e.g., one or more aerosol precursor components such as flavorants and aerosol formers, one or more heating elements, and / or one or more wicks).

[0063] The aerosol delivery device of the present disclosure may include an outer shell or housing that is not substantially tubular in shape, but may be formed to be substantially larger in size—that is, substantially "palm-sized" so as to be held in the palm of a user. The shell or housing may be configured to include a mouthpiece and / or may be configured to receive a separate housing (e.g., a cartridge / cartridge) that may include consumable elements such as an aerosol precursor composition, and may include a vaporizer or atomizer.

[0064] Most preferably, the aerosol delivery device of the present disclosure includes some combination of the following components: a power source (i.e., a power supply); at least one control component (e.g., a device for actuating, controlling, regulating, and stopping the power for generating heat, such as by controlling the current flowing from the power source to other components of the article - i.e., a microcontroller or microprocessor); a heating element or heating component (e.g., a resistive heating element or other component, which element or component, alone or in combination with one or more additional components, may generally be referred to as an "atomizer"); an aerosol precursor composition (e.g., a liquid such as ingredients commonly referred to as "smoke juice", "e-liquid" and "e-juice" that are generally capable of generating an aerosol when sufficient heat is applied); and a mouthpiece or mouth end area that allows inhalation on the aerosol delivery device to inhale the aerosol (e.g., a defined airflow path through the article so that the generated aerosol can be drawn out of the airflow path during inhalation).

[0065] The more specific forms, configurations and arrangements of the components within the aerosol delivery system of the present disclosure will be apparent from the further disclosure provided below. In addition, the selection and arrangement of various aerosol delivery device components can be understood in view of commercially available electronic aerosol delivery devices, such as those representative products cited in the background section of the present disclosure.

[0066] Figure 1 An exemplary embodiment of an aerosol delivery device 100 according to the present disclosure is provided in the accompanying drawings, which illustrate components that may be used in the aerosol delivery device. As seen in the cross-sectional view shown therein, the aerosol delivery device 100 may include a control body 102 and a cartridge 104 that may be permanently or removably aligned in a functional relationship. The control body 102 and the cartridge 104 may be engaged via a press fit (as shown), a threaded engagement, an interference fit, magnetic attraction, or the like. Specifically, connecting components such as those further described herein may be used. For example, the control body may include a coupling adapted to engage a connector on the cartridge.

[0067] In a specific embodiment, one or both of the control body 102 and the cartridge 104 may be referred to as disposable or reusable. For example, the control body may have a replaceable battery or a rechargeable battery and can therefore be integrated with any type of charging technology, including connection to a typical electrical outlet, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer such as via a universal serial bus (USB) cable. For example, an adapter is disclosed in U.S. Patent Publication No. 2014 / 0261495 to Novak et al., which includes a USB connector at one end and a control body connector at the opposite end, and the entire contents of the document are incorporated herein by reference. Further, in some embodiments, the cartridge may include a disposable cartridge, such as the cartridge disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0068] like Figure 1As shown, the control body 102 may include an outer body 106. A control component 108 (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller, etc.), a flow sensor 110 (e.g., a pressure sensor), a battery 112, and a light emitting diode (LED) 114 may be positioned within the outer body 106 in any of a variety of alignments. Other indicators (e.g., a tactile feedback component, an audio feedback component, etc.) may be included in addition to or in lieu of the LED 114. Additional representative types of components or indicators that produce visual cues, such as light emitting diode (LED) components, and their construction and use are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al., 8,499,766 to Newton, and 8,539,959 to Scatterday, and U.S. Patent Application Publication No. 2015 / 0216233 to Sears et al.; the foregoing references are incorporated herein by reference.

[0069] The cartridge 104 may include an outer body 116. The outer body 116 may enclose a reservoir 118, which may be in fluid communication with a liquid delivery element 120, which is suitable for wicking or otherwise delivering an aerosol precursor composition stored in the reservoir housing to a heating element 122. Various embodiments of materials configured to generate heat when an electric current is applied therethrough may be used to form the resistive heating element 122. Exemplary materials from which the coil may be formed include Kanthal (FeCrAl), nickel-chromium alloys, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)2), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), and ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics). As further described herein, the heating element may include various materials configured to provide electromagnetic radiation, including laser diodes.

[0070] A mouthpiece opening 124 may be present in the outer body 116 (eg, at the mouthpiece end) to allow a formed aerosol to be vented from the cartridge 104. These components are representative of components that may be present in a cartridge and are not intended to limit the scope of cartridge components encompassed by this disclosure.

[0071] The cartridge 104 may also include an electronic component 126, which may include an integrated circuit, a memory component, a sensor, etc. The electronic component 126 of the cartridge 104 may be adapted to communicate with the control component 108 of the control body 102 and / or with an external device by wired or wireless means. The electronic component 126 may be positioned anywhere within the cartridge 104.

[0072] Although the control component 108 and the flow sensor 110 are shown separately, it should be understood that the control component and the flow sensor can be integrated into an electronic circuit board, wherein the air flow sensor is directly attached to the electronic circuit board. Figure 1 The illustration is horizontally positioned because the electronic circuit board can be parallel to the central axis of the control body in the length direction. In some embodiments, the air flow sensor may include its own circuit board or other base element to which the sensor can be attached. In some embodiments, a flexible circuit board can be used. The flexible circuit board can be configured in a variety of shapes, including a substantially tubular shape.

[0073] The control body 102 and the cartridge 104 may include components adapted to facilitate fluid engagement therebetween. Figure 1 As shown, the control body 102 may include a coupling 128 having a cavity 130 defined therein. The cartridge 104 may include a base 132 adapted to engage the coupling 128, and may include a protrusion 134 adapted to fit within the cavity 130 defined by the coupling 128. This engagement may facilitate a stable connection between the control body 102 and the cartridge 104, and establish electrical connections between the battery 112 and the control component 108 in the control body, and between the heating element 122 and the electronic component 126 in the cartridge. Further, the outer body 106 may include an air inlet 136, which may be a recess in the housing, where it is connected to the coupling 128, which allows ambient air around the coupling to pass through and enter the housing, and then the air passes through the cavity 130 of the coupling and enters the cartridge 104 through the protrusion 134.

[0074] Useful couplings and bases according to the present disclosure are described in U.S. Patent Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. Figure 1The coupling 128 shown may define an outer periphery 138, which is configured to cooperate with the inner periphery 140 of the base 132. In one embodiment, the inner periphery of the base may define a radius, which is substantially equal to or slightly greater than the radius of the outer periphery of the coupling. Further, the coupling 128 may be defined at the outer periphery 138 with one or more protrusions 142, which are configured to engage one or more recesses 144 defined at the inner periphery of the base. However, various other structures, shapes and embodiments of components may be used to couple the base to the coupling. In some examples, the connection between the base 132 of the cartridge 104 and the coupling 128 of the control body 102 may be substantially permanent, while in other embodiments, the connection between them may be releasable, so that, for example, the control body may be reused with one or more additional cartridges, which may be disposable and / or refillable.

[0075] In some embodiments, the aerosol delivery device 100 can be substantially rod-shaped or substantially tubular or substantially cylindrical. In other embodiments, other shapes and sizes are contemplated—eg, rectangular or triangular cross-sections, multi-faceted shapes, keychain shapes, etc.

[0076] Figure 1 The reservoir 118 shown in the figure can be of any design configured to hold liquid, such as a container or block configured to absorb and / or absorb liquid - for example, fiber reservoirs are commonly used in existing embodiments of reservoirs. Alternatively, as described below, the reservoir 118 can include a porous monolith. Figure 1 As shown, the reservoir 118 may include one or more layers of nonwoven fibers formed substantially in the shape of a tube surrounding the interior of the outer body 116. An aerosol precursor composition may be retained in the reservoir 118.

[0077] The reservoir 118 can be in fluid communication with a liquid delivery element 120. The liquid delivery element 120 can deliver the aerosol precursor composition stored in the reservoir 118 to a heating element 122 in the form of a metal coil in this embodiment via capillary action. In this way, the heating element 122 and the liquid delivery element 120 are in a heating configuration. In some embodiments of existing aerosol delivery devices, the liquid delivery element includes glass fiber or other fiber materials. However, as described below, in other embodiments, the liquid delivery element may include a porous monolith.

[0078] In use, when a user inhales on the article 100, the sensor 110 detects the airflow, the heating element 122 is activated, and the components for the aerosol precursor composition are vaporized by the heating element 122. Inhaling on the mouth end of the article 100 causes ambient air to enter the air inlet 136 and pass through the cavity 130 in the coupling 128 and the central opening in the protrusion 134 of the base 132 of the cartridge 104. In the cartridge 104, the inhaled air combines with the formed vapor to form an aerosol. The aerosol is stirred, inhaled or otherwise drawn away from the heating element 122 and drawn out of the mouthpiece opening 124 in the mouth end of the article 100.

[0079] The aerosol delivery device may include an input device (e.g., a user interface). An input portion may be included to allow a user to control the functions of the device and / or output information to the user. Any component or combination of components may be used as an input portion for controlling the functions of the device. For example, one or more buttons may be used as described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touch screen may be used as described in U.S. Patent Application Serial No. 14 / 643,626 filed on March 10, 2015 by Sears et al., which is incorporated herein by reference. As a further example, a component suitable for gesture recognition based on a specified movement of the aerosol delivery device may be used as an input. See, for example, U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference.

[0080] In some embodiments, the input portion may include a computer or computing device such as a smart phone or tablet computer. Specifically, the aerosol delivery device may be connected to a computer or other device, such as via the use of a USB connector or similar protocol. The aerosol delivery device may also communicate with a computer or other device used as an input via wireless communication. For example, see the system and method for controlling a device via a read request described in U.S. Patent Application Publication No. 2016 / 0007651 to Ampolini et al., the disclosure of which is incorporated herein by reference. In such an embodiment, an application or other computer program can be used in conjunction with a computer or other computing device to input control instructions to the aerosol delivery device, such control instructions including, for example, the ability to form an aerosol of a specific composition by selecting a nicotine content and / or the content of additionally included flavorings.

[0081] The various components of the aerosol delivery device according to the present disclosure can be selected from the components described in the prior art and the components available on the market. Representative commercial products include AVIGO, VUSE, VUSECONNECT, VUSE FOB and VUSE HYBRID of RJReynolds Vapor. Examples of batteries that can be used according to the present disclosure are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the entire disclosure of which is incorporated herein by reference.

[0082] As described above, the aerosol delivery device may include a sensor or detector (e.g., flow sensor 110) for controlling the supply of power to the heating element 122 when aerosol generation is desired (e.g., during inhalation during use). Thus, for example, a manner or method is provided for turning off power to the heating element when inhalation is not being performed on the aerosol delivery device during use, and for turning on power during inhalation to actuate or trigger heat generated by the heating element. Additional representative types of sensing or detecting mechanisms, their structure and construction, their components, and general descriptions of their methods of operation 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.

[0083] The aerosol delivery device most preferably comprises a control mechanism for controlling the amount of electrical power to the heating element during inhalation. Representative electronic components, their structures and constructions, their features, and general descriptions of their methods of operation 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. and U.S. Pat. No. 8,205,622 to Pan; U.S. Patent Publication No. 2009 / 0230117 to Fernando et al.; U.S. Patent Publication No. 2014 / 0060554 to Collett et al. and U.S. Patent Publication No. 2014 / 0270727 to Ampolini et al.; and U.S. Patent Publication No. 2015 / 0257445 to Henry et al.; the foregoing documents are incorporated herein by reference.

[0084] Representative types of substrates, reservoirs, or other components for supporting aerosol precursors are described in U.S. Pat. No. 8,528,569 to Newton, U.S. Pat. No. 2014 / 0261487 to Chapman et al., U.S. Pat. No. 2014 / 00597800 to Davis et al., and U.S. Pat. No. 2015 / 0216232 to Bless et al.; the foregoing documents are incorporated herein by reference. In addition, various wicking materials, as well as the construction and operation of those wicking materials within a particular type of electronic cigarette, are described in U.S. Pat. No. 8,910,640 to Sears et al.; the document is incorporated herein by reference.

[0085] Aerosol precursor compositions, also referred to as vapor precursor compositions, may include a variety of components, including, for example, polyols (e.g., glycerol, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorings. Most preferably, the aerosol precursor composition includes a combination or mixture of various ingredients or components. The selection of specific aerosol precursor components and the relative amounts of the components used may be varied in order to control the overall chemical composition of the mainstream aerosol produced by the aerosol generation configuration. Of particular interest are aerosol precursor compositions characterized by being generally liquid. For example, representative aerosol precursor compositions that are generally liquid may be in the form of a liquid solution, a viscous gel, a mixture of miscible components, or a liquid containing suspended or dispersed components. Typical aerosol precursor compositions are capable of evaporating when exposed to high temperatures under those conditions experienced during the use of the aerosol generation configuration characterized by the present disclosure; thus, vapors and aerosols that can be inhaled can be produced.

[0086] For the aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition is most preferably combined with tobacco or a component derived from tobacco. On the one hand, tobacco can be provided as several parts or pieces of tobacco, such as finely ground, ground or powdered tobacco flakes. On the other hand, tobacco can be provided in the form of an extract (e.g., an extract from nicotine), such as a spray-dried extract, which is combined with many water-soluble components of tobacco. Alternatively, the tobacco extract can have the form of an extract with a relatively high nicotine content, which is also combined with a small amount of components from other extracts of tobacco. On the other hand, components derived from tobacco can be provided in relatively pure form, such as some flavorings derived from tobacco. On the one hand, the component derived from tobacco and which can be used in a highly purified or substantially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[0087] As mentioned above, highly purified tobacco-derived nicotine (e.g., pharmaceutical grade nicotine with a purity greater than 98% or greater than 99%) or its derivatives can be used in the device of the present disclosure. Representative extracts containing nicotine can be provided using the technology described in U.S. Patent No. 5,159,942 of Brinkley et al., which is incorporated herein by reference. In certain embodiments, the product of the present disclosure may include nicotine in any form from any source, whether tobacco-derived or synthetically derived. Nicotine compounds for products of the present disclosure may include nicotine in free alkali form, salt form, as a complex or as a solvate. See, for example, the discussion of nicotine in free alkali form in U.S. Patent No. 2004 / 0191322 of Hansson, which is incorporated herein by reference. At least a portion of nicotine compounds can be used in the form of a resin complex of nicotine, wherein nicotine is combined in an ion exchange resin, such as nicotine polacrilex. See, for example, U.S. Pat. No. 3,901,248 to Lichtneckert et al., which is incorporated herein by reference. At least a portion of nicotine can be used in the form of a salt. Nicotine salts can be provided using the composition types and techniques described in Cox et al. U.S. Pat. No. 2,033,909 and Perfetti, Beitrage Tabakforschung Ltd., 12, 43-54 (1983). In addition, nicotine salts can be obtained from sources such as Pfaltz and Bauer Co., Ltd. and K&K Laboratories, ICN Biochemicals Co., Ltd. departments. Exemplary pharmaceutically acceptable nicotine salts include nicotine salts of tartrate (e.g., nicotine tartrate and nicotine bitartrate), chloride (e.g., nicotine hydrochloride and nicotine dihydrochloride), sulfate, perchlorate, ascorbate, fumarate, citrate, malate, lactate, aspartate, salicylate, tosylate, succinate, pyruvate, etc.; nicotine salt hydrate (e.g., nicotine zinc chloride monohydrate), etc. In certain embodiments, at least a portion of the nicotine compound is a salt formed with an organic acid moiety, including but not limited to levulinic acid discussed in U.S. Patent Publication No. 2011 / 0268809 to Brinkley et al., which is incorporated herein by reference.

[0088] The aerosol precursor composition may also include so-called "aerosol-forming materials". In some cases, such materials have the ability to produce visible (or invisible) aerosols when evaporated under conditions experienced during normal use of the aerosol generating device characterized by the present disclosure when exposed to high temperatures. Such aerosol-forming materials include various polyols or polyhydroxy alcohols (e.g., glycerol, propylene glycol, and mixtures thereof). Various aspects of the present disclosure also include aerosol precursor components that can be characterized as water, saline, moisture, or aqueous liquids. During the conditions of normal use of certain aerosol generating devices, the water incorporated into those aerosol generating configurations can evaporate to produce components of the generated aerosol. Therefore, for the purposes of the present disclosure, the water present in the aerosol precursor composition can be considered to be an aerosol-forming material.

[0089] Can adopt a variety of optional flavoring agents or materials, these flavoring agents or materials can change the organoleptic properties or properties of the mainstream aerosol inhaled generated by the aerosol delivery system of the present disclosure.For example, this optional flavoring agent can be used in an aerosol precursor composition or material to change the taste, fragrance and organoleptic properties of the aerosol.Some flavoring agents can be provided from sources other than tobacco.Exemplary flavoring agents can be natural or artificial in nature, and can be used as concentrates or spice packets.

[0090] Exemplary flavoring agents include vanillin, ethyl vanillin, cheese, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach and citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, cloves, lavender, cardamom, ginger, honey, fennel, sage, cinnamon, sandalwood, jasmine, West Indian bittersweet tree, cocoa beans, licorice; and spices and spice packages traditionally used as the flavor types and characteristics of cigarettes, cigars and pipe tobacco. Syrups such as high fructose corn syrup can also be used. Before preparing the final aerosol precursor mixture, certain flavoring agents can be included in the aerosol-forming material (e.g., certain water-soluble flavoring agents can be included in water, menthol can be included in propylene glycol, and certain composite flavor packages can be included in propylene glycol). However, in some aspects of the present disclosure, the aerosol precursor composition does not contain any flavoring, flavor characteristics or additives.

[0091] Aerosol precursor compositions may also include ingredients (e.g., organic acids, ammonium salts, or organic amines) with acidic or alkaline characteristics. For example, some organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included in aerosol precursor formulations comprising nicotine, and the amount of these organic acids (based on total organic acid content) is preferably equimolar with nicotine. For example, aerosol precursors may include levulinic acid from about 0.1 to about 0.5 moles per mole of nicotine, succinic acid from about 0.1 to about 0.5 moles per mole of nicotine, lactic acid from about 0.1 to about 0.5 moles per mole of nicotine, pyruvic acid from about 0.1 to about 0.5 moles per mole of nicotine, or various permutations and combinations thereof, until the total amount of organic acids present therein is reached and the total amount of nicotine present in the aerosol precursor composition is equimolar to the concentration. However, in some aspects of the present disclosure, aerosol precursor compositions do not contain any acidic (or alkaline) features or additives.

[0092] As a non-limiting example, a representative aerosol precursor composition or substance may include glycerol, propylene glycol, water, saline and nicotine, and any or all of these components in combination or mixture. For example, in one case, a representative aerosol precursor composition may include (based on weight) about 70% to about 100% glycerol, and typically about 80% to about 90% glycerol; about 5% to about 25% water, typically about 10% to about 20% water; and about 0.1% to about 5% nicotine, typically about 2% to about 3% nicotine. In a specific non-limiting example, a representative aerosol precursor composition may include about 84% glycerol, about 14% water and about 2% nicotine. A representative aerosol precursor composition may also include different amounts of propylene glycol, optional flavorings or other additives based on weight. In some cases, as needed or desired, an aerosol precursor composition may include any glycerol, water and saline up to about 100% weight.

[0093] The components and compositions of representative types of aerosol precursors are also described and characterized in the following documents: U.S. Patent No. 7,217,320 to Robinson et al., U.S. Patent No. 8,881,737 to Collett et al., U.S. Patent No. 9,254,002 to Chong et al., U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Publication No. 2015 / 0030823 to Lipowicz et al., and U.S. Patent Publication No. 2015 / 0020830 to Koller, and WO No. 2014 / 182736 to Bowen et al., all of which are incorporated herein by reference. Other aerosol precursors that may be used include those already included in the following products: RJ Reynolds Vapor's products; BLU™ products from Lorillard Technologies; MISTICMENTHOL products from Mistic Ecigs; and VYPE products from CN Creative Ltd. Also contemplated are so-called "tobacco juices" for electronic cigarettes that have been available from JohnsonCreek Ltd.

[0094] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating member provides acceptable sensory and desired performance characteristics. For example, preferably a sufficient amount of aerosol-forming materials such as glycerol and / or propylene glycol may be used to ensure that a visible mainstream aerosol is generated that is similar in many respects to the appearance of tobacco smoke. The amount of aerosol precursor in the aerosol generating system may depend on factors such as the number of puffs desired for each aerosol generating member. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system, specifically the aerosol generating member, is less than about 5 = 2 grams, typically less than about 1.5 grams, typically less than about 1 gram, typically less than about 0.5 grams.

[0095] Nos. 5,967,148 to Harris et al., 5,934,289 to Watkins et al., 5,954,979 to Counts et al., 6,040,560 to Fleischhauer et al., 8,365,742 to Hon., 8,402,976 to Fernando et al., 8,689,804 to Fernando et al., and 9,220,30 Other features, controllers, or components that may be included in the aerosol delivery system of the present disclosure are described in U.S. Patent No. 2, Tucker et al., U.S. Patent No. 2013 / 0192623, Leven et al., U.S. Patent No. 2013 / 0298905, Kim et al., U.S. Patent No. 2013 / 0180553, Sebastian et al., and U.S. Patent No. 2014 / 0000638, and Novak et al., which are incorporated herein by reference.

[0096] According to the further disclosure provided herein, it will be apparent to those skilled in the art that the above description of the use of the article can be applied to the various embodiments described herein with some modifications. However, the above description of use is not intended to limit the use of the article, but to provide all necessary requirements of the disclosure consistent with the present disclosure. Figure 1 Any of the elements shown in the articles shown in or any other elements described above may be included in an aerosol delivery device according to the present disclosure.

[0097] In one or more embodiments, the present disclosure may relate to the use of a porous monolith in one or more components of an aerosol delivery device. As used herein, a "porous monolith" or "porous monolith" is intended to mean a unit comprising a substantially monomeric unit, which in some embodiments may be a single piece formed, composed or formed, which has no joints or seams and comprises a substantially unified, but not necessarily rigid, whole. In some embodiments, a monolith according to the present disclosure may be undifferentiated, i.e., formed from a single material, or may be formed from a plurality of permanently combined units such as sintered agglomerates. Thus, in some embodiments, a porous monolith may comprise an integral porous monolith.

[0098] In some embodiments, the use of porous monoliths specifically relates to the use of porous glass in components of an aerosol delivery device. As used herein, "porous glass" is intended to mean glass having a three-dimensional interconnected porous microstructure. The term specifically excludes materials made from bundles of glass fibers (i.e., fabrics or nonwovens). Thus, porous glass may exclude fiberglass. Porous glass may also be referred to as controlled pore glass (CPG) and may be referred to by the trade name Porous glass suitable for use according to the present disclosure can be prepared by known methods, such as, for example, by metastable phase separation in borosilicate glass via a sol-gel process, followed by liquid extraction (e.g., acid extraction or combined acid and alkaline extraction) of one of the phases formed, or followed by glass powder sintering. The porous glass can specifically be a high-silica glass, such as one containing 90% or more, 95%, 96% or more, or 98% or more silicon dioxide. Materials for porous glass according to the present disclosure and methods for preparing porous glass suitable for use are described in U.S. Pat. Nos. 2,106,744 to Hood et al., 3,485,687 to Chapman et al., 4,657,875 to Nakashima et al., 9,003,833 to Kotani et al., U.S. Patent Publication No. 2013 / 0045853 to Kotani et al., 2013 / 0067957 to Zhang et al., 2013 / 0068725 to Takashima et al., and 2014 / 0075993 to Himanshu, which are incorporated herein by reference. Although the term porous "glass" may be used herein, it should not be construed as limiting the scope of the present disclosure, as "glass" may encompass a variety of silica-based materials.

[0099] In some embodiments, porous glass can be defined in relation to its average pore size. For example, porous glass can have an average pore size of about 1 nanometer to about 1000 microns, about 2 nanometers to about 500 microns, about 5 nanometers to about 200 microns, or about 10 nanometers to about 100 microns. In certain embodiments, the porous glass used according to the present disclosure can be distinguished based on the average pore size. For example, small-pore porous glass can have an average pore size of 1 nanometer to 500 nanometers, mesoporous porous glass can have an average pore size of 500 nanometers to 10 microns, and macroporous porous glass can have an average pore size of 10 microns to 1000 microns. In some embodiments, macroporous porous glass can be preferably used as a storage element, and small-pore porous glass and / or mesoporous porous glass can be preferably used as a conveying element.

[0100] In some embodiments, the porous glass can also be defined with respect to its surface area. For example, the porous glass can have a surface area of ​​at least 100 m2 / g, at least 150 m2 / g, at least 200 m2 / g, or at least 250 m2 / g, such as about 100 m2 / g to about 600 m2 / g, about 150 m2 / g to about 500 m2 / g, or about 200 m2 / g to about 450 m2 / g.

[0101] In some embodiments, the porous glass can be defined in relation to its porosity (i.e., the volume fraction of the material defining the pores). For example, the porous glass can have a porosity of at least 20%, at least 25%, or at least 30% by volume, such as a porosity of about 20% to about 80%, about 25% to about 70%, or about 30% to about 60% by volume. In certain embodiments, a lower porosity may be desired, such as a porosity of about 5% to about 50%, about 10% to about 40%, or about 15% to about 30% by volume.

[0102] In some embodiments, the porous glass can be further defined in relation to its density. For example, the porous glass can have a density of 0.25 g / cm3 to about 3 g / cm3, about 0.5 g / cm3 to about 2.5 g / cm3, or about 0.75 g / cm3 to about 2 g / cm3.

[0103] In some embodiments, the use of porous monoliths specifically relates to the use of porous ceramics in components of aerosol delivery devices. As used herein, "porous ceramic" is intended to mean a ceramic material having a three-dimensional interconnected porous microstructure. In U.S. Pat. No. 3,090,094 to Schwartzwalder et al., U.S. Pat. No. 3,833,386 to Frisch et al., U.S. Pat. No. 4,814,300 to Helferich, U.S. Pat. No. 5,171,720 to Kawakami, U.S. Pat. No. 5,185,110 to Kunikazu et al., U.S. Pat. No. 5,227,342 to Anderson et al., U.S. Pat. No. 5,645,891 to Liu et al., N. Materials for porous ceramic materials according to the present disclosure and methods for preparing porous ceramics suitable for use are described in U.S. Patent Nos. 5,750,449 to Niihara et al., 6,753,282 to Fleischmann et al., 7,208,108 to Otsuka et al., 7,537,716 to Matsunaga et al., and 8,609,235 to Hotta et al., which are incorporated herein by reference. Although the term porous "ceramic" may be used herein, it should not be construed as limiting the scope of the present disclosure, as "ceramic" may encompass a variety of alumina-based materials.

[0104] In some embodiments, the porous ceramic can also be defined in relation to its average pore size. For example, the porous ceramic can have an average pore size of about 1 nanometer to about 1000 microns, about 2 nanometers to about 500 microns, about 5 nanometers to about 200 microns, or about 10 nanometers to about 100 microns. In certain embodiments, the porous ceramics used in accordance with the present disclosure can be distinguished based on the average pore size. For example, a small-pore porous ceramic can have an average pore size of 1 nanometer to 500 nanometers, a mesoporous porous ceramic can have an average pore size of 500 nanometers to 10 microns, and a macroporous porous ceramic can have an average pore size of 10 microns to 1000 microns. In some embodiments, macroporous porous ceramics can be preferably used as storage elements, and small-pore porous ceramics and / or mesoporous porous ceramics can be preferably used as transport elements.

[0105] In some embodiments, the porous ceramic can also be defined with respect to its surface area. For example, the porous ceramic can have a surface area of ​​at least 100 m2 / g, at least 150 m2 / g, at least 200 m2 / g, or at least 250 m2 / g, such as about 100 m2 / g to about 600 m2 / g, about 150 m2 / g to about 500 m2 / g, or about 200 m2 / g to about 450 m2 / g.

[0106] In some embodiments, the porous ceramic can be defined in relation to its porosity (i.e., the volume fraction of the material defining the pores). For example, the porous ceramic can have a porosity of at least 20%, at least 25%, or at least 30% by volume, such as a porosity of about 20% to about 80%, about 25% to about 70%, or about 30% to about 60% by volume. In certain embodiments, lower porosities may be desired, such as porosities of about 5% to about 50%, about 10% to about 40%, or about 15% to about 30% by volume.

[0107] In some embodiments, the porous glass can be further defined with respect to its density. For example, the porous ceramic can have a density of 0.25 g / cm3 to about 3 g / cm3, about 0.5 g / cm3 to about 2.5 g / cm3, or about 0.75 g / cm3 to about 2 g / cm3.

[0108] Although silica-based materials (e.g., porous glass) and alumina-based materials (e.g., porous ceramics) may be discussed separately herein, it should be understood that in some embodiments, the porous monolith may include various aluminosilicate materials. For example, various zeolites may be used in accordance with the present disclosure. Thus, for example, the porous monolith discussed herein may include one or both of porous glass and porous ceramic, which may be provided as a composite material. In one embodiment, such a composite material may include SiO2 and Al2O3.

[0109] The porous monoliths used in accordance with the present disclosure can be provided in a variety of sizes and shapes. Preferably, the porous monoliths can be substantially elongated, substantially flat or planar, substantially curved (e.g., "U-shaped"), substantially in the form of a walled cylinder, or any other form suitable for use in accordance with the present disclosure. Additional example shapes of porous monoliths are described below and shown in the accompanying drawings.

[0110] In one or more embodiments, the porous monolith according to the present disclosure may be characterized in relation to the wicking rate. As a non-limiting example, the wicking rate can be calculated by measuring the mass uptake of a known liquid, and a microbalance tensiometer or similar instrument can be used to measure the rate (in milligrams per second). Preferably, the wicking rate is substantially within the range of the desired aerosol mass produced during the duration of suction of the aerosol-forming article comprising the porous monolith. The wicking rate may be, for example, in the range of about 0.05 mg / sec to about 15 mg / sec, about 0.1 mg / sec to about 12 mg / sec, or about 0.5 mg / sec to about 10 mg / sec. The wicking rate may vary based on the liquid being wicked. In some embodiments, the wicking rate as described herein may be referenced to substantially pure water, substantially pure glycerol, substantially pure propylene glycol, a mixture of water and glycerol, a mixture of water and propylene glycol, a mixture of glycerol and propylene glycol; or a mixture of water, glycerol and propylene glycol. The wicking rate may also vary based on the use of the porous monolith. For example, a porous monolith used as a liquid transport element may have a greater wicking rate than a porous monolith used as a reservoir.The wicking rate can be varied by controlling one or more of pore size, pore size distribution, and wettability, as well as the composition of the material being wicked.

[0111] As described above, some existing embodiments of aerosol delivery devices include a liquid delivery element and / or a reservoir that includes a fibrous material. However, the fibrous material may suffer certain damage. In this regard, given that the heating element is positioned near the liquid delivery element, scorching may occur at the fibrous liquid delivery element, which may adversely affect the fragrance of the aerosol produced and / or the structural integrity of the liquid delivery element. Depending on the relative position of the components, scorching may also occur at the fibrous reservoir.

[0112] Further, fibrous materials can often be relatively weak and susceptible to tearing or other failure when subjected to stresses such as may occur during repeated drops or other severe accidents. Additionally, using fibrous materials in the air flow path during assembly can present challenges in terms of ensuring that there are no loose fibers. It can also be difficult to form and maintain the liquid delivery element and reservoir in a desired shape due to the flexible nature of the fibrous materials.

[0113] Thus, the aerosol delivery device of the present disclosure may include a reservoir and / or a liquid transport element comprising a porous monolith. As can be appreciated, the use of a porous monolith may not suffer from the potential damage described above. In this regard, relatively more durable materials may be selected, such as porous glass or porous ceramics that may not tear. In addition, such materials may not suffer from scorching. In addition, the absence of fibers in the porous monolith eliminates the problem of relative movement of fibers in the airflow path defined by it. Further, the porous monolith can be formed in essentially any shape and can be shape-stable.

[0114] For example, Figure 2 A modified cross-sectional view of a cartridge 204 for an aerosol delivery device is shown. The cartridge 204 may include the cartridge 104 described above (see Figure 1 ) some or all of the components. Further, the cartridge 204 can be used with the above-described control body 102 and / or other embodiments of the control body.

[0115] As shown, the cartridge 204 may include an outer body 216 and a base 232 coupled to one end of the outer body. A mouthpiece opening 224 may be positioned at an opposite end of the outer body 216. Electronic components 226 and a heating element 222 may be positioned within the outer body 216.

[0116] The mouthpiece opening 224 may be defined in a mouthpiece 246 that may engage an end of the outer body 216 opposite the base 232. A first heating terminal 248 and a second heating terminal 250 may be coupled to the heating element 222. Further, an electronic component terminal 252 may engage the electronic component 226. The first heating terminal 248 and the second heating terminal 250 may also engage the electronic component 226. The terminals 248, 250, 252 may extend into the base 232 to allow for electrical connection to a control body as described above.

[0117] In addition, the cartridge 204 may include a monolithic reservoir and liquid delivery element 254. The term "monolithic" used herein in the context of the monolithic reservoir and liquid delivery element 254 means that the reservoir and liquid delivery element are formed as a continuous piece with a seamless transition from the reservoir to the liquid delivery element. In this regard, the monolithic reservoir and liquid delivery element 254 may include a porous monolithic piece such as a porous glass or porous ceramic as described above, which may be integral.

[0118] The integrated reservoir and liquid delivery element 254 can contain an aerosol precursor composition. The integrated reservoir and liquid delivery element 254 can be positioned adjacent to the heating element 222. Thus, the heating element 222 can heat the aerosol precursor composition contained by the integrated reservoir and liquid delivery element 254 to generate a vapor.

[0119] Figure 3 A cross-sectional view of an integral reservoir and a liquid delivery element 254 is shown. As shown, in some embodiments, the integral reservoir and the liquid delivery element 254 may be defined with at least one channel 255 extending at least partially therethrough. The heating element 222 may be positioned in the first section 256 of the channel 255. Therefore, the heating element 222 may be substantially surrounded by and in contact with the integral reservoir and the liquid delivery element 254 to heat the aerosol precursor composition contained therein to produce vapor. In some embodiments, the first heating terminal 248 and / or the second heating terminal 250 may extend into the first section 256 of the channel 255 to engage the opposite end of the heating element 222. As shown, the heating element 222 may include a coiled metal wire.

[0120] like Figure 3 As shown, the passage 255 extending at least partially through the integrated reservoir and liquid delivery element 254 may also define a second section 258. Figure 2 As shown, the electronic component 226 can be received in the second section 258 of the channel 255. In this regard, the electronic component 226 can be positioned between the first heating terminal 248 and the second heating terminal 250. Therefore, in this embodiment, the heating element 222, the heating terminals 248, 250, and the electronic component 226 are at least partially received in the channel 255. As described below, the first section 256 and the second section of the channel 255 can define an airflow path through the cartridge.

[0121] The heating element 222 can define a central longitudinal axis that can be substantially parallel to the longitudinal axis of the outer body 216. For example, the longitudinal axis of the heating element 222 can be coaxial with the longitudinal axis of the outer body 216. Further, the longitudinal axis of the electronic component 226 can extend substantially parallel to the longitudinal axis of the outer body 216. Further, the longitudinal axis of the channel 255 can extend substantially parallel to the longitudinal axis of the outer body 216. For example, the channel 255 can be coaxial with the longitudinal axis of the outer body 216.

[0122] The integrated reservoir and liquid delivery element 254 may extend between a base end 260 and a mouthpiece end 262. The second section 258 of the channel 255 may extend from the base end 260 of the integrated reservoir and liquid delivery element 254 to the first section 256 of the channel 255. The first section 258 of the channel 255 may extend from the second section 258 of the channel 255 to the mouthpiece end 262 of the integrated reservoir and liquid delivery element 254.

[0123] Thus, an airflow path through the cartridge 204 can extend from the base end 260, through the integrated reservoir and liquid delivery element 254, to the mouthpiece end 262. More specifically, the airflow path can extend through the base 232, past the electronic components 226 in the second section 258 of the channel 255, through the heating element 222 in the first section 256 of the channel 255, and out through the mouthpiece opening 224 defined in the mouthpiece 246. Thus, vapor generated by heating an aerosol precursor composition contained in the integrated reservoir and liquid delivery element 254 using the heating element 222 can combine with air to form an aerosol that is directed toward a user through the mouthpiece 246.

[0124] Thus, the heating element 222 can be positioned proximate to the mouthpiece 246. Since the flow path from the heating element to the mouthpiece opening 224 is relatively short, this configuration can reduce the likelihood of condensation of fluid from vapor generated by the heating element 222 in the cartridge 204. In this regard, any such condensation can reduce the efficiency of the aerosol delivered to the user and can cause problems with leakage of fluid from the cartridge 204.

[0125] Note that in this embodiment, the integrated reservoir and liquid delivery element 254 can direct the airflow through the cartridge 204. In this regard, the channel 255 can direct the airflow to the heating element 222, which can be substantially surrounded by the integrated reservoir and liquid delivery element 254. Thus, it may not be necessary to use a separate flow director, which can reduce the number of parts of the cartridge as well as material and / or assembly costs.

[0126] Further, the integrated reservoir and liquid delivery element 254 contains the aerosol precursor composition and directs the aerosol precursor composition to the heating element 222. Thus, the integrated reservoir and liquid delivery element 254 can be used to replace the separate reservoir 118 and liquid delivery element 120 (see Figure 1 ). In this regard, the porosity of the integral reservoir and liquid delivery element 254 can allow fluid to move therethrough. Thus, when the heating element 222 heats the aerosol precursor composition in the integral reservoir and liquid delivery element 254 positioned proximate to the heating element, the aerosol precursor composition can be redistributed within the integral reservoir and liquid delivery element (e.g., via capillary action). Thus, the integral integral reservoir and liquid delivery element 254 can be replenished with aerosol precursor composition from other locations within the integral reservoir and liquid delivery element proximate to the heating element 222.

[0127] In some embodiments, the monolithic reservoir and the liquid delivery element 254 may be defined with a variable porosity. In other words, the porosity of the monolithic reservoir and the liquid delivery element 254 may vary according to the position therein. Therefore, the volume fraction of the material defining the pores may vary. With the aid of another example, in some embodiments, the number of pores per unit volume and / or the size of the pores may vary. Note that the variable porosity used herein is different from the inherent variation of the porosity at each point in the volume of the porous monolith, but refers to the porosity gradient that occurs between the zones or regions therein. As described below, by changing the porosity of the monolithic reservoir and the liquid delivery element 254, the characteristics of the monolithic reservoir and the liquid delivery element may vary according to the position therein.

[0128] As can be appreciated, the cartridge including the integral reservoir and liquid delivery element may be defined in other forms. In this regard, Figure 4 A cartridge 304 is shown according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 304 may include an outer body 316 and a base 332 coupled to one end of the outer body. A mouthpiece opening 324 may be positioned at an opposite end of the outer body 316. A heating element 322 may be positioned within the outer body 316.

[0129] The mouthpiece opening 324 may be defined in a mouthpiece 346 that may engage an end of the outer body 316 opposite the base 332. A first heating terminal 348 and a second heating terminal 350 may be coupled to the heating element 322. The electronic component 326 (see Figure 5 ) may be located between the first heating terminal 348 and the second heating terminal 350 and as described above and for example in Figure 2 As shown in FIG. 3 , the electronic component terminals may engage the electronic components. Further, the terminals may extend into the base 332 to allow electrical connection with the control body as described above.

[0130] In addition, the cartridge 304 may include an integral reservoir containing an aerosol precursor composition and a liquid delivery element 354. The integral reservoir and liquid delivery element 354 may extend between a base end 360 and a mouthpiece end 362. The integral reservoir and liquid delivery element 354 may include a porous monolith such as a porous glass or porous ceramic, and in some embodiments, the integral reservoir and liquid delivery element may define a variable porosity.

[0131] Thus, the cartridge 304 may be substantially similar in many respects to Figure 2 Therefore, for the purpose of simplicity, the barrel 304 and Figure 2 The specific details common to the cartridge 204 will not be repeated. However, the cartridge 304 may differ in one or more aspects.

[0132] In this regard, Figure 4 As shown, the heating element 322 can extend at least partially around and contact the integrated reservoir and liquid delivery element 354. More specifically, the integrated reservoir and liquid delivery element 354 can define a protrusion 364, which can be located at the distal end of the integrated reservoir and liquid delivery element. In this embodiment, the protrusion 364 can be positioned at the mouthpiece end 362 of the integrated reservoir and liquid delivery element 354. Figure 4 As shown, the heating element 322 may extend at least partially around the protrusion 364 .

[0133] like Figure 5 As shown, the integrated reservoir and liquid delivery element 354 can define one or more channels 355 that extend at least partially through the integrated reservoir and liquid delivery element 354. The channel 355 can define a slot 366. As schematically shown, the electronic component 326 can be received in the slot 366. Further, the channel 355 can define a first groove 368 and a second groove 370. The grooves 368, 370 can extend between the protrusion 364 and the slot 366 on each side of the integrated reservoir and liquid delivery element 354.

[0134] like Figure 4 As shown, the heating terminals 348, 350 can extend through the slot 366 and the grooves 368, 370. Therefore, the heating terminals 348, 350 can engage the ends of the heating element 322. Further, the electronic component 326 (see Figure 5 ) can be received in the slot 366 between the first heating terminal 348 and the second heating terminal 350. Thus, the heating terminals 348, 350 and the electronic component 326 can be at least partially received in the channel 355. In addition, as can be appreciated, the airflow can define a flow path that passes through the base 332, around the integral reservoir and liquid delivery element 354 through the slot 366 and the grooves 368 and 370, through the heating element 322, and out of the mouthpiece 346 through the mouthpiece opening 324, where vapor is added to the airflow. Thus, the airflow can be directed through the channel 355, which extends at least partially through the integral reservoir and liquid delivery element 354.

[0135] Figure 6 A cartridge 404 is shown according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 404 may include an outer body 416 and a base 432 coupled to one end of the outer body. A mouthpiece 446 may be engaged with an end of the outer body 416 opposite the base 432. The mouthpiece 446 may define a mouthpiece opening as described above.

[0136] The heating element 422 may be positioned within the outer body 416. Figure 7 As shown, the cartridge 404 may also include a first heating terminal 448 and a second heating terminal 450 that may be coupled to the heating element 422. The electronic component 426 may be located between the first heating terminal 448 and the second heating terminal 450 and as described above and for example in Figure 2 As shown in FIG. 4 , the electronic component terminals may engage the electronic components. Further, the terminals may extend into the base 432 to allow electrical connection with the control body as described above.

[0137] In addition, if Figure 6 As shown, the cartridge 404 may include an integral reservoir and liquid delivery element 454 containing an aerosol precursor composition. The integral reservoir and liquid delivery element 454 may extend between a base end 460 and a mouthpiece end 462. The integral reservoir and liquid delivery element 454 may define a protrusion 464, and the heating element 422 may extend at least partially in contact with the protrusion 464. The integral reservoir and liquid delivery element 454 may include a porous integral piece such as a porous glass or a porous ceramic, and in some embodiments, the integral reservoir and liquid delivery element may be defined with a variable porosity.

[0138] Thus, cartridge 404 may be substantially similar in many respects to Figure 4 Therefore, for the purpose of simplicity, the barrel 404 and Figure 4 The specific details common to the cartridge 304 will not be repeated. However, the cartridge 404 may differ in one or more aspects.

[0139] In this regard, Figure 6 As shown, the protrusion 464 defined by the integrated reservoir and liquid delivery element 454 can be located at its base end 460 rather than at the mouthpiece end 462. Further, the integrated reservoir and liquid delivery element 454 can include one or more channels 455. For example, as Figure 8 As shown, channel 455 may define compartment 458 .

[0140] Further, if Figure 8 As shown, the channel 455 may define a recess 472. The recess 472 may extend from the base end 460 of the integrated reservoir and liquid delivery element 454 to an opening 474 leading to the compartment 458. Figure 7 As shown, the heating terminals 448, 450 and the electronic component 426 can extend through the recess 472 into the compartment 458. Thus, the heating terminals 448, 450 and the electronic component 426 can be at least partially received in the channel 455. Using the recess 472 at the base end 460 of the integral reservoir and liquid delivery element 454 rather than extending the compartment 458 to the base end can allow the heating element 422 to engage the heating terminals 448, 450.

[0141] Further, if Figure 6 As shown, the channel 455 can be defined with a first groove 468 and a second groove 470. The grooves 468, 470 can extend on each side of the integrated reservoir and liquid delivery element 454. Specifically, the grooves 468, 470 can start at the heating element 422 that engages the protrusion 464 adjacent to the recess 472 and terminate at the mouthpiece end 462 of the integrated reservoir and liquid delivery element 454. Thus, the airflow can be defined with a flow path that passes through the base 332, enters the recess 472 (see, e.g., Figure 8 ), through the heating element 422, around the integral reservoir and liquid delivery element 472 through the grooves 468, 470, and out of the mouthpiece 446 through the mouthpiece opening, where vapor is added to the airflow. Thus, the airflow can be directed through the channel 455, which extends at least partially through the integral reservoir and liquid delivery element 454.

[0142] In the above-described embodiments of cartridges 204, 304, 404, the electronic component is received between the first heating terminal and the second heating terminal. By way of example, the configuration is Fig. 9 The components shown in FIG. 1 include Figure 6 The barrel 404. As shown, the heating terminals 448, 450 may support the electronic component 426 therebetween.

[0143] In this regard, as shown, the heating terminals 448, 450 can each define a lateral support section 476 positioned on opposite sides of the electronic component 426. The lateral support section 476 can limit lateral movement of the electronic component 426 extending between the first heating terminal 448 and the second heating terminal 450 in a lateral direction. Further, the heating terminals 448, 450 can each define a major surface support section 478 that can engage the rear major surface 426A of the electronic component 426.

[0144] The electronic component terminal 452 can engage the front major surface 426B of the electronic component 426. In addition, in some embodiments, the first heating terminal 448 can include a tab 480 that provides power to the front major surface 426B of the electronic component 426 and engages the front major surface 426B of the electronic component 426. Therefore, forward movement of the electronic component 426 can be blocked by the electronic component terminal 452 and the tab 480 of the first heating terminal 448. Conversely, rearward movement of the electronic component 426 can be blocked by the major surface support section 478 of the heating terminals 448, 450.

[0145] However, as described below, in other embodiments, the electronic components may be positioned and supported in different ways. Fig.10 A cartridge 504 according to an additional exemplary embodiment of the present disclosure is shown. As shown, the cartridge 504 may include an outer body 516 and a base 532 coupled to one end of the outer body. A mouthpiece 546 may be engaged with an end of the outer body 516 opposite the base 532. The mouthpiece 546 may define a mouthpiece opening as described above.

[0146] The heating element 522 can be positioned within the outer body 516. The first heating terminal 548 and the second heating terminal 550 can be coupled to the heating element 522. The electronic component 526 can be received in the outer body 516 via the electronic component terminals 552 (see Fig.12 ) may engage electronic component 526. Further, terminals 548, 550, 552 may extend into base 532 to allow electrical connection with a control body as described above.

[0147] In addition, the cartridge 504 can include an integral reservoir containing an aerosol precursor composition and a liquid delivery element 554. The integral reservoir and liquid delivery element 554 can extend between a base end 560 and a mouthpiece end 562. The integral reservoir and liquid delivery element 554 can define a protrusion 564, and the heating element 522 can extend at least partially in contact with the protrusion 564.

[0148] like Fig.11 As shown, the integrated reservoir and liquid delivery element 554 may include one or more channels 555 that extend at least partially through the integrated reservoir and liquid delivery element 554. The channel 555 may define a first groove 568 and a second groove 570. Fig.10 As shown, the first heating terminal 548 and the second heating terminal 550 can extend in the first groove 568 and the second groove 570, respectively. Therefore, the heating terminals 548, 550 can be at least partially received in the channel 555. The integral reservoir and liquid delivery element 554 can include a porous monolithic piece such as porous glass or porous ceramic, and in some embodiments, the integral reservoir and liquid delivery element can be defined with a variable porosity.

[0149] Thus, cartridge 504 may be substantially similar in many respects to Figure 4 Therefore, for the purpose of simplicity, the barrel 504 and Figure 4 The specific details common to the cartridge 304 will not be repeated. However, the cartridge 504 may differ in one or more aspects.

[0150] like Fig.10As shown, the electronic component 526 can be positioned between the base 532 and the integrated reservoir and liquid delivery element 554. In this regard, the longitudinal axis of the electronic component 526 can extend substantially perpendicular to the longitudinal axis of the outer body 516. Further, as shown Fig.12 As shown, the first heating terminal 548 and the second heating terminal 550 can extend substantially perpendicular to the longitudinal axis of the electronic component 526. In this regard, as described above with respect to Fig.10 As described above, the heater terminals 548, 550 may be received in recesses 568, 570 defined in the integral reservoir and liquid delivery element 554. Fig.12 As shown, the first heating terminal 548 may be defined with a protrusion 548A extending laterally therefrom, and the second heating terminal 550 may be defined with a protrusion 550A extending laterally therefrom. The protrusions 548A, 550A and the electronic component terminal 552 may engage the main surface of the electronic component 526. Therefore, the protrusions 548A, 550A and the electronic component terminal 552 defined by the heating terminals 548, 550 may press the electronic component 526 against the base 532, so that the electronic component is held in place.

[0151] Further, the electronic component 526 may include a plurality of contacts. The tab 548A of the first heating terminal 548 may engage the first contact 582A. The tab 550A of the second heating terminal 550 may engage the second contact 582B. Further, the electronic component terminal 552 may engage the third contact 582C. In this regard, the heating terminals 548, 550 may provide power to the electronic component 526, and the electronic component terminals may establish an electrical connection with the electronic component so that data may be transmitted to the cartridge 504 (see Fig.10 ) and the control subject as described above.

[0152] Reference Fig.10 , the airflow may define a flow path through the base 532, through the electronic components 526, around the integral reservoir and liquid delivery element 554 through the grooves 568, 570, through the heating element 522, and out of the mouthpiece 546 through the mouthpiece opening where vapor is added to the airflow. Thus, the airflow may be directed through the channel 555 (see Fig.11 ), the channel 555 at least partially extends through the integral reservoir and liquid delivery element 554. Thus, the flow path can generally extend beside the electronic component 526 rather than along the electronic component 526. In this regard, the electronic component 526 can define a semi-circular shape, and the longitudinal axis of the electronic component 526 can extend substantially perpendicular to the longitudinal axis of the outer body 516, so that the airflow can extend beside the electronic device rather than through or along the electronic component. Thus, the electronic component 526 can be substantially removed from the air flow path through the cartridge 504.

[0153] In additional embodiments, methods for generating steam are provided. Fig.13 As shown, the method may include containing an aerosol precursor composition in an integrated reservoir and liquid delivery element in operation 602. Further, the method may include evaporating at least a portion of the aerosol precursor composition at the integrated reservoir and liquid delivery element in operation 604.

[0154] In some embodiments, evaporating at least a portion of the aerosol precursor composition at the integral reservoir and liquid delivery element in operation 604 may include directing an electric current to a heating element substantially surrounded by the integral reservoir and liquid delivery element. In another embodiment, evaporating at least a portion of the aerosol precursor composition at the integral reservoir and liquid delivery element in operation 604 may include directing an electric current to a heating element extending around at least a portion of the integral reservoir and liquid delivery element. The method may also include directing an airflow through one or more channels that extend at least partially through the integral reservoir and liquid delivery element. Further, containing the aerosol precursor composition in the integral reservoir and liquid delivery element in operation 602 may include containing the aerosol precursor composition in an integral porous monolith.

[0155] In additional embodiments, a method for making an aerosol delivery device is provided. The method may include forming an integral reservoir and a liquid delivery element from a porous integral material. Further, the method may include positioning a heating element with the integral reservoir and the liquid delivery element in the outer body such that the heating element is proximate to the integral reservoir and the liquid delivery element. The method may additionally include dispensing an aerosol precursor composition into the integral reservoir and the liquid delivery element.

[0156] In some embodiments, forming the integral reservoir and liquid delivery element may include injection molding the integral reservoir and liquid delivery element. The method may also include engaging the first heating terminal and the second heating terminal with the heating element. Forming the integral reservoir and liquid delivery element from a porous integral material may include insert molding at least one of the heating element, the first heating terminal, and the second heating terminal into the integral reservoir and liquid delivery element. Further, in some embodiments, forming the integral reservoir and liquid delivery element from a porous integral material may include forming the integral reservoir and liquid delivery element from a porous ceramic.

[0157] As described above, embodiments of the present disclosure include an integral reservoir and fluid delivery element formed from a unitary porous monolith. However, as described below, in other embodiments, the fluid delivery element and reservoir may be provided as separate elements.

[0158] in this regard, Fig.14A cartridge 704 is shown according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 704 may include an outer body 716 and a base 732 coupled to one end of the outer body. A mouthpiece opening 724 may be positioned at an opposite end of the outer body 716. A heating element 722 may be positioned within the outer body 716. As shown, in one embodiment, the longitudinal axis of the heating element 722 may be substantially parallel to the longitudinal axis of the outer body 716.

[0159] The mouthpiece opening 724 may be defined in a mouthpiece 746 that may engage an end of the outer body 716 opposite the base 732. A first heating terminal 748 and a second heating terminal 750 may be coupled to the heating element 722. The electronic component 726 may be positioned between the first heating terminal 748 and the second heating terminal 750. The longitudinal axis of the electronic component 726 may extend substantially parallel to the longitudinal axis of the outer body 716. As described above and for example in Fig. 9 As shown in FIG. 1 , the electronic component terminal 752 may be engaged with the electronic component 726. Further, the terminals 748, 750, 752 may extend into the base 732 to allow electrical connection with the control body as described above. In this regard, the terminals, electronic components and base may be connected to the base 732. Fig. 9 The corresponding elements in are substantially similar or identical.

[0160] In addition, the cartridge 704 can include a reservoir 718 received in the outer body 716. The reservoir 718 can contain an aerosol precursor composition. The reservoir 718 can define a tubular configuration. The reservoir 718 can extend between a base end 718a and a mouthpiece end 718b.

[0161] The cartridge 704 may further include a liquid delivery element 720. The liquid delivery element 720 may extend between the base end 720a and the mouthpiece end 720b. Further, the liquid delivery element 720 may extend between the reservoir 718 and the heating element 722. In this regard, the liquid delivery element 720 may be at least partially received in the reservoir 718 and surrounded by the reservoir 718.

[0162] One or both of the reservoir 718 and the liquid delivery element 720 may include a porous monolithic piece such as porous glass or porous ceramic. In an exemplary embodiment, the liquid delivery element 720 may include a porous monolithic piece, and the reservoir 718 may include a fiber mat (e.g., cellulose acetate) that may be wrapped around it. In some embodiments, the liquid delivery element 720 may be relatively more porous than the reservoir 718. In this regard, the liquid delivery element 720 may be configured to draw the aerosol precursor composition held in the reservoir 718 to the heating element 722. Further, in some embodiments, one or both of the reservoir 718 and the liquid delivery element 720 may be defined with a variable porosity.

[0163] Fig.15 A liquid delivery element 720 is shown. As shown, the liquid delivery element 720 can define at least one channel 755 extending at least partially therethrough. The channel 755 can define a first section 756 and a second section 766. The first section 756 of the channel 755 can extend from the mouthpiece end 720b of the liquid delivery element 720 to the second section 766 of the channel. The second section 766 of the channel 755 can extend from the first section 756 of the channel to the base end 720a of the liquid delivery element 720.

[0164] The electronic component 726 can be at least partially positioned within the liquid transport element 720. In this regard, the electronic component 726 can be received in the second section 766 of the channel 755. Further, the heating element 722 can be at least partially positioned within the liquid transport element 720. In this regard, the heating element 722 is positioned in and in contact with the first section 756 of the channel 755 in the illustrated embodiment.

[0165] In addition, if Fig.14 As shown, one or both of the first heating terminal 748 and the second heating terminal 750 can extend at least partially through the liquid delivery element 720. In this regard, the first heating terminal 748 and the second heating terminal 750 can extend from the base 732 through the second section 766 of the channel 755 to the heating element 722 at the first section 756 of the channel. The longitudinal axis of the liquid delivery element 720 can be substantially parallel to the longitudinal axis of the first heating terminal 748 and the longitudinal axis of the second heating terminal 750.

[0166] The airflow may define a flow path through the base 732, through the liquid delivery element 720, into the second section 766 of the channel 755, through the electronic components 726, through the heating element 722 in the first section 756 of the channel, and out of the mouthpiece 746 through the mouthpiece opening 724, where vapor is added to the airflow at the heating element 722. In this regard, the liquid delivery element 720 may define a flow director that directs air to the heating element 722 where vapor is generated. Thus, the use of a separate flow director may not be required.

[0167] Regarding the generation of steam, the reservoir 718 can hold an aerosol precursor composition. The liquid delivery element 720 can be substantially in contact with the reservoir 718 over its entire length. Further, the liquid delivery element 720 can extend around all or part of the inner periphery of the reservoir 718. For example, in the illustrated embodiment, the liquid delivery element 720 contacts the entire inner periphery of the hole 784 defined by the reservoir 718 at the mouthpiece end 720b. By providing a relatively large contact area between the reservoir 718 and the liquid delivery element 720, the fluid transmission from the reservoir to the liquid delivery element 720 can be improved. Similarly, the liquid delivery element 720 can be substantially around the heating element 722 to provide improved steam production.

[0168] Fig.16 and 17 A cartridge 804 is shown according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 804 can include an outer body 816 and a base 832 coupled to one end of the outer body. A mouthpiece opening can be defined in a mouthpiece 846 that can engage with an end of the outer body 816 opposite the base 832. A heating element 822 can be positioned within the outer body 816. As shown, in one embodiment, the longitudinal axis of the heating element 822 can be substantially parallel to the longitudinal axis of the outer body 816.

[0169] The first heating terminal 848 and the second heating terminal 850 can be coupled to the heating element 822. The electronic component 826 (see Fig.17 and 18 ) may be positioned between the first heating terminal 848 and the second heating terminal 850. By way of example, as described above with reference to Fig.14 As described and shown, the longitudinal axis of the electronic component 826 can extend substantially parallel to the longitudinal axis of the outer body 816. As described above and for example in Fig. 9 As shown in FIG. 1 , the electronic component terminal 852 can be engaged with the electronic component 826. Further, the terminals 848, 850, 852 can extend into the base 832 to allow electrical connection with the control body as described above. In this regard, the terminals, electronic components and base can be connected to the control body as described above. Fig. 9 The corresponding elements in are substantially similar or identical.

[0170] In addition, the cartridge 804 can include a reservoir 818 received in the outer body 816. The reservoir 818 can contain an aerosol precursor composition. The reservoir 818 can extend between a base end 818a and a mouthpiece end 818b. Fig.17 As shown, the reservoir 818 may be defined as a tubular configuration and include a bore 884 extending therethrough.

[0171] The cartridge 804 may also include a liquid delivery element 820. The liquid delivery element 820 may extend between the base end 820a and the mouthpiece end 820b. Further, the liquid delivery element 820 may extend between the reservoir 818 and the heating element 822 to deliver the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid delivery element 820 may be at least partially received in the aperture 884 defined by the reservoir 818 (see Fig.17 )middle.

[0172] One or both of the reservoir 818 and the liquid delivery element 820 may include a porous monolithic piece such as porous glass or porous ceramic. In an exemplary embodiment, the liquid delivery element 820 may include a porous monolithic piece, and the reservoir 818 may include a fiber mat (e.g., cellulose acetate) that may be wrapped around it. In some embodiments, the liquid delivery element 820 may be relatively more porous than the reservoir 818. In this regard, the liquid delivery element 820 may be configured to draw the aerosol precursor composition held in the reservoir 818 to the heating element 822. Further, in some embodiments, one or both of the reservoir 818 and the liquid delivery element 820 may be defined with a variable porosity.

[0173] like Fig.16 As shown, the heating element 822 can extend at least partially around the liquid delivery element 820. More specifically, the liquid delivery element 820 can define a protrusion 864, which can be located at the distal end of the liquid delivery element. In this embodiment, the protrusion 864 can be positioned at the mouthpiece end 820b of the liquid delivery element 820. Fig.16 As shown, the heating element 822 may extend at least partially around the protrusion 864 and contact the protrusion 864.

[0174] like Fig.18 As shown, the liquid delivery element 820 may be defined with one or more channels 855, which extend at least partially through the liquid delivery element 820. One or more channels 855 may include a slot 866. As schematically shown, the electronic component 826 may be received in the one or more channels 855 at the slot 866. Further, the one or more channels 855 defined in the liquid delivery element 820 may include a first terminal recess 868 (see Fig.17 ) and a second terminal groove 870. The protrusion 864 can extend from the mouthpiece end 820b of the liquid delivery element 820 to the terminal grooves 868, 870. The terminal grooves 868, 870 can extend between the protrusion 864 and the narrow groove 866 on each side of the liquid delivery element 820. The narrow groove 866 can extend from the terminal grooves 868, 870 to the base end 820a of the liquid delivery element 820.

[0175] like Fig.16 and 17 As shown, the heating terminals 848, 850 may extend through one or more channels 855 at the slots 866 and terminal recesses 868, 870 (see Fig.18 In this regard, the first heating terminal 848 and the second heating terminal 850 can be positioned between the liquid delivery element 820 and the reservoir 818. The longitudinal axis of the liquid delivery element 820 can be substantially parallel to the longitudinal axis of the first heating terminal 848 and the longitudinal axis of the second heating terminal 850.

[0176] As described above, electronic component 826 (see e.g. Fig.17 and 18 ) can be at least partially positioned within the liquid delivery element 820. In this regard, the electronic component 826 can be received in one or more channels 855 at the slot 866 between the first heating terminal 848 and the second heating terminal 850.

[0177] Further, the channel 855 defined in the liquid delivery element 820 may include one or more airflow grooves. In the illustrated embodiment, the liquid delivery element 820 is defined with a first airflow groove 886 and a second airflow groove 888. The airflow grooves 886, 888 may be positioned between the end grooves 868, 870 and extend along the longitudinal length of the liquid delivery element 820 at the outer surface of the liquid delivery element 820. In this regard, the airflow may be defined with a flow path that passes through the base 832, around the liquid delivery element 820 through the airflow grooves 886, 888, through the heating element 822, and out of the mouthpiece 846 through the mouthpiece opening, where vapor is added to the airflow at the heating element 822. Therefore, a separate flow guide may not be required.

[0178] With respect to the generation of vapor, the reservoir 818 can contain an aerosol precursor composition. The liquid delivery element 820 can be in contact with the reservoir 818 over substantially its entire length except at the protrusion 864. In addition, the liquid delivery element 820 can contact a relatively large portion of the inner circumference of the hole 884 extending through the reservoir 818 (e.g., as shown in FIG. 1 ). Fig.17 820a). By providing a relatively large contact area between the reservoir 818 and the liquid delivery element 820, fluid transfer from the reservoir to the liquid delivery element can be improved. Similarly, the heating element 822 can substantially surround the liquid delivery element 820 at the protrusion 864 to provide improved vapor production.

[0179] Fig.19 and 20A cartridge 904 is shown according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 904 may include an outer body 916 and a base 932 coupled to one end of the outer body. A mouthpiece opening 924 may be defined in a mouthpiece 946 that may engage with an end of the outer body 916 opposite the base 932. A heating element 922 may be positioned within the outer body 916. As shown, in one embodiment, the longitudinal axis of the heating element 922 may be substantially parallel to the longitudinal axis of the outer body 916.

[0180] The first heating terminal 948 and the second heating terminal 950 can be coupled to the heating element 922. The electronic component 926 (see Fig.19 ) can be received in the outer body 916. The longitudinal axis of the electronic component 926 can extend substantially perpendicular to the longitudinal axis of the outer body 916. Further, the first heating terminal 948 and the second heating terminal 950 can extend substantially perpendicular to the longitudinal axis of the electronic component 926. The heating terminals 948, 950 and the electronic component terminals can engage the electronic component 926 and extend into the base 932 to allow electrical connection with the control body as described above. In this regard, Fig.19 The terminals, base and electronic components can be Fig.12 The terminals, bases and electronic components shown in the drawings are substantially similar or identical. Therefore, for the purpose of brevity, details about these components and the functions performed thereby will not be repeated.

[0181] In addition, the cartridge 904 may include a reservoir 918 received in the outer body 916. The reservoir 918 may contain an aerosol precursor composition. The reservoir 918 may extend between a base end 918a and a mouthpiece end 918b. The electronic component 926 may be positioned between the base end 918a and the base 932 of the reservoir 918. The reservoir 918 may be defined as a tubular configuration and include a hole 984 extending therethrough (see Fig. 20 ).

[0182] The cartridge 904 may also include a liquid delivery element 920. The liquid delivery element 920 may extend between the base end 920a and the mouthpiece end 920b. The electronic component 926 may be positioned between the base end 920a and the base 932. Further, the liquid delivery element 920 may extend between the reservoir 918 and the heating element 922 so as to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid delivery element 920 may be at least partially received in the hole 984 defined by the reservoir 918. For example, the liquid delivery element 920 may be defined as a cylindrical configuration, wherein the protrusion 964 extends outwardly from the liquid delivery element at the mouthpiece end 920b.

[0183] One or both of the reservoir 918 and the liquid delivery element 920 may include a porous monolithic piece such as porous glass or porous ceramic. In an exemplary embodiment, the liquid delivery element 920 may include a porous monolithic piece, and the reservoir 918 may include a fiber mat (e.g., cellulose acetate) that may be wrapped around it. In some embodiments, the liquid delivery element 920 may be relatively more porous than the reservoir 918. In this regard, the liquid delivery element 920 may be configured to draw the aerosol precursor composition held in the reservoir 918 to the heating element 922. Further, in some embodiments, one or both of the reservoir 918 and the liquid delivery element 920 may be defined with a variable porosity.

[0184] like Fig.19 As shown, the heating element 922 can extend at least partially around the liquid delivery element 920. More specifically, the heating element 922 can extend at least partially around and contact the protrusion 964 where the liquid delivery element 920 is inserted from the hole 984 defined by the reservoir 918 (see Fig. 20 ) extends out.

[0185] like Fig. 20 As shown, the heating terminals 948, 950 can extend through the hole 984 defined by the reservoir 918. In this regard, the first heating terminal 948 and the second heating terminal 950 can be positioned next to the liquid delivery element 920 within the hole 984. The longitudinal axis of the liquid delivery element 920 can be substantially parallel to the longitudinal axis of the first heating terminal 948 and the longitudinal axis of the second heating terminal 950.

[0186] In some embodiments, the airflow may define a flow path through the base 932, through the reservoir 918, through the aperture 984, past the heating element 922, and out of the mouthpiece 946 through the mouthpiece opening 924, where vapor is added to the airflow. However, in other embodiments, the airflow may additionally or alternatively define a flow path through the base 932, around the reservoir 918, past the heating element 922, and out of the mouthpiece 946 through the mouthpiece opening 924, where vapor is added to the airflow.

[0187] In each of these embodiments, there may be no need to use a separate deflector through which the air flows. Fig.19 and 20 As shown, the cartridge 904 may further include a reservoir tube 990. The reservoir tube 990 may surround the reservoir 918 such that airflow is directed between the reservoir tube 990 and the outer body 916. In this regard, the reservoir tube 990 may be configured to hold the reservoir 918 in a tubular configuration and to separate the reservoir from the outer body 916 to allow airflow therebetween.

[0188] With respect to the generation of vapor, the reservoir 918 may contain an aerosol precursor composition. The liquid delivery element 920 may be in contact with the reservoir 918 substantially along its entire length except at the protrusion 964. Further, as Fig. 20 As shown, the liquid delivery element 920 can contact a relatively large portion of the inner circumference of the reservoir 918. By providing a relatively large contact area between the reservoir 918 and the liquid delivery element 920, fluid transfer from the reservoir to the liquid delivery element can be improved. Similarly, the heating element 922 can substantially surround the liquid delivery element 920 at the protrusion 964 to provide improved vapor production.

[0189] Fig.21 and 22 A cartridge 1004 is shown according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 1004 can include an outer body 1016 and a base 1032 coupled to one end of the outer body. A mouthpiece opening 1024 can be defined in a mouthpiece 1046 that can engage with an end of the outer body 1016 opposite the base 1032. A heating element 1022 can be positioned within the outer body 1016. As shown, in one embodiment, the longitudinal axis of the heating element 1022 can be substantially parallel to the longitudinal axis of the outer body 1016.

[0190] The first heating terminal 1048 and the second heating terminal 1050 can be coupled to the heating element 1022. The electronic component 1026 can be received in the outer body 1016. The longitudinal axis of the electronic component 1026 can extend substantially perpendicular to the longitudinal axis of the outer body 1016. Further, the first heating terminal 1048 and the second heating terminal 1050 can extend substantially perpendicular to the longitudinal axis of the electronic component 1026. The terminals 1048, 1050 and the electronic component terminals can engage the electronic component 1026 and extend into the base 1032 to allow electrical connection with the control body as described above. In this regard, Fig.21 The terminals, base and electronic components can be Fig.12 The terminals, bases and electronic components shown in the drawings are substantially similar or identical. Therefore, for the purpose of brevity, details about these components and the functions performed thereby will not be repeated.

[0191] In addition, the cartridge 1004 may include a reservoir 1018 received in the outer body 1016. The reservoir 1018 may contain an aerosol precursor composition. The reservoir 1018 may extend between a base end 1018a and a mouthpiece end 1018b. The electronic component 1026 may be positioned between the base end 1018a and the base 1032 of the reservoir 1018. The reservoir 1018 may be defined as a modified tubular structure including an opening 1084 extending therethrough (see Fig. 22).

[0192] The cartridge 1004 may also include a liquid delivery element 1020. The liquid delivery element 1020 may extend between a base end positioned near the base 1032 and a mouthpiece end positioned near the mouthpiece 1046. The electronic component 1026 may be positioned between the base end of the liquid delivery element 1020 and the base 1032. Further, the liquid delivery element 1020 may extend between the reservoir 1018 and the heating element 1022 so as to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid delivery element 1020 may be at least partially received in the opening 1084 defined by the reservoir 1018. For example, the liquid delivery element 1020 may be defined as a cylindrical configuration, wherein the protrusion 1064 extends outwardly from the liquid delivery element at the mouthpiece end of the liquid delivery element.

[0193] One or both of the reservoir 1018 and the liquid delivery element 1020 may include a porous monolithic piece such as porous glass or porous ceramic. In an exemplary embodiment, the liquid delivery element 1020 may include a porous monolithic piece, and the reservoir 1018 may include a fiber mat (e.g., cellulose acetate) that may be wrapped around it. In some embodiments, the liquid delivery element 1020 may be relatively more porous than the reservoir 1018. In this regard, the liquid delivery element 1020 may be configured to draw the aerosol precursor composition held in the reservoir 1018 to the heating element 1022. Further, in some embodiments, one or both of the reservoir 1018 and the liquid delivery element 1020 may be defined with a variable porosity.

[0194] like Fig.21 As shown, the heating element 1022 can extend at least partially around the liquid delivery element 1020. More specifically, the heating element 1022 can extend at least partially around and contact the protrusion 1064 where the liquid delivery element 1020 is inserted from the opening 1084 defined by the reservoir 1018 (see Fig. 22 ) extends out.

[0195] like Fig. 22 As shown, the heating terminals 1048, 1050 can extend through an opening 1084 defined by the reservoir 1018. In this regard, the first heating terminal 1048 and the second heating terminal 1050 can be positioned next to the liquid delivery element 1020 within the opening 1084. The longitudinal axis of the liquid delivery element 1020 can be substantially parallel to the longitudinal axis of the first heating terminal 1048 and the longitudinal axis of the second heating terminal 1050.

[0196] Further, the cartridge 1004 may include a flow guide 1092. The flow guide 1092, which may be tubular, may extend through the reservoir 1018. Fig. 22 As shown, the flow guide 1092 can be received in the opening 1084 extending through the reservoir 1018, or the flow guide can be received in a separate hole extending through the reservoir. The flow guide 1092 can define a longitudinal axis that extends substantially parallel to the longitudinal axis of the liquid delivery element 1020 and substantially parallel to the longitudinal axis of the outer body 1016. However, as shown in FIG. Fig. 22 As shown, the flow director 1092 can be offset from the central longitudinal axis of the outer body 1016 and positioned beside the fluid delivery element 1020.

[0197] Thus, in some embodiments, the airflow may define a flow path through the base 1032, through the flow director 1092, past the heating element 1022, and out of the mouthpiece 1046 through the mouthpiece opening 1024, where vapor is added to the airflow. Thus, in some embodiments, a separate flow director may be employed to direct the airflow as desired.

[0198] With respect to the generation of vapor, the reservoir 1018 may contain an aerosol precursor composition. The liquid delivery element 1020 may be in contact with the reservoir 1018 substantially along its entire length except at the protrusion 1064. Further, as Fig. 22 As shown, the liquid delivery element 1020 can contact a relatively large portion of the inner surface of the reservoir 1018. By providing a relatively large contact area between the reservoir 1018 and the liquid delivery element 1020, fluid transfer from the reservoir to the liquid delivery element can be improved. Similarly, the heating element 1022 can substantially surround the liquid delivery element 1020 at the protrusion 1064 to provide improved vapor production.

[0199] In additional embodiments, methods for making an aerosol delivery device are provided. Fig.23 As shown, the method may include positioning the heating element, the reservoir, and the liquid transport element in the outer body in operation 1102 so that the liquid transport element contacts the reservoir and the heating element. Positioning the heating element, the reservoir, and the liquid transport element in the outer body in operation 1102 may include aligning respective longitudinal axes of the heating element, the reservoir, and the liquid transport element in operation 1103.

[0200] In some embodiments, the method may further include positioning the liquid delivery element at least partially within the reservoir. Positioning the liquid delivery element at least partially within the reservoir may include wrapping the liquid delivery element with the reservoir. The method may additionally include inserting a heating element into a channel extending at least partially through the liquid delivery element. In another embodiment, the method may further include coupling the heating element to an outer surface of the liquid delivery element.

[0201] In additional embodiments, a method for making an aerosol delivery device is provided. The method may include forming a liquid delivery element from a porous monolithic material. Further, the method may include positioning a heating element, a reservoir, and a liquid delivery element in an outer body such that the liquid delivery element is in contact with the reservoir and the heating element is proximate to the liquid delivery element. The method may additionally include dispensing an aerosol precursor composition into the reservoir.

[0202] In some embodiments, forming the liquid transport element may include injection molding the liquid transport element. The method may also include engaging the first heating terminal and the second heating terminal with the heating element. Forming the liquid transport element from a porous monolithic material may include insert molding at least one of the heating element, the first heating terminal, and the second heating terminal into the liquid transport element. In addition, forming the liquid transport element from a porous monolithic material may include forming the liquid transport element from a porous ceramic.

[0203] As described herein, the elements of the cartridge of the present disclosure may include a porous monolith. In this regard, the monolithic reservoir and liquid delivery element, reservoir and / or liquid delivery element of the present disclosure may include a porous monolith. The porous monolith may be shape-stable, thereby facilitating the assembly of the cartridge. For example, the porous monolith may be substantially rigid. Further, the shape-stable porous monolith may be suitable for guiding airflow through the cartridge. In contrast, embodiments of the liquid delivery element formed by glass fiber and the reservoir formed by cellulose acetate may be flexible, and their shapes may change when in contact, so that the assembly of the cartridge including such parts may be relatively more difficult, and these parts may not be suitable for guiding the airflow caused by the pressure changes in the cartridge that may change its shape. Further, the parts comprising the porous monolith may be molded or otherwise formed to define a shape that may be difficult to form by a flexible material.

[0204] As further described herein, each porous monolith disclosed herein may be defined with a variable porosity. Variable porosity may be used to store and guide aerosol precursor compositions to desired locations within the porous monolith. For example, a relatively high porosity may be used at a desired location where a fluid is stored or transported. On the contrary, a relatively small porosity may be used at a location where leakage of the porous monolith is more of a concern. Thus, for example, in an embodiment of a cartridge comprising a monolithic reservoir and a liquid delivery element, a relatively more porous region may be configured to store and guide aerosol precursor compositions to a heating element. In an embodiment of a cartridge comprising a reservoir and a liquid delivery element as separate elements, a relatively more porous region in the reservoir may be configured to store and draw aerosol precursor compositions to the liquid delivery element. Additionally or alternatively, a relatively more porous region in the liquid delivery element may be configured to draw aerosol precursor compositions within the liquid delivery element to the heating element. In this regard, the aerosol precursor composition may flow relatively more easily through a portion of the porous monolith defined with a relatively large porosity.

[0205] Therefore, one or more regions of the porous monolith may be defined with a relatively large porosity to accommodate storage and promote the movement of the aerosol precursor composition through the region. These regions may extend along at least a portion of the longitudinal length of the porous monolith, thereby facilitating the movement of the aerosol precursor composition toward the heating element, which may be positioned near its end. Further, such regions with relatively large porosity may be partially or completely surrounded by regions with relatively small porosity to resist leakage of the aerosol precursor composition from the porous monolith. In some embodiments, the most leaky part of the porous monolith may be an area exposed to the airflow through the barrel, which may be close to the heating element. Therefore, the porous monolith may include relatively small pores near the heating element, while the porous monolith may include relatively large pores near the reservoir. The porosity gradient will naturally pull the liquid aerosol precursor composition from the region of larger pores to the domain of smaller pores. Therefore, by changing the porosity of the porous monolith, the fluid storage and transport characteristics of the porous monolith can be changed according to the position therein.

[0206] In addition, for a given cartridge size, the use of a cartridge constructed as described herein can provide benefits in terms of increased aerosol precursor composition capacity. For example, Figure 1 The cartridge 104 shown in FIG. 1 may have a total aerosol precursor composition capacity of about 0.6 cubic centimeters (cc) for the liquid delivery element 120 and the reservoir 118. However, the use of a liquid delivery element, a reservoir, or a monolithic reservoir and a liquid delivery element comprising a porous monolith may provide an increased aerosol precursor composition capacity in a cartridge having substantially the same outer dimensions. In this regard, Figure 2 , 4, 6, 10, 14, 16, 19 and 21 shown in the embodiment of the cartridge 204, 304, 404, 504, 704, 804, 904, 1004 can have a total aerosol precursor composition capacity of 1.1cc, 0.9cc, 1.1cc, 1.0cc, 1.1cc, 1.1cc, 0.9cc and 1.1cc, respectively. In this regard, in the embodiment of the cartridge disclosed herein, the use of the space within the outer body to receive the aerosol precursor composition is maximized.

[0207] Further, the use of a cartridge constructed as described herein may provide benefits in terms of improved vapor production. Figure 1 The heating element 122 in the cartridge 104 includes a relatively small coil in view of the relatively small diameter of the liquid delivery element 120, but Figure 2 , 4 , 6, 10, 14, 16, 19 and 21 shown in the cartridge 204, 304, 404, 504, 704, 804, 904, 1004 heating element can be about twice as long in terms of the length of the metal wire that limits the heating element. In this regard, the liquid delivery element or the integral reservoir and the liquid delivery element can be limited to an increased internal or external dimension, such a size is configured to accommodate a relatively large heating element. Using a relatively large heating element can allow a greater amount of heat to be generated, thereby allowing steam and / or a greater amount of steam to be generated more quickly.

[0208] 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 foregoing description and the associated drawings. Therefore, it should be understood that the present invention is not limited to the specific embodiments disclosed, and various modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used in a general and descriptive sense, not for the purpose of limitation.

Claims

1. A nebulizer for an aerosol delivery device, the nebulizer comprising: a porous monolith formed of a ceramic, the porous monolith comprising a reservoir defining a channel, the reservoir configured to retain an aerosol precursor composition along the channel, and comprising a liquid delivery element in contact with the channel along a majority of the channel of the reservoir and configured to deliver the aerosol precursor composition through a portion of the liquid delivery element; as well as A evaporation element is positioned relative to the porous monolith so as to be configured for evaporation of the aerosol precursor composition.

2. The atomizer according to claim 1, characterized in that The porous monolith has a substantially square or substantially rectangular cross-section.

3. The atomizer according to claim 1, characterized in that The evaporation element is a heater.

4. The atomizer according to claim 3, characterized in that At least a portion of the first end of the ceramic monolith is substantially planar, and the heater is at least partially positioned on the substantially planar portion of the ceramic monolith.

5. An aerosol delivery device comprising outer shell; a porous monolith formed of ceramic and positioned within the outer shell, the porous monolith including a reservoir defining a channel, the reservoir configured to retain an aerosol precursor composition along the channel, and including a liquid delivery element in contact with the channel along a majority of the channel of the reservoir and configured to deliver the aerosol precursor composition through a portion of the liquid delivery element; A vaporization element is positioned within the outer shell relative to the porous monolith so as to be configured for vaporizing the aerosol precursor composition to form a vapor.

6. The aerosol delivery device according to claim 5, characterized in that Also included is an air inlet, a mouth end, and an aerosol port formed at the mouth end.

7. The aerosol delivery device according to claim 6, characterized in that The air flow passing between the air inlet and the aerosol port is configured to pass substantially across the surface of the porous monolith.

8. The aerosol delivery device according to claim 5, characterized in that The porous monolith has a substantially square or substantially rectangular cross-section.

9. The aerosol delivery device according to claim 5, characterized in that The evaporation element is a heater.

10. The aerosol delivery device of claim 9, wherein: At least a portion of the first end of the ceramic monolith is substantially planar, and the heater is at least partially positioned on the substantially planar portion of the ceramic monolith.

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