Aerosol delivery device including control body, atomizer body and cartridge, and related methods

Abstract

To provide an aerosol delivery device and a method of operating the same.SOLUTION: The aerosol delivery device may include a control body 200, an atomizer body including an atomizer, and a cartridge including a reservoir configured to contain an aerosol precursor composition. The control body may be configured to releasably engage the atomizer body, and the atomizer body may be configured to releasably engage the cartridge. The atomizer may be configured to receive an electrical current from the control body and receive the aerosol precursor composition from the cartridge to produce aerosol.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to aerosol delivery devices, such as electronic cigarettes, and more particularly to aerosol delivery devices that include a nebulizer that may be configured to heat an aerosol precursor composition, which may be made from, derived from, or otherwise incorporate tobacco, to form an inhalable substance for human consumption. [Background technology]

[0002] Many devices have been proposed over the years as an improvement or replacement for smoking products that require the burning of tobacco for use. Many of these devices are designed to provide the sensations associated with smoking a cigarette, cigar or pipe, but are said to lack the significant incomplete combustion and pyrolysis products that result from the burning of tobacco. To this end, many alternative smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the smoking sensations of a cigarette, cigar or pipe without significantly burning tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art of U.S. Patent No. 8,881,737 to Collett et al., U.S. Patent Application Publication No. 2013 / 0255702 to Griffith Jr. et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., U.S. Patent Application Publication No. 2014 / 0096782 to Ampolini et al., and U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al., which are incorporated by reference in their entireties. Also see, for example, the various embodiments of products and heating configurations described in the background art sections of U.S. Patent No. 5,388,594 to Counts et al. and U.S. Patent No. 8,079,371 to Robinson et al., which are incorporated by reference in their entireties. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Pat. No. 8,881,737 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0000638 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2014 / 0096782 [Patent Document 6] US Patent Application Publication No. 2015 / 0059780 [Patent Document 7] U.S. Pat. No. 5,388,594 [Patent Document 8] U.S. Pat. No. 8,079,371 Summary of the Invention [Problem to be solved by the invention]

[0004] However, it may be desirable to provide an aerosol delivery device having alternative configurations. Accordingly, advances relating to aerosol delivery devices may be desirable. [Means for solving the problem]

[0005] The present disclosure relates to an aerosol delivery device and a method of operating the same. The present disclosure includes, but is not limited to, the following exemplary implementations:

[0006] Exemplary implementation form 1: An aerosol delivery device comprising a cartridge having a control body, a sprayer body including a sprayer, and a reservoir configured to accommodate an aerosol precursor composition, and a valve assembly configured to distribute the aerosol precursor composition to the sprayer body when the cartridge is engaged with the sprayer body, wherein the valve assembly includes a distribution seal and a reservoir seal, the control body is configured to releasably engage with the sprayer body, the sprayer body is configured to releasably engage with the cartridge, and the sprayer is configured to receive an electric current from the control body and receive the aerosol precursor composition from the cartridge to generate an aerosol.

[0007] Exemplary implementation 2: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which the cartridge comprises one or more airflow openings extending from the nebulizer body to the mouthpiece, the airflow openings being configured to direct the aerosol therethrough. Exemplary implementation 3: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which at least one of the airflow openings penetrates the valve assembly. Exemplary implementation 4: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which the valve assembly defines a distribution capillary, the valve assembly further comprising a first plate and a second plate disposed adjacent to each other with a space defined therebetween, the distribution capillary extending through the first plate to the space between the first plate and the second plate. Exemplary implementation 5: An aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein a gap is defined between the radially outer edge of the first plate and the radially outer edge of the second plate and the inner surface of the reservoir.

[0008] Exemplary implementation 6: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, where the sprayer body further comprises a nozzle configured to pierce the reservoir seal and engage with the distribution seal. Exemplary implementation 7: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, where the valve assembly further comprises a frame, and where the reservoir seal is molded to the frame. Exemplary implementation 8: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, where the sprayer comprises a liquid transport element comprising a porous monolith. Exemplary implementation 9: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, where the sprayer further comprises a heating element comprising a wire at least partially embedded in the liquid transport element. Exemplary implementation 10: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein the liquid transport element defines a tube and the nebulizer further comprises a capillary rod configured to penetrate the liquid transport element and direct the aerosol precursor composition therethrough. Exemplary implementation 11: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein the control body further comprises a microphone, the microphone configured to detect a user's inhalation on the cartridge.

[0009] Exemplary implementation 12: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which the sprayer includes an outer body, a terminal base, a flow director, and a liquid transport element including a porous monolith, and the sprayer chamber is created by the flow director, the terminal base, and the inner surface of the liquid transport element. Exemplary implementation 13: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which the flow director includes a central inlet air channel, a transition barrier, and one or more radial inlet air holes, configured such that air entering through the inlet air channel is directed through one or more radial inlet air holes by a transition barrier. Exemplary implementation 14: The aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, in which the flow director further includes one or more inlet liquid flow chambers configured to deliver an aerosol precursor composition to the liquid transport element. Exemplary implementation 15: An aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein the outer body includes one or more steam openings, and the flow director further includes one or more radial inlet steam holes, one or more radial steam channels, and one or more vertical steam holes configured to direct the aerosol through one or more radial inlet steam holes, one or more radial steam channels, one or more vertical steam holes of the flow director, and one or more steam openings of the outer body, and into one or more steam channels of the cartridge.

[0010] Exemplary implementation 16: A method of operating an aerosol delivery device, comprising: directing an aerosol precursor composition from a reservoir of a cartridge through a valve assembly and out of the cartridge by directing the aerosol precursor composition through a distribution seal and a reservoir seal of the reservoir; receiving the aerosol precursor composition into a sprayer body; directing the aerosol precursor composition to a sprayer in the sprayer body; and directing an electric current from a control body to the sprayer to generate an aerosol.

[0011] Exemplary implementation 17: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein the valve assembly defines a distribution capillary, and directing the aerosol precursor composition out of the cartridge through the valve assembly further comprises directing the aerosol precursor composition between a first plate and a second plate disposed adjacent to one another with a space defined therebetween, and out of the space through a distribution capillary that penetrates the first plate. Exemplary implementation 18: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein directing the aerosol precursor composition out of the cartridge through the valve assembly further comprises engaging a nozzle of the sprayer body with the valve assembly. Exemplary implementation 19: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein engaging the nozzle with the valve assembly comprises directing the nozzle through a reservoir seal of the valve assembly. Exemplary implementation 20: A method of operating an aerosol delivery device of any preceding exemplary implementation, or any combination of any preceding exemplary implementation, wherein engaging the nozzle with the valve assembly further comprises engaging the nozzle with a dispensing seal of the valve assembly with a dispensing capillary.

[0012] Exemplary implementation 21: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein receiving the aerosol precursor composition in the sprayer body comprises directing the aerosol precursor composition between a nozzle and a capillary rod. Exemplary implementation 22: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein directing the aerosol precursor composition to a sprayer in the sprayer body comprises directing the aerosol precursor composition between a capillary rod and a liquid transport element of the sprayer. Exemplary implementation 23: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, further comprising directing the aerosol through one or more airflow openings through the cartridge. Exemplary implementation 24: The method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, wherein directing the aerosol through one or more airflow openings through the cartridge includes directing the aerosol through a valve assembly.

[0013] Exemplary implementation 25: A method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, further comprising: directing the aerosol precursor composition to the nebulizer in the nebulizer body through one or more radial flow openings in the outer body of the nebulizer and through one or more inlet liquid flow channels in the flow director of the nebulizer. Exemplary implementation 26: A method of operating an aerosol delivery device of any of the preceding exemplary implementations, or any combination of any of the preceding exemplary implementations, further comprising directing the aerosol to one or more vapor channels of the cartridge through one or more radial inlet vapor holes, one or more radial vapor channels, and one or more vertical vapor holes of the flow director and one or more vapor openings of the outer body of the nebulizer.

[0014] These and other features, aspects and advantages of the present disclosure will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more features or elements described in the present disclosure, regardless of whether such features or elements are explicitly combined or otherwise recited in a particular exemplary implementation described herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the present disclosure appear as intended, i.e., combinable, in any of its aspects and exemplary implementations, unless the context of the disclosure clearly dictates otherwise.

[0015] It will therefore be understood that this summary is provided only for the purpose of summarizing some exemplary implementations to provide a basic understanding of some aspects of the present disclosure. It will therefore be understood that the above exemplary implementations are merely examples and should not be construed in any way to narrow the scope or spirit of the present disclosure. Other exemplary implementations, aspects and advantages will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of some described exemplary implementations.

[0016] Having described the present disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 shows a side view of an aerosol delivery device including a cartridge and a control body in an assembled configuration according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 illustrates the control body of FIG. 1 in an exploded configuration, according to an exemplary embodiment of the present disclosure. [Diagram 3] 2 illustrates the cartridge of FIG. 1 in an exploded configuration, according to an exemplary embodiment of the present disclosure. [Figure 4]FIG. 1 shows a perspective view of an aerosol delivery device including a cartridge, a nebulizer body and a control body in a separated configuration according to an exemplary embodiment of the present disclosure. [Diagram 5] 5 shows an exploded view of the cartridge of FIG. 4, including a reservoir and a valve assembly, according to an exemplary embodiment of the present disclosure. [Figure 6] 6 shows a perspective view of the filling of the reservoir of FIG. 5 according to an exemplary embodiment of the present disclosure. [Figure 7] 6 shows a perspective view of the valve assembly of FIG. 5 according to an exemplary embodiment of the present disclosure. [Figure 8] 5 illustrates an exploded view of the sprayer body of FIG. 4, including an outer body, a sprayer, and a coupler, according to an exemplary embodiment of the present disclosure. [Figure 9] 9 illustrates an exploded view of the sprayer of FIG. 8 according to an exemplary embodiment of the present disclosure. [Figure 10] 5 illustrates an exploded view of the coupler and terminal of the sprayer body of FIG. 4 according to an exemplary embodiment of the present disclosure. [Figure 11] 11 illustrates a perspective view of the coupler and terminal of FIG. 10 in an assembled configuration according to an exemplary embodiment of the present disclosure. [Figure 12] 5 illustrates a partially assembled and partially exploded view of a portion of the sprayer body of FIG. 4 according to an exemplary embodiment of the present disclosure. [Figure 13] 5 shows a modified cross-sectional view of the aerosol delivery device of FIG. 4 according to an exemplary embodiment of the present disclosure. [Figure 14] 5 shows a modified cross-sectional view of the aerosol delivery device of FIG. 4 at a cartridge according to an exemplary embodiment of the present disclosure. [Figure 15] 15 illustrates an expanded view of region Z of FIG. 14, in accordance with an exemplary embodiment of the present disclosure. [Figure 16] FIG. 5 illustrates a perspective end view of the cartridge of FIG. 4 according to an exemplary embodiment of the present disclosure. [Figure 17] 1 illustrates a schematic diagram of a method of operating an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 18] 13 illustrates a cartridge and a sprayer according to an additional exemplary embodiment of the present disclosure. [Figure 19] 19 illustrates the sprayer of FIG. 18 in an assembled configuration, according to an exemplary embodiment of the present disclosure. [Figure 20] 19 illustrates the sprayer of FIG. 18 in an exploded configuration, according to an exemplary embodiment of the present disclosure. [Figure 21] 19 illustrates a cartridge for use with the sprayer of FIG. 18 according to an exemplary embodiment of the present disclosure. [Figure 22] FIG. 22 illustrates a bottom view of the cartridge of FIG. 21 according to an exemplary embodiment of the present disclosure. [Diagram 23] 19 shows a liquid transport element and a heating element for use with the sprayer of FIG. 18 according to an exemplary embodiment of the present disclosure. [Figure 24] 19 illustrates a flow director for use with the sprayer of FIG. 18, according to an exemplary embodiment of the present disclosure. [Diagram 25] 25 shows a cross-sectional view of the flow director of FIG. 24 according to an exemplary embodiment of the present disclosure. [Figure 26] 19 shows a partial cross-sectional view of the sprayer of FIG. 18 according to an exemplary embodiment of the present disclosure. [Figure 27] 19 shows different partial cross-sectional views of the sprayer of FIG. 18 according to an exemplary embodiment of the present disclosure. [Figure 28] FIG. 24 illustrates a partial front view of the cartridge of FIG. 23 according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] 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 variations unless the context clearly dictates otherwise.

[0019] This disclosure provides a description of an aerosol delivery device. The aerosol delivery device may use electrical energy to heat a material (preferably without significantly burning the material) to form an inhalable substance. Most preferably, such an article is small enough to be considered a "handheld" device. The aerosol delivery device may provide some or all of the sensation of smoking a cigarette, cigar, or pipe (e.g., the type of inhalation and exhalation, the type of taste or flavor, the sensory effect, the physical feel, the type of use, the visual stimuli as provided by a visible aerosol, etc.) without substantially burning any components of the article or device. The aerosol delivery device may not generate smoke in the sense of an aerosol resulting from the by-products of tobacco combustion or pyrolysis, rather, the article or device most preferably generates vapors (including vapors within the aerosol that may be considered to be described as smoky, which may be considered to be a visible aerosol) due to volatilization or vaporization of certain components of the article or device, although in other embodiments, the aerosol may be invisible. In a highly preferred embodiment, the aerosol delivery device may incorporate tobacco and / or tobacco-derived components. As such, the aerosol delivery device can be characterized as an electronic smoking article, such as an electronic cigarette ("e-cigarette").

[0020] Although the system is generally described herein with respect to embodiments related to aerosol delivery devices, 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 articles. For example, the description provided herein may be used in combination with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and related packaging 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.

[0021] The aerosol delivery device of the present disclosure can also be characterized as a vapor product or drug delivery article. Thus, such an article or device can be configured to provide one or more substances (e.g., flavors and / or pharmacologic actives) in an inhalable form or state. For example, the inhalable substance can be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in aerosol form (i.e., a suspension or droplets of fine solid particles in a gas). For ease of understanding, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible and whether or not in a form that can be considered smoky.

[0022] When in use, the aerosol delivery device of the present disclosure may be subjected to many of the physical actions used by an individual when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe, which is used by lighting tobacco and inhaling. For example, a user of the aerosol delivery device of the present disclosure may hold the article as with a traditional type of smoking article, draw on one end of the article to inhale the aerosol produced by the article, take puffs at selected time intervals, and so on.

[0023] The aerosol delivery device of the present disclosure generally includes a number of components disposed within an outer shell or body. The overall design of the outer shell or body can vary, and the type or configuration of the outer body can vary, which can define the overall dimensions and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar can be formed from a single integral shell, or the elongated body can be formed from two or more separable parts. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and can resemble the shape of a conventional cigarette or cigar. However, in other embodiments, various other shapes and configurations can be used (e.g., rectangular or fob-shaped).

[0024] In one embodiment, all components of the aerosol delivery device are housed in one outer body or shell. Alternatively, the aerosol delivery device can have two or more shells that are joined and separable. For example, the aerosol delivery device can have a control body at one end that includes a shell that houses one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the item) and a removably attached shell at the other end that houses a disposable part (e.g., a disposable flavor-containing cartridge). More specific forms, configurations and arrangements of components in a single-shell type unit or in a multiple-part separable shell type unit will become apparent in light of the further disclosure provided herein. Furthermore, the design and arrangement of components of various aerosol delivery devices can be understood in light of commercially available electronic aerosol delivery devices.

[0025] The aerosol delivery device of the present disclosure most preferably includes some combination of a driving source (i.e., a power source), at least one control component (e.g., a means for activating, controlling, regulating, and / or terminating power for heat generation, such as by controlling the flow of current from the driving source to other components of the aerosol delivery device), a heater or heat generating member (e.g., an electrical resistance heating element or component commonly referred to as part of an "atomizer"), and an aerosol precursor composition (e.g., a liquid that can generally produce an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouth end region or tip that allows the aerosol delivery device to be drawn upon for aerosol inhalation (e.g., a defined air flow path through the article such that the generated aerosol may be drawn therefrom by suction).

[0026] The alignment of components within the aerosol delivery device of the present disclosure can be varied. In certain embodiments, the aerosol precursor composition can be positioned near the end of the aerosol delivery device, which may be configured to be positioned in close proximity to the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. In general, the heating element can be positioned close enough to the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorants, medicinal agents, etc., that may be provided for delivery to the user) to form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be rephrased to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, inhalable substances are released in the form of vapors or aerosols or mixtures thereof, and such terms are used interchangeably herein unless otherwise specified.

[0027] As mentioned above, the aerosol delivery device may incorporate a battery and / or other power source (e.g., a capacitor) to provide sufficient current to provide various functions to the aerosol delivery device, such as powering the heater, powering the control system, powering the indicators, etc. The power source may take various embodiments. Preferably, the power source provides sufficient power to rapidly heat the heating element to form the aerosol and power the aerosol delivery device throughout use for a desired duration. The power source is preferably sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Additionally, preferred power sources are lightweight enough so as not to impair the desired smoking experience.

[0028] More specific forms, configurations and arrangements of components in the aerosol delivery device of the present disclosure will become clear in light of the further disclosure provided below. In addition, the selection of various aerosol delivery device components can be understood in consideration of commercially available electronic aerosol delivery devices. In addition, the arrangement of components in the aerosol delivery device can be understood in consideration of commercially available electronic aerosol delivery devices. Examples of commercially available products that may include the components, their operation methods, materials contained therein, and / or other attributes thereof, to manufacturers, designers and / or assignees of the devices of the present disclosure and components and related technology that may be used in the aerosol delivery device of the present disclosure, are described in U.S. Patent Application No. 15 / 222,615 to Watson et al., filed July 28, 2016, which is incorporated herein by reference in its entirety.

[0029] One exemplary embodiment of an aerosol delivery device 100 is shown in FIG. 1. In particular, FIG. 1 shows the aerosol delivery device 100 including a control body 200 and a cartridge 300. The control body 200 and the cartridge 300 may be permanently or removably aligned in a functional relationship. Various mechanisms may connect the cartridge 300 to the control body 200 to provide a threaded engagement, a press-fit engagement, an interference fit, a magnetic engagement, and the like. In some embodiments, the aerosol delivery device 100 may be substantially rod-like, substantially tubular, or substantially cylindrical in shape when the cartridge 300 and the control body 200 are in an assembled configuration. However, as noted above, in other embodiments, various other configurations may be used, such as a rectangular or fob shape. Additionally, while the aerosol delivery device is described herein as generally resembling the dimensions and shape of a conventional smoking article, in other embodiments, a different configuration and a large-volume reservoir, which may be referred to as a "tank," may be used.

[0030] In certain embodiments, one or both of the cartridge 300 and the control body 200 may be referred to as disposable or reusable. For example, the control body 200 may have replaceable or rechargeable batteries and / or capacitors and thus may be combined with any type of recharging technology, including connection to a typical AC electrical outlet, connection to an automobile charger (i.e., cigarette lighter), and connection to a computer via a Universal Serial Bus (USB) cable or the like. Additionally, in some embodiments, the cartridge 300 may include a disposable cartridge as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0031] 2 shows an exploded view of a control body 200 of an aerosol delivery device 100 (see FIG. 1 ) according to an exemplary embodiment of the present disclosure. As shown, the control body 200 may include a coupler 202, an outer body 204, a seal member 206, an adhesive member 208 (e.g., KAPTON® tape), a flow sensor 210 (e.g., a puff sensor or a pressure switch), a control component 212, a spacer 214, a power source 216 (e.g., a capacitor and / or a battery, which may be rechargeable), a circuit board having an indicator 218 (e.g., a light emitting diode (LED)), a connector circuit 220, and an end cap 222. An example of a power source is described in U.S. Pat. No. 9,484,155 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0032] With respect to the flow sensor 210, representative current regulation components and other current control components, including various microcontrollers, sensors and switches for aerosol delivery devices, are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874 and 4,947,875 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. Also reference is made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., all of which are incorporated herein by reference in their entirety.

[0033] In one embodiment, the indicator 218 may comprise one or more light emitting diodes. The indicator 218 may be in communication with the control component 212 via the connector circuit 220 and may be illuminated, for example, as detected by the flow sensor 210 during a user drawing on a cartridge coupled to the coupler 202. The end cap 222 may be configured to make the illumination provided thereunder by the indicator 218 visible. Thus, the indicator 218 may be illuminated during use of the aerosol delivery device 100 to mimic the lighting end of a smoking article. However, in other embodiments, the indicator 218 may be provided in various numbers, may be of different shapes, and may be an opening in the outer body (e.g., to emit a sound when such an indicator is present).

[0034] Additional components may be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that may be associated with the mouth end of the device that detects the user's lip movements associated with drawing and subsequently causes 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 in a smoking device 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 drive cycles having multiple differential phases; and U.S. Pat. No. 5,934,289 to Watkins et al. , discloses photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for varying the resistance of 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 WO 2010 / 003480 to 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.Additional examples of electronic aerosol delivery articles and components related to the disclosed materials or components that may be used herein 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, U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., and U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 01 to Hon Nos. 96518 and 2009 / 0188490 to Oglesby et al., 2010 / 0024834 to Wang, 2010 / 0307518 to Wang, WO 2010 / 091593 to Hon, and WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, the disclosures of which are all incorporated herein by reference in their entirety.

[0035] 3 illustrates a cartridge 300 of the aerosol delivery device 100 (see FIG. 1) in an exploded configuration. As illustrated, the cartridge 300 may include a base 302, a control component terminal 304, electronics 306, a flow director 308, a nebulizer 310, a reservoir 312 (e.g., a reservoir substrate), an outer body 314, a mouthpiece 316, a label 318, and first and second heating terminals 320, 321 according to an exemplary embodiment of the present disclosure.

[0036] In some embodiments, the first and second heating terminals 320, 321 may be embedded or otherwise coupled to the flow director 308. For example, the first and second heating terminals 320, 321 may be insert molded into the flow director 308. Thus, the flow director 308 and the first and second heating terminals are collectively referred to herein as a flow director assembly 322. Additional description of the first and second heating terminals 320, 321 and the flow director 308 can be found in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., which is incorporated herein by reference in its entirety.

[0037] The sprayer 310 may include a liquid transport element 324 and a heating element 326. The cartridge may further include a base shipping plug engaged to the base and / or a mouthpiece shipping plug engaged to the mouthpiece to protect the base and mouthpiece and prevent contaminants from entering therein prior to use, as disclosed, for example, in U.S. Patent No. 9,220,302 to DePiano et al., which is incorporated herein by reference in its entirety.

[0038] The base 302 may be coupled to a first end of the outer body 314, and the mouthpiece 316 may be coupled to an opposing second end of the outer body to substantially or completely enclose other components within the cartridge 300. For example, the control component terminals 304, electronics 306, flow director 308, sprayer 310, and reservoir 312 may be substantially or completely retained within the outer body 314. A label 318 may at least partially surround the outer body 314 and optionally the base 302, and may include information thereon, such as a product identifier. The base 302 may be configured to engage with the coupler 202 of the control body 200 (see, e.g., FIG. 2). In some embodiments, the base 302 may include an anti-rotation mechanism that substantially prevents relative rotation between the cartridge and the control body, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0039] Reservoir 312 may be configured to hold an aerosol precursor composition. Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat. No. 8,881,737 to Collett et al., and U.S. Pat. No. 9,254,002 to Chong et al., and U.S. Patent Application Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Application Publication No. 2015 / 0020823 to Lipowicz et al., and U.S. Patent Application Publication No. 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include the aerosol precursors incorporated in RJ Reynolds Vapor Company's VUSE® products, Lorillard Technologies' BLU products, Mistic Ecigs' MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. Also desirable are so-called "smoke juices" for e-cigarettes available from Johnson Creek Enterprises LLC. Embodiments of effervescent materials may be used with the aerosol precursors, for example, as described in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which is incorporated herein by reference. Further, the use of foamable materials has been described, for example, in U.S. Pat. No. 4,639,368 to Niazi et al., U.S. Pat. No. 5,178,878 to Wehling et al., U.S. Pat. No. 5,223,264 to Wehling et al., U.S. Pat. No. 6,974,590 to Pather et al., U.S. Pat. No. 7,381,667 to Bergquist et al., U.S. Pat. No. 8,424,541 to Crawford et al., U.S. Pat. No. 8,627,828 to Strickland et al., and U.S. Pat. No. 9,307,787 to Sun et al., as well as U.S. Patent Application Publication No. 2010 / 0018539 to Brinkley et al. and WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference.Additional descriptions of embodiments of the aerosol precursor compositions, including descriptions of tobacco or tobacco-derived components contained in the aerosol precursor compositions, are provided in U.S. Patent Application Nos. 15 / 216,582 and 15 / 216,590, both to Davis et al., filed on July 21, 2016, and which are incorporated by reference in their entireties herein.

[0040] The reservoir 312 may comprise multiple layers of non-woven fibers formed into a tube shape that surrounds the interior of the outer body 314 of the cartridge 300. Thus, for example, a liquid component may be adsorbed and held by the reservoir 312. The reservoir 312 is in fluid communication with the liquid transport element 324. Thus, the liquid transport element 324 may be configured to transport liquid from the reservoir 312 to the heating element 326 via capillary action or other liquid transport mechanisms.

[0041] As shown, the liquid transport element 324 may be in direct contact with the heating element 326. As further shown in FIG. 3, the heating element 326 may comprise a wire defining multiple coils wound around the liquid transport element 324. In some embodiments, the heating element 326 may be formed by winding a wire around the liquid transport element 324, as described in U.S. Pat. No. 9,210,738 to Ward et al., which is incorporated by reference in its entirety. Additionally, in some embodiments, the wire may define a variable coil spacing, as described in U.S. Pat. No. 9,277,770 to DePiano et al., which is incorporated by reference in its entirety. The heating element 326 may be formed using various embodiments of materials configured to generate heat when an electric current is applied thereto. Examples of materials from which the wire coil may be formed include Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi), molybdenum silicide (MoSi), aluminum doped molybdenum disilicide (Mo(Si,Al)), graphite and graphite based materials, and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0042] However, various other embodiments of methods may be used to form the heating element 326, and various other embodiments of heating elements may be used in the sprayer 310. For example, stamped heating elements may be used in the sprayer, as described in U.S. Patent Application Publication No. 2014 / 0270729 to DePiano et al., which is incorporated by reference herein in its entirety. In addition to the above, additional exemplary heating elements and materials for use therein are described in U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 ... Sprinkel et al., and U.S. Patent No. 5,311,133 to Sprinkel et al. No. 5,228,460 to Jr. et al., U.S. Patent No. 5,322,075 to Deevi et al., U.S. Patent No. 5,353,813 to Deevi et al., U.S. Patent No. 5,468,936 to Deevi et al., U.S. Patent No. 5,498,850 to Das, U.S. Patent No. 5,659,656 to Das, U.S. Patent No. 5,498,855 to Deevi et al., U.S. Patent No. 5,530,225 to Hajaligol, U.S. Patent No. 5,665,262 to Hajaligol, U.S. Patent No. 5,573,692 to Das et al., and U.S. Patent No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties. Additionally, in other embodiments, chemical heating may be used. As mentioned above, various additional examples of heaters and materials used to form heaters are described in US Pat. No. 8,881,737 to Collett et al., which is incorporated herein by reference.

[0043] In the aerosol delivery device of the present invention, various heater components may be used. In various embodiments, one or more microheaters or similar solid heaters may be used. Microheaters suitable for use in the device of the present disclosure, and nebulizers incorporating microheaters, are described in U.S. Patent No. 8,881,737 to Collett et al., the entirety of which is incorporated herein by reference.

[0044] The first heating terminal 320 and the second heating terminal 321 (e.g., negative and positive heating terminals) are configured to engage opposing ends of the heating element 326 and form an electrical connection with the control body 200 (e.g., see FIG. 2) when the cartridge 300 is connected thereto. Furthermore, when the control body 200 is coupled to the cartridge 300, the electronics 306 may form an electrical connection with the control body via the control component terminals 304. Thus, the control body 200 may use the electronic control component 212 (see FIG. 2) to determine whether the cartridge 300 is authentic and / or perform other functions. Furthermore, various examples of electronic control components and functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference in its entirety.

[0045] During use, a user may draw on the mouthpiece 316 of the cartridge 300 of the aerosol delivery device 100 (see FIG. 1). This may draw air through an opening in the control body 200 (see, e.g., FIG. 2) or the cartridge 300. For example, in one embodiment, an opening may be defined between the coupler 202 and the outer body 204 of the control body 200 (see, e.g., FIG. 2), as described in U.S. Pat. No. 9,220,302 to DePiano et al., which is incorporated herein by reference in its entirety. However, in other embodiments, the air flow may be received through other portions of the aerosol delivery device 100. As described above, in some embodiments, the cartridge 300 may include a flow director 308. The flow director 308 may be configured to direct the air flow received from the control body 200 to the heating element 326 of the nebulizer 310.

[0046] A sensor in the aerosol delivery device 100 (e.g., flow sensor 210 in the control body 200, see FIG. 2) may sense a puff. When a puff is sensed, the control body 200 may direct current to the heating element 326 through a circuit including the first heating terminal 320 and the second heating terminal 321. The heating element 326 may thus vaporize the aerosol precursor composition directed by the liquid transport element 324 from the reservoir 312 to the aerosolization zone. In this way, the mouthpiece 326 may pass air and entrained vapor (i.e., components of the aerosol precursor composition in an inhalable form) from the cartridge 300 towards the consumer who inhales it.

[0047] Various other details regarding components that may be included in cartridge 300 are described, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., which is incorporated herein by reference in its entirety. Additional components that may be included in cartridge 300, and details relating thereto, are described, for example, in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., filed May 23, 2014, which is incorporated herein by reference in its entirety.

[0048] The various components of the aerosol delivery device according to the present disclosure may be selected from those described and commercially available in the art, see, for example, the reservoir and heater system for the controllable delivery of multiple aerosolizable materials in an electronic smoking article disclosed in U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0049] In another embodiment, substantially the entire cartridge may be formed from one or more carbon materials, which may provide advantages in terms of biodegradability and lack of wires. In this regard, the heating element may comprise carbon foam, the reservoir may comprise carbonized fabric, and graphite may be used to form electrical connections with the power supply and control components. Exemplary embodiments of carbon-based cartridges are described in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., which is incorporated herein by reference in its entirety.

[0050] However, in some embodiments, it may be desirable to provide an aerosol delivery device having alternative configurations. In this regard, FIG. 4 illustrates an aerosol delivery device 400 according to an exemplary embodiment of the present disclosure. Unless otherwise described and / or illustrated, the components of aerosol delivery device 400 may be substantially similar or identical to corresponding components described above.

[0051] As shown, the aerosol delivery device may include a control body 200. The control body 200 may be similar or identical to the control body 200 described above (see FIG. 2), and therefore the description thereof will not be repeated. However, in some embodiments, the flow sensor 210 (see FIG. 2) may include a microphone configured to detect a user's inhalation on the cartridge 500. Additionally, other embodiments of the control body may be used in the aerosol delivery device, such as a fob-shaped control body.

[0052] Further, the aerosol delivery device 400 may include a cartridge 500. The cartridge 500 may differ from the embodiment of the cartridge 300 described above with respect to Figures 1 and 3. In this regard, the cartridge 500 may not include a nebulizer. Rather, the aerosol delivery device 400 may further include a nebulizer body 600, which may include a nebulizer, as described in detail below. Thus, while the aerosol delivery device 100 described above with respect to Figure 1 includes two separable components (i.e., the control body 200 and the cartridge 300), the aerosol delivery device 400 of Figure 4 includes three separable components (i.e., the control body 200, the cartridge 500, and the nebulizer body 600).

[0053] More specifically, the control body 200 may be configured to releasably engage with the sprayer body 600. Additionally, the sprayer body 600 may be configured to releasably engage with the cartridge 500. As described below, the sprayer of the sprayer body 600 may be configured to receive electrical current from the control body 200 and receive an aerosol precursor composition from the cartridge 500 to generate an aerosol.

[0054] FIG. 5 illustrates an exploded view of a cartridge 500. As illustrated, the cartridge 500 may include a reservoir 502 and a valve assembly 504. The reservoir 502 may be configured to contain an aerosol precursor composition 506. In some embodiments, the reservoir 502 may comprise a translucent or transparent material such that a user can see the amount of aerosol precursor composition 506 remaining therein. The aerosol precursor composition 506 may be dispensed or otherwise directed into the reservoir 502. For example, as shown in FIG. 6, a fill needle 508 may be directed into the reservoir 502 and the aerosol precursor composition 506 may be dispensed therefrom.

[0055] The valve assembly 504 may then be inserted into the reservoir 502. The valve assembly 504 may seal the aerosol precursor composition 506 within the reservoir 502. Thus, the valve assembly 504 may retain the aerosol precursor composition 506 within the reservoir 502 without requiring the use of a reservoir substrate. However, as described below, the valve assembly 504 may allow the aerosol precursor composition 506 to flow to the sprayer body 600 when engaged therewith.

[0056] In some embodiments, the valve assembly 504 may be attached to the reservoir 502. For example, the valve assembly 504 may be ultrasonically welded to the reservoir 502. As can be appreciated, various other mechanisms and techniques, such as the use of adhesives, may be used to hold the valve assembly 504 in engagement with the reservoir 502. However, the use of ultrasonic welding may be preferred in that it may provide an airtight seal without the need for additional components or materials to form the seal. This may prevent non-destructive removal of the valve assembly 504 from the reservoir 502, such that the reservoir cannot be refilled, as described in more detail below.

[0057] FIG. 7 shows an enlarged view of the valve assembly 504. As shown, the valve assembly 504 may include a frame 510. As described above, a base 512 of the frame 510 may be ultrasonically welded to an inner surface of the reservoir 502 to form the cartridge 500 (see, e.g., FIG. 5). Additionally, the frame 510 may include at least one connector portion 514, a first plate 516, a second plate 518, and at least one spacer 520. The connector portion 514 may extend from the base 512 to the first plate 516. The first plate 516 and the second plate 518 may be disposed adjacent to one another with a space defined therebetween. In this regard, the spacer 520 may extend between and separate the first plate 516 and the second plate 518 such that the first plate and the second plate are separated. The distribution capillary 522 may extend through the first plate 516 to a space defined between the first plate and the second plate 518 .

[0058] Additionally, the valve assembly 504 may include one or more seals. In particular, the valve assembly 504 may include a reservoir seal 524. The reservoir seal 524 may be configured to seal against the interior of the reservoir 502 to seal the aerosol precursor composition 506 within the reservoir (see, e.g., FIG. 5). The reservoir seal 524 may be molded (e.g., insert molded) into the frame 510.

[0059] Additionally, the valve assembly 504 may include a distributor seal 526. The distributor seal 526 may be disposed in the distributor capillary 522. In particular, the distributor seal 526 may be configured to seal the distributor capillary 522 closed.

[0060] The reservoir seal 524 and / or the distribution seal 526 may be molded into the frame 510. For example, the distribution seal 526 and / or the reservoir seal 524 may be overmolded onto the frame 510. By molding one or both of the seals 524, 526 into the frame 510, a strong bond may be formed between them that engages the frame and retains the seal.

[0061] In some embodiments, the frame 510 may comprise a plastic material. An exemplary commercially available material that may be included in the frame 510 is TRITAN copolyester sold by Eastman Chemical Company of Kingsport, Tenn. Additionally, in some embodiments, the reservoir seal 524 and / or the distribution seal 526 may comprise silicone, thermoplastic polyurethane, or other elastomeric material.

[0062] With regard to additional components of the aerosol delivery device 400 (see FIG. 4), the sprayer body 600 is shown in a partially exploded configuration in FIG. 8. As shown, the sprayer body 600 may include an outer body 602. The outer body 602 may be configured to engage with a base 604. For example, the outer body 602 may comprise a metallic material (e.g., stainless steel) that may be crimped to the base 604, which may comprise a plastic material. When the outer body 602 is engaged with the base 604, various other components of the sprayer body 600 may be substantially enclosed therein.

[0063] For example, the sprayer body 600 may further comprise a sprayer 606. An exemplary embodiment of the sprayer 606 is shown in FIG. 9. As shown, the sprayer 606 may comprise a liquid transport element 608 and a heating element 610. Furthermore, the liquid transport element 608 may comprise a porous monolith. For example, the liquid transport element 608 may comprise a ceramic.

[0064] The heating element 610 may comprise a wire that may be wound around the liquid transport element 608. In some embodiments, the wire may comprise titanium, Kanthal (FeCrAl), Nichrome, Molybdenum Disilicide (MoSi2), Molybdenum Silicide (MoSi), Molybdenum Disilicide doped with Aluminum (Mo(Si,Al)2), graphite and graphite-based materials, ceramics (e.g., positive or negative temperature coefficient ceramics), tungsten and tungsten-based alloys, or any other suitable material as described elsewhere herein. The use of tungsten and tungsten-based alloys may be desirable in that these materials may define a suitable coefficient of expansion for use with many ceramics that may be used in the liquid transport element 608.

[0065] The wire of the heating element 610 may be at least partially embedded in the liquid transport element 608. In this regard, the wire of the heating element 610 may be embedded in the liquid transport element 608 before the liquid transport element is fired in a high temperature oven known as a kiln. For example, the wire may be wrapped around a long section of the substrate from which the ceramic is formed before firing the material. Examples of such substrates used to form the ceramic in the liquid transport element 608 may include clays, oxides, non-oxides, and composites. Thereby, the wire may be at least partially embedded in the substrate while being wrapped around it. The substrate and wire may then be fired in a kiln. The product may then be divided into individual atomizers 606 having the desired length by a gang saw or other cutting device.

[0066] The sprayer 606 may further comprise a capillary rod 612. In this regard, the liquid transport element 608 may define a tube. In other words, the liquid transport element 608 may include an opening extending longitudinally therethrough. The capillary rod 612 may thereby extend longitudinally through the liquid transport element 608. The capillary rod 612 may thus be configured to direct the aerosol precursor composition through the liquid transport element 608. In this regard, the spacing between the capillary rod 612 and the inner surface of the liquid transport element 608 may define a capillary channel through which the aerosol precursor composition is directed. The aerosol precursor composition may then be drawn generally radially outward through the liquid transport element 608 during operation of the heating element 610.

[0067] The atomizer body 600 (see FIG. 4) may further include a first atomizer seal 614 shown in FIG. 9. The first atomizer seal 614 may engage a first end of the liquid transport element 608 and a first end of the capillary rod 612, which may define a head 616. The liquid transport element 608 may thereby be sealed to the head 616 of the capillary rod 612 to prevent leakage of the aerosol precursor composition therebetween.

[0068] 10 illustrates an exploded view of the base 604 and a number of terminals configured to engage with the base. The terminals include a first heating terminal 618, a second heating terminal 620, and an electronics terminal 622. The electronics terminal 622 may be engaged with electronics 624 that verifies that the sprayer body 600 (see, e.g., FIG. 8) is authentic and / or provides other functionality described elsewhere herein.

[0069] The assembled configuration of the terminals 618, 620, 622 (see FIG. 10) and base 604 is shown in FIG. 11. As shown, the first heating terminal 620 may include a first clip 626. Additionally, the second heating terminal 620 may include a second clip 628.

[0070] As shown in FIG. 12, the first clip 626 and the second clip 628 may be aligned such that the liquid transport element 608 may be received therein and held in place. In this regard, the liquid transport element 608 may be inserted from the side through an opening in each clip 626, 628 and engaged therewith. The first clip 626 and the second clip 628 may contact opposing ends of the heating element 610 such that electrical current may be conducted therethrough via the first heating terminal 618 and the second heating terminal 620. In some embodiments, the clips 626, 628 may be welded (e.g., laser welded) to the heating element 610 to provide a secure connection therewith. For example, a laser beam may be directed at each of the clips 626, 628, causing a weld to form the clip and the heating element 610.

[0071] The sprayer body 600 (see, e.g., FIG. 4) may further include a second sprayer seal 630 and a sprayer body seal 632. As shown in FIG. 8, the sprayer body seal 632 may extend over the liquid transport element 608 and the heating terminals 618, 620 and engage with the base 604. As further shown in FIG. 8, the second sprayer seal 630 may be configured to engage with a second end of the liquid transport element 608. Thereby, the sprayer body seal 632 may extend over the liquid transport element 608 and the first and second heating terminals 618, 620 such that the liquid transport element cannot be detached from the first clip 626 (see, e.g., FIG. 12). Similarly, the second sprayer seal 630 may extend over the liquid transport element 608 and the second heating terminal 620 such that the liquid transport element cannot be detached from the second clip 628 (see, e.g., FIG. 12). Thus, the liquid transport element 608 may remain engaged with the heating terminals 618 , 620 .

[0072] Additionally, the second atomizer seal 630 and the atomizer body seal 632 may form a seal. In this regard, the atomizer body seal 632 may seal against the base 604 and the outer body 602 when the outer body is engaged therewith. The second atomizer seal 630 and the atomizer body seal 632 may engage with an inner surface of the outer body 602, respectively, to prevent leakage. In particular, the second atomizer seal 630 may engage with an inner surface of the outer body 602, such that the aerosol precursor composition does not leak between the liquid transport element 608 and the outer body, but instead is directed through a longitudinal opening defined through the liquid transport element.

[0073] Additionally, the sprayer body seal 632 may engage with the inner surface of the outer body 602 and the base 604. This allows air to enter the sprayer body 602 only while a user is inhaling through the base 604 through the sprayer body seal 632. In this regard, the sprayer body seal 632 may include one or more air flow openings 634 configured to receive air from the base 604 and direct the air to the outside of the sprayer 606. As described below, the aerosol generated in the sprayer 606 may then be directed from the sprayer body 600 through the cartridge 500 (see, e.g., FIG. 4) to the user.

[0074] The operation of the aerosol delivery device 400 is described in further detail below. As shown in Figure 13, the nebulizer body 600 may be engaged with the control body 200. Additionally, the cartridge 500 may be engaged with the nebulizer body 600 such that the nebulizer body is disposed between the control body and the cartridge 500. However, as can be appreciated, the nebulizer body 600, control body 200 and cartridge 500 may be disposed differently in other embodiments.

[0075] A connection between the control body 200 and the atomizer body 600 via the first and second heating terminals 618, 620 and the electronics terminals 622 (see, e.g., FIG. 10 ) allows the control body 200 to direct an electric current to the atomizer 606 when a puff using the aerosol delivery device 400 is detected. In this regard, the longitudinal end of the cartridge 500 opposite the atomizer body 600 may define a mouthpiece 528. When a user inhales on the mouthpiece 528, air 223 may be directed through an air intake 224 that may be defined between the coupler 202 and the outer body 204 of the control body 200. The air 223 drawn through the air intake 224 may be drawn through the coupler 202 of the control body 200 and then through the base 604 and the atomizer body seal 632 into the atomizing cavity 638 of the atomizer body 600. Additionally, the air 223 can cool the electronic components 624 (see, for example, FIG. 10) as it passes through the base 604, reducing the risk of temperature-related degradation thereof.

[0076] Because its exterior surface includes an O-ring 640 that may engage and seal with an interior surface of the reservoir 502 of the cartridge 500, air 223 may be drawn through the air intake 224 as opposed to through the connection between the cartridge 500 and the sprayer body 600. Additionally, the reservoir 502 may define a detent 530 on its interior surface that may engage with a recess 642, thereby allowing the sprayer body 600 to maintain a secure engagement with the cartridge 500. To the extent that air enters the aerosol delivery device 400 between the control body 200 and the sprayer body 600 rather than through the air intake 224, this air may combine in the spray cavity 638 with air received through the air intake 224.

[0077] Detent 530 and recess 642 may additionally or alternatively serve other functions. In this regard, in some embodiments, engagement of detent 530 with recess 642 may be required to enable operation of the device. For example, engagement of detent 530 with recess 642 may complete a circuit with electronics 624 (see, e.g., FIG. 10 ) required for operation of the aerosol delivery device.

[0078] As air is drawn in through the air intake 224, the flow sensor 210 (see FIG. 2) may detect the drawing. This may cause the control body 200 to conduct an electrical current through the heating terminals 618, 620 to the nebulizer 606. As the nebulizer 606 heats, the aerosol precursor composition 506 may be vaporized in the nebulizer. In this regard, the aerosol precursor composition 506 may be held in the precursor cavity 532 within the reservoir 502. The aerosol precursor composition 506 may be directed to the nebulizer 606 through the valve assembly 504.

[0079] In this regard, the valve assembly 504 may be configured to dispense the aerosol precursor composition 506 to the sprayer body 600 when engaged therewith. In other cases, the valve assembly 504 may remain in a closed configuration to retain the aerosol precursor composition 506 within the reservoir 502. More specifically, the sprayer body 600 may include a nozzle 644. The nozzle 644 may be configured to engage the valve assembly 504. In this regard, the nozzle 644 may be configured to pierce the reservoir seal 524 and engage the dispensing seal 526. Thus, the aerosol precursor composition 506 retained within the precursor cavity 532 may be directed through the valve assembly 504 to the nozzle 644.

[0080] 14 and 15, the aerosol precursor composition 506 may flow through a gap defined between the radially outer edges of the first and second plates 516 and 518 of the valve assembly 504 and the inner surface of the reservoir 502 into a space defined between the first and second plates. More specifically, FIG. 15 shows an expanded view of region Z of FIG. 14. As shown, capillary action may draw the aerosol precursor composition 506 between the first and second plates 516 and 518.

[0081] In some embodiments, the inner surfaces of the first plate 516 and the second plate 518 may define an angle with respect to one another. In particular, the first plate 516 and the second plate 518 may be shaped and configured such that the inner surfaces are furthest from one another proximate their outer edges and closest to one another proximate the distribution capillary 522. The distance between the first plate 516 and the second plate may thereby decrease from the outer edges of the plates toward their centers. For example, the inner surfaces of the first plate 516 and the second plate 518 may define an angle with respect to one another, which angle may be between about 1 degree and about 5 degrees in some embodiments. By configuring the first plate 516 and the second plate 518 in this manner, a "ventilator" may be created that draws the aerosol precursor composition toward the distribution capillary 522. Thus, the aerosol precursor composition can be drawn into a distribution capillary 522 (see, e.g., FIG. 13 ) defined through the first plate, resulting in a flow of the aerosol precursor composition toward any orientation in which the aerosol precursor composition contacts the first plate 516 and the second plate 518. Furthermore, the entrained volume of the aerosol precursor composition 506 within the valve assembly 504 and downstream components can allow for continuous operation (e.g., about 15-20 puffs) in any orientation before the orientation of the aerosol delivery device 400 (see, e.g., FIG. 13 ) needs to be changed to a direction in which the aerosol precursor composition contacts the first plate 516 and the second plate 518.

[0082] Additionally, the distribution seal may seal against the nozzle 644, thereby isolating a nozzle orifice at the end of the nozzle 644 to draw the aerosol precursor composition from the fluid volume between the first plate 516 and the second plate 518. This configuration operates as a heat pump, providing additional efficiency in the transport of the aerosol precursor composition, more efficiently extracting substantially all of the aerosol precursor composition from the precursor cavity 532. In other words, the design is configured such that the cartridge 500 can be "dried" and the contained aerosol precursor composition can be substantially completely consumed such that the consumer does not perceive any residual aerosol precursor composition remaining in the precursor cavity 532.

[0083] 13, the aerosol precursor composition 506 may be directed through a nozzle 644 to a liquid transport element 608. The aerosol precursor composition 506 may then be vaporized by a heating element 610 directly or via heating of the liquid transport element 608. The resulting vapor or aerosol 646 may then be generated in the atomizing cavity 638 and then directed to a user. In this regard, the outer body 602 of the sprayer unit 600 may include one or more air flow openings 648 therethrough and in fluid communication with the atomizing cavity 638. Additionally, the one or more air flow openings 534 may be defined through the reservoir seal 524 of the valve assembly 504 and aligned with the air flow openings 648 through the outer body 602 of the sprayer unit 600.

[0084] Additionally, the reservoir 502 may include one or more airflow openings 536 extending from the valve assembly 504 to the mouthpiece 528. The airflow openings 536 through the reservoir 502 may be separate from the precursor cavity 532 in which the aerosol precursor composition 506 is received. In this regard, the airflow openings 536 may be defined through the material forming the reservoir 502 in a circumferential direction around the precursor cavity 532. Thus, the aerosol 646 may be directed from the nebulization cavity 638 through the mouthpiece 528 to the user.

[0085] 13, the cartridge 500 may include the aerosol precursor composition 506, and the nebulizer body 600 may include the nebulizer 606. At the same time, by allowing replacement of the cartridge 500 without requiring replacement of the nebulizer 606, costs associated with use of the aerosol delivery device 400 may be reduced. In this regard, in some embodiments, the nebulizer 606 may have a service life configured to nebulize an amount of the aerosol precursor composition 506 contained in about 200 to about 300 cartridges 500 before requiring replacement.

[0086] In contrast, the cartridge 500 may be configured to be discarded after the aerosol precursor composition 506 has been depleted therefrom. In this regard, the cartridge 500 may be configured to prevent its refilling. FIG. 16 shows a view of the cartridge 500 in the valve assembly 504. As shown, the reservoir seal 524 may define an orifice 538 configured to guide and receive the nozzle 644 of the sprayer body 600 (see, e.g., FIG. 13 ), as described above. As can be appreciated, a user may attempt to use the orifice 538 to refill the reservoir 502 with the aerosol precursor composition. However, the valve assembly 504 may be configured to resist refilling.

[0087] In this regard, the frame 510 may include one or more protrusions 540 extending outwardly from the reservoir seal 524. In some embodiments, the protrusions 540 may be defined by the connector portion 514 (see FIG. 7) of the frame 510. As a result of the protrusions 540 projecting outwardly from the reservoir seal 524, it may be impossible for a bottle nozzle or glass dripper to form a face seal with the reservoir seal, and a face seal may be required to allow fluid flow through the reservoir seal. In this regard, the reservoir seal 524 and the dispensing seal 526 (see FIG. 7) may define a valve that closes in an unbiased configuration and opens during engagement with the nozzle 644 when the cartridge 500 engages the sprayer body 600 (see, e.g., FIG. 13). As a result of resisting the formation of a seal with most bottle nozzles and glass drippers, the reservoir seal 524 may resist refilling of the reservoir 502.

[0088] Additionally, the use of two or more protrusions 540 around the orifice 538 may limit the width of any nozzle that may engage the orifice 538, further limiting the types of nozzles that may penetrate the orifice and / or form a face seal therewith. In some embodiments, the orifice may define a diameter of about 1 millimeter to about 3 millimeters, which may be too small for a standard e-liquid bottle nozzle or glass dropper tip to be inserted into. Additionally, the use of both the reservoir seal 524 and the dispensing seal 526, each formed from an elastomeric material and separated from one another, may make it difficult to refill the reservoir 502 using a hypodermic needle.

[0089] Also, attempts to refill the cartridge 500 by forming a seal with the inner surface of the base 512 of the frame 510 to refill the reservoir 502 may fail. In this regard, the air flow openings 534 defined in the reservoir seal 524 allow the aerosol precursor composition to flow out of the cartridge 500 through the air flow openings 536 defined in the reservoir 502 (see FIG. 13 ), thereby resisting refilling of the reservoir 502.

[0090] Additionally, as discussed above, the valve assembly 504 may be embedded within and attached to the reservoir 502 (e.g., via ultrasonic welding). In this manner, the valve assembly 504 may not be removed from the reservoir 502 without damaging one or both of these components, thereby further resisting refilling of the cartridge 500. Additionally, given that the sprayer 606 is included in a separate sprayer body 600 (see, e.g., FIG. 13 ) rather than the cartridge 500, the cartridge may be priced relatively inexpensively, thereby mitigating cost savings as a driver for users seeking to refill the cartridge.

[0091] In an additional embodiment, a method of operating an aerosol delivery device is provided. As shown in FIG. 17, the method may include directing an aerosol precursor composition from a reservoir of the cartridge through a valve assembly and out of the cartridge in operation 702. Directing the aerosol precursor composition from a reservoir of the cartridge through the valve assembly and out of the cartridge in operation 702 may include directing the aerosol precursor composition through a distribution capillary, a distribution seal in the distribution capillary, and a reservoir seal in the reservoir. Additionally, the method may include receiving the aerosol precursor composition in an atomizer body in operation 704. The method may further include directing the aerosol precursor composition to a atomizer in the atomizer body in operation 706. The method may further include directing an electric current from the control body to the atomizer to generate an aerosol in operation 708.

[0092] In some embodiments, directing the aerosol precursor composition out of the cartridge through the valve assembly in operation 702 may further include directing the aerosol precursor composition out of the space between a first plate and a second plate disposed adjacent to one another with a space defined therebetween and through a distributor capillary that passes through the first plate. Directing the aerosol precursor composition out of the cartridge through the valve assembly in operation 702 may further include engaging a nozzle of the atomizer body with the valve assembly. Engaging the nozzle with the valve assembly may include directing the nozzle through a reservoir seal of the valve assembly. Engaging the nozzle with the valve assembly may further include engaging the nozzle with a distributor seal of the valve assembly with the distributor capillary.

[0093] In some embodiments, receiving the aerosol precursor composition into the sprayer body at operation 704 includes directing the aerosol precursor composition between a nozzle and a capillary rod. Directing the aerosol precursor composition into the sprayer in the sprayer body at operation 706 may include directing the aerosol precursor composition between a capillary rod and a liquid transport element of the sprayer. The method may further include directing the aerosol through one or more airflow openings through the cartridge. Directing the aerosol through one or more airflow openings through the cartridge may include directing the aerosol through a valve assembly.

[0094] As can be understood, the devices and methods of the present disclosure may vary. In this regard, FIG. 18 illustrates a cartridge 800 and a nebulizer 900 according to an additional exemplary embodiment of the present disclosure. In particular, FIG. 18 illustrates the cartridge 800 and the nebulizer 900 in an assembled configuration and engaged with each other. The nebulizer 900 may be configured to engage with a control body, such as the control body 200 (see, e.g., FIG. 2) described above. It should be noted that with respect to this embodiment, the nebulizer 900 may also comprise a nebulizer body, and thus the terms nebulizer and nebulizer body may be used interchangeably. Unless otherwise described and / or illustrated, the components of the aerosol delivery device according to this embodiment may be substantially similar or identical to the corresponding components described above.

[0095] 19 and 20 show the sprayer 900 in isolation. FIG. 19 shows the sprayer 900 in an assembled configuration (with the label 902 removed), and FIG. 20 shows the sprayer body in an exploded configuration. As shown, the sprayer 900 may include a label 902, a base 904, a sprayer air valve 906, a terminal base 908, a first heating terminal 910, a second heating terminal 912, a liquid transport element 914, a flow director 916, an outer O-ring 918, and an outer body 920. As shown in FIG. 19, the outer body 920 may include a nozzle 922 and a plurality of steam openings 924.

[0096] In various embodiments, the control body may be configured to releasably engage the sprayer 900. Additionally, the sprayer 900 may be configured to releasably engage the cartridge 800. As described below, the sprayer 900 may be configured to receive electrical current from the control body and receive an aerosol precursor composition from the cartridge 800 to generate an aerosol.

[0097] Referring to FIG. 20, the sprayer 900 may also include a terminal base 908. In various embodiments, the terminal base may be constructed from a plastic material, including but not limited to silicone, thermoplastic polyurethane, or another elastomeric material. An exemplary commercially available material that may be used for the terminal base is TRITAN copolyester sold by Eastman Chemical Company of Kingsport, Tennessee. In the illustrated embodiment, the first heating terminal 910 and the second heating terminal 912 extend through the terminal base 908. In various embodiments, the first heating terminal 910 and the second heating terminal 912 may be insert molded into the terminal base 908. In this manner, the terminal base 908 may comprise an overmold with the first heating terminal 910 and the second heating terminal 912 fixedly attached therein.

[0098] 21 and 22 show separate views of a cartridge 800. As shown, the cartridge 800 may include an internal reservoir 802 and a central passageway 804. The cartridge may also include a dispensing valve 806 and a substantially circular vapor flow groove 808 defined in a bottom surface of the cartridge 800 that leads to a pair of vertical cartridge vapor channels 810. Similar to the above embodiment, the reservoir 802 may be configured to contain an aerosol precursor composition. In some embodiments, the cartridge 800 may include a translucent or transparent material so that a user can see the amount of aerosol precursor composition remaining therein. The aerosol precursor composition may be dispensed or otherwise directed into the reservoir 802. The valve 806 may seal the aerosol precursor composition in the reservoir 802. However, as described below, the valve 806 may allow the aerosol precursor composition to flow to the nebulizer 900 when engaged therewith.

[0099] FIG. 23 illustrates an exemplary embodiment of a liquid transport element 914. Also illustrated are a heating element 926, a first heating terminal 910, and a second heating terminal 912 for use with the sprayer 900. Note that the terminal base 908 is not shown to simplify the illustration. In various embodiments, the liquid transport element 914 may comprise a porous monolith. For example, the liquid transport element 608 may comprise a ceramic. As illustrated, the heating element 926 may comprise a wire that may be wound around the inner surface of the liquid transport element 914. In some embodiments, the wire may comprise titanium, Kanthal (FeCrAl), Nichrome, Molybdenum Disilicide (MoSi2), Molybdenum Silicide (MoSi), Molybdenum Disilicide doped with Aluminum (Mo(Si,Al)2), graphite and graphite-based materials, ceramics (e.g., positive or negative temperature coefficient ceramics), tungsten and tungsten-based alloys, or any other suitable material as described elsewhere herein. The use of tungsten and tungsten-based alloys may be desirable in that these materials may define a coefficient of expansion suitable for use with many ceramics that may be used in the liquid transport element 914 .

[0100] The wires of the heating element 926 may be at least partially embedded in the liquid transport element 914. In this regard, the wires of the heating element 926 may be embedded in the liquid transport element 914 before the liquid transport element is fired in a high temperature oven known as a kiln. In various embodiments, the first heating terminal 910 contacts one end of the heating element 926 and the second heating terminal 912 contacts another end of the heating element 926 such that an electric current can be passed through the heating element 926.

[0101] As discussed above, in some embodiments, thermal coupling of the heating element 926 to the liquid transport element 914 may occur via embedding or partially embedding the heating element 926 in the liquid transport element 914. In other embodiments, thermal coupling of the heating element to the liquid transport element may occur via "direct write," which may include computer-assisted surface deposition of a specialized alloyed flowable metal to a substrate. In other embodiments, the heating element may be coupled to the liquid transport element via plating, electroplating, direct deposition (e.g., sputtering), and / or other suitable methods.

[0102] 23, in various embodiments, the liquid transport element 914 may include an external electrical connection 927 that may be an external component of the electrical path between the heating terminals 910 and 912 and the heating element 926. In the illustrated embodiment, the external electrical connection 927 comprises a helical coil in and / or on the outer surface of the liquid transport element 914. In various embodiments, the external electrical connection may have functional properties with respect to the thermal performance of the heating element and the liquid transport element. As with the heating elements described above, the external electrical connection may be a directly written or partially embedded element.

[0103] In some embodiments, it may be desirable to reduce heat transfer from the heating element to the device (most directly through the sprayer housing) and therefore to the user, and / or to reduce thermal degradation of the device (as described herein with respect to air cooling of electrical components), and / or to increase the efficiency of the heat generated by the heating element and applied to the aerosol precursor composition to effect mass transfer of the precursor to an aerosol or vapor (with associated efficiency benefits such as reduced power consumption and increased overall system efficiency). Thus, in some embodiments, the external electrical connections are constructed from a material with a different thermal conductivity than the liquid transport element, and thus may create a thermal gradient across the liquid transport element where the thermal conductivity across the inner surface of the liquid transport element is greater than the thermal conductivity across the outer surface.

[0104] In some embodiments, the mass of the material can also be utilized to provide an increase in the time delta difference in heat transfer through the liquid transport element. Additionally, many processes, including direct writing and the processes described above, can be utilized to selectively change the properties of the liquid transport element. Additionally, the application of co- or post-fire processes that can "dope" the surface of the material and penetrate to a selected depth of the substrate depending on the porosity of the substrate, material composition, process and application, are possible approaches. In various embodiments, electrically conductive non-porous ceramic-based materials can also be utilized for the liquid transport element. In this regard, a thermal gradient exists across the cross section of the liquid transport element, with regions of significant high temperature across the inner surface of the liquid transport element, resulting in phase transition and mobilization of the precursor composition, while the outer surface of the liquid transport element remains relatively cool and may serve to insulate and isolate heat to the atomization chamber.

[0105] Alternatively, it may be desirable to simply insulate the direct area of ​​the external electrical connection that interfaces with the first and second heating terminals. In such an embodiment, the external electrical connection may also function as a resistive heater itself. In this capacity, the external electrical connection and the heating element may have different resistive properties such that the external electrical connection may help overcome the initial thermal gradient required in the initial heating stage of the user actuation process. In such an embodiment, the external electrical connection may not reach the temperature required to mobilize the precursor. Rather, the external electrical connection may heat to a temperature lower than that of the heating element. This may increase the vapor production over time by decreasing the time delta from actuation to aerosol generation. In this capacity, the external electrical connection may also warm nearby precursors located within and adjacent to the liquid transport element by reducing the viscosity of the precursor, facilitating increased transport to the liquid transport element.

[0106] FIG. 24 shows an isometric view of a flow director 916 for use with the sprayer 900. FIG. 25 shows a cross-sectional view of the flow director 916. In various embodiments, the flow director 916 may have a generally "T" shape including an upper flange 925 and a lower cylinder 927. The flow director further includes a central inlet air channel 928, a series of inlet air holes 930, a transition barrier 931, and a series of inlet steam holes 932. The inlet steam holes 932 lead to a series of radial steam channels 934 disposed on the upper flange 925, each of which leads to a vertical steam hole 936. The flow director also includes a series of inlet liquid flow passages 938 disposed on the upper flange 925, which abut against the upper surface of the liquid transport element 914 when assembled therewith. 25 appear to pass through holes in the outer surface of the top flange 925, it is noted that in such embodiments, these holes are sealed or otherwise blocked to create a direct flow path through the radial steam channels 934 and into the vertical steam holes 936 (see FIG. 26). In other embodiments, the radial steam channels may terminate at the vertical steam holes such that there are no openings along the outer surface of the top flange.

[0107] The operation of the exemplary embodiment of the aerosol delivery device is described in further detail below. As described above, the sprayer 900 can be engaged with the control body 200, and as shown in Figures 26 and 27, the cartridge 800 can be engaged with the sprayer 900, such that the sprayer 900 is disposed between the control body 200 and the cartridge 800. However, as can be appreciated, the sprayer 900, the control body 200 and the cartridge 800 may be disposed differently in other embodiments.

[0108] In this regard, the nozzle 922 of the sprayer 900 may be configured to engage with the dispensing valve 806 of the cartridge 800 when the cartridge 800 is coupled to the sprayer 900 and control body 200. In this manner, the aerosol precursor composition 506 can flow through the cartridge 800 and into the nozzle 922 of the outer body 920 of the sprayer 900. Due to the relative position of the flow director 916 when coupled to the outer body 920 and via capillary action, the aerosol precursor composition 506 can be drawn through a series of radial flow openings 940 into the top of the upper flange 925 of the flow director 916 (see FIG. 26). From there, the aerosol precursor composition can be drawn through an inlet liquid flow passage 938 that extends vertically through the upper flange 925 of the flow director 916 to the top surface of the liquid transport element 914 (see FIG. 27). In this manner, an atomizer chamber 942 is formed inside the liquid transport element 914, bounded by the flow director 916 and the terminal base 908. In some embodiments, the aerosol precursor composition can be drawn through the inlet liquid flow passage 938 onto the exterior surface of the liquid transport element 914 in addition to, or instead of, the top surface of the liquid transport element 914.

[0109] The connection between the control body 200 and the atomizer 900 via the first and second heating terminals 910, 912 allows the control body 200 to direct current to the atomizer 900 when a puff using the aerosol delivery device 400 is detected. In this regard, the longitudinal end of the cartridge 800 opposite the atomizer 900 may define a mouthpiece. When a user inhales on the mouthpiece, air 223 may be directed through the atomizer base 904 and the atomizer air valve 906 into the central inlet air channel 928 of the flow director 916. In particular, when air is drawn into the aerosol delivery device, the flow sensor 210 (see FIG. 2) may detect the drawing. This may cause the control body 200 to direct current to the atomizer 900 through the heating terminals 910, 912. In some embodiments, the upstream air 223 may cool electronic components before flowing into the central air channel 928 to reduce the risk of temperature-related degradation thereof. As the nebulizer 900 heats, the aerosol precursor composition 506 may be vaporized by the heating element 926 through heating of the liquid transport element 914, which absorbs the aerosol precursor composition 506 therein. Thus, the resulting vapor or aerosol 646 may be generated on the inner surface of the liquid transport element 914 and / or within the nebulizer chamber 942.

[0110] As the air 223 flows through the central inlet air channel 928, it is directed by a transition barrier 931 (see FIG. 26 ) through a series of first inlet air holes 930 in the lower cylinder 927 and into the atomizer chamber 942 (i.e., over the inner surface of the liquid transport element 914), where it becomes a vapor or aerosol 646. Due to the shape and relative arrangement of the flow director 916 and the outer body 920, including a bypass feature 933 in the outer body 920 configured to fit into and block the central opening at the top of the flow director 916, the resulting vapor or aerosol 646 travels up through a series of radial vapor channels 934 in the top flange 925 of the flow director 916, through a series of vertical vapor holes 932, and through at least a portion of the multiple vapor openings 924 in the outer body 920.

[0111] It should be noted that the aerosol's "tortuous path" through the inlet steam holes 932, radial steam channels 934, and vertical steam holes 936 and through the top flange 925 of the flow director 916 may have the functional role of forming a series of impact surfaces configured to capture sub-optimal (i.e., relatively large) aerosol droplets. In this manner, droplets having a relatively large mass may not remain entrained in the airflow as their path makes a 90° turn through the inlet steam holes 932, radial steam channels 934, and vertical steam holes 936, and thus may impact into the top flange 925 where they may flow back into the atomizer chamber 942.

[0112] 28 illustrates the flow of vapor or aerosol 646 through cartridge 800 leading to central passageway 804. Circular vapor flow groove 808 of cartridge 800 is configured to be substantially aligned with a plurality of vapor openings 924 of outer body 920 of sprayer 900 when cartridge 800 is coupled to sprayer 900. Thus, vapor or aerosol 646 flowing through the plurality of vapor openings 924 can be directed by vapor flow groove 808 into vertical cartridge vapor channels 810. As shown in the figure, vertical vapor channels 810 lead to respective horizontal vapor channels 812, which in turn lead to central passageway 804 of cartridge 800.

[0113] As described above with respect to additional implementations, the cartridge 800 may contain the aerosol precursor composition 506. By allowing replacement of the cartridge 800 without simultaneously requiring replacement of the nebulizer 900, costs associated with use of the aerosol delivery device may be reduced. In this regard, in some embodiments, the nebulizer 900 may have a service life configured to nebulize an amount of the aerosol precursor composition 506 contained in about 200 to about 300 cartridges 800 before requiring replacement.

[0114] In contrast, the cartridge 900 may be configured to be discarded after the aerosol precursor composition 506 has been depleted therefrom. In this regard, the cartridge 800 may be configured to prevent its refilling, as similarly described with respect to the illustrated embodiment above. For example, FIG. 22 shows a bottom view of the cartridge 800. As shown, the dispensing valve 806 may define an orifice 814 configured to guide and receive the nozzle 922 of the sprayer 900, as described above. As can be appreciated, a user may attempt to refill the reservoir 802 with the aerosol precursor composition. However, the cartridge 800 may be configured to resist refilling.

[0115] In this regard, the cartridge 800 may include one or more protrusions 816 extending inwardly toward the dispense seal 806 from an area proximate the vapor flow groove 808. As a result of the protrusions 816 protruding inwardly toward the dispense seal 806, a bottle nozzle or glass dripper may be unable to form a face seal with the dispense seal and a face seal may be required to allow fluid flow through the dispense seal. In this regard, the dispense seal 806 may close in an unbiased configuration and define a valve that opens during engagement with the nozzle 922 when the cartridge 800 engages the sprayer 900. As a result of resisting the formation of a seal with most bottle nozzles and glass drippers, the dispense seal 806 may resist refilling of the reservoir 802. Additionally, the use of two or more protrusions 816 around the orifice 814 may limit the width of any nozzle that may engage the orifice 806, further limiting the types of nozzles that may penetrate the orifice and / or form a face seal therewith. In some embodiments, the orifice may define a diameter of about 1 millimeter to about 3 millimeters, which may be too small to insert a standard e-liquid bottle nozzle or glass dropper tip.

[0116] 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 control body; A sprayer body including a sprayer; a reservoir configured to contain an aerosol precursor composition; and a valve assembly configured to dispense an aerosol precursor composition into the atomizer body when the cartridge is engaged with the atomizer body; A cartridge comprising: Equipped with the valve assembly comprising a distributor seal and a reservoir seal; the control body is configured to releasably engage the sprayer body, the sprayer body is configured to releasably engage the cartridge; An aerosol delivery device, wherein the nebulizer is configured to receive an electrical current from the control body and an aerosol precursor composition from the cartridge to generate an aerosol.

2. 10. The aerosol delivery device of claim 1, wherein the cartridge comprises one or more airflow openings extending from the nebulizer body to the mouthpiece, the airflow openings configured to direct the aerosol therethrough.

3. The aerosol delivery device of claim 2 , wherein at least one of the air flow openings extends through the valve assembly.

4. 2. The aerosol delivery device of claim 1, wherein the valve assembly defines a distributor capillary, the valve assembly further comprising a first plate and a second plate disposed adjacent to one another with a space defined therebetween, the distributor capillary extending through the first plate to the space between the first plate and the second plate.

5. 5. The aerosol delivery device of claim 4, wherein a gap is defined between the radially outer edges of the first plate and the second plate and an inner surface of the reservoir.

6. 10. The aerosol delivery device of claim 1, wherein the nebulizer body further comprises a nozzle configured to extend through the reservoir seal and engage the dispensing seal.

7. 10. The aerosol delivery device of claim 1, wherein the valve assembly further comprises a frame, and the reservoir seal is molded to the frame.

8. 10. The aerosol delivery device of claim 1, wherein the nebulizer comprises a liquid transport element comprising a porous monolith.

9. 10. The aerosol delivery device of claim 8, wherein the nebulizer further comprises a heating element comprising a wire at least partially embedded in the liquid transport element.

10. 10. The aerosol delivery device of claim 9, wherein the liquid transport element defines a tube, and the nebulizer further comprises a capillary rod configured to penetrate the liquid transport element and direct the aerosol precursor composition therethrough.

11. The aerosol delivery system of claim 1 , wherein the control body further comprises a microphone, the microphone configured to detect a user's inhalation on the cartridge.

12. 2. The aerosol delivery system of claim 1, wherein the nebulizer comprises an outer body, a terminal base, a flow director, and a liquid transport element comprising a porous monolith, and the nebulizer chamber is formed by the flow director, the terminal base, and the inner surface of the liquid transport element.

13. 13. The aerosol delivery system of claim 12, wherein the flow director comprises a central inlet air channel, a transition barrier and one or more radial inlet air holes, the radial inlet air holes being configured such that air entering through the inlet air channel is directed through the one or more radial inlet air holes by the transition barrier.

14. 14. The aerosol delivery system of claim 13, wherein the flow director further comprises one or more inlet liquid flow chambers configured to deliver the aerosol precursor composition to the liquid transport element.

15. 15. The aerosol delivery system of claim 14, wherein the outer body includes one or more steam openings, the flow director includes one or more radial inlet steam holes, one or more radial inlet steam holes and one or more vertical steam holes, and wherein the aerosol is configured to be directed through the one or more radial inlet steam holes, the one or more radial steam channels, the one or more vertical steam holes of the flow director and the one or more steam openings of the outer body to one or more steam channels of the cartridge.

16. 1. A method of operating an aerosol delivery device, comprising: directing the aerosol precursor composition from the reservoir of the cartridge through the valve assembly and out of the cartridge by directing the aerosol precursor composition through a distribution seal and a reservoir seal of the reservoir; Receiving an aerosol precursor composition within a nebulizer body; directing an aerosol precursor composition into a nebulizer within the nebulizer body; and directing an electrical current from the control body to the nebulizer to generate an aerosol; A method of operating an aerosol delivery device comprising:

17. 17. The method of operating an aerosol delivery device of claim 16, wherein the valve assembly defines a distribution capillary, and directing the aerosol precursor composition through the valve assembly and out of the cartridge further comprises directing the aerosol precursor composition between a first plate and a second plate disposed adjacent to one another with a space defined therebetween and out of the space through a distribution capillary extending through the first plate.

18. 20. The method of claim 17, wherein directing the aerosol precursor composition through the valve assembly and out of the cartridge further comprises engaging a nozzle of the atomizer body with the valve assembly.

19. 20. The method of claim 18, wherein engaging the nozzle with the valve assembly comprises directing the nozzle through a reservoir seal of the valve assembly.

20. 20. The method of claim 19, wherein engaging the nozzle with the valve assembly further comprises engaging the nozzle with a dispensing seal of the valve assembly at the dispensing capillary.

21. 20. The method of claim 18, wherein receiving the aerosol precursor composition within the atomizer body comprises directing the aerosol precursor composition between a nozzle and a capillary rod.

22. 22. The method of claim 21, wherein directing the aerosol precursor composition to a nebulizer within the nebulizer body comprises directing the aerosol precursor composition between a capillary rod and a liquid transport element of the nebulizer.

23. 20. The method of claim 16, further comprising directing the aerosol through one or more airflow openings extending through the cartridge.

24. 24. The method of claim 23, wherein directing the aerosol through one or more air flow openings extending through the cartridge comprises directing the aerosol through a valve assembly.

25. 17. The method of operating an aerosol delivery device of claim 16, wherein directing the aerosol precursor composition to a nebulizer in the nebulizer body comprises directing the aerosol precursor composition through one or more radial flow openings in an outer body of the nebulizer and through one or more inlet liquid flow passages in a flow director of the nebulizer.

26. 26. The aerosol delivery method of claim 25, further comprising directing the aerosol through one or more radial inlet steam holes, one or more radial steam channels and one or more vertical steam holes of the flow director and one or more steam holes of the outer body of the atomizer to one or more steam channels of the cartridge.

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