Aerosol delivery device having improved sealing arrangement - Patents.com

Abstract

The present invention includes an aerosol delivery device including a cartridge, an atomizer assembly disposed about a connecting end of the cartridge, and a control body operably engaged with the cartridge about the connecting end. The atomizer assembly includes a base defining a first surface engageable with the connecting end to define a reservoir chamber containing an aerosol precursor composition, an atomizer disposed about the first surface of the base, a liquid transport element defining opposing first and second ends having exposed end faces in fluid communication with the reservoir chamber, and a reservoir chamber seal arrangement comprising a first seal member circumferentially sealing the opposing first and second ends of the liquid transport element and exposing the end faces such that the reservoir chamber is sealed by the reservoir chamber seal arrangement except for the exposed end faces of the liquid transport element.

Description

[Technical field]

[0001] The present disclosure relates to an aerosol delivery device, and more particularly to an aerosol delivery device including a seal arrangement that may utilize a seal member to laterally and axially position an atomizer within a cartridge. The aerosol delivery device of the present disclosure may utilize an aerosol precursor composition for the generation of an aerosol by an atomizer (e.g., smoking articles for obtaining components of tobacco, tobacco extracts, nicotine, synthetic nicotine, non-nicotine flavorings, and other materials in an inhalable form, commonly referred to as heat-not-burn systems or e-cigarettes). The components of such articles may be made from or derived from tobacco, or these articles may otherwise feature tobacco for human consumption, and may vaporize components of tobacco and / or other tobacco-related materials to form an inhalable aerosol for human consumption. [Background technology]

[0002] Many smoking articles have been proposed over the years as an improvement or replacement for the smoking product based on tobacco combustion.Exemplary replacements include devices in which solid or liquid fuel is burned to transfer heat to tobacco, or devices in which chemical reactions are used to provide such a heat source.Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., the entirety of which is incorporated herein by reference.

[0003] The gist of the improvement or replacement of smoking articles has typically been to provide the sensation associated with smoking cigarettes, cigars or pipes without delivering significant amounts of incomplete combustion and pyrolysis products.To this end, many smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or provide the smoking sensation of cigarettes, cigars or pipes without significantly burning tobacco.See, for example, the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art described in U.S. Patent No. 7,726,320 to Robinson et al. and U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al. and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically-powered heating sources referenced by trade names and commercial sources described in U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically-powered heating sources referenced by trade names and commercial sources are described in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is also incorporated herein by reference in its entirety.Other representative cigarettes or smoking articles that have been described and, in some cases, are commercially available include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 4,922,901, U.S. Pat. No. 4,947,874, and U.S. Pat. No. 4,947,875 to Brooks et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,249,586 to Counts ... No. 5,388,594 to Higgins et al., U.S. Pat. No. 5,666,977 to Adams et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513, No. 253 to Robinson et al., U.S. Pat. No. 7,726,320 to Hamano, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. Appl. Pub. Nos. 2009 / 0095311 to Hon, U.S. Pat. Appl. Pub. Nos. 2006 / 0196518 to Hon, U.S. Pat. Appl. Pub. Nos. 2009 / 0126745 to Hon, and 2009 / 0188490 to Thorens et al. No. 2009 / 0272379, U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al., U.S. Patent Application Publication Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, and WO 2010 / 091593 to Hon.

[0004] In some cases, some smoking articles, especially those using conventional paper wrapping materials, also tend to scorch the paper wrapping material covering the ignitable fuel source due to the high temperature achieved by the fuel source in close proximity to the paper wrapping material. This can reduce the enjoyment of the smoking experience for some consumers and can mask or undesirably alter the flavor delivered to the consumer by the aerosol delivery component of the smoking article. In a further example, conventional smoking articles can generate relatively significant levels of gases such as carbon monoxide and / or carbon dioxide during use (e.g., as a product of carbon combustion). In yet another example, conventional smoking articles can suffer from poor performance in aerosolizing aerosol-forming components. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Pat. No. 9,078,473 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] US Patent Application Publication No. 2013 / 0255702 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2015 / 0220232 [Patent Document 6] US Patent Application Publication No. 2015 / 0245659 [Patent Document 7] U.S. Pat. No. 4,735,217 [Patent Document 8] U.S. Pat. No. 4,922,901 [Patent Document 9] U.S. Pat. No. 4,947,874 [Patent Document 10] U.S. Pat. No. 4,947,875 [Patent Document 11] U.S. Pat. No. 5,060,671 [Patent Document 12] U.S. Pat. No. 5,249,586 [Patent Document 13] U.S. Pat. No. 5,388,594 [Patent Document 14] U.S. Pat. No. 5,666,977 [Patent Document 15] U.S. Patent No. 6,053,176 [Patent Document 16] U.S. Patent No. 6,164,287 [Patent Document 17] U.S. Pat. No. 6,196,218 [Patent Document 18] U.S. Patent No. 6,810,883 [Patent Document 19] U.S. Patent No. 6,854,461 [Patent Document 20] U.S. Patent No. 7,832,410 [Patent Document 21] U.S. Patent No. 7,513,253 [Patent Document 22] U.S. Pat. No. 7,896,006 [Patent Document 23] U.S. Patent No. 6,772,756 [Patent Document 24] US Patent Application Publication No. 2009 / 0095311 [Patent Document 25] US Patent Application Publication No. 2006 / 0196518 [Patent Document 26] US Patent Application Publication No. 2009 / 0126745 [Patent Document 27] US Patent Application Publication No. 2009 / 0188490 [Patent Document 28] US Patent Application Publication No. 2009 / 0272379 [Patent Document 29] US Patent Application Publication No. 2009 / 0260641 [Patent Document 30] US Patent Application Publication No. 2009 / 0260642 [Patent Document 31] US Patent Application Publication No. 2008 / 0149118 [Patent Document 32] US Patent Application Publication No. 2010 / 0024834 [Patent Document 33] US Patent Application Publication No. 2010 / 0307518 [Patent Document 34] International Publication No. 2010 / 091593 Summary of the Invention [Problem to be solved by the invention]

[0006] It would therefore be desirable to provide a smoking article that addresses one or more of the technical problems sometimes associated with conventional smoking articles, in particular, it would be desirable to provide a smoking article that is easy to use and offers improved components. [Means for solving the problem]

[0007] The present disclosure relates to an aerosol delivery device that can be used to generate a vapor. The present disclosure includes, but is not limited to, the following exemplary embodiments.

[0008] Exemplary embodiment 1: A cartridge comprising an outer housing formed from an outer wall, the outer housing having a mouth end and an opposing connecting end; an atomizer assembly disposed about the connecting end of the outer housing, the atomizer assembly comprising: a base defining a first surface and an opposing second surface, the first surface being engageable with the connecting end of the outer housing to define a reservoir chamber between the outer wall of the outer housing and the first surface of the base for containing an aerosol precursor composition; an atomizer disposed about the first surface of the base for atomizing the aerosol precursor composition and forming an aerosol; and a liquid transport element disposed about the first surface of the base for transporting an aerosol from the reservoir chamber through an end face of the liquid transport element into contact with the atomizer. an atomizer assembly comprising: a liquid transport element defining opposed first and second ends having exposed end faces in fluid communication with a reservoir chamber to direct an aerosol precursor composition therethrough; and a reservoir chamber seal arrangement comprising a first seal member disposed about a first surface of the base such that the reservoir chamber is sealed by the reservoir chamber seal arrangement except for the exposed end faces of the liquid transport element, the first seal member receiving the opposed first and second ends of the liquid transport element to circumferentially seal the opposed first and second ends of the liquid transport element and expose their end faces; and a control body operably engaged with the cartridge about a connecting end of the outer housing.

[0009] Exemplary embodiment 2: An aerosol delivery device of exemplary embodiment 1, or any combination of the preceding exemplary embodiments, wherein the reservoir chamber seal configuration comprises a flow director defining a base portion, a flow tube extending from the base portion and arranged such that a first seal member is disposed between the flow director and a first surface of the base, and the flow tube is in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

[0010] Exemplary embodiment 3: The aerosol delivery device of exemplary embodiments 1-2, or any combination of the preceding exemplary embodiments, wherein the base further comprises a retaining member extending from its first surface and engaging the flow director, the retaining member being positioned to compress the flow director against the first seal member and the first surface of the base, thereby sealing the reservoir chamber except for the exposed end face of the liquid transport element.

[0011] Exemplary embodiment 4: An aerosol delivery device of exemplary embodiments 1-3, or any combination of the preceding exemplary embodiments, wherein the retaining member comprises one or more pairs of arms extending generally perpendicularly from a first surface of the base and one or more pairs of respective protrusions extending toward a center of the base, the protrusions engaging a base portion of the flow director to compress the base portion of the flow director against the first sealing member and the first surface of the base, thereby sealing the reservoir chamber except for the exposed end face of the liquid transport element.

[0012] Exemplary embodiment 5: The aerosol delivery device of exemplary embodiments 1-4, or any combination of the preceding exemplary embodiments, wherein the first sealing member comprises a pair of opposing annular members having open receiving portions, a pair of opposing connection flanges extending between the open receiving portions, the opposing first and second ends of the liquid transport element are circumferentially sealed by the open receiving portions, one of the first and second ends of the liquid transport element is at least partially received in one of the open receiving portions such that the end faces are exposed, and the reservoir chamber is sealed by a reservoir chamber seal arrangement at an interface between the base portion of the flow director and the flanges and receiving portions of the liquid transport element excluding the exposed end faces of the liquid transport element.

[0013] Exemplary embodiment 6: The aerosol delivery device of exemplary embodiments 1-5, or any combination of the preceding exemplary embodiments, wherein the cartridge further comprises a mouthpiece channel extending at least partially along a length of the reservoir chamber, the mouthpiece channel defining an open first end and an open terminal end, the open first end being in fluid communication with the mouth end of the outer housing and the open terminal being in fluid communication with a flow tube of the flow director such that the aerosol is directed through the mouthpiece channel.

[0014] Exemplary embodiment 7: The aerosol delivery device of exemplary embodiments 1-6, or any combination of the preceding exemplary embodiments, wherein the reservoir chamber seal arrangement comprises a second seal member disposed at an open end of the mouthpiece channel to provide a seal between the flow tube and the mouthpiece channel.

[0015] Exemplary embodiment 8: The aerosol delivery device of exemplary embodiments 1-7, or any combination of the preceding exemplary embodiments, further comprising electrical contacts proximate the second surface of the base and providing electrical communication between the atomizer and a power source within the control body when the cartridge is engaged with the control body.

[0016] Exemplary embodiment 9: An aerosol delivery device of exemplary embodiments 1-8, or any combination of the preceding exemplary embodiments, wherein the electrical terminal in electrical communication with the atomizer extends from the first surface of the base through the second surface of the base to contact the electrical contact.

[0017] Exemplary embodiment 10: An aerosol delivery device of exemplary embodiments 1-9, or any combination of the preceding exemplary embodiments, wherein the atomizer comprises a coil having a plurality of turns, the liquid transport element defines an outer surface extending longitudinally between the end faces, and the plurality of turns of the coil are wound around the outer surface and between the end faces of the liquid transport element.

[0018] Exemplary embodiment 11: A cartridge for an aerosol delivery device, comprising: an outer housing formed from an exterior wall, the outer housing having a mouth end and an opposing connecting end; an atomizer assembly disposed about the connecting end of the outer housing, the base defining a first surface and an opposing second surface, the first surface being engageable with the connecting end of the outer housing to define a reservoir chamber between the outer wall of the outer housing and the first surface of the base for containing an aerosol precursor composition; an atomizer disposed about the first surface of the base to atomize the aerosol precursor composition and form an aerosol; and a liquid transport element, the first seal member disposed about the first surface of the base for transporting liquid from the reservoir chamber. 1. A cartridge for an aerosol delivery device comprising: an atomizer assembly comprising: a liquid transport element defining first and second opposed ends having exposed end faces in fluid communication with a reservoir chamber to direct an aerosol precursor composition through the end faces of the liquid transport element and into contact with the atomizer; and a reservoir chamber seal arrangement comprising a first seal member disposed around a first surface of the base and adapted to receive the first and second opposed ends of the liquid transport element and circumferentially seal the first and second opposed ends of the liquid transport element and expose their end faces, such that the reservoir chamber is sealed by the reservoir chamber seal arrangement except for the exposed end faces of the liquid transport element.

[0019] Exemplary embodiment 12: The cartridge of exemplary embodiment 11, or any combination of the preceding exemplary embodiments, wherein the reservoir chamber seal configuration comprises a flow director defining a base portion, a flow tube extending from the base portion such that a first seal member is disposed between the flow director and a first surface of the base, and the flow tube is in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

[0020] Exemplary embodiment 13: The cartridge of exemplary embodiments 11-12, or any combination of the preceding exemplary embodiments, wherein the base further comprises a retaining member extending from a first surface thereof and engaging the flow director, the retaining member being arranged to compress the flow director against the first seal member and the first surface of the base, thereby sealing the reservoir chamber except for the exposed end face of the liquid transport element.

[0021] Exemplary embodiment 14: A cartridge of exemplary embodiments 11-13, or any combination of the preceding exemplary embodiments, wherein the retaining member comprises one or more pairs of arms extending generally perpendicularly from a first surface of the base and one or more pairs of respective protrusions extending toward a center of the base, the protrusions engaging a base portion of the flow director to compress the base portion of the flow director against the first sealing member and the first surface of the base, thereby sealing the reservoir chamber except for an exposed end face of the liquid transport element.

[0022] Exemplary embodiment 15: The cartridge of exemplary embodiments 11-14, or any combination of the preceding exemplary embodiments, wherein the first seal member comprises a pair of opposing annular members having connection flanges with open receivers, the pair of opposing connection flanges extending between the open receivers such that the opposing first and second ends of the liquid transport element are circumferentially sealed by the open receivers and the end faces are exposed, one of the first and second ends of the liquid transport element is at least partially received in one of the open receivers, and the reservoir chamber is sealed by a reservoir chamber seal arrangement at an interface between the base portion of the flow director and the flanges and receivers of the liquid transport element excluding the exposed end faces of the liquid transport element.

[0023] Exemplary embodiment 16: The cartridge of exemplary embodiments 11-15, or any combination of the preceding exemplary embodiments, further comprising a mouthpiece channel extending at least partially along a length of the reservoir chamber, the mouthpiece channel defining an open first end and an open terminal end, the open first end in fluid communication with the mouth end of the outer housing and the open terminal in fluid communication with a flow tube of the flow director, whereby the aerosol is directed through the mouthpiece channel.

[0024] Exemplary embodiment 17: The cartridge of exemplary embodiments 11-16, or any combination of the preceding exemplary embodiments, wherein the reservoir chamber seal arrangement comprises a second seal member, the second seal member being disposed at an open end of the mouthpiece channel to provide a seal between the flow tube and the mouthpiece channel.

[0025] Exemplary embodiment 18: A cartridge of exemplary embodiments 11-17, or any combination of the preceding exemplary embodiments, wherein the atomizer comprises a coil having a plurality of turns, the liquid transport element defines an outer surface extending longitudinally between the end faces, and the plurality of turns of the coil are wound around the outer surface and between the end faces of the liquid transport element.

[0026] Exemplary embodiment 19: A method of manufacturing a cartridge for an aerosol delivery device, comprising providing an atomizer assembly comprising: a base defining a first surface and an opposing second surface; an atomizer disposed about the first surface of the base for atomizing an aerosol precursor composition to form an aerosol; a liquid transport element disposed about the first surface of the base; and a reservoir chamber seal arrangement comprising a first seal member disposed about the first surface of the base and adapted to receive opposed first and second ends of the liquid transport element and circumferentially seal the opposed first and second ends of the liquid transport element and expose end faces thereof; The method includes disposing an atomizer assembly around a connecting end of a side housing, the outer housing having a closed mouth end opposite the connecting end, and engaging a first surface of the base with the connecting end of the outer housing to define a reservoir chamber for containing an aerosol precursor composition between an outer wall of the outer housing and the first surface of the base, such that the reservoir chamber is sealed by a reservoir chamber seal arrangement except for an exposed end face of the liquid transport element, the exposed end face of the liquid transport element being in fluid communication with the reservoir chamber to direct the aerosol precursor composition from the reservoir chamber through the end face of the liquid transport element and into contact with the atomizer.

[0027] Exemplary embodiment 20: The method of exemplary embodiment 19, or any combination of the preceding exemplary embodiments, wherein providing the atomizer assembly includes providing a flow director having a flow tube defining a base portion, the flow tube extending from the base portion and positioned such that a first sealing member is disposed between the flow director and a first surface of the base, the flow tube being in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

[0028] It will be understood that the above summary is provided only for the purpose of summarizing certain exemplary aspects to provide a basic understanding of certain aspects of the present disclosure. It will therefore be understood that the above exemplary aspects are merely examples of certain aspects and should not be construed in any way to narrow the scope or spirit of the present disclosure. It will be understood that the scope of the present disclosure encompasses many potential aspects, some of which are further described below, in addition to those summarized herein. Furthermore, other features, aspects and advantages of the present disclosure will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the described aspects.

[0029] These and other features, aspects and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four or more of the above-described embodiments, as well as any combination of two, three, four or more features or elements described in this disclosure, regardless of whether such features or elements are expressly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, appear as intended to be combinable, unless the context clearly dictates otherwise.

[0030] To aid in the understanding of aspects of the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference numerals refer to like elements, and which are illustrative only and are not to be construed as limiting the present disclosure. [Brief description of the drawings]

[0031] [Figure 1] 1 shows a front view of an aerosol delivery device having an improved sealing arrangement according to an exemplary embodiment of the present disclosure. [Diagram 2]1 shows a top perspective view of a control body of an aerosol delivery device having an improved sealing configuration according to an exemplary embodiment of the present disclosure. [Figure 3A] 1A-1C show various views of a cartridge having an atomizer assembly for an aerosol delivery device having an improved sealing arrangement according to an exemplary embodiment of the present disclosure. [Figure 3B] 1A-1C show various views of a cartridge having an atomizer assembly for an aerosol delivery device having an improved sealing arrangement according to an exemplary embodiment of the present disclosure. [Figure 4] 1 shows a front view of an atomizer assembly for an aerosol delivery device having an improved sealing arrangement according to an exemplary embodiment of the present disclosure. [Diagram 5] 1 shows a top perspective view of a base for an atomizer assembly for an aerosol delivery device having an improved sealing arrangement according to an exemplary embodiment of the present disclosure. [Figure 6] 1 shows a top perspective view of a first seal member of a reservoir chamber seal arrangement for an atomizer assembly for an aerosol delivery device having an improved seal arrangement according to an exemplary embodiment of the present disclosure. [Figure 7] FIG. 1 shows a side view of a first seal member and a liquid transport element of a reservoir chamber seal arrangement for an atomizer assembly for an aerosol delivery device having an improved seal arrangement according to an exemplary embodiment of the present disclosure. [Figure 8] FIG. 1 shows a top perspective view of a first seal member, an atomizer and a liquid transport element of a reservoir chamber seal arrangement for an atomizer assembly for an aerosol delivery device having an improved seal arrangement according to an exemplary embodiment of the present disclosure. [Figure 9] 1 shows a front view of an atomizer assembly including a reservoir chamber seal arrangement for an aerosol delivery device having an improved seal arrangement according to an exemplary embodiment of the present disclosure. [Figure 10]1 shows a method flow diagram of a method of manufacturing a cartridge for an aerosol delivery device having an improved sealing arrangement according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] The present disclosure will now be described in further detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0033] The present disclosure provides a description of an article, e.g., an aerosol delivery device (and its assembly and / or manufacture), in which an aerosol precursor composition is heated (preferably without significant combustion of the material) to form an aerosol and / or inhalable substance. Most preferably, such an article is small enough to be considered a "handheld" device. In some embodiments, the article is characterized as a smoking article. As used herein, the term "smoking article" is intended to mean an article and / or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the mode of inhalation and exhalation, the type of taste or flavor, organoleptic effects, physical feel, mode of use, visual stimulation such as that provided by a visible aerosol, etc.) without substantially burning any component of the article and / or device. The term "smoking article" as used herein does not necessarily mean that, during operation, the article or aerosol delivery device produces smoke in the sense of an aerosol resulting from the by-products of combustion or pyrolysis of tobacco, but rather, that the article or device produces vapors (including vapors within an aerosol that are considered to be a visible aerosol that may be considered to be described as smoke-like) due to volatilization or vaporization of certain components, elements, etc. of the article and / or device. In certain embodiments, articles or devices characterized as smoking articles incorporate tobacco and / or tobacco-derived components.

[0034] As described above, the aerosol delivery device may provide many of the sensations (e.g., inhalation and exhalation patterns, flavor or flavor types, sensory stimulant effects, physical feel, mode of use, visual stimuli such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke) without substantially combusting any of its components. For example, a user of an aerosol delivery device according to certain exemplary embodiments of the present disclosure may hold and use the device in the same manner as a smoker would use a conventional smoking article, draw on one end of the component to inhale the aerosol generated by the component, take puffs at selected time intervals, etc.

[0035] The article or device of the present disclosure may also be characterized as being a vapor product, an aerosol delivery device, or a drug delivery article. Thus, such an article or device may be configured to provide one or more substances in an inhalable form or state. For example, the inhalable substance is substantially in vapor form (e.g., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance is in aerosol form (e.g., a suspension of fine solid particles or liquid droplets in a gas). For ease of understanding, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in a form or type suitable for human inhalation, whether or not visible and in a form that may be considered smoky. In some embodiments, the terms "vapor" and "aerosol" may be interchangeable. Thus, for simplicity, the terms "vapor" and "aerosol" used to describe the present disclosure are understood to be interchangeable unless otherwise specified.

[0036] Smoking articles of the present disclosure, when in use, are subject to many of the physical actions of an individual when using a conventional smoking article (e.g., a cigarette, cigar, or pipe that is used by igniting it with a flame and then inhaling the burnt and / or combusted tobacco). For example, a user of a smoking article of the present disclosure holds the article as a conventional smoking article, draws on one end of the article to inhale the aerosol produced by the article, and takes a puff for a selected time interval.

[0037] Although the system is generally described herein with respect to embodiments related to smoking articles, such as so-called "electronic cigarettes," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of items. For example, the description provided herein may be used in combination with tobacco heating products and related packaging embodiments for any of the products disclosed herein. Thus, it should be understood that the description of the features, components, features, and methods disclosed herein are discussed with respect to embodiments related to aerosol delivery devices by way of example only, and may be embodied and used in a variety of other products and methods.

[0038] The aerosol delivery device of the present disclosure generally includes a number of components disposed within an outer body or shell, which may be referred to as an outer housing. The overall design of the outer body or shell may vary, and the type or configuration of the outer body may vary, which may form the overall size and shape of the aerosol delivery device. In some exemplary embodiments, an elongated body resembling the shape of a cigarette or cigar may be formed from a single integral housing, or the elongated housing may be formed from two or more separable bodies, such as a cartridge and a control body. For example, the aerosol delivery device may comprise an elongated shell or body that may be substantially tubular in shape and may resemble the shape of a traditional cigarette or cigar. In another example, the aerosol delivery device may be substantially rectangular, trapezoidal, or may have a substantially rectangular cuboid shape. In one example, all components of the aerosol delivery device are housed within one housing. Alternatively, the aerosol delivery device may comprise two or more housings that are joined and separable. For example, the aerosol delivery device can have one part with a housing that contains one or more reusable components (e.g., a rechargeable battery and / or a rechargeable supercapacitor, and various electronics for controlling the operation of the article), and a separate second part (e.g., a mouthpiece) and / or disposable components (e.g., a disposable flavor-containing cartridge that contains aerosol precursor materials, flavors, etc.) that can be removably connected. More specific forms, configurations, and arrangements of components within a single-housing type unit or within a multiple-part separable-housing type unit will become apparent in light of the further disclosure provided herein. Furthermore, the design and component arrangements of various aerosol delivery devices can be understood in light of commercially available electronic aerosol delivery devices.

[0039] As described in further detail below, the control body of the aerosol delivery device of the present disclosure may comprise some combination of a power source (e.g., an electrical power source), at least one control component (e.g., a means for activating, controlling, regulating and deactivating power, such as by controlling the flow of current from the power source to other components of the article (e.g., a microprocessor, either individually or as part of a microcontroller, a printed circuit board (PCB) including a microprocessor and / or a microcontroller, etc.)), and a receiving chamber. Such a control body may be configured to receive one or more cartridges containing an aerosol precursor composition capable of generating an aerosol upon application of sufficient heat from an atomizer. In certain embodiments, the cartridge may define a reservoir chamber for housing the aerosol precursor composition, an atomizer, and a mouthpiece configured to allow inhalation for aerosol inhalation (e.g., a defined airflow path through the combined cartridge and control body such that the generated aerosol may be drawn therefrom upon inhalation). More specific forms, configurations and arrangements of components within the aerosol delivery system of the present disclosure will become apparent in light of the further disclosure provided below. Moreover, the selection and arrangement of the various aerosol delivery system components can be understood in consideration of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure.

[0040] In various aspects, an aerosol precursor composition may be aerosolized to form an aerosol. The aerosol precursor composition may contain a tobacco product or a composite of tobacco and other materials. Other embodiments may use non-tobacco products. Thus, the aerosol precursor composition may vary, and mixtures of different aerosol precursor compositions may be used.

[0041] According to certain embodiments of the present disclosure, it may be advantageous to provide an aerosol delivery device that is easy to use and provides improved components. One exemplary embodiment of an aerosol delivery device, generally designated 10, is provided in FIG. 1. As shown in FIG. 1, the aerosol delivery device 10 defines a longitudinal axis Y that extends from a first end 12 to an opposite second end 14 of the aerosol delivery device 10. The aerosol delivery device 10 may, in some embodiments, be substantially rod-shaped or substantially tubular, cylindrical, or elliptical. Although the aerosol delivery device 10 is shown in FIG. 1 as being generally tubular and elliptical in shape, other suitable shapes and dimensions (e.g., rectangular or triangular cross-section, etc.) are encompassed by the present disclosure.

[0042] The aerosol delivery device 10 can include a cartridge 200 and a control body 300, which may be operably engaged with one another, either permanently or removably, in a functional relationship. The operable engagement between the cartridge 200 and the control body 300 can be press-fit, threaded, interference fit, magnetic, ultrasonic welding, snap fit, etc. In an exemplary embodiment, the control body 300 defines a receiving chamber 302 (FIG. 2) within an outer shell or housing 304 into which the cartridge 200 is insertable and securable by operable engagement therewith.

[0043] For example, the outer shell or housing 304 of the control body 300 includes an open connecting end 306 (see FIG. 2 ) and an opposite closed distal end 308. The open connecting end 306 may define an opening leading to the receiving chamber 302. As described in more detail below, the control body 300 may include an indicator 310 configured to provide a visual indication of one or more conditions of the device 100. In various exemplary embodiments, the cartridge 200 may be received by the control body 300 (particularly the receiving chamber 302) in a use position. As described in more detail below, in the use position, the atomizer may be powered to aerosolize and deliver to a consumer an aerosol precursor composition contained within the cartridge 200.

[0044] In an exemplary embodiment, as shown in Figures 3A and 3B and in further detail in Figure 4, the cartridge 200 includes an atomizer assembly 400 that may be operably engaged with a power source (not shown) housed in the control body 300. In an exemplary embodiment, the control body 300 and the cartridge 200 may be operably engaged with one another in a functional relationship such that the power source provides power to the atomizer assembly 400, and / or additional control functions, as described in further detail herein. The atomizer assembly 400 may be disposed within the cartridge 200 or may be disposed within the control body 300 and may be configured to operably engage with the reservoir chamber 210 of the cartridge 200. Further aspects of such devices are described in U.S. Patent Application Publication No. 2016 / 0050975 to Worm et al., filed August 21, 2014, and U.S. Patent Application Publication No. 2017 / 0181471 to Phillips et al., filed December 28, 2015, the disclosures of which are incorporated herein by reference.

[0045] According to certain exemplary embodiments, any of the cartridge 200, the control body 300 and / or the atomizer assembly 400 may be referred to as disposable in that the device 10 may be configured for only a limited number of uses with a limited number of cartridges (e.g., until the power source no longer provides sufficient power to the device 10), after which the entire device, including the control body 300, may be discarded. Alternatively, the cartridge 200, the control body 300 and / or the atomizer assembly 400 may be reusable. For example, the control body 300 may have a replaceable power source (e.g., a replaceable battery) such that the device 10 may be reused through multiple power source changes and with many cartridges. Similarly, the device 10 may be rechargeable and thus combined with any type of recharging technology. For example, device 10 may have replaceable or rechargeable batteries, solid-state batteries, thin-film solid-state batteries, rechargeable supercapacitors, etc., and may therefore be combined with any type of recharging technology, including connection to a wall charger, a connection to an automobile charger (i.e., cigarette lighter), and a connection to a computer via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), etc., a connection to a photovoltaic cell (sometimes called a solar cell) or solar panel, a wireless charger, such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. In an embodiment, control body 300 may be inserted and / or coupled to a separate charging station for charging the rechargeable battery of device 10. In some embodiments, the charging station itself may include a rechargeable power source that recharges the device's rechargeable batteries.

[0046] Certain additional examples of possible power sources are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., the disclosures of each of which are incorporated herein by reference in their entireties. Reference is also made to the control schemes described in U.S. Patent No. 9,423,152 to Ampolini et al., the disclosures of which are incorporated herein by reference in their entireties.

[0047] In another exemplary embodiment, the cartridge 200, separately or in combination with the atomizer assembly 400, may comprise a disposable single-use cartridge. For example, the reservoir chamber 210 of the cartridge 200, together with or apart from the operably engaged atomizer assembly 400, may contain a limited amount of aerosol precursor composition therein to provide the sensations (e.g., inhalation and exhalation patterns, taste or flavor types, sensory stimulating effects, etc.) of smoking a particular amount of a conventional smoking article (e.g., a cigarette, a cigar, a pipe, etc.). In an exemplary embodiment, the cartridge 200 may contain a particular amount of aerosol precursor composition therein equivalent to the amount of conventional smoking article that would be consumed to obtain the sensation of smoking a typical amount of a conventional smoking article (e.g., a typical package of cigarettes, i.e., 20 cigarettes). Additionally or alternatively, the cartridge 200 and the control body 300 may be securely engaged with each other to prevent tampering and / or manipulation of the aerosol precursor composition stored in the reservoir chamber 210. 3A and 3B show a single reservoir chamber, one of ordinary skill in the art will appreciate that the aerosol delivery device 10 may include a cartridge defining any number of reservoir chambers 210. In some embodiments, the components of the aerosol precursor composition may be separated and compartmentalized in separate reservoirs.

[0048] The cartridge 200, in one exemplary embodiment, comprises an outer housing formed from an exterior wall 201. The outer housing has a closed mouth end 202 and an opposing connecting end 204. The exterior wall 201 extends from the mouth end 202 to the connecting end 204 along a direction parallel to the longitudinal axis Y of the aerosol delivery device 10. The connecting end 306 of the control body 300 may be operatively engaged with the cartridge 200 about its connecting end 204.

[0049] The outer housing of the cartridge 200 may be formed from any suitable material, including moldable plastic materials such as, for example, polycarbonate, polyethylene, acrylonitrile butadiene 25 styrene (ABS), polyamide (nylon), or polypropylene. In other exemplary embodiments, the outer housing may be made from different materials, such as, for example, different plastic materials, metal materials (such as, but not limited to, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), graphite materials, glass materials, ceramic materials, natural materials (such as, but not limited to, wood), composite materials, or any combination thereof. In certain exemplary embodiments, a transparent or translucent window or other indicator (e.g., an LED) may be formed in the outer housing to provide a visual indicator of the amount of aerosol precursor composition remaining in the reservoir chamber 210 of the cartridge 200.

[0050] In an exemplary embodiment, the cartridge 200 comprises a storage portion defining a reservoir chamber 210 and a mouthpiece portion. The mouthpiece portion may include a mouthpiece 206 disposed proximate the mouth end 202 of the cartridge 200. Additionally, in an embodiment, the mouthpiece portion may comprise a disposable device. Disposable components for use with the control body are disclosed in U.S. Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety. The mouthpiece 206 may define a mouthpiece opening 207 in fluid communication with the reservoir chamber 210. In an embodiment, the mouthpiece portion disposed proximate the mouth end 202 of the cartridge 200 may include a tapered portion having a smaller diameter than other portions of the cartridge 200 (e.g., the reservoir chamber 210). The mouthpiece portion of some embodiments is separable from the storage portion of the cartridge 200, while in other embodiments, the mouthpiece portion may be integral with the storage portion of the cartridge 200. In either case, the mouthpiece portion and the storage portion of cartridge 200 may be made from the same or different materials. In various embodiments with a separable mouthpiece, the mouthpiece portion may be coupled to the storage portion in various ways, including, for example, via one or more of a snap fit, an interference fit, a thread, a magnetic and / or a bayonet connection. In other embodiments, the mouthpiece portion may be integral with the storage portion and thus not separable.

[0051] According to an embodiment, the aerosol delivery device 10 may include a mouthpiece channel 216 formed from an outer wall 217 disposed within the reservoir chamber 210. For example, the mouthpiece channel 216 may be formed from an outer wall 217 extending at least partially along a length of the reservoir chamber 210. The outer wall 217 may be disposed within the outer wall 201 of the cartridge 200. Furthermore, the mouthpiece channel 216 may define an open first end 214 disposed proximate to the mouth end 202 of the cartridge 200 and an open distal end 219. The open first end 214 may provide for the exit of the formed aerosol from the aerosol delivery device 10. In particular, the open first end 214 of the mouthpiece channel 216 may be configured to be in fluid communication with the mouth end 202 of the outer wall 201, and in particular, in fluid communication with a mouthpiece opening 207 defined in the mouth end 202 of the cartridge 200.

[0052] 3A, the mouthpiece channel 216 may be generally tubular and cylindrical in shape. Additionally, the mouthpiece channel 216 may extend from the mouthpiece opening 207 to an open end 219 of the mouthpiece channel 216 along a direction parallel to the longitudinal axis Y of the aerosol delivery device 10. In some embodiments, the mouthpiece channel 216 may taper as it extends from the open first end 214 to the open end 219 of the mouthpiece channel 216.

[0053] In an exemplary embodiment, the mouthpiece portion and / or the reservoir portion of the cartridge 200 (e.g., in the mouthpiece 206) may include a filter configured to receive an aerosol in response to drawing applied to the cartridge 200. In various embodiments, the filter may be provided as a circular disk disposed radially and / or longitudinally proximate the open first end 214 or the open distal end 219 of the mouthpiece channel 216 in some aspects. In this manner, upon drawing on the cartridge 200, the filter may receive the aerosol flowing through the mouthpiece channel 216. In some embodiments, the filter may comprise separate segments. For example, some embodiments may include segments that provide filtration, segments that provide resistance to draw, hollow segments that provide space for the aerosol to cool, other filter segments, and any one or any combination of the above. In some embodiments, the mouthpiece 206 may include a filter that may also provide flavor additives. In some embodiments, the filter may include one or more filter segments that may be replaceable. For example, in some embodiments, one or more filter segments, including, for example, filter segments providing different draw resistance and / or different flavors, may be interchangeable to customize a consumer's experience with the device. Some examples of flavoring materials and / or ingredients configured to add flavor may be found in Hejazi, U.S. Patent Application Publication No. 2020 / 0352256, Hejazi, U.S. Patent Application Publication No. 2019 / 0289909, and Hejazi, U.S. Patent Application Publication No. 2020 / 0288787, each of which is incorporated herein by reference in its entirety.

[0054] In an exemplary embodiment, an outer wall 217 forming the mouthpiece channel 216 may include an outer surface, and the outer wall 201 may include an inner surface 212. The inner surface 212 of the outer wall 201, which cooperates with the outer surface of the outer wall 217 forming the mouthpiece channel 216 to form the cartridge 200, may partially define a reservoir chamber 210 configured to hold a quantity of an aerosol precursor composition therein.

[0055] The aerosol precursor composition may contain one or more different components, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Representative types of additional aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., PCT Publication WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (1988) by R.J. Reynolds Tobacco Company Monograph, the disclosures of which are incorporated herein by reference. In certain embodiments, the aerosol precursor composition can generate a visible aerosol upon application of sufficient heat (and optionally cooling with air), and the aerosol precursor composition can generate a "smoky" aerosol. In other embodiments, the aerosol precursor composition can generate an aerosol that is substantially invisible, but is recognized as being present by other characteristics, such as flavor or texture. Thus, the nature of the aerosol generated can be variable depending on the particular components of the aerosol delivery component. The aerosol precursor composition can be chemically simple compared to the chemistry of the smoke generated by burning tobacco.

[0056] In some embodiments, the aerosol precursor composition may incorporate nicotine, which may be present in various concentrations. The source of nicotine may vary, and the nicotine incorporated in the aerosol precursor composition may be derived from a single source or a combination of two or more sources. For example, in some embodiments, the aerosol precursor composition may include nicotine derived from tobacco. In other embodiments, the aerosol precursor composition may include nicotine derived from other organic plant sources, such as non-tobacco plant sources including plants of the Solanaceae family. In other embodiments, the aerosol precursor composition may include synthetic nicotine. In some embodiments, the nicotine incorporated in the aerosol precursor composition may be derived from non-tobacco plant sources, such as other members of the Solanaceae family. The aerosol precursor composition may additionally or alternatively include other active ingredients, including, but not limited to, botanical ingredients (e.g., lavender, peppermint, chamomile, basil, rosemary, thyme, eucalyptus, ginger, cannabis, ginseng, maca, and herbal teas), stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins such as B6, B12, and C, and cannabinoids such as tetrahydrocannabinol (THC) and cannabidiol (CBD)). It is noted that the aerosol precursor composition may include any ingredient, derivative, or combination of any of the above.

[0057] As described herein, the aerosol precursor composition may contain or be derived from one or more botanical substances or components, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the aerosol precursor composition may contain synthetically derived active compounds naturally occurring in plants. The aerosol precursor composition may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, tangerine peel, papaya, rose, sage, tea, e.g., green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, and rosehip. rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, coriander leaf, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Egyptian mint (Mentha niliaca), Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, horse mint (Mentha longifolia), Mentha suaveolens variegata, pennyroyal mint (Mentha pulegium), spearmint varieties (Mentha spicata cv) and Mentha suaveolens.

[0058] A wide variety of flavoring agents or materials that modify the sensory or organoleptic characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some embodiments, such flavoring agents may be provided from sources other than tobacco and may be natural or artificial in nature. For example, certain flavoring agents may be applied to or incorporated into the aerosol precursor composition and / or the region of the smoking article where the aerosol is generated. In some embodiments, such agents may be provided directly to the heating cavity or region proximate to the heat source or provided together with the aerosol precursor composition. Exemplary flavoring agents may include, for example, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups such as high fructose corn syrup may also be suitable for use.

[0059] As used herein, the terms "flavor," "flavoring," "flavoring agent," and the like refer to materials that, where local regulations permit, may be used to create a desired taste, aroma, or other somatosensory sensation in products for adult consumers. These include naturally occurring flavor materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia), and the like.leaf), chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie, bourbon, scotch, whiskey, ginseng, ginger ... citron, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, any species of the genus Mentha mint oil, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, tangerine peel, rose, tea, e.g. green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, curcuma, coriander leaves, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil , chives, carbica, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol or mannitol), as well as other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, e.g. liquids such as oils, solids such as powders, or gases.

[0060] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0061] In some embodiments, flavors may include sensates intended to achieve somatic sensations, usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of aroma or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, a numbing effect, etc. Suitable heating effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucolyptol, WS-3.

[0062] Flavoring agents may also contain acidic or basic properties (e.g., organic acids such as levulinic acid, succinic acid, pyruvic acid, and benzoic acid). In some embodiments, flavoring agents may be combined with the elements of the aerosol precursor composition as desired. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. Any of the materials such as flavorants, casings, and the like that may be useful in combination with tobacco materials to affect their sensory properties, including organoleptic properties as described herein, may be combined with the aerosol precursor composition. Organic acids may be incorporated in particular into the aerosol precursor composition to affect the flavor, sensory, or organoleptic properties of drugs such as nicotine that may be combined with the aerosol precursor composition. For example, organic acids such as levulinic acid, lactic acid, pyruvic acid, and benzoic acid may be included in the aerosol precursor composition with nicotine in amounts up to equimolar to nicotine (based on total organic acid content). Any combination of organic acids may be suitable. For example, in some embodiments, the aerosol precursor composition may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, up to a concentration where the total amount of organic acids present is equimolar to the total amount of nicotine present in the aerosol precursor composition. Various additional examples of organic acids used to generate the aerosol precursor composition are described in U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al., which is incorporated herein by reference in its entirety.

[0063] The selection of such additional ingredients may vary based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972), and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties.

[0064] In an exemplary embodiment, the atomizer assembly 400 may be disposed around the connecting end 202 of the outer housing. As shown in FIG. 4, the atomizer assembly 400 may include a base 402 defining a first surface 404 and an opposing second surface 406. The first surface 404 of the base 402 may be engageable with the connecting end 202 of the outer housing of the cartridge 200. In an exemplary embodiment, the base 402 may be insertable into the connecting end 202 of the cartridge 200 or may be fixedly or removably attached to the cartridge 200 using a press-fit engagement, a threaded engagement, an interference fit engagement, a magnetic engagement, a bayonet lock engagement, a snap fit, or the like. The base 402 may also be securely fixed and / or attached to the cartridge 200 by ultrasonic welding or the like. Although the base 402 and the cartridge 200 are shown as separate members, the base 402 and the cartridge 200 may be integrally formed. As shown in FIG. 4, for example, the base 402 includes one or more protrusions 408 (two are shown in FIG. 4) that may engage recesses, grooves or other structures (not shown) in the inner surface 212 of the outer wall 201. In certain other exemplary embodiments, other mechanisms for engaging the base 402 with the cartridge 200 may be contemplated, such as other retention mechanisms including, for example, a retention ball, one or more resilient members such as, for example, one or more O-rings, and / or one or more resilient mechanisms that engage the inner surface 212 of the cartridge. In other embodiments, the cartridge 200 may include one or more protrusions and / or spring mechanisms and corresponding detent mechanisms configured to retain the base 402. In still other embodiments, the inner surface 212 of the cartridge 200 may have a reduced diameter (and / or one or more portions having a reduced diameter) that may be configured to retain the base 402 therein. In other embodiments, the base 402 and / or the cartridge 200 may include an actively retractable feature (e.g., a feature that is actively retractable by a consumer), one or more wedge features, and / or one or more features that may form a releasable connection between the base 402 and the cartridge 200. For example, in some embodiments, the cartridge 200 and the base 402 may have a releasable thread-type connection.A combination of two or more of these retention mechanisms may be used.

[0065] In an alternative embodiment, the base 402 is engageable with the receiving chamber 302 of the control body 300, such that the connecting end 202 of the cartridge 200 is engageable with the base 402 after insertion into the control body 300. Nevertheless, when the base 402 is engaged with the cartridge 200, and the cartridge 200 is engaged with the control body 300, the base 402 may be disposed proximate to the connecting end 302 of the control body 300 along the direction of the Y-axis of the device 10.

[0066] 3A and 3B, when the base 402 is engageable (e.g., insertable) with the connecting end 202 of the outer housing of the cartridge 200, a reservoir chamber 210 containing an aerosol precursor composition is defined between an inner surface 212 of an outer wall 201 forming the cartridge 200 and a first surface 404 of the base 402. Optionally, the reservoir chamber 210 is defined between the inner surface 212 of the outer wall 201 forming the cartridge 200, an outer surface of an outer wall 217 forming the mouthpiece channel 216, and the first surface 404 of the base 402.

[0067] Various other details regarding components configured to connect the cartridge 200 and the control body 300 are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., the entirety of which is incorporated herein by reference.

[0068] The control body 300 may similarly comprise a cartridge retention assembly configured to hold the cartridge 200 in a use position with or without the base 402. In one exemplary embodiment, as shown, the cartridge retention assembly comprises a magnetic plug 410 disposed proximate the second surface 406 of the base 402 and engaging a corresponding magnetic element (not shown) in the receiving chamber 302 of the control body 300 to temporarily "lock" the cartridge 300 in place within the receiving chamber 302 of the control body 300. For example, the receiving chamber 302 may be made from a ferromagnetic material to which the magnetic plug 410 is attracted. The magnetic plug 410 may be disposed such that an exposed portion is substantially flush with the second surface 406 of the base 402 (as shown), may be recessed within the second surface 406 of the base 402, and / or may extend at least partially from the second surface 406 of the base 402.

[0069] In certain other exemplary embodiments, the cartridge retention assembly includes a spring-loaded latch mechanism, and when the base 402 is engaged with the cartridge 200, it is pushed into and fully received in the receiving chamber 302. In other exemplary embodiments, other retention mechanisms may be used. For example, in certain embodiments, one or more retention balls may form part of the cartridge retention assembly. In other embodiments, the cartridge retention assembly may include other retention mechanisms including, for example, one or more resilient members, such as one or more O-rings, and / or one or more resilient mechanisms that extend into the receiving chamber 302 to engage a portion of the outer wall 201 of the cartridge 200 and / or the base 402. In other embodiments, the outer wall 201 of the cartridge 200 and / or the receiving chamber 302 may include one or more protrusions and / or spring mechanisms and corresponding detent mechanisms configured to retain the cartridge 200 and / or the base 402 in the receiving chamber 302. In yet other embodiments, the inner surface of the receiving chamber 302 may have a reduced diameter (and / or one or more portions having a reduced diameter) that may be configured to retain the cartridge 200 and / or base 402 in the receiving chamber 302. In other embodiments, the control body 300 may include an actively retractable mechanism (e.g., a mechanism actively retractable by a consumer) configured to engage the cartridge 200 and retain the cartridge 200 in the receiving chamber 302. In other embodiments, the control body 300 may include one or more wedge mechanisms configured to engage the cartridge 200 and / or base 402 and retain the cartridge 200 and / or base 402 in the receiving chamber 302. In still other embodiments, one or more other mechanisms of the cartridge 200 / base 402 and / or one or more mechanisms of the control body 300 may form a releasable connection between the receiving chamber 302 and the cartridge 200 / base 402. For example, in one embodiment, the cartridge 200 / base 402 and receiving chamber 302 may have a releasable threaded connection. A combination of two or more of these retention mechanisms may also be used.Various other details regarding components configured to connect the cartridge 200 and the control body 300 are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., the entirety of which is incorporated herein by reference.

[0070] In various embodiments, one or more components of the cartridge retaining assembly may be made from any material, including, for example, but not limited to, metal or plastic materials. For example, an embodiment may include one or more components of the cartridge retaining assembly made from a metal material, such as, for example, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc. In an embodiment, one or more components of the cartridge retaining assembly may be made from a moldable plastic material, such as, for example, polycarbonate, polyethylene, acrylonitrile butadiene styrene (ABS), polyamide (nylon), or polypropylene. In an embodiment, one or more components of the cartridge retaining assembly may be made from different materials, such as, for example, different plastic materials, different metal materials, graphite materials, glass materials, ceramic materials, natural materials (such as, but not limited to, wood), composite materials, or any combination thereof.

[0071] In some embodiments, the control body 300 may include an ejection mechanism. As such, the ejection mechanism may be configured to eject the cartridge and / or base from the control body. In one embodiment, the ejection mechanism may comprise a spring-loaded plate and a latch mechanism, where the spring-loaded plate directly or indirectly engages the cartridge 200 / base 402 such that in the use position, the spring is compressed and held in place by the latch. The latch may be operatively connected to a consumer-actuated button configured to release the latch when actuated by the consumer. In some embodiments, the ejection mechanism comprises part of a spring-loaded cartridge retention assembly. However, in other embodiments, the ejection mechanism may comprise an independent mechanism. The ejection mechanism may be actuated via a button located on the control body 300. However, in other embodiments, the ejection mechanism may be actuated in other ways.

[0072] In some embodiments, the base 402 may include an anti-rotation mechanism that substantially prevents relative rotation between the cartridge 200 and the control body 300, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety. The base 402 may also include a sealing mechanism configured to substantially limit and / or prevent the aerosol precursor composition and / or any formed aerosol from passing through the anti-rotation mechanism. The anti-rotation mechanism and the sealing mechanism may be combined into a single structure or may be separate.

[0073] For example, the sealing mechanism may include a gasket, O-ring, ridge, flange, or the like that extends circumferentially around the periphery of the base 402 and engages the inner surface 212 of the outer wall 201 of the cartridge 200. For example, as shown in FIG. 4, the sealing mechanism comprises an O-ring 412 received in a circumferentially extending groove in the base 402. The O-ring 412 may thus act to seal the atomizer assembly 400 from the control body 300. The O-ring 412 may also act to resist separation of the base 402 from the cartridge 200. The O-ring 412 may be any type of elastomeric material, or any other type of similar material that provides similar benefits. The O-ring 412 may thus substantially prevent the aerosol and / or aerosol precursor composition from escaping the aerosol delivery device 10 through any means other than the mouthpiece channel 216 and / or the open first end 214 of the mouthpiece channel 216.

[0074] Turning now to FIG. 5, the base 402 may define a recess 414 formed in the first surface 404 of the base 402. The recess 414 may be formed as an indentation in the first surface 404 of the base 402 that extends toward the second surface 406 of the base 402. The recess 414 may extend to various depths within the base 402 such that one or more plateaus of various depths are defined within the base 402. As shown in FIG. 5, there are five different plateaus defined by the recess 414, with a bottom surface 416 at the lowest depth. One or more openings 418 may be defined in the bottom surface 416 of the recess 414 and may extend therethrough to the second surface 406. There may be one, two, three, four, five or more openings 418. When there are multiple openings 418, each of the openings 418 may have the same or different shapes and diameters. In an exemplary embodiment, the opening 418 may be configured to provide fluid communication between the mouthpiece channel 216 and the control body 300 when the atomizer assembly 400 is engaged with the connecting end 202 of the outer wall 201. In particular, the opening 418 may allow air entering the control body 300 through one or more inlet orifices 312 defined in the outer shell 304 of the control body 300 upon inhalation of the device 10 to entrain the formed aerosol and be delivered to the consumer through the mouthpiece channel 216. Thus, the inlet orifices 312 defined in the control body 300 and the opening 418 in the base 402 may be in fluid communication via the defined flow path.

[0075] Returning to FIG. 4, one or more elements of the atomizer assembly 400 may be disposed around the base 402. For example, the atomizer assembly 400 may include an atomizer 420 disposed around the first surface 404 of the base 402 to atomize the aerosol precursor composition and form an aerosol. The liquid transport element 422 may be disposed around the first surface 404 of the base 402 and define opposing first and second ends 424, 426 having an exposed end face 428 (FIG. 7) in fluid communication with the reservoir chamber 210 to direct the aerosol precursor composition from the reservoir chamber 210 through the end face 428 of the liquid transport element 422 to contact the atomizer 420. The atomizer 420 may be disposed between the first end 424 and the second end 426 of the liquid transport element 422. The liquid transport element 422 may include a wicking and / or porous material that provides for movement of the aerosol precursor composition therethrough (e.g., via capillary action) so that the aerosol precursor composition may be drawn into proximity of the atomizer 420.

[0076] As shown in FIG. 4, for example, the atomizer 420 may comprise a wire coil 430 having a plurality of turns and providing resistive heating. The atomizer 420 may be integrally formed with or operatively engaged with the first and second electrical terminals 422A, 422B (e.g., negative and positive terminals) and in electrical communication with the first and second electrical terminals 422A, 422B. For example, portions of the atomizer 420 may be welded, soldered, brazed, etc. to the respective first and second electrical terminals 422A, 422B. For example, if the coil 430 defines a wire, the opening 424 may be defined through the base 402 (e.g., defined on a second deepest surface within the recess 414 and extending to the second surface 406, as shown in FIG. 5). This may allow the first and second electrical terminals 422A, 422B to extend from the first surface 404 of the base 402 to the second surface 406 of the base 402. In an exemplary embodiment, the first and second electrical terminals 422A, 422B operably engage and / or indirectly or directly contact an electrical contact 426 proximate the second surface 406 of the base 402. The electrical contact 426 may provide electrical communication between the atomizer 420 and a power source in the control body 300 when the cartridge 200 is engaged with the control body 300. The electrical contact 426 may be defined in the second surface 406 of the base 402 to provide electrical communication between the atomizer 420 and a power source in the control body 300 when the cartridge 200 is engaged with the control body 303. The contacts 426 may be disposed such that an exposed portion is substantially flush with the second surface 406 of the base 402 (as shown), may be recessed into the second surface 406 of the base 402, and / or may extend at least partially from the second surface 406 of the base 402. Correspondingly, the control body 300 may include electrical contacts (not shown) configured to contact the electrical contacts 426 of the base 402 such that the electrical contacts 426 of the base 402 contact the contacts of the control body 300, respectively, when the control body 300 and the cartridge 200 are mated together to establish an electrical connection therebetween.The first and second electrical terminals 422A, 422B are thereby configured to engage with the coil 430 of the atomizer 420 and form an electrical connection with the control body 300 when the cartridge 200 is connected to the control body 300.

[0077] In an exemplary embodiment, the wire material may include, in some aspects, Kanthal (FeCrAl), Nichrome, Molybdenum Disilicide (MoSi2), Molybdenum Disilicide doped with Aluminum (Mo(Si,Al)2), ceramic (e.g., positive temperature coefficient ceramic), titanium and / or related alloys, although in other aspects, various other materials may be used. According to some aspects, the coil 430 may be formed by winding a wire around the liquid transport element 422, as described in U.S. Pat. No. 9,210,738 to Ward et al., which is incorporated herein by reference in its entirety. However, various other aspects of the method may be used to form the atomizer 420, and various other components may be used in the atomizer 420. For example, the atomizer 420 may be configured to heat the aerosol precursor composition disposed within the liquid transport element 422 via radiative heating, as described in U.S. Patent Application No. 14 / 808,405, filed July 24, 2015, and U.S. Patent Application No. 14 / 958,651, filed December 3, 2015, the contents of which are incorporated herein by reference in their entireties. In another embodiment, the atomizer 420 may be configured to heat the aerosol precursor composition via inductive heating, as described in U.S. Patent Application No. 14 / 958,651, filed December 3, 2015, and U.S. Patent Application No. 14 / 934,763, filed November 6, 2015, the contents of which are incorporated herein by reference in their entireties. Although the atomizer 420 is shown as a wire having multiple coils 430 wound around the liquid transport 422 element, additional forms of the atomizer 420 are encompassed by the present disclosure, such as atomizers in the form of foils, foams, disks, spirals, fibers, wires, films, threads, strips, meshes, ribbons, and / or cylinders. Other methods of aerosolizing the aerosol precursor composition other than heating are also contemplated by the present disclosure. For example, the atomizer 420 can be a piezoelectric mesh that vibrates to atomize the aerosol precursor composition, an ultrasonic atomizer that uses ultrasound to create an aerosol, and the like.

[0078] The atomizer 420 may be in direct or indirect contact with the liquid transport element 422. For example, as shown, the atomizer 420 may be in direct contact with an outer surface 432 defined by the liquid transport element 422. The outer surface 432 may extend longitudinally between the end faces 428. Multiple turns of the coil 430 of the atomizer 420 may be wound around the outer surface 432 of the liquid transport element 422 and between the end faces 428. In this regard, the liquid transport element 422 may be configured to draw the aerosol precursor composition held in the reservoir chamber 210 into direct contact with the coil 430.

[0079] The liquid transport element 422 may comprise a porous monolith. In one exemplary embodiment, the liquid transport element 422 may comprise a porous monolith composed of a single element or multiple elements connected together to form a unitary element, while in other exemplary embodiments, the liquid transport element 422 is composed of two or more separable elements, so that the liquid transport element 422 is not considered "monolithic". As used herein, "porous monolithic material" or "porous monolith" is intended to mean that in some embodiments, the liquid transport element 422 comprises a substantially single unit, which may be a single piece formed, constructed, or created to be substantially uniform throughout, without joints or seams, and not necessarily rigid. In some embodiments, a monolith according to the present disclosure may be homogenous, i.e., formed from a single material, or formed from multiple units permanently combined, such as a sintered assembly. Thus, in some embodiments, the porous monolith may comprise a unitary porous monolith. In an exemplary embodiment, the porous monolith defines a central opening 434 ( FIG. 7 ) that extends between the end faces 428 of the liquid transport element 422 .

[0080] In certain other exemplary embodiments, the liquid transport element 422 is non-fibrous, meaning that the liquid transport element 422 is formed from a solid material having a microtextured surface, rather than a surface formed by a plurality of bundled fibers. As described herein, "microtextured" refers to a surface having topographical three-dimensional features on a micrometer scale (e.g., a plurality of three-dimensional surface features having an average height of less than about 250 microns) that are discontinuous in appearance, such that the surface includes a plurality of uneven portions. Non-limiting examples include ceramic materials, particularly silicon-based materials, such as silicon nitride materials or silicon dioxide materials. However, other materials such as glass or quartz can be used. Certain thermoplastic materials, such as cyclic olefin copolymers (COC), can also be used.

[0081] In certain exemplary embodiments, the liquid transport element 422 comprises a cylindrical shape such that the outer surface 432 is curved. However, in certain other exemplary embodiments, the liquid transport element 422 may comprise a rectangular prism shape, a cone shape, a triangular prism shape, or another type of shape such that the outer surface 432 is not curved or is only partially curved. In certain other exemplary embodiments, the liquid transport element 422 is U-shaped, V-shaped, T-shaped, or any other similar shape.

[0082] Returning to FIG. 4, the atomization assembly 400 may further include a reservoir chamber seal arrangement comprising a first seal member 436. An exemplary embodiment of the first seal member 436 is shown in more detail in FIG. 6. The first seal member 436 may be disposed around the first surface 404 of the base 402 and receive the opposing first and second ends 424, 426 of the liquid transport element 422 to circumferentially seal the opposing first and second ends 424, 426 of the liquid transport element 422 and expose its end face 428, while positioning the atomizer 420 laterally (i.e., along the transverse axis X of the device 10 (FIG. 3B)) and axially (i.e., along the longitudinal axis Z of the liquid transport element 422, which extends between the first end 424 and the second end 426 (FIG. 3A)) within the cartridge 200. Thus, the reservoir chamber 210 may be sealed by the reservoir chamber seal arrangement, except for the end face 428 of the liquid transport element 422 .

[0083] The first seal member 436 may be disposed within a recess 414 formed in the first surface 404 of the base 402. In particular, the first seal member 436 may be disposed within a first plateau 438 in the recess 414, which is shallower than the others. The first plateau 438 may be formed to have a shape that matches the shape of the first seal member 436. Thus, the first seal member 436 may be in direct contact with the first plateau 438 of the base 402. Otherwise, the first seal member 436 may be disposed on or adjacent to the first surface 404 of the base 402 such that the first seal member 436 is in indirect contact with the first plateau 438 of the base 402 (e.g., a slight clearance is provided between the first seal member 436 and the first surface 404, a substrate is provided therebetween, etc.). In an alternative embodiment, the first seal member 436 is disposed adjacent the opposing second surface 406 of the base 402 .

[0084] In an exemplary embodiment, the first seal member 436 comprises a monolithic structure formed as a single or integral member or from one or more elements fused together to form a single or integral structure. In the illustrated embodiment, the first seal member 436 is made from a molded elastic polymeric material, such as silicone. In an embodiment in which the first seal member 436 is silicone, the compression range (which may be determined based on the shore hardness of the silicone) may be targeted to remain within a tolerance stack-up that corresponds to the tolerance variations of the surrounding portions of the atomizing assembly 400. For example, if the first seal member 436 is a 2 mm thick gasket of 60A silicone, the compression range may be targeted to a nominal compression of 15%. The elements surrounding the first seal member 436 (e.g., the flow director 446) should then be designed to be acceptable to compress the first seal member 436 to a thickness of 1.7 mm (nominal) and keep the compression within a compression range of 10% to 20%.

[0085] As shown in FIG. 6, the first seal member 436 comprises a pair of opposing annular members including a receiving portion 440 with an opening disposed therein (e.g., substantially centrally) along with opposing connecting flanges 444 (FIG. 9) defining sides 442 extending between the open receiving portions 440 to collectively define a circumferential periphery of the first seal member 436. A central opening 437 may be defined inwardly of the circumferential periphery of the first seal member 436. The open receiving portion 440 may be in the form of an open cylinder, although other shapes may define the open receiving portion 440. As shown in FIG. 6, for example, the open receiving portion 440 is in the form of an open cylinder. One of the first and second ends 424, 426 of the liquid transport element 422 may be at least partially or completely received in one of the aperture receivers 440 such that the liquid transport element 422 is laterally and axially positioned within the cartridge 200 and the opposed first and second ends 424, 426 of the liquid transport element 422 are circumferentially sealed by the aperture receiver 440 and the end face 428 is exposed. Thus, the coil 430 of the atomizer 420 may be disposed between the aperture receivers 440 and within the central opening 437 of the first seal member 436 when the liquid transport element 422 is received by the first seal member 436, as shown in FIG.

[0086] 9, the reservoir chamber seal arrangement may further comprise a flow director 446 comprising a flow tube 450 defining a base portion 448 having opposing top and bottom planar surfaces, the flow tube 450 extending from the top planar surface. The flow tube 450 may comprise a generally cylindrical shape having one or more portions. As shown in FIG. 9, for example, there are two portions of the flow tube 450, a first portion 450A that contacts the base portion 448 and a second portion 450B that extends from the first portion 450A. The first portion 450A may have a diameter larger than the diameter of the second portion 450B, but smaller than the diameter of the base portion 448. As shown in FIG. 3A and FIG. 3B, the end 219 of the mouthpiece channel 216 may contact the first portion 450A. In an exemplary embodiment, the circumference of the mouthpiece channel 216 (specifically its end 219) may have substantially the same diameter as the diameter of the first portion 450A, although the two diameters may be different. For example, as shown in Figures 3A and 3B, the second portion 450B of the flow director 446 is inserted into the open end 219 of the mouthpiece channel 216, although in an exemplary embodiment the open end 219 of the mouthpiece channel 216 may be inserted into the flow tube 450, or the two may abut one another. Alternatively, the mouthpiece channel 216 may be configured to directly engage another component of the reservoir chamber seal arrangement.

[0087] The flow director 446 may include an opening, which is defined in the center of the base portion 448 and extends from the top plane to the bottom plane through the flow tube 450 aligned therewith. The opening may have a constant inner diameter along the length of the flow director 446 extending along the Y direction. However, as shown in FIG. 3A, the opening has an inner diameter that varies along the length of the flow director 446. For example, as shown in FIG. 3A, the inner diameter of the opening in the base portion is larger than the inner diameter of the opening in the first portion 450A and the second portion 450B, where the opening has a constant inner diameter in the base portion 448, tapers to a narrower inner diameter in the first portion 450A, and has a constant inner diameter in the second portion 450B that is smaller than the inner diameter in the base portion 448. Thus, the opening in the flow director 446 may act as a funnel to funnel the formed aerosol from the atomizer toward the mouthpiece channel 216. In this exemplary embodiment, the flow tube 450 may be aligned with and in fluid communication with the atomizer 420 to direct the formed aerosol to the mouth end 202 of the outer housing of the cartridge 200. The aerosol may be formed within an aerosolization region 452 defined between the atomizer 420, which is adjacent to and disposed about the liquid transport element 422, and the open end 219 of the mouthpiece channel 216. In particular, the aerosolization region 452 may be adjacent to an opening formed in a bottom planar surface of the flow director base portion 448 and the atomizer 420.

[0088] The flow director 446 may be positioned such that the first seal member 436 is disposed between a bottom plane of the flow director 446 and the first surface 404 of the base 402. For example, the circumferential periphery of the first seal member 436 (i.e., the aperture receiver 440 is centrally disposed such that the opposing connection flanges 444 extend between the aperture receivers 440) may be directly engaged and sealingly engaged with a bottom plane of the base portion 448 of the flow tube 450, such that when the flow tube 450 is compressed against the first seal member 436 and the first surface 404 of the base 402, the reservoir chamber 210 is sealed except for the exposed end surface 428 of the liquid transport element 422. To this end, the bottom plane of the base portion 448 may be shaped and sized to form a seal between the circumferential periphery and the outer surface 432 of the liquid transport element 422. In this manner, the reservoir chamber 210 is sealed by the reservoir chamber seal arrangement at the interface between the base portion 448 of the flow director 446 and the circumferential periphery (i.e., the flange 444 and the receiver 440 of the liquid transport element 422) excluding the exposed end face 428 of the liquid transport element 422. Thus, a single integral part forms a seal for the reservoir chamber (e.g., both the seal at the base portion 448 of the flow director 446 and the seal around the circumferential periphery (excluding the exposed end face 428) of the liquid transport element 422).

[0089] 3A and 3B, the reservoir chamber seal arrangement may also include a second seal member 454 disposed at the open end 219 of the mouthpiece channel 216 to provide a seal between the flow tube 450 and the mouthpiece channel 216. As shown, the second seal member 454 may be disposed to at least partially or substantially surround the second portion 450B of the flow tube 450 and inserted into the open end 219 of the mouthpiece channel 216. In this manner, the second seal member 454 may act as a seal between the reservoir chamber 210 and the mouthpiece channel 216 to reduce / prevent leakage of the aerosol precursor composition from the reservoir chamber 210 into the mouthpiece channel 216 and to substantially prevent the formed aerosol from leaking out of the mouthpiece channel 216. The second seal member 454 may be the same or similar material as the first seal member 436, or may be a different material.

[0090] To hold the reservoir chamber seal arrangement in place within the cartridge 200, the base 402 may further comprise a retaining member 456 extending from its first surface 404 and engaging the flow director 446. The retaining member 456 may be arranged to compress the flow director 446 against the first seal member 436 and the first surface 404 of the base 402, thereby sealing the reservoir chamber 210 except for the exposed end surface 428 of the liquid transport element 422. For example, as shown in Figures 4 and 9, the retaining member 456 comprises one or more arms 458 extending generally perpendicularly from the first surface 404 of the base 402 and a protrusion 460 extending toward the center of the base 402 (i.e., toward the longitudinal axis Y of the device 10). The protrusion 460 may engage with an upper planar surface of the base portion 448 of the flow director 4242 to compress the base portion 448 of the flow director 446 against the first seal member 436 and the first surface 404 of the base 402, thereby sealing the reservoir chamber 210 except for the exposed end face 428 of the liquid transport element 422, while maintaining the alignment of the flow tube 450 with the atomizer 420. In the illustrated embodiment, the retaining member 456 includes two pairs of arms 458 disposed at opposite lateral ends, which together compress the flow director 446 against the first seal member 436 and the first surface 404 of the base 402.

[0091] In certain other exemplary embodiments, the retaining member 456 may comprise any other type of structure / arrangement capable of holding the flow director 446 and / or the first seal member 436 in alignment. For example, the retaining member 456 may directly engage (e.g., via a press-fit engagement, a magnetic engagement, a snap-fit ​​engagement, an interference fit engagement, etc.) with the first seal member 436 and / or the liquid transport element 422 and / or the atomizer 420. In this manner, the reservoir chamber seal arrangement may be configured to substantially restrict and / or prevent the aerosol precursor composition disposed within the reservoir chamber 210 from entering the control body 300 or the mouthpiece channel 216.

[0092] According to certain embodiments, when the mouthpiece channel 216 substantially abuts and / or is disposed within or around the flow tube 450, the operable engagement therebetween and the interface between the circumferential periphery of the liquid transport element 422 may provide a substantially airtight or substantially fluid-tight seal, except for the exposed end 428 of the liquid transport element 422. This operable engagement may advantageously prevent and / or substantially limit aerosol, vapor, etc., formed by the atomizer 420 from entering the reservoir chamber 210. Additionally or alternatively, this operable engagement may advantageously prevent and / or substantially limit aerosol precursor composition held within the reservoir chamber 210 from entering the mouthpiece channel 216, the opening 418, and / or the control body 300. Thus, when the nebulization assembly 400 is engaged with the connecting end 202 of the outer wall 201 of the cartridge 200 and the control body 300 is operably engaged with the cartridge 200 around the connecting end 202 of the outer housing, the mouthpiece channel 216 substantially abuts the flow tube 450, and the opening 418 in the bottom surface 416 of the recess 414 may provide fluid communication between the mouthpiece channel 216 and the control body 300 such that air entering the control body through the intake orifice 312 may mix with the aerosol precursor composition in the aerosolization zone 452 to form an aerosol, vapor, or the like, and then may exit the aerosol delivery device 10 via the open first end 214 of the mouthpiece channel 216 and through the mouthpiece opening 207 defined in the mouth end 202 of the outer housing.

[0093] Turning now to the control body 300, the control body 300 may include a control component (not shown) (e.g., a microprocessor, either separately or as part of a microcontroller), as described in certain exemplary embodiments of U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference in its entirety. The control component may be configured to operably engage with a power source to receive power for controlling various operations of the aerosol delivery device 10. According to certain aspects, the control component may be configured to receive electrical signals from additional and / or alternative control components (e.g., separate control components, etc.). Furthermore, the control component terminals may be configured to provide electrical communication (i.e., current, data signals, etc.) between the two control components. Additionally or alternatively, a single control component (not shown) may be configured to control various operations of the aerosol delivery device 10, as previously described herein. For example, a housing disposed within control body 300 may be configured to house control components and / or control component terminals therein, as described in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., the entirety of which is incorporated herein by reference.

[0094] Certain aspects of the control operations performed by the control component may include, for example, determining whether the cartridge 200 is authentic and / or performing other functions in conjunction therewith, such as indicating low battery, device status, etc. Additionally, various examples of control components and functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference in its entirety.

[0095] Still other features, controls or components that may be incorporated into the aerosol delivery device 10 of the present disclosure include those disclosed in U.S. Pat. No. 5,967,148 to Harris et al., U.S. Pat. No. 5,934,289 to Watkins et al., U.S. Pat. No. 5,954,979 to Counts et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 8,365,742 to Hon, U.S. Pat. No. 8,402,976 to Fernando et al., U.S. Pat. No. 8,402,976 to DePiano, which are incorporated herein by reference. No. 9,220,302 to O et al., U.S. Patent Application Publication No. 2010 / 0163063 to Fernando et al., U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent Application Publication No. 2013 / 0298905 to Leven et al., U.S. Patent Application Publication No. 2013 / 0180553 to Kim et al., and U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., and U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al. For example, a printed circuit board (PCB) including a microprocessor and / or microcontroller (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor), a manually actuable button, an indicator 310 (e.g., a light emitting diode (LED)), any combination thereof, and the like.

[0096] In some embodiments, an input element may be included (which may replace or supplement the cartridge sensor and / or a manually actuated button configured to activate the atomizer). Any component or combination of components may be utilized as an input to control the function of the device 10. For example, one or more push buttons may be used, as described in U.S. Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference in its entirety. Similarly, a touch screen may be used, as described in U.S. Patent Application Publication No. 2016 / 0262454 to Sears et al., which is incorporated herein by reference in its entirety. As a further example, a component adapted for gesture recognition based on specific movements of the aerosol delivery device 10 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 in its entirety. As yet another example, a capacitance sensor may be implemented in the aerosol delivery device 10 to allow the consumer to provide input, such as by touching a surface of the device on which the capacitance sensor is implemented.

[0097] Additional components may be utilized in the aerosol delivery device 10 of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that may be associated with the mouth end of the device that detects the consumer's lip motion associated with a puff and then triggers heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle within a smoking system that includes an identifier that detects non-uniformity in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes predefined executable power cycles having multiple differential phases; and U.S. Pat. No. 5,934,289 to Watkins et al. The specifications disclose photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for varying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT Publication No. WO 2010 / 003480 by Flick discloses a fluid flow sensing system indicative of a puff with an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0098] Mechanisms for controlling the power output from the power source are also contemplated. For example, the current activation / deactivation mechanism may include a temperature-activated on / off switch or a lip pressure-activated switch, or a touch sensor (e.g., a capacitive touch sensor) configured to sense contact between the consumer (e.g., the consumer's mouth or finger) and one or more surfaces of the aerosol delivery device 10. An exemplary mechanism that can provide such puff activation capability includes a model 163PC01D36 silicon sensor manufactured by MicroSwitch Division of Honeywell, Inc. of Freeport, Illinois. With such a sensor, the atomizer 420 can be rapidly activated by changes in pressure when the consumer inhales on the device. Additionally, a flow sensing device, such as one that uses the principle of hot wire anemometry, may be used to energize the atomizer 420 sufficiently quickly after sensing a change in airflow. A further puff-activated switch that can be used is a pressure differential switch, such as model number MPL-502-V, range A, manufactured by Micro Pneumatic Logic, Inc. of Fort Lauderdale, Florida. Another suitable puff-activated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled to a comparator for detecting a predetermined threshold pressure. Yet another suitable puff-activated mechanism is a vane deflected by airflow, the movement of which is detected by a motion-sensing means. Yet another suitable activation mechanism is a piezoelectric switch. Also useful is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc., Freeport, Illinois. Further examples of demand-operated electrical switches that may be used in circuits according to the present disclosure are described in U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, and the like will be apparent to those skilled in the art with knowledge of this disclosure.In certain embodiments, the cartridge 200 and / or control body 300 may include a pressure sensing tube or other passageway that provides a fluid connection between the puff-activated switch and the reservoir chamber 210 so that pressure changes during inhalation are easily identified by the switch. Other exemplary puff-activated devices that may be useful according to the present disclosure are disclosed in U.S. Patent Nos. 4,922,901, 4,947,874 and 4,947,874 to Brooks et al., 5,372,148 to McCafferty et al., 6,040,560 to Fleischhauer et al., 7,040,314 to Nguyen et al., and 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties.

[0099] Further examples of components related to electronic aerosol delivery articles and disclosed materials or components that may be used in the article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. Nos. 8,156,944 and 8,375,957, 8,794,231 to Thorens et al., 8,851,083 to Oglesby et al., 8,915,254 and 8,925,555 to Monsees et al., 9,220,302 to DePiano et al., and U.S. Patent Application Publication No. 2006 / 01965 to Hon. No. 18 and U.S. Patent Application Publication No. 2009 / 0188490, U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT Publication No. WO 2010 / 091593 to Hon, and PCT Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety.

[0100] With reference to Fig. 10, an embodiment of the disclosure may provide a method, generally designated 500, of manufacturing a cartridge for an aerosol delivery device as described hereinabove. The method 500 may include a first step 502 of providing an atomizer assembly comprising a base defining a first surface and an opposing second surface, an atomizer disposed about the first surface of the base to atomize an aerosol precursor composition and form an aerosol, a liquid transport element disposed about the first surface of the base, and a reservoir chamber seal arrangement comprising a first seal member disposed about the first surface of the base and receiving the opposing first and second ends of the liquid transport element to circumferentially seal the opposing first and second ends of the liquid transport element and expose an end face thereof. The method 500 may include a second step 504 of disposing the atomizer assembly about a connecting end of an outer housing of the cartridge, the outer housing having a closed mouth end opposite the connecting end. The method 500 may include a third step 506, which includes engaging a first surface of the base with a connecting end of the outer housing to define a reservoir chamber for containing the aerosol precursor composition between an outer wall of the outer housing and the first surface of the base, such that the reservoir chamber is sealed by a reservoir chamber seal arrangement except for an exposed end face of the liquid transport element, and the exposed end face of the liquid transport element is in fluid communication with the reservoir chamber to direct the aerosol precursor composition from the reservoir chamber through the end face of the liquid transport element to contact the atomizer.

[0101] In an exemplary embodiment, the first step 502 of providing an atomizer assembly may include providing a flow director having a flow tube defining a base portion, the flow director having a flow tube extending from the base portion and positioned such that a first seal member is disposed between the flow director and a first surface of the base, the flow tube being in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

[0102] In various embodiments, the present disclosure also relates to a kit providing various components described herein. For example, the kit may include a control body and one or more cartridges and / or atomizer assemblies. The kit of the present invention may further include a case (or other packaging, carrying or storage components) that houses one or more of the additional kit components. The case may be a reusable hard or soft container. Additionally, the case may simply be a box or other packaging structure. In some embodiments, a brush or other cleaning accessory may be included in the kit. The cleaning accessory may be configured to be inserted into the receiving chamber of the control body, or in other embodiments, may be inserted into a separate opening that allows the user to remove debris from the receiving chamber.

[0103] The above description of the use of the article may be applied to the various embodiments described herein through minor modifications that may be apparent to one of ordinary skill in the art in light of the further disclosure provided herein, however, the above description of use is not intended to limit the use of the article, but is provided to comply with all necessary disclosure requirements of the present disclosure.

[0104] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol delivery device comprising: a cartridge comprising an outer housing formed from an outer wall, the outer housing having a mouth end and an opposite connecting end; an atomizer assembly disposed about the connecting end of the outer housing, a base defining a first surface and an opposite second surface, the first surface engageable with a connecting end of the outer housing to define a reservoir chamber containing an aerosol precursor composition between an outer wall of the outer housing and the first surface of the base; an atomizer disposed about the first surface of the base to atomize the aerosol precursor composition to form an aerosol; a liquid transport element disposed about the first surface of the base and defining opposed first and second ends having exposed end faces in fluid communication with the reservoir chamber to direct the aerosol precursor composition from the reservoir chamber through the end faces of the liquid transport element and into contact with the atomizer; a reservoir chamber sealing arrangement, the reservoir chamber sealing arrangement comprising a first sealing member disposed around a first surface of the base, the first sealing member receiving opposite first and second ends of the liquid transport element to circumferentially seal the opposite first and second ends of the liquid transport element and expose the end faces thereof, such that the reservoir chamber is sealed by the reservoir chamber sealing arrangement except for the exposed end faces of the liquid transport element; an atomizer assembly comprising: a control body operably engaged with the cartridge about the connecting end of the outer housing; 1. An aerosol delivery device comprising:

2. 2. The aerosol delivery device of claim 1, wherein the reservoir chamber seal configuration comprises a flow director defining a base portion and including a flow tube, the flow tube extending from the base portion and positioned such that a first seal member is disposed between the flow director and a first surface of the base, and the flow tube is in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

3. 3. The aerosol delivery device of claim 2, wherein the base further comprises a retaining member extending from a first surface thereof that engages with the flow director, the retaining member being positioned to compress the flow director against the first seal member and the first surface of the base, thereby sealing the reservoir chamber except for the exposed end face of the liquid transport element.

4. 4. The aerosol delivery device of claim 3, wherein the retaining member comprises one or more pairs of arms extending generally perpendicularly from the first surface of the base and one or more respective protrusions extending toward the center of the base, the protrusions engaging with the base portion of the flow director to compress the base portion of the flow director against the first sealing member and the first surface of the base, thereby sealing the reservoir chamber except for the exposed end face of the liquid transport element.

5. The aerosol delivery device of claim 4, wherein the first sealing member comprises a pair of opposing annular members having an open receiving portion together with a pair of opposing connection flanges, the pair of opposing connection flanges extending between the open receiving portions, the opposing first and second ends of the liquid transport element being circumferentially sealed by the open receiving portions and one of the first and second ends of the liquid transport element being at least partially received in one of the open receiving portions so that the end face is exposed, and the reservoir chamber is sealed by a reservoir chamber sealing configuration at the interface between the base portion of the flow director and the flange and receiving portion of the liquid transport element excluding the exposed end face of the liquid transport element.

6. 4. The aerosol delivery device of claim 3, wherein the cartridge further comprises a mouthpiece channel extending at least partially along the length of the reservoir chamber, the mouthpiece channel defining an open first end and an open terminal end, the open first end being fluidly connected to the mouth end of the outer housing and the open terminal being fluidly connected to the flow tube of the flow director so that the aerosol is directed through the mouthpiece channel.

7. 7. The aerosol delivery device of claim 6, wherein the reservoir chamber seal arrangement comprises a second seal member disposed at the open end of the mouthpiece channel to provide a seal between the flow tube and the mouthpiece channel.

8. 10. The aerosol delivery device of claim 1, further comprising an electrical contact proximate the second surface of the base that provides electrical communication between the atomizer and a power source within the control body when the cartridge is engaged with the control body.

9. 9. The aerosol delivery device of claim 8, wherein the electrical terminal in electrical communication with the atomizer extends from the first surface of the base through the second surface of the base to contact the electrical contact.

10. 10. The aerosol delivery device of claim 1, wherein the atomizer comprises a coil having a plurality of turns, the liquid transport element defines an outer surface extending longitudinally between end faces, and the plurality of turns of the coil are wound around the outer surface and between the end faces of the liquid transport element.

11. 1. A cartridge for an aerosol delivery device, comprising: an outer housing formed from an outer wall, the outer housing having a mouth end and an opposite connecting end; an atomizer assembly disposed about the connecting end of the outer housing, a base defining a first surface and an opposite second surface, the first surface engageable with the connecting end of the outer housing to define a reservoir chamber containing an aerosol precursor composition between an outer wall of the outer housing and the first surface of the base; an atomizer disposed about the first surface of the base to atomize the aerosol precursor composition to form an aerosol; a liquid transport element disposed about the first surface of the base and defining opposite first and second ends having exposed end faces in fluid communication with the reservoir chamber to direct the aerosol precursor composition from the reservoir chamber through the end faces of the liquid transport element and into contact with the atomizer; an atomizer assembly comprising: a reservoir chamber sealing arrangement, the reservoir chamber sealing arrangement comprising a first sealing member disposed around a first surface of the base and adapted to receive first and second opposite ends of the liquid transport element and circumferentially seal the first and second opposite ends of the liquid transport element, exposing the end faces thereof, such that the reservoir chamber is sealed by the reservoir chamber sealing arrangement except for the exposed end faces of the liquid transport element; A cartridge for an aerosol delivery device comprising:

12. 12. The cartridge of claim 11, wherein the reservoir chamber seal arrangement comprises a flow director defining a base portion and including a flow tube, the flow tube extending from the base portion and positioned such that the first seal member is disposed between the flow director and a first surface of the base, the flow tube being in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

13. 13. The cartridge of claim 12, wherein the base further comprises a retaining member extending from a first surface thereof and engaging the flow director, the retaining member being arranged to compress the flow director against the first seal member and the first surface of the base, thereby sealing the reservoir chamber except for an exposed end face of the liquid transport element.

14. 14. The cartridge of claim 13, wherein the retaining member comprises one or more pairs of arms extending generally perpendicularly from the first surface of the base and one or more respective protrusions extending toward the center of the base, the protrusions engaging with the base portion of the flow director to compress the base portion of the flow director against the first seal member and the first surface of the base, thereby sealing the reservoir chamber except for the exposed end face of the liquid transport element.

15. 15. The cartridge of claim 14, wherein the first seal member comprises a pair of opposing annular members having an open receiving portion together with a pair of opposing connection flanges, the pair of opposing connection flanges extending between the open receiving portions, one of the first and second ends of the liquid transport element being at least partially received in one of the open receiving portions so that the opposing first and second ends of the liquid transport element are circumferentially sealed by the open receiving portion and the end face is exposed, and the reservoir chamber is sealed by a reservoir chamber seal arrangement at an interface between the base portion of the flow director and the flange and receiving portion of the liquid transport element excluding the exposed end face of the liquid transport element.

16. 14. The cartridge of claim 13, wherein the cartridge further comprises a mouthpiece channel extending at least partially along the length of the reservoir chamber, the mouthpiece channel defining an open first end and an open terminal end, the open first end being in fluid communication with the mouth end of the outer housing and the open terminal being in fluid communication with the flow tube of the flow director, thereby directing the aerosol through the mouthpiece channel.

17. 17. The cartridge of claim 16, wherein the reservoir chamber seal arrangement comprises a second seal member, the second seal member being disposed at an open end of the mouthpiece channel to provide a seal between the flow tube and the mouthpiece channel.

18. 18. A cartridge according to any one of claims 11 to 17, wherein the atomizer comprises a coil having a plurality of turns, the liquid transport element defining an outer surface extending longitudinally between end faces, and the plurality of turns of the coil being wound around the outer surface and between the end faces of the liquid transport element.

19. 1. A method of manufacturing a cartridge for an aerosol delivery device, comprising: providing an atomizer assembly comprising: a base defining a first surface and an opposite second surface; an atomizer disposed about the first surface of the base for atomizing an aerosol precursor composition to form an aerosol; a liquid transport element disposed about the first surface of the base; and a reservoir chamber seal arrangement comprising a first seal member disposed about the first surface of the base for receiving first and second opposite ends of the liquid transport element and circumferentially sealing the first and second opposite ends of the liquid transport element and exposing end faces thereof; disposing an atomizer assembly around a connecting end of an outer housing of the cartridge, the outer housing having a closed mouth end opposite the connecting end; engaging a first surface of the base with the connecting end of the outer housing so that the reservoir chamber is sealed by the reservoir chamber seal arrangement except for an exposed end face of the liquid transport element to define a reservoir chamber containing the aerosol precursor composition between the outer wall of the outer housing and the first surface of the base; the exposed end face of the liquid transport element is in fluid communication with the reservoir chamber to direct the aerosol precursor composition from the reservoir chamber through the end face of the liquid transport element and into contact with the atomizer; method.

20. 20. The method of claim 19, wherein providing the atomizer assembly includes providing a flow director having a flow tube defining a base portion, the flow tube extending from the base portion and positioned such that a first seal member is disposed between the flow director and a first surface of the base, the flow tube being in fluid communication with the atomizer to direct the formed aerosol to the mouth end of the outer housing.

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