Aerosol delivery device with liquid transport element comprising porous monolith, and methods of producing aerosol delivery device

Abstract

To provide an aerosol delivery device, methods of producing such a device, and elements of such a device.SOLUTION: An aerosol delivery device 204 comprises: an outer body 216; a heating element 222 received in the outer body; a reservoir received in the outer body; and a liquid transport element 254 at least partially received in the reservoir and engaged with the heating element, the liquid transport element comprising a porous monolith.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to an aerosol delivery device, and more particularly to an aerosol delivery device (e.g., commonly referred to as an electronic cigarette) that may utilize electrically generated heat for the generation of an aerosol. The aerosol delivery device may be configured to heat an aerosol precursor that may be manufactured from tobacco, derived from tobacco, or otherwise incorporate materials that may incorporate tobacco, and the precursor may be capable of forming an inhalable substance for human consumption.

Background Art

[0002] Over the years, many devices have been proposed as improved or alternative smoking products that require the combustion 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 not to deliver significant amounts of incomplete combustion and pyrolysis products resulting from the combustion of tobacco. For this purpose, many products, aroma generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat a volatile material or to provide the smoking sensation of a cigarette, cigar, or pipe without significantly burning the tobacco. See, for example, the various alternatives, aerosol delivery devices, and heat sources described in the background art of Robinson et al.'s U.S. Patent No. 7,726,320, Griffith Jr. et al.'s U.S. Patent Application Publication No. 2013 / 0255702, and Sears et al.'s U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference. Also, see, for example, the various types of articles, aerosol delivery devices, and electrical heat sources referred to by trademark name and commercial supplier described in Bless et al.'s U.S. Patent Application Publication No. 2015 / 0216236, which is incorporated herein by reference.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Means for Solving the Problems

[0004] It would be desirable to provide a reservoir and a liquid transport element for an aerosol precursor composition for use in an aerosol delivery device. The reservoir and the liquid transport element are provided to improve the formation of an aerosol delivery device. It would also be desirable to provide an aerosol delivery device manufactured to utilize such a reservoir and a liquid transport element.

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

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

[0007] In some embodiments, the liquid transport element may define one or more channels that at least partially penetrate it. The heating element may be at least partially housed within one or more channels. The aerosol delivery device may further include a first heating terminal and a second heating terminal that are connected to the heating element and at least partially housed within one or more channels. Further, the aerosol delivery device may include electronic components that are at least partially housed within one or more channels. The electronic components may be disposed between the first heating terminal and the second heating terminal. The longitudinal axis of the electronic components may extend substantially parallel to the longitudinal axis of the outer body.

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

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

[0010] In an additional aspect, a method of manufacturing an aerosol delivery device is provided. The method may include disposing a heating element, a reservoir, and a liquid transport element within an outer body such that the liquid transport element contacts the reservoir and the heating element. Disposing the heating element, the reservoir, and the liquid transport element within the outer body may include aligning the longitudinal axes of the heating element, the reservoir, and the liquid transport element, respectively.

[0011] In some embodiments, the method may further include disposing at least a portion of the liquid transport element within the reservoir. Disposing at least a portion of the liquid transport element within the reservoir may include surrounding the liquid transport element with the reservoir. Further, the method may include inserting a heating element into a channel that at least partially penetrates the liquid transport element. The method may further include coupling the heating element to an outer surface of the liquid transport element.

[0012] Accordingly, the present disclosure includes, but is not limited to, the following embodiments.

[0013] Embodiment 1: An aerosol delivery device comprising an outer body, a heating element housed within the outer body, a reservoir housed within the outer body, and a liquid transport element at least partially housed within the reservoir and engaged with the heating element, wherein the liquid transport element includes a porous monolith.

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

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

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

[0017] Embodiment 5: The device of any preceding or subsequent embodiment or combination thereof, wherein the liquid transport element defines one or more channels that at least partially penetrate it.

[0018] Embodiment 6: An apparatus according to any preceding or subsequent embodiment or a combination thereof, wherein a heating element is at least partially received within one or more channels.

[0019] Embodiment 7: An apparatus according to any preceding or subsequent embodiment or a combination thereof, further comprising a first heating terminal and a second heating terminal that are connected to the heating element and at least partially received within one or more channels.

[0020] Embodiment 8: An apparatus according to any preceding or subsequent embodiment or a combination thereof, further comprising an electronic component at least partially received within one or more channels.

[0021] Embodiment 9: An apparatus according to any preceding or subsequent embodiment or a combination thereof, wherein the electronic component is disposed between the first heating terminal and the second heating terminal.

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

[0023] Embodiment 11: An apparatus according to any preceding or subsequent embodiment or a combination thereof, wherein a liquid transport element at least partially extends around the liquid transport element.

[0024] Embodiment 12: An apparatus according to any preceding or subsequent embodiment or a combination thereof, further comprising a flow director that defines a longitudinal axis extending substantially parallel to a longitudinal axis of the liquid transport element.

[0025] Embodiment 13: An apparatus according to any preceding or subsequent embodiment or a combination thereof, further comprising a base engaged with the outer body and an electronic component disposed between the reservoir and the base.

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

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

[0028] Embodiment 16: A method of manufacturing an aerosol delivery device, the method comprising disposing a heating element, a reservoir, and a liquid transport element within an outer body such that the liquid transport element is in contact with the reservoir and the heating element, and disposing the heating element, the reservoir, and the liquid transport element within the outer body includes aligning the longitudinal axes of the heating element, the reservoir, and the liquid transport element.

[0029] Embodiment 17: A method according to any preceding or subsequent embodiment or a combination thereof, further comprising disposing at least a portion of the liquid transport element within the reservoir.

[0030] Embodiment 18: A method according to any preceding or subsequent embodiment or a combination thereof, wherein disposing at least a portion of the liquid transport element within the reservoir includes surrounding the liquid transport element with the reservoir.

[0031] Embodiment 19: A method according to any preceding or subsequent embodiment or a combination thereof, further comprising inserting the heating element into a channel that at least partially penetrates the liquid transport element.

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

[0033] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description when read 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 or recited in any one or more of the claims, whether or not such features or elements are explicitly combined or recited in the description of a particular embodiment or the claims of this specification. The present disclosure is intended to be read as a whole so that any separable features or elements of the present disclosure appear as intended to be combinable in any of its aspects and embodiments, unless the context of the present disclosure clearly indicates otherwise.

[0034] The present disclosure has been described in the foregoing general terms and reference will now be made to the accompanying drawings, which are not necessarily drawn to scale.

Brief Description of the Drawings

[0035]

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DETAILED DESCRIPTION OF THE INVENTION

[0036] The present disclosure will be described in more detail below with reference to its exemplary embodiments. These exemplary embodiments are described so that the present disclosure is thorough and complete and fully conveys the scope of the present disclosure to those skilled in the art. In fact, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments described herein. Rather, these embodiments are provided so that the present disclosure meets the 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.

[0037] As described below, embodiments of the present disclosure relate to an aerosol delivery system. The aerosol delivery system according to the present disclosure uses electrical energy to heat a material (preferably without significantly burning the material and / or without significantly chemically changing the material) to form an inhalable substance, and the components of such a system most preferably have a form of an article small enough to be regarded as a handheld device. That is, no smoke is generated using the components of the preferred aerosol delivery system (i.e., from the by-products of tobacco combustion or pyrolysis), rather, using those preferred systems generates vapors / aerosols due to the volatilization or vaporization of certain components incorporated therein. In a preferred embodiment, the components of the aerosol delivery system may be characterized as electronic cigarettes, and these electronic cigarettes most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0038] The aerosol generating components of certain preferred aerosol delivery systems can provide a number of sensations (e.g., the rituals of inhalation and exhalation, types of taste or flavor, sensory stimulation effects, physical feel, usage rituals, visual stimulation as provided by the visible aerosol, etc.) that are experienced when smoking a cigarette, cigar, or pipe that is used by igniting and burning tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of the aerosol generating components of the present disclosure can hold and use the components in the same manner as a smoker uses a conventional type of smoking article, inhale from one end of the components to inhale the aerosol generated by the components, and smoke at selected time intervals, etc. However, the devices described herein are not limited to devices having substantially defined shapes and dimensions like a conventional cigarette. Rather, the devices of the present invention can take any shape and can be substantially larger than a conventional cigarette.

[0039] The aerosol delivery device of the present disclosure can also be characterized as a vapor generating article or a drug delivery article. Thus, such an article or device can be configured to provide one or more substances (e.g., a flavor and / or a pharmaceutically active ingredient) in an inhalable form or state. For example, the inhalable substance can be in a substantially vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For clarity, the term "aerosol" as used herein means a form or type of vapor, gas, and aerosol suitable for human inhalation, regardless of whether it is visible or can be regarded as being in a smoky form.

[0040] The aerosol delivery device of the present disclosure generally includes a number of components provided within an outer body or shell, which may generally be referred to as a housing. The overall design of the outer body or shell can be changed, and the form or configuration of the outer body that can define the overall dimensions and shape of the aerosol delivery device can be changed. In an exemplary embodiment, an elongated body similar in shape to a cigarette or cigar may be formed from a single integral housing, or the elongated housing may be formed from two or more separable bodies. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and can be similar in shape to a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are housed within one housing. Alternatively, the aerosol delivery device can include two or more housings that are joined and separable. For example, the aerosol delivery device can have a control body at one end that includes a housing for accommodating one or more components (e.g., a battery and / or a capacitor for controlling the operation of the article and various electronic devices), and a removably attached outer body or shell at the other end for accommodating aerosol-forming components (e.g., one or more aerosol precursor components such as a flavor and an aerosol-forming agent, one or more heating elements, and / or one or more wicks).

[0041] The aerosol delivery device of the present disclosure can include an outer housing or shell that is not substantially tubular in shape but is substantially of a larger dimension, i.e., can be formed to be substantially "palm-sized" for holding in the palm of a user's hand. The housing or shell can be configured to include a mouthpiece and / or can include a consumable element such as an aerosol precursor composition, and can be configured to house a separate shell (e.g., a cartridge) that can include a vaporizer or atomizer.

[0042] The aerosol delivery device of the present disclosure most preferably includes a power source (i.e., a power supply), at least one control component (e.g., means for actuating, controlling, regulating, and stopping the power for heating by controlling the flow of current from the power source to other components of the article (e.g., a microcontroller or microprocessor)), a heating element or heating member (e.g., an electrical resistance heating element or other component that can generally be referred to as a "atomizer" alone or in combination with one or more additional elements), an aerosol precursor composition (e.g., components generally referred to as "smoke juice", "e-liquid", and "e-juice", generally a liquid that can generate an aerosol when sufficient heat is applied), and a mouthpiece and oral region that enables suction of the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the article such that the generated aerosol can be drawn therefrom by inhalation).

[0043] The more specific forms, configurations, and arrangements of the components within the aerosol delivery system of the present disclosure will become apparent in light of the further disclosure provided below. Further, the selection and arrangement of the various aerosol delivery system components can be understood in consideration of commercially available electronic aerosol delivery devices such as the representative products referenced in the background art section of the present disclosure.

[0044] An exemplary embodiment of an aerosol delivery device 100 showing components that can be utilized in an aerosol delivery device according to the present disclosure is shown in FIG. 1. As can be seen in the cross-sectional view shown therein, the aerosol delivery device 100 can include a control body 102 and a cartridge 104 that can be permanently or removably aligned in a functional relationship. The control body 102 and the cartridge 104 can be engaged by press-fitting, screw engagement, interference fit, magnetic attraction, etc. (as shown). In particular, connection components as further described herein may be used. For example, the control body may include a coupler configured to engage a connector on the cartridge.

[0045] In certain embodiments, one or both of the control body 102 and the cartridge 104 can be referred to as disposable or reusable. For example, the control body may have a replaceable or rechargeable battery and thus may be integrated with any type of recharge technology including connection to a typical electrical outlet, connection to a vehicle charger (i.e., cigarette socket), and connection to a computer via a universal serial bus (USB) cable. For example, an adapter including a USB connector at one end and a control body connector at the opposite end is disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is hereby incorporated by reference in its entirety. Further, in some embodiments, the cartridge may include a disposable cartridge as disclosed in U.S. Patent No. 8910639 to Chang et al., which is hereby incorporated by reference in its entirety.

[0046] As shown in FIG. 1, the control body 102 can include an outer body 106. Control components 108 (e.g., a printed circuit board (PCB), integrated circuit, memory component, microcontroller, etc.), a flow sensor 110 (e.g., a pressure sensor), a battery 112, and a light emitting diode (LED) 114 may be disposed within the outer body 106 in any of a variety of arrangements. In addition to or as an alternative to the LED 114, additional indicators (e.g., a tactile feedback component, an audio feedback component, etc.) can be included. Components that provide a visual stimulus, such as a light emitting diode (LED) component, or additional representative types of indicators and their configurations and uses are incorporated herein by reference in U.S. Patent No. 5,154,192 to Sprinkel et al., U.S. Patent No. 8,499,766 to Newton, U.S. Patent No. 8,539,959 to Scatterday, and U.S. Patent Application Publication No. 2015 / 0216233 to Sears et al.

[0047] The cartridge 104 can include an outer body 116. The outer body 116 may surround a reservoir 118 that is in fluid communication with a liquid transport element 120. The liquid transport element 120 is configured to draw or otherwise transport an aerosol precursor composition stored within a reservoir housing to a heating element 122. To form the resistive heating element 122, materials of various embodiments configured to generate heat when an electric current is applied therethrough may be used. Examples of materials that may form a wire coil include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi 2 ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) 2 ), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and threads), and ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics). As further described herein, the heating element may include various materials configured to provide electromagnetic radiation, such as a laser diode.

[0048] In order to allow the formed aerosol to flow out of the cartridge 104, the mouth opening 124 may be present within the outer body 116 (e.g., at the mouth end). Such components are representative of components that may be present within the cartridge and are not intended to limit the scope of the cartridge components encompassed by the present disclosure.

[0049] The cartridge 104 may also include electronic components 126 that may include integrated circuits, memory components, sensors, etc. The electronic components 126 of the cartridge 104 may be configured to communicate with the control component 108 of the control body 102 and / or an external device by wired or wireless means. The electronic components 126 may be disposed anywhere within the cartridge 104.

[0050] Although the control component 108 and the flow sensor 110 are shown separately, it is understood that the control component and the flow sensor may be integrated as an electronic circuit board to which the air flow sensor is directly attached. Further, the electronic circuit board may be disposed horizontally with respect to the view of FIG. 1 in that the electronic circuit board may be parallel to the central axis of the control body in the longitudinal direction. In some embodiments, the air flow sensor may include its own circuit board or other base element to which it may be attached. In some embodiments, a flexible circuit board may be utilized. The flexible circuit board may be configured in various shapes including a substantially tubular shape.

[0051] The control body 102 and the cartridge 104 may include components configured to facilitate fluid engagement therebetween. As shown in FIG. 1, the control body 102 can include a coupler 128 having a cavity 130 defined therein. The cartridge 104 can include a base 132 configured to engage the coupler 128 and can include a protrusion 134 configured to fit within the cavity 130 defined by the coupler 128. Such engagement facilitates a stable connection between the control body 102 and the cartridge 104 and can establish an electrical connection between the battery 112 and control components 108 within the control body and the heating element 122 and electronic components 126 within the cartridge. Further, the outer body 106 can include an air inlet 136, which can be a notch within the shell, where the notch connects to the coupler 128, thereby allowing ambient air around the coupler to pass into the shell, then through the cavity 130 of the coupler, and then into the cartridge 104 via the protrusion 134.

[0052] Useful couplers and bases according to the present disclosure are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., the disclosure of which is hereby incorporated by reference in its entirety. For example, as seen in FIG. 1, the coupler 128 may define an outer perimeter 138 configured to mate with the inner perimeter 140 of the base 132. In one embodiment, the inner perimeter of the base may define a radius that is substantially equal to or slightly larger than the radius of the outer perimeter of the coupler. Further, the coupler 128 may define one or more protrusions 142 on the outer perimeter 138 configured to engage one or more recesses 144 defined in the inner perimeter of the base. However, various other embodiments of structure, shape, and components may be used to couple the base to the coupler. In some embodiments, the connection between the base 132 of the cartridge 104 and the coupler 128 of the control body 102 may be substantially permanent, whereas in other embodiments, the connection therebetween may be releasable such that, for example, the control body can be reused with one or more additional cartridges that may be disposable and / or refillable.

[0053] In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped or substantially tubular or substantially cylindrical. In other embodiments, additional shapes and dimensions are included, such as rectangular or triangular cross-sections, polyhedral shapes, fob shapes, and the like.

[0054] The reservoir 118 shown in FIG. 1 can take any design configured to hold liquid, such as a container or mass configured to absorb and / or adsorb liquid. For example, in existing embodiments of the reservoir, fibrous reservoirs are often used. Alternatively, as described below, the reservoir 118 may include a porous monolith. As shown in FIG. 1, the reservoir 118 can include one or more layers of non-woven fibers substantially formed in the shape of a tube surrounding the interior of the outer body 116. The aerosol precursor composition can be held within the reservoir 118.

[0055] The reservoir 118 can be in fluid connection with the liquid transport element 120. In this embodiment, the liquid transport element 120 can transport the aerosol precursor composition stored in the reservoir 118 to the heating element 122, which is in the form of a metal wire coil, via capillary action. Thus, the heating element 122 is in a heating configuration with the liquid transport element 120. In some embodiments of existing aerosol delivery devices, the liquid transport element includes glass fibers or other fibrous materials. However, as described below, in other embodiments, the liquid transport element may include a porous monolith.

[0056] In use, when the user sucks on article 100, an air flow is detected by sensor 110, heating element 122 is activated, and components of the aerosol precursor composition are vaporized by heating element 122. When sucking on the mouth end of article 100, ambient air enters intake port 136 and passes through cavity 130 in coupler 128 and a central opening in protrusion 134 of base 132 of cartridge 104. In cartridge 104, the sucked air mixes with the formed vapor to form an aerosol. The aerosol is either blown from heating element 122, inhaled, or otherwise sucked and exits through mouth opening 124 within the mouth end of article 100.

[0057] The aerosol delivery device may include an input device (e.g., a user interface). The input may be included to enable the user to control the functions of the device and / or to output information to the user. Any component or combination of components may be utilized as an input for controlling the functions of the device. For example, as described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference, one or more push buttons may be used. Similarly, as described in U.S. Patent Application No. 14 / 643,626 to Sears et al., filed on March 10, 2015, which is incorporated herein by reference, a touch screen may be used. As an additional example, components adapted for gesture recognition based on specific movements of the aerosol delivery device may be used as an input. See, for example, U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference.

[0058] In some embodiments, the input may include a computer or computing device such as a smartphone or tablet. Specifically, the aerosol delivery device may be wired to a computer or other device, such as via the use of a USB connector or a similar protocol. The aerosol delivery device may also communicate with a computer or other device that acts as an input via wireless communication. See, for example, the systems and methods for controlling a device via a read request as described in U.S. Patent Application Publication No. 2016 / 0007651 to Ampolini et al., the disclosure of which is incorporated herein by reference in its entirety. In such embodiments, an application or other computer program may be used in connection with the computer or computing device to input control instructions to the aerosol delivery device, and such control instructions may include, for example, the ability to form an aerosol of a particular composition by selecting the nicotine content and / or the content of additional flavorings contained therein.

[0059] The various components of the aerosol delivery device according to the present disclosure can be selected from components described in the art and commercially available. Representative commercial products include AVIGO, VUSE, VUSE CONNECT, VUSE FOB, and VUSE HYBRID from R.J. Reynolds Vapor Company. Examples of batteries that can be used in accordance with the present disclosure are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0060] As described above, the aerosol delivery device can incorporate a sensor or detector (e.g., flow sensor 110) for controlling the supply of power to the heating element 122 when aerosol generation is desired (e.g., when inhaled during use). In this way, for example, a mode or method is provided to turn off the power supply to the heating element when the aerosol delivery device is not being inhaled during use and to turn on the power supply to activate or cause heat generation by the heating element during inhalation. Additional representative types of sensing or detection mechanisms, their structures and configurations, their components, and their general methods of operation are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr., U.S. Patent No. 5,372,148 to McCafferty et al., and PCT International Publication No. 2010 / 003480 to Flick, which are incorporated herein by reference.

[0061] Most preferably, the aerosol delivery device incorporates a control mechanism for controlling the amount of electrical power to the heating element during inhalation. Representative types of electronic components, their structures and configurations, their characteristics, and their general methods of operation are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent No. 4,947,874 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, U.S. Patent Application Publication No. 2009 / 0230117 to Fernando et al., U.S. Patent Application Publication No. 2014 / 0060554 to Collett et al., and U.S. Patent Application Publication No. 2014 / 0270727 to Ampolini et al., and U.S. Patent Application Publication No. 2015 / 0257445 to Henry et al., which are incorporated herein by reference.

[0062] Representative types of substrates, reservoirs or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014 / 0261487 to Chapman et al., U.S. Patent Application Publication No. 2014 / 0059780 to Davis et al. and U.S. Patent Application Publication No. 2015 / 0216232 to Bless, which are incorporated herein by reference. Further, various wicking materials and the construction and operation of those wicking materials within certain types of electronic cigarettes are described in U.S. Patent No. 8,910,640 to Sears, which is incorporated herein by reference.

[0063] An aerosol precursor composition, also referred to as a vapor precursor composition, may include various components such as, for example, polyhydric alcohols (e.g., glycerin, propylene glycol or mixtures thereof), nicotine, tobacco, tobacco extracts and / or flavorants. Most preferably, the aerosol precursor composition is composed of a combination or mixture of various raw materials or components. The selection of specific aerosol precursor components and the relative amounts of those components used may be varied to control the overall chemical composition of the mainstream aerosol produced by the aerosol generating device. Of particular interest are aerosol precursor compositions that can be characterized as being generally liquid in nature. For example, a representative generally liquid aerosol precursor composition can have the form of a solution, a viscous gel, a mixture of miscible components, or a liquid incorporating suspended or dispersed components. A typical aerosol precursor composition can be vaporized when exposed to heat under the conditions experienced during use of the aerosol generating device, which is a feature of the present disclosure, and can thus produce vapors and aerosols that can be inhaled.

[0064] In an aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition most preferably incorporates tobacco or tobacco-derived components. In some respects, the tobacco may be provided as a portion or piece of tobacco, such as micronized, shredded, or powdered tobacco flakes. In other respects, the tobacco may be provided in the form of an extract (e.g., an extract from which nicotine is derived), such as a spray-dried extract incorporating many of the water-soluble components of the tobacco. Alternatively, the tobacco extract may have the form of a relatively high-concentration nicotine-containing extract incorporating also a small amount of other extract components derived from the tobacco. In other respects, tobacco-derived components may be provided in a relatively pure form, such as a particular flavorant derived from the tobacco. In some respects, a component derived from the tobacco and that can be used in a highly purified form or in an essentially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[0065] As described above, highly purified tobacco-derived nicotine (e.g., pharmaceutical-grade nicotine having a purity greater than 98% or greater than 99%) or derivatives thereof can be used in the devices of the present disclosure. Representative nicotine-containing extracts can be provided using the techniques described in U.S. Patent No. 5,159,942 to Brinkley et al., which is incorporated herein by reference. In certain embodiments, the products of the present disclosure can include any form of nicotine obtained from any source, whether tobacco-derived or synthetically-derived. The nicotine compounds used in the products of the present disclosure can include nicotine in free base form, salt form, as a complex, or as a solvate. See, for example, the description of nicotine in free base form in U.S. Patent Application Publication No. 2004 / 0191322 to Hansson, which is incorporated herein by reference. At least a portion of the nicotine compound can be used in the form of a resin complex of nicotine, such as nicotine polacrillex, in which nicotine is bound in an ion exchange resin. See, for example, U.S. Patent No. 3,901,248 to Lichtneckert et al., which is incorporated herein by reference. At least a portion of the nicotine can be used in salt form. The salts of nicotine can be provided using starting materials and techniques of the types described in U.S. Patent No. 2,033,909 to Cox and Perfetti, Beitrage Tabakforschung Int., 12, 43-54 (1983). Further, the salts of nicotine are available from suppliers such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc. Exemplary pharmaceutically acceptable salts of nicotine include tartrates (e.g., nicotine tartrate and nicotine bitartrate), chloride compounds (e.g., nicotine hydrochloride and nicotine dihydrochloride), sulfates, perchlorates, ascorbates, fumarates, citrates, malates, lactates, aspartates, salicylates, tosylates, succinates, pyruvates, nicotine salts, nicotine hydrates (e.g., nicotine zinc chloride monohydrate), and the like.In certain embodiments, at least a portion of the nicotine compound is in the form of a salt having an organic acid moiety including, but not limited to, levulinic acid, as described in Brinkley et al., U.S. Patent Application Publication No. 2011 / 0268809, which is incorporated herein by reference.

[0066] The aerosol precursor composition may also incorporate so-called "aerosol-forming materials." Such materials may, in some cases, have the ability to produce a visible (or invisible) aerosol when exposed to heat and vaporized under the conditions experienced during normal use of the aerosol generating device, which is a feature of the present disclosure. Such aerosol-forming materials include various polyols or polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures thereof). Aspects of the present disclosure also incorporate aerosol precursor components that can be characterized as water, saline, moisture, or aqueous liquids. Under normal use conditions of certain aerosol generating devices, the water incorporated within those aerosol generating devices can evaporate to provide components of the generated aerosol. Thus, for the purposes of the present disclosure, the water present within the aerosol precursor composition can be considered an aerosol-forming material.

[0067] It is possible to use a wide variety of optional flavorants or materials that change the sensory characteristics or properties of the inhaled mainstream aerosol produced by the aerosol delivery system of the present disclosure. For example, any such optional flavorant may be used within the aerosol precursor composition or substance to change the flavor, aroma, and sensory stimulation characteristics of the aerosol. Certain flavorants may be provided from sources other than tobacco. Exemplary flavorants may be of natural or artificial nature and may be used as concentrates or flavor packages.

[0068] Exemplary flavoring agents include vanilla, ethyl vanillin, cream, tea, coffee, fruits (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, frankincense, jasmine, cassia, cocoa, licorice, and flavoring agents and flavor packages of the types and characteristics conventionally used in the flavoring of cigarettes, cigars, and pipe tobacco. Also, syrups such as high fructose corn syrup can be used. Prior to the formulation of the final aerosol precursor mixture, certain flavoring agents may be incorporated into the aerosol-forming material (e.g., certain water-soluble flavoring agents can be incorporated into water, menthol can be incorporated into propylene glycol, and certain complex flavor packages can be incorporated into propylene glycol). However, in some aspects of the present disclosure, the aerosol precursor composition does not contain any flavoring, flavor characteristics, or additives.

[0069] The aerosol precursor composition may also contain ingredients that exhibit acidic or basic properties (e.g., organic acids, ammonium salts, or organic amines). For example, in an aerosol precursor formulation incorporating nicotine, certain organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included, preferably in an equimolar amount with nicotine (based on the total organic acid content). For example, the aerosol precursor may contain about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of succinic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, or various permutations and combinations thereof, up to a concentration where the total amount of organic acid present is equimolar with the total amount of nicotine present in the aerosol precursor composition. However, in some aspects of the present disclosure, the aerosol precursor composition does not contain any acidic (or basic) properties or additives.

[0070] As a non-limiting example, representative aerosol precursor compositions or substances can include glycerin, propylene glycol, water, saline, and nicotine, as well as any one or any combination or mixture of these components. For example, in one instance, a representative aerosol precursor composition can include, on a weight basis, from about 70% to about 100% glycerin, often from about 80% to about 90% glycerin, from about 5% to about 25% water, often from about 10% to about 20% water, and from about 0.1% to about 5% nicotine, often from about 2% to about 3% nicotine. In one particular non-limiting example, a representative aerosol precursor composition can include about 84% glycerin, about 14% water, and about 2% nicotine. Representative aerosol precursor compositions can also include various amounts of propylene glycol, any flavoring agent, or other additives, on a weight basis. Optionally, the aerosol precursor composition can include, as necessary or desired, up to about 100 weight percent of any of glycerin, water, and saline.

[0071] Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Patent No. 7,217,320 to Robinson, U.S. Patent No. 8,881,737 to Collett, U.S. Patent No. 9,254,002 to Chong, U.S. Patent Application Publication No. 2013 / 0008457 to Zheng, U.S. Patent Application Publication No. 2015 / 0020823 to Lipowicz, U.S. Patent Application Publication No. 2015 / 0020830 to Koller, and International Publication No. 2014 / 182736 to Bowen, the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those incorporated in the VUSE(R) product of R.J. Reynolds Vapor Company, the BLU(TM) product of Lorillard Technologies, the MISTIC MENTHOL product of Mistic Ecigs, and the VYPE product of CN Creative Ltd. Also desirable are so-called "smoke juices" for electronic cigarettes available from Johnson Creek Enterprises LLC.

[0072] The amount of aerosol precursor incorporated within the aerosol delivery system is an amount such that the aerosol generating component provides an acceptable feel and desirable performance characteristics. For example, in order to generate a visible mainstream aerosol that in many respects resembles the appearance of tobacco smoke, it is highly preferred that a sufficient amount of aerosol forming material (e.g., glycerin and / or propylene glycol) be used. The amount of aerosol precursor within the aerosol generation system may depend on factors such as the desired number of puffs per aerosol generating component. Typically, the amount of aerosol precursor incorporated within the aerosol delivery system, particularly within the aerosol generating component, is less than about 2 g, generally less than about 1.5 g, often less than about 1 g, and frequently less than about 0.5 g.

[0073] Other features, control units or components that can be incorporated into the aerosol delivery system of the present disclosure are incorporated herein by reference in U.S. Patent No. 5,967,148 to Harris, U.S. Patent No. 5,934,289 to Watkins, U.S. Patent No. 5,954,979 to Counts, U.S. Patent No. 6,040,560 to Fleischhauer, U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,402,976 to Fernando, U.S. Patent No. 8,689,804 to Fernando and U.S. Patent No. 9,220,302 to DePiano, U.S. Patent Application Publication No. 2013 / 0192623 to Tucker, U.S. Patent Application Publication No. 2013 / 0298905 to Leven, U.S. Patent Application Publication No. 2013 / 0180553 to Kim, U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian and U.S. Patent Application Publication No. 2014 / 0261495 to Novak.

[0074] The above description of the use of the article can be applied to the various embodiments described herein through minor modifications that may be apparent to those skilled in the art in light of the further disclosure provided herein. However, the above description of the use is not intended to limit the use of the article and is provided to comply with all necessary disclosure requirements of the present disclosure. Any of the elements shown in FIG. 1 or otherwise described above in the article can be included in the aerosol delivery device according to the present disclosure.

[0075] In one or more embodiments, the present disclosure can relate to the use of a porous monolith material within one or more components of an aerosol delivery device. As used herein, "porous monolith material" or "porous monolith" is intended to mean, in some embodiments, a substantially single unit that can be a single piece that is formed, constructed, or made to be substantially uniform throughout, without joints or seams, and not necessarily rigid. In some embodiments, the monolith according to the present disclosure can be homogeneous, i.e., it may be formed from a single material or from a plurality of units permanently combined, such as a sintered aggregate. Thus, in some embodiments, the porous monolith may include an integral porous monolith.

[0076] In some embodiments, the use of the porous monolith may be particularly relevant to the use of porous glass within components of the aerosol delivery device. As used herein, "porous glass" is intended to refer to a glass having a three-dimensional interconnected porous microstructure. This term can specifically exclude materials made from bundles of glass fibers (i.e., woven or non-woven fabrics). Thus, fibrous glass can be excluded from porous glass. Porous glass may also be referred to as controlled pore glass (CPG) and may be known by the trade name VYCOR(R). Porous glass suitable for use according to the present disclosure can be prepared, for example, by liquid extraction (e.g., acidic extraction or a combination of acidic and alkaline extraction) of one of the formed phases following metastable phase separation in borosilicate glass, by sol-gel methods, or by sintering of glass powders using known methods. Porous glass can in particular be a high-silica glass containing 90 wt% or more, 95 wt%, 96 wt% or more, or 98 wt% or more silica. Porous glass materials and methods for preparing porous glass that may be suitable for use according to the present disclosure are described in U.S. Patent No. 2,106,744 to Hood et al., U.S. Patent No. 2,215,039 to Hood et al., U.S. Patent No. 3,485,687 to Chapman et al., U.S. Patent No. 4,657,875 to Nakashima et al., U.S. Patent No. 9,003,833 to Kotani et al., U.S. Patent Application Publication No. 2013 / 0045853 to Kotani et al., U.S. Patent Application Publication No. 2013 / 0067957 to Zhang et al., U.S. Patent Application Publication No. 2013 / 0068725 to Takashima et al. and U.S. Patent Application Publication No. 2014 / 0075993 to Himanshu, the disclosures of which are incorporated herein by reference. Although the term porous "glass" may be used herein, the scope of the present disclosure should not be construed as being limited in that "glass" can include various silica-based materials.

[0077] The porous glass can be defined in terms of its average pore diameter in some embodiments. For example, the porous glass can have an average pore diameter of about 1 nm to about 1000 μm, about 2 nm to about 500 μm, about 5 nm to about 200 μm or about 10 nm to about 100 μm. In certain embodiments, the porous glass for use in accordance with the present disclosure can be distinguished based on the average pore diameter. For example, the porous glass with a small pore diameter can have an average pore diameter from 1 nm to 500 nm, the porous glass with an intermediate pore diameter can have an average pore diameter from 500 nm to 10 μm, and the porous glass with a large pore diameter can have an average pore diameter from 10 μm to 1000 μm. In some embodiments, the porous glass with a large pore diameter can preferably be useful as a storage element, and the porous glass with a small pore diameter and / or the porous glass with an intermediate pore diameter can preferably be useful as a transport element.

[0078] The porous glass can also be defined in terms of its surface area in some embodiments. For example, the porous glass can have a surface area of at least 100 m 2 / g, at least 150 m 2 / g, at least 200 m 2 / g or at least 250 m 2 / g, for example, about 100 m 2 / g to about 600 m 2 / g, about 150 m 2 / g to about 500 m 2 / g or about 200 m 2 / g to about 450 m 2 / g.

[0079] The porous glass can be defined, in some embodiments, in terms of its porosity (i.e., the volume fraction of the material defining the pores). For example, the porous glass can have a porosity of at least 20% by volume, at least 25% by volume or at least 30% by volume, such as from about 20% by volume to about 80% by volume, from about 25% by volume to about 70% by volume or from about 30% by volume to about 60% by volume. In certain embodiments, a relatively low porosity, such as from about 5% by volume to about 50% by volume, from about 10% by volume to about 40% by volume or from about 15% by volume to about 30% by volume, may be desirable.

[0080] The porous glass can be further defined, in some embodiments, in terms of its density. For example, the porous glass can have a density of 0.25 g / cm 3 to about 3 g / cm 3 , from about 0.5 g / cm 3 to about 2.5 g / cm 3 or from about 0.75 g / cm 3 to about 2 g / cm 3 .

[0081] In some embodiments, the use of the porous monolith may be particularly relevant to the use of porous ceramics within components of the aerosol delivery device. As used herein, "porous ceramic" is intended to refer to a ceramic material having a three-dimensional interconnected porous microstructure. Porous ceramic materials suitable for use according to the present disclosure, and methods of making porous ceramics, are described in U.S. Patent No. 3,090,094 to Schwartzwalder et al., U.S. Patent No. 3,833,386 to Frisch et al., U.S. Patent No. 4,814,300 to Helferich, U.S. Patent No. 5,171,720 to Kawakami, U.S. Patent No. 5,185,110 to Kunikazu et al., U.S. Patent No. 5,227,342 to Anderson et al., U.S. Patent No. 5,645,891 to Liu et al., U.S. Patent No. 5,750,449 to Niihara et al., U.S. Patent No. 6,753,282 to Fleischmann et al., U.S. Patent No. 7,208,108 to Otsuka et al., U.S. Patent No. 7,537,716 to Matsunaga et al., U.S. Patent No. 8,609,235 to Hotta et al., the disclosures of which are incorporated herein by reference. Although the term porous "ceramic" may be used herein, the scope of the present disclosure should not be construed as being limited in that "ceramic" can include a variety of alumina-based materials.

[0082] Similarly, in some embodiments, the porous ceramic can be defined in terms of its average pore size. For example, the porous ceramic can have an average pore size of from about 1 nm to about 1000 μm, from about 2 nm to about 500 μm, from about 5 nm to about 200 μm, or from about 10 nm to about 100 μm. In certain embodiments, the porous ceramic for use in accordance with the present disclosure can be distinguished based on its average pore size. For example, the porous ceramic with a small pore size can have an average pore size from 1 nm to 500 nm, the porous ceramic with an intermediate pore size can have an average pore size from 500 nm to 10 μm, and the porous ceramic with a large pore size can have an average pore size from 10 μm to 1000 μm. In some embodiments, the porous ceramic with a large pore size can preferably be useful as a storage element, and the porous ceramic with a small pore size and / or the porous ceramic with an intermediate pore size can preferably be useful as a transport element.

[0083] The porous ceramic can also, in some embodiments, be defined in terms of its surface area. For example, the porous ceramic can have a surface area of at least 100 m 2 / g, at least 150 m 2 / g, at least 200 m 2 / g, or at least 250 m 2 / g, for example, from about 100 m 2 / g to about 600 m 2 / g, from about 150 m 2 / g to about 500 m 2 / g, or from about 200 m 2 / g to about 450 m 2 / g.

[0084] The porous ceramic can, in some embodiments, be defined in terms of its porosity (i.e., the volume fraction of the material that defines the pores). For example, the porous ceramic can have a porosity of at least 20% by volume, at least 25% by volume or at least 30% by volume, such as from about 20% by volume to about 80% by volume, from about 25% by volume to about 70% by volume or from about 30% by volume to about 60% by volume. In certain embodiments, a relatively low porosity, such as from about 5% by volume to about 50% by volume, from about 10% by volume to about 40% by volume or from about 15% by volume to about 30% by volume, may be desirable.

[0085] The porous ceramic can, in some embodiments, be further defined in terms of its density. For example, the porous ceramic can have a density of 0.25 g / cm 3 to about 3 g / cm 3 , from about 0.5 g / cm 3 to about 2.5 g / cm 3 or from about 0.75 g / cm 3 to about 2 g / cm 3 .

[0086] Silica-based materials (e.g., porous glass) and alumina-based materials (e.g., porous ceramic) can be described separately herein, but it is understood that in some embodiments, the porous monolith can include various aluminosilicate materials. For example, according to the present disclosure, various zeolites may be utilized. Thus, for example, the porous monolith described herein may include one or both of porous glass and porous ceramic that can be provided as a composite material. In one embodiment, such a composite material may include SiO 2 and Al 2 O 3 .

[0087] The porous monoliths used in accordance with the present disclosure can be provided in a variety of dimensions and shapes. Preferably, the porous monoliths can be in a substantially elongated, substantially flat or planar, substantially curved (e.g., "U-shaped"), substantially walled cylindrical form, or other form suitable for use in accordance with the present disclosure. Additional exemplary shapes of the porous monoliths are described below and shown in the figures.

[0088] In one or more embodiments, the porous monoliths according to the present disclosure can be characterized in terms of uptake rate. By way of non-limiting example, the uptake rate can be calculated by measuring the known mass uptake of a liquid, and the rate (mg / s) can be measured using a microbalance tensiometer or similar device. Preferably, the uptake rate is substantially within the range of the desired mass of aerosol produced over the duration of smoking using an aerosol-forming article comprising the porous monolith. The uptake rate can be, for example, in the range of about 0.05 mg / s to about 15 mg / s, about 0.1 mg / s to about 12 mg / s or about 0.5 mg / s to about 10 mg / s. The uptake rate can vary depending on the liquid being taken up. In some embodiments, the uptake rates described herein can be based on substantially pure water, substantially pure glycerin, substantially pure propylene glycol, a mixture of water and glycerin, a mixture of water and propylene glycol, a mixture of glycerin and propylene glycol, or a mixture of water, glycerin and propylene glycol. Also, the uptake rate can vary depending on the use of the porous monolith. For example, a porous monolith used as a liquid transport element can have a higher uptake rate than a porous monolith used as a reservoir. The uptake rate may be varied by controlling one or more of pore size, pore size distribution and wettability, as well as by the composition of the material being taken up.

[0089] As described above, some existing embodiments of aerosol delivery devices include a liquid transport element and / or a reservoir that includes a fibrous material. However, the fibrous material can suffer from certain disadvantages. In this regard, considering that a heating element is disposed proximate to the liquid transport element, there is a possibility of charring occurring in the fibrous liquid transport element, which can thereby adversely affect the flavor of the generated aerosol and / or the structural integrity of the liquid transport element. Depending on the relative positions of the components, charring can also occur in the fibrous reservoir.

[0090] Furthermore, fibrous materials are generally relatively weak and may be prone to tearing or other failures when subjected to stresses that can occur during repeated dropping events or other severe accidents. Additionally, using fibrous materials within the air flow path can pose challenges during assembly with regard to ensuring that there are no loose fibers. Due to the flexible nature of fibrous materials, it can also be difficult to form and hold the liquid transport element and reservoir in the desired shape.

[0091] Accordingly, the aerosol delivery device of the present disclosure may include a reservoir and / or a liquid transport element that includes a porous monolith. As can be appreciated, using a porous monolith may avoid the potential disadvantages described above. In this regard, a relatively tear-resistant and durable material such as porous glass or porous ceramic may be selected. Additionally, such materials are less prone to charring. Further, the absence of fibers within the porous monolith eliminates issues regarding the movement of fibers within the air flow path defined therethrough. Additionally, the porous monolith may be formed in substantially any shape and the shape can be stable.

[0092] For example, FIG. 2 shows a modified cross-sectional view of a cartridge 204 for an aerosol delivery device. Cartridge 204 may include some or all of the components of cartridge 104 (see FIG. 1) described above. Additionally, cartridge 204 may be usable with the control body 102 and / or other embodiments of the control body described above.

[0093] As shown, the cartridge 204 may include an outer body 216 and a base 232 connected to one end of the outer body. The mouth opening 224 may be disposed at the opposite end of the outer body 216. The electronic component 226 and the heating element 222 may be disposed within the outer body 216.

[0094] The mouth opening 224 may be defined within a mouthpiece 246 that may engage an end of the outer body 216 opposite the base 232. The first heating terminal 248 and the second heating terminal 250 may be connected to the heating element 222. Further, the electronic component terminal 252 may engage the electronic component 226. The first and second heating terminals 248, 250 may also engage the electronic component 226. The terminals 248, 250, 252 may extend into the base 232 to enable electrical connection with the control body as described above.

[0095] Furthermore, the cartridge 204 may include an integrated reservoir and liquid transport element 254. As used herein with respect to the integrated reservoir and liquid transport element 254, the term "integrated" refers to a reservoir and liquid transport element that is a single, formed continuous piece with a seamless transition from the reservoir to the liquid transport element. In this regard, the integrated reservoir and liquid transport element 254 may include a porous monolith that may be integral, such as porous glass or porous ceramic as described above.

[0096] The integrated reservoir and liquid transport element 254 may contain an aerosol precursor composition. The integrated reservoir and liquid transport element 254 may be disposed in proximity to the heating element 222. Thereby, the heating element 222 may heat the aerosol precursor composition contained in the integrated reservoir and liquid transport element 254 to generate vapor.

[0097] Figure 3 shows a cross-sectional view of the integrated reservoir and liquid transport element 254. As shown, in some embodiments, the integrated reservoir and liquid transport element 254 may define at least one channel 255 that at least partially penetrates it. The heating element 222 may be disposed within a first portion 256 of the channel 255. Thereby, the heating element 222 may be substantially surrounded by and in contact with the integrated reservoir and liquid transport element 254 to heat the aerosol precursor composition contained therein to generate vapor. In some embodiments, the first heating terminal 248 and / or the second heating terminal 250 may extend into the first portion 256 of the channel 255 and engage both ends of the heating element 222. As shown, the heating element 222 may include a coiled wire.

[0098] As shown in FIG. 3, the channel 255 that at least partially penetrates the integrated reservoir and liquid transport element 254 may further define a second portion 258. As shown in FIG. 2, the electronic component 226 may be housed within the second portion 258 of the channel 255. In this regard, the electronic component 226 may be disposed between the first heating terminal 248 and the second heating terminal 250. Thus, in this embodiment, the heating element 222, the heating terminals 248, 250, and the electronic component 226 are at least partially housed within the channel 255. As will be described later, the first portion 256 and the second portion of the channel 255 may define an air flow channel through the cartridge.

[0099] The heating element 222 may define a longitudinal central axis, which may be substantially parallel to the longitudinal axis of the outer body 216. For example, the longitudinal axis of the heating element 222 may be coaxial with the longitudinal axis of the outer body 216. Further, the longitudinal axis of the electronic component 226 may extend substantially parallel to the longitudinal axis of the outer body 226. Further, the channel 255 may extend substantially parallel to the longitudinal axis of the outer body 226. For example, the channel 255 may be coaxial with the longitudinal axis of the outer body 226.

[0100] The integrated reservoir and liquid transport element 254 may extend between a proximal end 260 and a mouthpiece end 262. A second portion 258 of the channel 255 may extend from the proximal end 260 of the integrated reservoir and liquid transport element 254 to the first portion 256 of the channel 255. The first portion 256 of the channel 255 may extend from the second portion 258 of the channel 255 to the mouthpiece end 262 of the integrated reservoir and liquid transport element 254.

[0101] Thereby, an air flow path through the cartridge 204 may penetrate through the integrated reservoir and liquid transport element 254 from the proximal end 260 to the mouthpiece end 262. More specifically, the air flow path may pass through the base 232, pass through the electronic component 226 within the second portion 258 of the channel 255, pass through the heating element 222 within the first portion 256 of the channel 255, and penetrate out through the mouth opening 224 defined within the mouthpiece 246. Thus, vapor generated by heating the aerosol precursor composition contained within the integrated reservoir and liquid transport element 254 using the heating element 222 may combine with air to form an aerosol that is directed to the user through the mouthpiece 246.

[0102] Thereby, the heating element 222 may be disposed in proximity to the mouthpiece 246. In this configuration, since the flow path from the heating element to the mouth opening 224 is relatively short, the possibility of fluid condensing from the vapor generated by the heating element 222 within the cartridge 204 may be reduced. In this regard, such condensation may reduce the efficiency of the aerosol delivered to the user and may cause problems with respect to fluid leakage from the cartridge 204.

[0103] Note that in this embodiment, the integrated reservoir and liquid transport element 254 can direct an air flow through the cartridge 204. In this regard, the channel 255 may direct the air flow to the heating element 222, and the heating element 222 may be substantially surrounded by the integrated reservoir and liquid transport element 254. Thus, the use of a separate flow director may not be required, which can reduce the number of parts, materials, and / or assembly costs of the cartridge.

[0104] Furthermore, the integrated reservoir and liquid transport element 254 contains the aerosol precursor composition and directs the aerosol precursor composition to the heating element 222. Thus, the integrated reservoir and liquid transport element 254 may be used instead of the separate reservoir 118 and liquid transport element 120 (see FIG. 1). In this regard, the porosity of the integrated reservoir and liquid transport element 254 can allow for the movement of fluid therethrough. Thereby, when the heating element 222 heats the aerosol precursor composition within the integrated reservoir and liquid transport element 254 disposed adjacent thereto, the aerosol precursor composition may be redistributed within the integrated reservoir and liquid transport element (e.g., via capillary action). Thus, the aerosol precursor composition may be replenished in the integrated reservoir and liquid transport element 254 adjacent to the heating element 222 by the aerosol precursor composition from other locations within the integrated reservoir and liquid transport element.

[0105] In some embodiments, the integrated reservoir and liquid transport element 254 may define a variable porosity. In other words, the porosity of the integrated reservoir and liquid transport element 254 may vary depending on the location therein. Thereby, the volume fraction of the material defining the pores can vary. As an additional example, in some embodiments, the number of pores per unit volume and / or the pore size can vary. As used herein, variable porosity can be distinguished from the inherent variation of porosity at individual points in the volume of the porous monolith, and instead refers to a porosity gradient that occurs between intervals or regions therein. As will be described below, by varying the porosity of the integrated reservoir and liquid transport element 254, the characteristics of the integrated reservoir and liquid transport element can vary depending on the location therein.

[0106] As can be appreciated, a cartridge including an integrated reservoir and liquid transport element may define other forms. In this regard, FIG. 4 shows a cartridge 304 according to an additional exemplary embodiment of the present disclosure. As illustrated, the cartridge 304 may include an outer body 316 and a base 332 coupled to one end of the outer body. A mouth opening 324 may be disposed at the opposite end of the outer body 316. A heating element 322 may be disposed within the outer body 316.

[0107] The mouth opening 324 may be defined within a mouthpiece 346 that may engage an end of the outer body 316 opposite the base 332. A first heating terminal 348 and a second heating terminal 350 may be coupled to the heating element 322. Electronic components 326 (see FIG. 5) may be disposed between the first heating terminal 348 and the second heating terminal 350, and as described above, for example as shown in FIG. 2, electronic component terminals may engage the electronic components. Further, the terminals may extend into the base 332 to enable electrical connection with the control body as described above.

[0108] In addition, the cartridge 304 may include an integral reservoir for containing the aerosol precursor composition and a liquid transport element 354. The integral reservoir and the liquid transport element 354 may extend between a proximal end 360 and a mouthpiece end 362. The integral reservoir and the liquid transport element 354 may include a porous monolith such as porous glass or porous ceramic, and in some embodiments, the integral reservoir and the liquid transport element may define a variable porosity.

[0109] Thus, the cartridge 304 may be substantially similar to the cartridge 204 of FIG. 2 in some respects. Therefore, for the sake of brevity, the details of the cartridge 304 common to the cartridge 204 of FIG. 2 will not be repeated. However, the cartridge 304 may differ in one or more respects.

[0110] In this regard, as shown in FIG. 4, the heating element 322 may at least partially extend around and in contact with the integral reservoir and the liquid transport element 354. More specifically, the integral reservoir and the liquid transport element 354 may define a protrusion 364 that may be disposed at the distal end of the integral reservoir and the liquid transport element. In this embodiment, the protrusion 364 may be disposed at the mouthpiece end 362 of the integral reservoir and the liquid transport element 354. As shown in FIG. 4, the heating element 322 may at least partially extend around the protrusion 364.

[0111] As shown in FIG. 5, the integral reservoir and the liquid transport element 354 may define one or more channels 355 that at least partially penetrate it. The channel 355 may define a slot 366. As schematically shown, the electronic component 326 may be housed within the slot 366. Further, the channel 355 may define a first groove 368 and a second groove 370. The grooves 368, 370 may extend on both sides of the integral reservoir and the liquid transport element 354 between the protrusion 364 and the slot 366.

[0112] As shown in FIG. 4, the heating terminals 348, 350 may extend through the slots 366 and the grooves 368, 370. Thereby, the heating terminals 348, 350 may engage with the ends of the heating element 322. Further, the electronic component 326 (see FIG. 5) may be received within the slot 366 between the first heating terminal 348 and the second heating terminal 350. Thus, the heating terminals 348, 350 and the electronic component 326 may be at least partially received within the channel 355. Further, as can be understood, the air flow passes through the base 332, through the slots 366 and the grooves 368, 370, around the integrated reservoir and the liquid transport element 354, through the heating element 322 to which the vapor is added, and may define a flow path out of the mouthpiece 346 through the mouth opening 324. Thus, the air flow may be directed through the channel 355 that at least partially penetrates the integrated reservoir and the liquid transport element 354.

[0113] FIG. 6 shows a cartridge 404 according to an additional exemplary embodiment of the present disclosure. As illustrated, the cartridge 404 may include an outer body 416 and a base 432 coupled to one end of the outer body. The mouthpiece 446 may engage with the end of the outer body 416 opposite the base 432. The mouthpiece 446 may define a mouth opening as described above.

[0114] The heating element 422 may be disposed within the outer body 416. As shown in FIG. 7, the cartridge 404 may further include a first heating terminal 448 and a second heating terminal 450 that may be coupled to the heating element 422. As described above, for example, as shown in FIG. 2, the electronic component 426 may be disposed between the first heating terminal 448 and the second heating terminal 450, and the electronic component terminals may engage with the electronic component. Further, the terminals may extend into the base 432 to enable electrical connection with the control body as described above.

[0115] In addition, as shown in FIG. 6, the cartridge 404 may include an integral reservoir for containing the aerosol precursor composition and a liquid transport element 454. The integral reservoir and the liquid transport element 454 may extend between a proximal end portion 460 and a mouthpiece end portion 462. The integral reservoir and the liquid transport element 454 may define a convex portion 464 around which the heating element 422 may at least partially extend and contact. The integral reservoir and the liquid transport element 454 may include a porous monolith such as porous glass or porous ceramic, and in some embodiments, the integral reservoir and the liquid transport element may define a variable porosity.

[0116] Thus, the cartridge 404 may be substantially similar to the cartridge 304 of FIG. 4 in some respects. Therefore, for the sake of brevity, the details of the cartridge 404 common to the cartridge 304 of FIG. 4 will not be repeated. However, the cartridge 404 may differ in one or more respects.

[0117] In this regard, as shown in FIG. 6, the convex portion 464 defined by the integral reservoir and the liquid transport element 454 may be disposed at its proximal end portion 460 rather than at the mouthpiece end portion 462. Further, the integral reservoir and the liquid transport element 454 may include one or more channels 455. For example, as shown in FIG. 8, the channel 455 may define a partition 458.

[0118] Furthermore, as shown in FIG. 8, channel 455 may define a recess 472. The recess 472 may extend from the proximal end 460 of the integrated reservoir and liquid transport element 454 to an opening 474 into compartment 458. Thereby, as shown in FIG. 7, heating terminals 448, 450 and electronic component 426 may extend into compartment 458 through recess 472. Thus, heating terminals 448, 450 and electronic component 426 may be at least partially received within channel 455. By using recess 472 at the proximal end 460 of the integrated reservoir and liquid transport element 454 rather than extending compartment 458 to the proximal end, engagement of heating element 422 with heating terminals 448, 450 may be made possible.

[0119] Furthermore, as shown in FIG. 6, channel 455 may define a first groove 468 and a second groove 470. Grooves 468, 470 may extend along both sides of the integrated reservoir and liquid transport element 454. Specifically, grooves 468, 470 may begin at heating element 422 engaged with a protrusion 464 adjacent to recess 472 and end at the mouthpiece end 462 of the integrated reservoir and liquid transport element 454. Thus, an air flow may enter recess 472 (see, e.g., FIG. 8) through base 432, pass through heating element 422 to which vapor is added, pass around the integrated reservoir and liquid transport element 454 through grooves 468, 470, and exit out of mouthpiece 446 through the mouth opening, defining a flow path. Thus, the air flow may be directed through channel 455 that at least partially penetrates the integrated reservoir and liquid transport element 454.

[0120] In the above-described embodiments of cartridges 204, 304, 404, the electronic component is received between the first heating terminal and the second heating terminal. This configuration is shown, for example, in the assembly shown in FIG. 9 included in cartridge 404 of FIG. 6. As shown, heating terminals 448, 450 may support electronic component 426 therebetween.

[0121] In this regard, as shown, the heating terminals 448, 450 may each define a lateral support portion 476 disposed on both sides of the electronic component 426. The lateral support portion 476 may suppress lateral movement of the electronic component 426 in the lateral direction extending between the first heating terminal 448 and the second heating terminal 450. Further, the heating terminals 448, 450 may each define a main surface support portion 478 that may engage with the rear main surface 426A of the electronic component 426.

[0122] The electronic component terminal 452 may engage with the front main surface 426B of the electronic component 426. Further, in some embodiments, the first heating terminal 448 may include a tab 480 that supplies power to and engages with the front main surface 426B of the electronic component 426. Thereby, forward movement of the electronic component 426 can be resisted by the electronic component terminal 452 and the tab 480 of the first heating terminal 448. Conversely, rearward movement of the electronic component 426 may be resisted by the main surface support portions 478 of the heating terminals 448, 450.

[0123] However, as will be described later, in other embodiments, the electronic components may be arranged and supported in different ways. In this regard, FIG. 10 shows a cartridge 504 according to an additional exemplary embodiment of the present disclosure. As shown, the cartridge 504 may include an outer body 516 and a base 532 connected to one end of the outer body. The mouthpiece 546 may engage with the end of the outer body 516 opposite the base 532. The mouthpiece 546 may define a mouth opening as described above.

[0124] The heating element 522 may be disposed within the outer body 516. The first heating terminal 548 and the second heating terminal 550 may be connected to the heating element 522. The electronic component 526 may be housed within the outer body 516. The electronic component terminal 552 (see FIG. 12) may engage with the electronic component 526. Further, the terminals 548, 550, 552 may extend into the base 532 to enable electrical connection with the control body as described above.

[0125] In addition, the cartridge 504 may include an integral reservoir that houses the aerosol precursor composition and a liquid transport element 554. The integral reservoir and the liquid transport element 554 may extend between a proximal end portion 560 and a mouthpiece end portion 562. The integral reservoir and the liquid transport element 554 may define a protrusion 564 around which the heating element 522 may at least partially extend and contact.

[0126] As shown in FIG. 11, the integral reservoir and the liquid transport element 554 may include one or more channels 555 that at least partially penetrate it. The channels 555 may define a first groove 568 and a second groove 570. As shown in FIG. 10, the first heating terminal 548 and the second heating terminal 550 may each extend into the first groove 568 and the second groove 570, respectively. Thus, the heating terminals 548, 550 may be at least partially housed within the channels 555. The integral reservoir and the liquid transport element 554 may include a porous monolith such as porous glass or porous ceramic, and in some embodiments, the integral reservoir and the liquid transport element may define a variable porosity.

[0127] Thus, the cartridge 504 may be substantially similar to the cartridge 304 of FIG. 4 in some respects. Accordingly, for the sake of brevity, the details of the cartridge 504 that are common to the cartridge 304 of FIG. 4 will not be repeatedly described. However, the cartridge 504 may differ in one or more respects.

[0128] As shown in FIG. 10, the electronic component 526 may be disposed between the base 532 and the integral reservoir and liquid transport element 554. In this regard, the longitudinal axis of the electronic component 526 may extend substantially perpendicular to the longitudinal axis of the outer body 516. Further, as shown in FIG. 12, the first heating terminal 548 and the second heating terminal 550 may extend substantially perpendicular to the longitudinal axis of the electronic component 526. In this regard, as described above with respect to FIG. 10, the heating terminals 548, 550 may be received within grooves 568, 570 defined within the integral reservoir and liquid transport element 554. However, as shown in FIG. 12, the first heating terminal 548 may define a tab 548A, and the second heating terminal 550 may define a tab 550A that extends laterally therefrom. The tabs 548A, 550A and the electronic component terminal 552 may engage the main surface of the electronic component 526. Thereby, the tabs 548A, 550A defined by the heating terminals 548, 550 and the electronic component terminal 552 may press the electronic component 526 against the base 532 so that the electronic component is held in a predetermined position.

[0129] Further, the electronic component 526 may include a plurality of contacts. The tab 548A of the first heating terminal 548 may engage the first contact 582A. The tab 550A of the second heating terminal 550 may engage the second contact 582B. Further, the electronic component terminal 552 may engage the third contact 582C. In this regard, as described above, the heating terminals 548, 550 may supply power to the electronic component 526, and the electronic component terminal may establish an electrical connection with the electronic component so that data can be transferred between the cartridge 504 (see FIG. 10) and the control body.

[0130] Referring to FIG. 10, the air flow may define a flow path that passes through the base 532, through the electronic component 526, through the grooves 568, 570 around the integrated reservoir and liquid transport element 554, through the heating element 522 to which vapor is added, and out of the mouthpiece 546 through the mouth opening. Thus, the air flow may be directed through a channel 555 (see FIG. 11) that at least partially penetrates the integrated reservoir and liquid transport element 554. Thereby, the flow path may generally extend laterally rather than along the electronic component 526. In this regard, the electronic component 526 may define a semi-circle, and its longitudinal axis may extend substantially perpendicular to the longitudinal axis of the outer body 516, such that the air flow extends laterally rather than through or along the electronic component. Thus, the electronic component 526 may be substantially excluded from the air flow path through the cartridge 504.

[0131] In an additional embodiment, a method of generating vapor is provided. As shown in FIG. 13, the method may include, in step 602, housing an aerosol precursor composition within the integrated reservoir and liquid transport element. Further, the method may include, in step 604, vaporizing at least a portion of the aerosol precursor composition with the integrated reservoir and liquid transport element.

[0132] In some embodiments, vaporizing at least a portion of the aerosol precursor composition with the integrated reservoir and liquid transport element in step 604 may include conducting an electric current to a heating element substantially surrounded by the integrated reservoir and liquid transport element. In another embodiment, vaporizing at least a portion of the aerosol precursor composition with the integrated reservoir and liquid transport element in step 604 may include conducting an electric current to a heating element extending around at least a portion of the integrated reservoir and liquid transport element. The method may further include directing an air flow through one or more channels that at least partially penetrate the integrated reservoir and liquid transport element. Further, in step 602, housing the aerosol precursor composition within the integrated reservoir and liquid transport element may include housing the aerosol precursor composition within a single-piece porous monolith.

[0133] In additional embodiments, a method of manufacturing an aerosol delivery device is provided. The method may include forming an integrated reservoir and liquid transport element from a porous monolith material. Further, the method may include disposing a heating element and the integrated reservoir and liquid transport element within an outer body such that the heating element is proximate to the integrated reservoir and liquid transport element. The method may further include dispensing an aerosol precursor composition within the integrated reservoir and liquid transport element.

[0134] In some embodiments, forming the integrated reservoir and liquid transport element may include injection molding the integrated reservoir and liquid transport element. The method may further include engaging a first heating terminal and a second heating terminal with the heating element. Forming the integrated reservoir and liquid transport element from a porous monolith material may include insert molding at least one of the heating element, the first heating terminal, and the second heating terminal into the integrated reservoir and liquid transport element. Further, in some embodiments, forming the integrated reservoir and liquid transport element from a porous monolith material may include forming the integrated reservoir and liquid transport element from a porous ceramic.

[0135] As described above, embodiments of the present disclosure include an integral reservoir and a liquid transport element formed from a single porous monolith. However, as will be described later, in other embodiments, the liquid transport element and the reservoir may be provided as separate elements.

[0136] In this regard, FIG. 14 shows a cartridge 704 according to an additional exemplary embodiment of the present disclosure. As illustrated, the cartridge 704 may include an outer body 716 and a base 732 coupled to one end of the outer body. The mouth opening 724 may be disposed at the opposite end of the outer body 716. The heating element 722 may be disposed within the outer body 716. As illustrated, in one embodiment, the longitudinal axis of the heating element 722 may be substantially parallel to the longitudinal axis of the outer body 716.

[0137] The mouth opening 724 may be defined within a mouthpiece 746 that may engage an end of the outer body 716 opposite the base 732. The first heating terminal 748 and the second heating terminal 750 may be coupled to the heating element 722. The electronic component 726 may be disposed between the first heating terminal 748 and the second heating terminal 750. The longitudinal axis of the electronic component 726 may extend substantially parallel to the longitudinal axis of the outer body 716. The electronic component terminal 752 may engage the electronic component 726 as described above, for example, as shown in FIG. 9. Further, the terminals 748, 750, 752 may extend into the base 732 to enable electrical connection with the control body as described above. In this regard, the terminals, the electronic component, and the base may be substantially similar or identical to the corresponding elements of FIG. 9.

[0138] In addition, the cartridge 704 may include a reservoir 718 housed within the outer body 716. The reservoir 718 may contain an aerosol precursor composition. The reservoir 728 may define a tubular configuration. The reservoir 718 may extend between a proximal end 718a and a mouthpiece end 718b.

[0139] The cartridge 704 may further include a liquid transport element 720. The liquid transport element 720 may extend between a proximal end portion 720a and a mouthpiece end portion 720b. Further, the liquid transport element 720 may extend between the reservoir 718 and the heating element 722. In this regard, the liquid transport element 720 may be at least partially received within and surrounded by the reservoir 718.

[0140] One or both of the reservoir 718 and the liquid transport element 720 may include a porous monolith such as porous glass or porous ceramic. In an exemplary embodiment, the liquid transport element 720 may include a porous monolith, and the reservoir 718 may include a fiber mat (e.g., cellulose acetate) that may be wrapped therearound. In some embodiments, the liquid transport element 720 may be relatively more porous than the reservoir 718. In this regard, the liquid transport element 720 may be configured to draw an aerosol precursor composition held within the reservoir 718 toward the heating element 722. Further, in some embodiments, one or both of the reservoir 718 and the liquid transport element 720 may define a variable porosity.

[0141] FIG. 15 shows the liquid transport element 720. As shown, the liquid transport element 720 may define at least one channel 755 that at least partially penetrates therethrough. The channel 755 may include a first portion 756 and a second portion 766. The first portion 756 of the channel 755 may extend from the mouthpiece end portion 720b of the liquid transport element 720 to the second portion 766 of the channel. The second portion 766 of the channel 755 may extend from the first portion 756 of the channel to the proximal end portion 720a of the liquid transport element 720.

[0142] The electronic component 726 may be at least partially disposed inside the liquid transport element 720. In this regard, the electronic component 726 may be housed within the second portion 766 of the channel 755. Further, the heating element 722 may be at least partially disposed inside the liquid transport element 720. In this regard, in the illustrated embodiment, the heating element 722 is disposed within and in contact with the first portion 756 of the channel 755.

[0143] Further, as shown in FIG. 14, one or both of the first heating terminal 748 and the second heating terminal 750 may at least partially extend through the liquid transport element 720. In this regard, the first heating terminal 748 and the second heating terminal 750 may extend from the base 732 through the second portion 766 of the channel 755 to the heating element 722 in the first portion 756 of the channel. The longitudinal axis of the liquid transport element 720 may be substantially parallel to the longitudinal axes of the first heating terminal 748 and the second heating terminal 750.

[0144] The air flow may define a flow path that passes through the base 732, through the liquid transport element 720 into the second portion 766 of the channel 755, through the electronic component 726, through the heating element 722 in the first portion 756 of the channel where vapor is added, and out through the mouthpiece opening 724 and out of the mouthpiece 746. In this regard, the liquid transport element 720 may define a flow director that directs air to the heating element 722 where vapor is generated. Thus, the use of a separate flow director may not be required.

[0145] With respect to the generation of vapor, the reservoir 718 may contain the aerosol precursor composition. The liquid transport element 720 may be in contact with the reservoir 718 over substantially its entire length. Further, the liquid transport element 720 may extend around all or a portion of the inner circumference of the reservoir 718. For example, in the illustrated embodiment, the liquid transport element 720 is in contact with the entire inner circumference of the opening 784 defined by the reservoir 718 at the mouthpiece end 720b. By providing a relatively large contact area between the reservoir 718 and the liquid transport element 720, fluid transfer from the reservoir to the liquid transport element 720 can be improved. Similarly, the liquid transport element 720 may substantially surround the heating element 722 to improve the generation of vapor.

[0146] Figures 16 and 17 show a cartridge 804 according to additional exemplary embodiments of the present disclosure. As shown, the cartridge 804 may include an outer body 816 and a base 832 coupled to one end of the outer body. The mouth opening may be defined within a mouthpiece 846 that may engage an end of the outer body 816 opposite the base 832. The heating element 822 may be disposed within the outer body 816. As shown, in one embodiment, the longitudinal axis of the heating element 822 may be substantially parallel to the longitudinal axis of the outer body 816.

[0147] The first heating terminal 848 and the second heating terminal 850 may be coupled to the heating element 822. The electronic component 826 (see FIGS. 17 and 18) may be disposed between the first heating terminal 848 and the second heating terminal 850. The longitudinal axis of the electronic component 826 may extend substantially parallel to the longitudinal axis of the outer body 816, as described above and illustrated with respect to FIG. 14, for example. The electronic component terminal 852 may engage the electronic component 826 as described above, for example as shown in FIG. 9. Further, the terminals 848, 850, 852 may extend into the base 832 to enable electrical connection with the control body as described above. In this regard, the terminals, electronic component, and base may be substantially similar or identical to the corresponding elements of FIG. 9.

[0148] In addition, the cartridge 804 may include a reservoir 818 housed within the outer body 816. The reservoir 818 may contain the aerosol precursor composition. The reservoir 818 may extend between a proximal end portion 818a and a mouthpiece end portion 818b. As shown in FIG. 17, the reservoir 818 may define a tubular configuration and may include an opening 884 extending therethrough.

[0149] The cartridge 804 may further include a liquid transport element 820. The liquid transport element 820 may extend between a proximal end portion 820a and a mouthpiece end portion 820b. Further, the liquid transport element 820 may extend between the reservoir 818 and the heating element 822 to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid transport element 820 may be at least partially received within an opening 884 (see FIG. 17) defined through the reservoir 818.

[0150] One or both of the reservoir 818 and the liquid transport element 820 may include a porous monolith such as porous glass or porous ceramic. In an exemplary embodiment, the liquid transport element 820 may include a porous monolith, and the reservoir 818 may include a fiber mat (e.g., cellulose acetate) and may be wound therearound. In some embodiments, the liquid transport element 820 may be relatively more porous than the reservoir 818. In this regard, the liquid transport element 820 may be configured to draw the aerosol precursor composition held within the reservoir 818 toward the heating element 822. Further, in some embodiments, one or both of the reservoir 818 and the liquid transport element 820 may define a variable porosity.

[0151] As shown in FIG. 16, the heating element 822 may at least partially extend around the liquid transport element 820. More specifically, the liquid transport element 820 may define a protrusion 864 that can be disposed at the distal end of the liquid transport element. In this embodiment, the protrusion 864 may be disposed at the mouthpiece end 820b of the liquid transport element 820. As shown in FIG. 16, the heating element 822 may at least partially extend around and in contact with the protrusion 864.

[0152] As shown in FIG. 18, the liquid transport element 820 may define one or more channels 855 that at least partially penetrate it. The one or more channels 855 may include slots 866. As schematically shown, the electronic component 826 may be received within the one or more channels 855 at the slot 866. Further, the one or more channels 855 defined within the liquid transport element 820 may include a first terminal groove 868 (see FIG. 17) and a second terminal groove 870. The protrusion 864 may extend from the mouthpiece end 820b of the liquid transport element 820 to the terminal grooves 868, 870. The terminal grooves 868, 870 may extend on both sides of the liquid transport element 820 between the protrusion 864 and the slot 866. The slot 866 may extend from the terminal grooves 868, 870 to the proximal end 820a of the liquid transport element 820.

[0153] As shown in FIGS. 16 and 17, the heating terminals 848, 850 may extend through the one or more channels 855 (see FIG. 18) at the slot 866 and the terminal grooves 868, 870. In this regard, the first heating terminal 848 and the second heating terminal 850 may be disposed between the liquid transport element 820 and the reservoir 818. The longitudinal axis of the liquid transport element 820 may be substantially parallel to the longitudinal axes of the first heating terminal 848 and the second heating terminal 850.

[0154] As described above, the electronic component 826 (see, for example, FIGS. 17 and 18) may be at least partially disposed inside the liquid transport element 820. In this regard, the electronic component 826 may be received within one or more channels 855 in the slot 866 between the first heating terminal 848 and the second heating terminal 850.

[0155] Furthermore, the channel 855 defined within the liquid transport element 820 may include one or more air flow grooves. In the illustrated embodiment, the liquid transport element 820 defines a first air flow groove 886 and a second air flow groove 888. The air flow grooves 886, 888 are disposed between the terminal grooves 868, 870 and may extend along the longitudinal length of the liquid transport element 820 on its outer surface. In this regard, the air flow may pass through the base 832, through the air flow grooves 886, 888 around the liquid transport element 820, through the heating element 822 to which vapor is added, and define a flow path out of the mouthpiece 846 through the mouth opening. Thus, the use of a separate flow director may not be required.

[0156] Regarding vapor generation, the reservoir 818 may contain the aerosol precursor composition. The liquid transport element 820 may be in contact with the reservoir 818 substantially over its entire length except for the protrusion 864. Further, the liquid transport element 820 may be in contact with a relatively large portion of the inner circumference of the opening 884 extending through the reservoir 818 (e.g., about half of the base end portion 820a in the illustrated embodiment as shown in FIG. 17). By providing a relatively large contact area between the reservoir 818 and the liquid transport element 820, fluid transfer from the reservoir to the liquid transport element can be improved. Similarly, the heating element 822 may substantially surround the liquid transport element 820 at the protrusion 864 to improve vapor generation.

[0157] Figures 19 and 20 show a cartridge 904 according to additional exemplary embodiments of the present disclosure. As shown, the cartridge 904 may include an outer body 916 and a base 932 coupled to one end of the outer body. A mouthpiece opening 924 may be defined within a mouthpiece 946 that may engage an end of the outer body 916 opposite the base 932. A heating element 922 may be disposed within the outer body 916. As shown, in one embodiment, the longitudinal axis of the heating element 922 may be substantially parallel to the longitudinal axis of the outer body 916.

[0158] A first heating terminal 948 and a second heating terminal 950 may be coupled to the heating element 922. Electronic components 926 (see FIG. 19) may be housed within the outer body 916. The longitudinal axis of the electronic components 926 may extend substantially perpendicular to the longitudinal axis of the outer body 916. Further, the first heating terminal 948 and the second heating terminal 950 may extend substantially perpendicular to the longitudinal axis of the electronic components 926. The heating terminals 948, 950 and the electronic component terminals may engage the electronic components 926 and extend into the base 932 to enable electrical connection with the control body as described above. In this regard, the terminals, base and electronic components of FIG. 19 may be substantially similar or identical to the terminals, base and electronic components shown in FIG. 12. Accordingly, details regarding these components and the functions performed thereby will not be repeated for the sake of brevity.

[0159] In addition, the cartridge 904 may include a reservoir 918 housed within the outer body 916. The reservoir 918 may contain an aerosol precursor composition. The reservoir 918 may extend between a proximal end 918a and a mouthpiece end 918b. The electronic components 926 may be disposed between the proximal end 918a of the reservoir 918 and the base 932. The reservoir 918 may define a substantially tubular configuration and may include an opening 984 extending therethrough (see FIG. 20).

[0160] Cartridge 904 may further include a liquid transport element 920. The liquid transport element 920 may extend between a proximal end portion 920a and a mouthpiece end portion 920b. The electronic component 926 may be disposed between the proximal end portion 920a and the base 932. Further, the liquid transport element 920 may extend between the reservoir 918 and the heating element 922 to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid transport element 920 may be at least partially received within an opening 984 defined through the reservoir 918. For example, at the mouthpiece end portion 920b, the liquid transport element 920 may define a cylindrical configuration having a protrusion 964 extending outward therefrom.

[0161] One or both of the reservoir 918 and the liquid transport element 920 may include a porous monolith such as porous glass or porous ceramic. In an exemplary embodiment, the liquid transport element 920 may include a porous monolith, and the reservoir 918 may include a fiber mat (e.g., cellulose acetate) and may be wound therearound. In some embodiments, the liquid transport element 920 may be relatively more porous than the reservoir 918. In this regard, the liquid transport element 920 may be configured to draw the aerosol precursor composition held within the reservoir 918 toward the heating element 922. Further, in some embodiments, one or both of the reservoir 918 and the liquid transport element 920 may define a variable porosity.

[0162] As shown in FIG. 19, the heating element 922 may at least partially extend around the liquid transport element 920. More specifically, at a portion where the liquid transport element 920 extends out from an opening 984 (see FIG. 20) defined through the reservoir 918, the heating element 922 may at least partially extend around and contact the protrusion 964.

[0163] As shown in FIG. 20, the heating terminals 948, 950 may extend through an opening 984 defined through the reservoir 918. In this regard, the first heating terminal 948 and the second heating terminal 950 may be disposed beside the liquid transport element 920 within the opening 984. The longitudinal axis of the liquid transport element 920 may be substantially parallel to the longitudinal axis of the first heating terminal 948 and the longitudinal axis of the second heating terminal 950.

[0164] In some embodiments, the airflow may define a flow path that passes through the base 932, through the reservoir 918, through the opening 984, through the heating element 922 to which vapor is added, and out of the mouthpiece 946 through the mouth opening 924. However, in other embodiments, the airflow may additionally or alternatively define a flow path that passes through the base 932, around the reservoir 918, through the heating element 922 to which vapor is added, and out of the mouthpiece 946 through the mouth opening 924.

[0165] In each of these embodiments, the use of a separate flow director through which air flows may not be required. However, as shown in FIGS. 19 and 20, the cartridge 904 may further include a reservoir tube 990. The reservoir tube 990 may surround the reservoir 918 such that the airflow is directed between the reservoir tube 990 and the outer body 916. In this regard, the reservoir tube 990 may be configured to hold the reservoir 918 in a tubular configuration and separate the reservoir from the outer body 916 to allow airflow therebetween.

[0166] Regarding the generation of steam, the reservoir 918 may contain the aerosol precursor composition. The liquid transport element 920 may be in contact with the reservoir 918 over substantially its entire length, except for the protrusion 964. Further, as shown in FIG. 20, the liquid transport element 920 may contact a relatively large portion of the inner circumference of the reservoir 918. By providing a relatively large contact area between the reservoir 918 and the liquid transport element 920, fluid transfer from the reservoir to the liquid transport element can be improved. Similarly, the heating element 922 may substantially surround the liquid transport element 920 at the protrusion 964 to improve steam generation.

[0167] FIGS. 21 and 22 show a cartridge 1004 according to additional exemplary embodiments of the present disclosure. As illustrated, the cartridge 1004 may include an outer body 1016 and a base 1032 coupled to one end of the outer body. The mouth opening 1024 may be defined within a mouthpiece 1046 that may engage an end of the outer body 1016 opposite the base 1032. The heating element 1022 may be disposed within the outer body 1016. As illustrated, in one embodiment, the longitudinal axis of the heating element 1022 may be substantially parallel to the longitudinal axis of the outer body 1016.

[0168] The first heating terminal 1048 and the second heating terminal 1050 may be coupled to the heating element 1022. The electronic component 1026 may be housed within the outer body 1016. The longitudinal axis of the electronic component 1026 may extend substantially perpendicular to the longitudinal axis of the outer body 1016. Further, the first heating terminal 1048 and the second heating terminal 1050 may extend substantially perpendicular to the longitudinal axis of the electronic component 1026. The heating terminals 1048, 1050 and the electronic component terminals may engage the electronic component 1026 and extend into the base 1032 to enable electrical connection with the control body as described above. In this regard, the terminals, base, and electronic component of FIG. 21 may be substantially similar or identical to the terminals, base, and electronic component shown in FIG. 12. Accordingly, the details regarding these components and the functions performed thereby will not be repeated for the sake of brevity.

[0169] In addition, the cartridge 1004 may include a reservoir 1018 housed within the outer body 1016. The reservoir 1018 may contain the aerosol precursor composition. The reservoir 1018 may extend between a proximal end portion 1018a and a mouthpiece end portion 1018b. The electronic component 1026 may be disposed between the proximal end portion 1018a of the reservoir 1018 and the base 1032. The reservoir 1018 may define a deformed tubular configuration including an opening 1084 extending therethrough (see FIG. 22).

[0170] The cartridge 1004 may further include a liquid transport element 1020. The liquid transport element 1020 may extend between a proximal end portion disposed adjacent to the base 1032 and a mouthpiece end portion disposed adjacent to the mouthpiece 1046. The electronic component 1026 may be disposed between the proximal end portion of the liquid transport element 1020 and the base 1032. Further, the liquid transport element 1020 may extend between the reservoir 1018 and the heating element 1022 to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid transport element 1020 may be at least partially received within the opening 1084 defined through the reservoir 1018. For example, the liquid transport element 1020 may define a cylindrical configuration having a protrusion 1064 extending outward therefrom at its mouthpiece end portion.

[0171] One or both of the reservoir 1018 and the liquid transport element 1020 may include a porous monolith such as porous glass or porous ceramic. In an exemplary embodiment, the liquid transport element 1020 may include a porous monolith, and the reservoir 1018 may include a fiber mat (e.g., cellulose acetate) that may be wrapped around it. In some embodiments, the liquid transport element 1020 may be relatively more porous than the reservoir 1018. In this regard, the liquid transport element 1020 may be configured to draw the aerosol precursor composition held within the reservoir 1018 towards the heating element 1022. Further, in some embodiments, one or both of the reservoir 1018 and the liquid transport element 1020 may define a variable porosity.

[0172] As shown in FIG. 21, the heating element 1022 may at least partially extend around the liquid transport element 1020. More specifically, at the portion where the liquid transport element 1020 extends out from the opening 1084 (see FIG. 22) defined through the reservoir 1018, the heating element 1022 may at least partially extend around and contact the convex portion 1064.

[0173] As shown in FIG. 22, the heating terminals 1048, 1050 may extend through the opening 1084 defined through the reservoir 1018. In this regard, the first heating terminal 1048 and the second heating terminal 1050 may be disposed beside the liquid transport element 1020 within the opening 1084. The longitudinal axis of the liquid transport element 1020 may be substantially parallel to the longitudinal axes of the first heating terminal 1048 and the second heating terminal 1050.

[0174] Furthermore, the cartridge 1004 may include a flow director 1092. The flow director 1092, which may be tubular, may extend through the reservoir 1018. The flow director 1092 may be received within an opening 1084 that extends through the reservoir 1018, as shown in FIG. 22, or the flow director may be received within a separate opening through which it extends. The flow director 1092 may define a longitudinal axis that extends substantially parallel to the longitudinal axis of the liquid transport element 1020 and substantially parallel to the longitudinal axis of the outer body 1016. However, as shown in FIG. 22, the flow director 1092 may be offset from the longitudinal central axis of the outer body 1016 and may be disposed beside the liquid transport element 1020.

[0175] Thereby, in some embodiments, the airflow may define a flow path that passes through the base 1032, through the flow director 1092, through the heating element 1022 to which vapor is added, and out of the mouthpiece 1046 through the mouth opening 1024. Thus, in some embodiments, a separate flow director may be used to direct the airflow, if desired.

[0176] Regarding vapor generation, the reservoir 1018 may contain an aerosol precursor composition. The liquid transport element 1020 may be in contact with the reservoir 1018 over substantially its entire length, except for the protrusion 1064. Further, the liquid transport element 1020 may contact a relatively large portion of the inner surface of the reservoir 1018, as shown in FIG. 22. By providing a relatively large contact area between the reservoir 1018 and the liquid transport element 1020, fluid transfer from the reservoir to the liquid transport element can be improved. Similarly, the heating element 1022 may substantially surround the liquid transport element 1020 at the protrusion 1064 to improve vapor generation.

[0177] In an additional embodiment, a method of manufacturing an aerosol delivery device is provided. As shown in FIG. 23, the method may include, in step 1102, disposing a heating element, a reservoir, and a liquid transport element within an outer body such that the liquid transport element contacts the reservoir and the heating element. Disposing the heating element, the reservoir, and the liquid transport element within the outer body in step 1102 may include aligning the longitudinal axes of the heating element, the reservoir, and the liquid transport element in step 1103.

[0178] In some embodiments, the method may further include disposing the liquid transport element at least partially within the reservoir. Disposing the liquid transport element at least partially within the reservoir may include surrounding the liquid transport element with the reservoir. The method may further include inserting the heating element into a channel that at least partially penetrates the liquid transport element. In another embodiment, the method may further include coupling the heating element to an outer surface of the liquid transport element.

[0179] In an additional embodiment, a method of manufacturing an aerosol delivery device is provided. The method may include forming the liquid transport element from a porous monolith material. Further, the method may include disposing a heating element, a reservoir, and the liquid transport element within an outer body such that the liquid transport element contacts the reservoir and the heating element is proximate to the liquid transport element. The method may further include dispensing an aerosol precursor composition within the reservoir.

[0180] In some embodiments, forming the liquid transport element may include injection molding the liquid transport element. The method may further include engaging a first heating terminal and a second heating terminal with the heating element. Forming the liquid transport element from a porous monolith material may include insert molding at least one of the heating element, the first heating terminal, and the second heating terminal into the liquid transport element. Further, forming the liquid transport element from a porous monolith material may include forming the liquid transport element from a porous ceramic.

[0181] As described herein, the elements of the cartridges of the present disclosure may include a porous monolith. In this regard, the integrated reservoir and liquid transport elements, reservoir and / or liquid transport elements of the present disclosure may include a porous monolith. The porous monolith may have a stable shape, which may facilitate the assembly of the cartridge. For example, the porous monolith may be substantially rigid. Further, a porous monolith with a stable shape may be suitable for guiding an air flow through the cartridge. In contrast, embodiments of liquid transport elements formed from glass fibers and reservoirs formed from cellulose acetate are flexible and their shape changes upon contact, so the assembly of cartridges including such components may be relatively difficult, and such components may not be suitable for guiding an air flow because pressure changes within the cartridge may change their shape. Further, components including a porous monolith may be formed or otherwise shaped to define a shape that may be difficult to form from a flexible material.

[0182] As further described herein, each of the porous monoliths disclosed herein may define a variable porosity. The use of variable porosity may be employed to store an aerosol precursor composition and direct it to a desired location within the porous monolith. For example, a relatively high porosity may be employed where storage of a fluid or transport therethrough is desired. Conversely, a relatively low porosity may be employed where leakage from the porous monolith is of relatively great concern. Thus, for example, in an embodiment of a cartridge including an integral reservoir and a liquid transfer element, a relatively porous region may be configured to store an aerosol precursor composition and direct it to a heating element. In an embodiment of a cartridge including a reservoir and a liquid transport element as separate elements, a relatively porous region within the reservoir may be configured to store an aerosol precursor composition and draw it towards the liquid transport element. Additionally or alternatively, a relatively porous region within the liquid transport element may be configured to draw an aerosol precursor composition within the liquid transport element towards a heating element. In this regard, the aerosol precursor composition may flow relatively readily through portions of the porous monolith that define a relatively high porosity.

[0183] Accordingly, one or more regions of the porous monolith may define a relatively high porosity in order to accommodate storage and facilitate the movement of the aerosol precursor composition therethrough. Such regions may extend along at least a portion of the longitudinal length of the porous monolith, thereby facilitating the movement of the aerosol precursor composition to a heating element that may be disposed proximate thereto. Further, such regions of relatively high porosity may be partially or completely surrounded by regions of relatively low porosity in order to resist leakage of the aerosol precursor composition from the porous monolith. In some embodiments, the portion of the porous monolith that is most susceptible to leakage may be the region that is exposed to the airflow through the cartridge, which may be in proximity to the heating element. Thus, the porous monolith may include relatively small pores proximate the heating element, whereas the porous monolith may include relatively large pores proximate the reservoir. This porosity gradient will tend to draw the liquid aerosol precursor composition naturally from the region of large pores to the region of small pores. Accordingly, by varying the porosity of the porous monolith, its fluid storage and transport characteristics may vary depending on its position therein.

[0184] Furthermore, the use of a cartridge configured as described herein can provide advantages with respect to an increase in the volume of the aerosol precursor composition relative to the size of a given cartridge. For example, the cartridge 104 shown in FIG. 1 can have a total aerosol precursor composition volume of about 0.6 cubic centimeters (cc) with respect to the liquid transport element 120 and the reservoir 118. However, the use of a liquid transport element, reservoir, or integrated reservoir and liquid transport element that includes a porous monolith can increase the volume of the aerosol precursor composition within a cartridge having substantially the same outer dimensions. In this regard, the embodiments of the cartridges 204, 304, 404, 504, 704, 804, 904, 1004 shown in FIGS. 2, 4, 6, 10, 14, 16, 19, and 21 can have total aerosol precursor composition volumes of 1.1 cc, 0.9 cc, 1.1 cc, 1.0 cc, 1.1 cc, 1.1 cc, 0.9 cc, and 1.1 cc, respectively. In this regard, in embodiments of the cartridges disclosed herein, the use of the space within the outer body that houses the aerosol precursor composition is maximized.

[0185] Furthermore, the use of a cartridge configured as described herein can provide advantages with respect to improved vapor generation. In this regard, considering that the liquid transport element 120 defines a relatively small diameter, the heating element 122 included in the cartridge 104 of FIG. 1 includes a relatively small coil, whereas the heating elements of the cartridges 204, 304, 404, 504, 704, 804, 904, 1004 shown in FIGS. 2, 4, 6, 10, 14, 16, 19, and 21 can be about twice as long with respect to the length of the wire that defines the heating element. In this regard, the liquid transport element or the integrated reservoir and liquid transport element can define increased internal or external dimensions configured to accommodate a relatively large heating element. The use of a relatively large heating element can generate a relatively large amount of heat, thereby generating more rapid and / or more copious vapor.

[0186] Those having the benefit of the teachings shown in the above description and the related drawings will appreciate many modifications and other embodiments of the present disclosure. Accordingly, it is to be understood 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: An outer body; a heating element housed within the outer body; a reservoir contained within the outer body; a liquid transport element at least partially contained within the reservoir and engaged with the heating element; Including, An aerosol delivery device, wherein the liquid transport element comprises a porous monolith.

2. The aerosol delivery device of claim 1 , wherein the longitudinal axis of the heating element is substantially parallel to the longitudinal axis of the outer body.

3. 10. The aerosol delivery device of claim 1, wherein the porous monolith comprises at least one of a porous ceramic and a porous glass.

4. further comprising a first heating terminal and a second heating terminal coupled to the heating element; 10. The aerosol delivery device of claim 1, wherein the first heating terminal and the second heating terminal are disposed between the liquid transport element and the reservoir.

5. 10. The aerosol delivery device of claim 1, wherein the liquid transport element defines one or more channels at least partially therethrough.

6. The aerosol delivery device of claim 5 , wherein the heating element is at least partially contained within the one or more channels.

7. 6. The aerosol delivery device of claim 5, further comprising a first heating terminal and a second heating terminal coupled to the heating element and at least partially contained within the one or more channels.

8. 10. The aerosol delivery device of claim 7, further comprising an electronic component at least partially contained within the one or more channels.

9. 9. The aerosol delivery device of claim 8, wherein the electronic component is disposed between the first heating terminal and the second heating terminal.

10. The aerosol delivery device of claim 8 , wherein a longitudinal axis of the electronic component extends substantially parallel to a longitudinal axis of the outer body.

11. The aerosol delivery device of claim 1 , wherein the liquid transport element extends at least partially around the liquid transport element.

12. further comprising a flow director; 10. The aerosol delivery device of claim 1, wherein the flow director defines a longitudinal axis that extends substantially parallel to a longitudinal axis of the liquid transport element.

13. 10. The aerosol delivery device of claim 1, further comprising a base engaged with the outer body and an electronic component disposed between the reservoir and the base.

14. The aerosol delivery device of claim 13 , wherein a longitudinal axis of the electronic component extends substantially perpendicular to a longitudinal axis of the outer body.

15. further comprising a first heating terminal and a second heating terminal coupled to the heating element; 14. The aerosol delivery device of claim 13, wherein the first heating terminal and the second heating terminal extend substantially perpendicular to a longitudinal axis of the electronic component.

16. 1. A method of manufacturing an aerosol delivery device, the method comprising: disposing a heating element, a reservoir and a liquid transport element within the outer body such that the liquid transport element is in contact with the reservoir and the heating element; The method, wherein disposing the heating element, the reservoir and the liquid transport element within the outer body includes aligning respective longitudinal axes of the heating element, the reservoir and the liquid transport element.

17. The method of claim 16 , further comprising disposing a liquid transport element at least partially within the reservoir.

18. The method of claim 17 , wherein disposing the liquid transport element at least partially within the reservoir comprises encasing the liquid transport element by the reservoir.

19. The method of claim 16 , further comprising inserting a heating element into a channel that extends at least partially through the liquid transport element.

20. The method of claim 16 , further comprising coupling a heating element to an outer surface of the liquid transport element.

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