Aerosol delivery devices including bubble jet heads and related methods - Patents.com

Abstract

To provide an aerosol delivery device with improved functionality.SOLUTION: An aerosol delivery device 1400' includes a mechanism configured to deliver an aerosol precursor composition from a reservoir 1420 to an atomizer including a vaporization heating element to produce a vapor. For example, a bubble jet head may be configured to dispense the aerosol precursor composition to the atomizer. The bubble jet head 1433' may be fixedly coupled to the atomizer. The bubble jet head 1433' may include a precursor inlet, an ejection heating element, and a precursor nozzle. The atomizer may include a vaporization heating element.SELECTED DRAWING: Figure 15

Description

[Technical field]

[0001] The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices that utilize electrically generated heat for the generation of aerosols (e.g., smoking articles commonly referred to as e-cigarettes). An aerosol delivery device is provided that includes a mechanism for delivering an aerosol precursor composition to an atomizer. The smoking article can be configured to heat an aerosol precursor that incorporates a material made from or derived from tobacco or that otherwise incorporates tobacco, which can be vaporized to form an inhalable aerosol for human consumption. [Background technology]

[0002] Many smoking devices have been proposed for many years as an improvement or replacement for smoking products that require tobacco to be burned for use. Many of these devices are purportedly designed to provide the sensation associated with cigarette, cigar, or pipe smoking without delivering significant amounts of incomplete combustion and pyrolysis products resulting from tobacco combustion. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensation of cigarette, cigar, or pipe smoking without significant levels of tobacco combustion. See, for example, U.S. Patent No. 7,726,320 to Robinson et al., and U.S. Patent Publication Nos. 2013 / 0255702 to Griffith, Jr. et al. and 2014 / 0096781 to Sears et al., for various alternative smoking articles, aerosol delivery devices, and heat sources shown in the background art described therein (these patents and patent publications are incorporated herein by reference). See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by brand name and vendor in U.S. patent application Ser. No. 14 / 170,838 to Bless et al., filed Feb. 3, 2014, which is incorporated herein by reference.

[0003] However, it may be desirable to provide an aerosol delivery device with improved functionality. In this regard, it may be desirable to improve the delivery of the aerosol precursor composition to the nebulizer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0096781 [Patent Document 4] U.S. Patent Application Serial No. 14 / 170,838 Summary of the Invention

[0005] The present disclosure relates to an aerosol delivery system. Such a system has the ability to generate an aerosol as a result of heat generated by a power source and deliver the aerosol intended to be inhaled into the mouth of a user. Of particular interest are aerosol delivery systems that provide tobacco components in aerosol form, such as those provided to smokers by devices commonly known or characterized as e-cigarettes. As used herein, the term "aerosol" is intended to include forms or types of vapors, gases, and aerosols suitable for human inhalation, whether or not visible, and whether or not in a form that can be considered "smoke-like".

[0006] Various embodiments of mechanisms for delivering the aerosol precursor composition to the atomizer are provided. These mechanisms may include a bubble jet head, as described below. As described herein, a bubble jet head is a component configured to apply pressure to the fluid and heat the fluid (e.g., the aerosol precursor composition) to generate a vapor bubble, ejecting one or more droplets of the fluid therefrom. A bubble jet head may be defined as including an inlet (e.g., a precursor inlet), an ejection heating element, and a nozzle (e.g., a precursor nozzle), which may be housed within or defined by a wafer, substrate, or housing.

[0007] In one aspect, an aerosol delivery device is provided. The aerosol delivery device may include a reservoir at least partially filled with an aerosol precursor composition. Further, the aerosol delivery device may include a bubble jet head in fluid communication with the reservoir. The bubble jet head may be configured to dispense the aerosol precursor composition from the reservoir. Additionally, the aerosol delivery device may include a nebulizer configured to heat the aerosol precursor composition dispensed by the bubble jet head to generate an aerosol. The bubble jet head and the nebulizer may be fixedly coupled to one another.

[0008] In some embodiments, the aerosol delivery device may further include an outer body and a housing received within the outer body. The bubble jet head and the nebulizer may be fixedly coupled to each other via the housing. The bubble jet head may be coupled to the nebulizer via one or more spacers. Furthermore, the bubble jet head and the nebulizer may be electrically coupled via a flexible circuit.

[0009] In some embodiments, the nebulizer may include a housing, an evaporative heating element coupled to the housing, and a stiffening member coupled to and configured to support the housing. The stiffening member may define a cutout. The aerosol delivery device may additionally include an outer body, where the heated surface of the nebulizer is oriented at a non-zero angle relative to a longitudinal axis of the outer body.

[0010] In some embodiments, the aerosol delivery device may include an outer body. The heated surface of the nebulizer may be oriented substantially parallel to a longitudinal axis of the outer body. The bubble jet head may be configured to eject the aerosol precursor composition substantially perpendicular to the heated surface of the nebulizer. The heated surface of the nebulizer may be non-planar. The heated surface of the nebulizer may be substantially conical. The heated surface of the nebulizer may be textured.

[0011] In some embodiments, the reservoir may include a reservoir substrate configured to direct the aerosol precursor composition to the bubble jet head. The bubble jet head may be coupled to a distal end of the reservoir. The bubble jet head may be coupled to a side of the reservoir. The bubble jet head and atomizer may be positioned between the reservoir and the mouthpiece. Alternatively, the reservoir may be positioned between the mouthpiece and the atomizer and bubble jet head. The aerosol delivery device may further include a cartridge comprising a base and a control comprising a coupler. The base may be configured to engage the coupler to provide a mechanical and electrical connection between the cartridge and the control.

[0012] In an additional aspect, a combined dispenser / atomizer assembly is provided. The combined dispenser / atomizer assembly may include a housing, a bubble jet head including an exhaust heating element configured to dispense an aerosol precursor composition from a reservoir, and an atomizer including a vaporizing heating element configured to heat the aerosol precursor composition dispensed by the bubble jet head to generate an aerosol. The bubble jet head and the atomizer may be coupled to each other via the housing. The housing may be configured to be received within an outer body of the aerosol delivery device.

[0013] In some embodiments, the bubble jet head may further include a precursor inlet and a precursor nozzle. The atomizer may further include an aerosol outlet. An area of ​​the aerosol outlet may be greater than an area of ​​the precursor nozzle. A thermal mass of the exhaust heating element may be less than a thermal mass of the vaporization heating element. The exhaust heating element, the precursor nozzle, and the vaporization heating element may be axially aligned. The housing may define at least one of the precursor inlet, the precursor nozzle, and the aerosol outlet.

[0014] In an additional aspect, an aerosol delivery device is provided. The aerosol delivery device may include a reservoir at least partially filled with an aerosol precursor composition. Further, the aerosol delivery device may include a container including a precursor inlet in fluid communication with the reservoir, an exhaust heating element, and a precursor nozzle. The exhaust heating element may be configured to exhaust the aerosol precursor composition received through the precursor inlet through the precursor nozzle. Additionally, the aerosol delivery device may include a nebulizer configured to heat the aerosol precursor composition dispensed from the container to generate an aerosol. The exhaust heating element and the nebulizer may be fixedly coupled to one another.

[0015] In some embodiments, the sprayer may be received within the housing, and the housing and reservoir may be received within the outer body. In other embodiments, the housing may be coupled to the sprayer via one or more spacers. The housing and sprayer may be electrically coupled via a flexible circuit.

[0016] In some embodiments, the nebulizer may include a nebulizer housing, an evaporative heating element coupled to the housing, and a stiffening member coupled to and configured to support the housing. The stiffening member may define a cutout. The aerosol delivery device may additionally include an outer body, and the heated surface of the nebulizer may be oriented at a non-zero angle relative to a longitudinal axis of the outer body. In another embodiment, the heated surface of the nebulizer may be oriented substantially parallel to the longitudinal axis of the outer body.

[0017] In some embodiments, the precursor nozzle may be configured to eject the aerosol precursor composition substantially perpendicular to the heated surface of the atomizer. The heated surface of the atomizer may be non-planar. The heated surface of the atomizer may be substantially conical. The heated surface of the atomizer may be textured.

[0018] In some embodiments, the reservoir may include a reservoir substrate configured to direct the aerosol precursor composition to the precursor inlet. The housing may be coupled to a distal end of the reservoir. In another embodiment, the housing may be coupled to a side of the reservoir. The housing and atomizer may be positioned between the reservoir and the mouthpiece. In another embodiment, the reservoir may be positioned between the mouthpiece and the atomizer and the reservoir. The aerosol delivery device may additionally include a cartridge including a base and a control including a coupler. The base may be configured to engage the coupler to provide a mechanical and electrical connection between the cartridge and the control.

[0019] In an additional aspect, a combined dispenser / atomizer assembly is provided. The combined dispenser / atomizer assembly can include a housing, an exhaust heating element configured to dispense an aerosol precursor composition from a reservoir, and a vaporization heating element configured to heat the aerosol precursor composition dispensed by the exhaust heating element to generate an aerosol. The exhaust heating element and the vaporization heating element can be received within the housing, which can be configured to be received within an outer body of an aerosol delivery device.

[0020] In some embodiments, the combined dispenser / sprayer assembly may additionally include a precursor inlet, a precursor nozzle, a vaporization heating element, and an aerosol outlet. The area of ​​the aerosol outlet may be greater than the area of ​​the precursor nozzle. The thermal mass of the exhaust heating element may be less than the thermal mass of the vaporization heating element. The exhaust heating element, the precursor nozzle, and the vaporization heating element may be axially aligned. The housing may define at least one of the precursor inlet, the precursor nozzle, and the aerosol outlet.

[0021] In an additional aspect, a method for aerosolization in an aerosol delivery device is provided. The method may include directing an airflow from a control including a power source through a cartridge including a reservoir. The method may additionally include dispensing the aerosol precursor composition from the reservoir via a precursor inlet, an exhaust heating element, and a precursor nozzle. The method may further include heating (e.g., vaporizing) the aerosol precursor composition dispensed from the reservoir with a nebulizer.

[0022] In some embodiments, dispensing the aerosol precursor composition and heating the aerosol precursor composition may include independently applying power from a power source to an exhaust heating element and a nebulizer. Dispensing the aerosol precursor composition and heating the aerosol precursor composition may include directing power to the nebulizer after applying power to the exhaust heating element. The method may additionally include preheating the aerosol precursor composition with an exhaust heating element prior to dispensing the aerosol precursor composition. Further, the method may include detecting a temperature of the aerosol precursor composition, and preheating the aerosol precursor composition includes preheating the aerosol precursor composition to a desired temperature. Preheating the aerosol precursor composition may include applying a relatively smaller pulse width or pulse amplitude of power to the exhaust heating element compared to dispensing the aerosol precursor composition. In some embodiments, heating the aerosol precursor composition with the nebulizer may include heating the aerosol precursor composition with a vaporization heating element.

[0023] In an additional aspect, a method for aerosolization in an aerosol delivery device is provided. The method may include directing an airflow from a controller with a power source through a cartridge including a reservoir. Further, the method may include dispensing the aerosol precursor composition from the reservoir via a bubble jet head. Additionally, the method may include heating the aerosol precursor composition dispensed from the reservoir by the bubble jet head with a nebulizer.

[0024] In some embodiments, dispensing the aerosol precursor composition and heating the aerosol precursor composition may include independently applying power from a power source to a bubble jet head and a nebulizer. Dispensing the aerosol precursor composition and heating the aerosol precursor composition may include directing power to the nebulizer after applying power to the bubble jet head. The method may additionally include preheating the aerosol precursor composition with the bubble jet head prior to dispensing the aerosol precursor composition. Further, the method may include detecting a temperature of the aerosol precursor composition. Preheating the aerosol precursor composition may include preheating the aerosol precursor composition to a desired temperature. Preheating the aerosol precursor composition may include applying a relatively smaller pulse width or pulse amplitude of power to the bubble jet head compared to dispensing the aerosol precursor composition.

[0025] The present invention includes, but is not limited to, the following embodiments.

[0026] Example 1: a reservoir at least partially filled with an aerosol precursor composition; a bubble jet head in fluid communication with the reservoir, the bubble jet head configured to dispense an aerosol precursor composition from the reservoir; and a nebulizer configured to heat an aerosol precursor composition dispensed from the bubble jet head to generate an aerosol, wherein the bubble jet head and the nebulizer are fixedly coupled to one another.

[0027] Example 2: An outer body, and a receiving portion received within the outer body, The aerosol delivery device of any preceding or subsequent embodiment, wherein the bubble jet head and the nebulizer are fixedly coupled to each other via the housing.

[0028] Example 3: An aerosol delivery device as described in any preceding or subsequent embodiment, wherein the bubble jet head is coupled to the nebulizer via one or more spacers.

[0029] Example 4: An aerosol delivery device as described in any preceding or subsequent embodiment, wherein the bubble jet head and the nebulizer are electrically coupled via a flexible circuit.

[0030] Example 5: An aerosol delivery device as described in any preceding or subsequent embodiment, wherein the nebulizer comprises a housing, an evaporative heating element coupled to the housing, and a reinforcing member coupled to the housing and configured to support it.

[0031] Example 6: The aerosol delivery device of any preceding or subsequent embodiment, wherein the reinforcement member defines a cutout.

[0032] Example 7: The aerosol delivery device of any preceding or subsequent embodiment, further comprising an outer body, wherein the heated surface of the nebulizer is oriented at a non-zero angle relative to the longitudinal axis of the outer body.

[0033] Example 8: The aerosol delivery device of any preceding or subsequent embodiment, further comprising an outer body, wherein the heated surface of the nebulizer is oriented substantially parallel to the longitudinal axis of the outer body.

[0034] Example 9: The aerosol delivery device of any preceding or subsequent embodiment, wherein the bubble jet head is configured to eject the aerosol precursor composition substantially perpendicular to the heated surface of the nebulizer.

[0035] Example 10: The aerosol delivery device of any preceding or subsequent embodiment, wherein the heated surface of the nebulizer is non-planar.

[0036] Example 11: The aerosol delivery device of any preceding or subsequent embodiment, wherein the heated surface of the nebulizer is substantially conical.

[0037] Example 12: The aerosol delivery device of any preceding or subsequent embodiment, wherein the heated surface of the nebulizer is textured.

[0038] Example 13: An aerosol delivery device as described in any preceding or subsequent embodiment, wherein the reservoir comprises a reservoir substrate configured to direct an aerosol precursor composition to a bubble jet head.

[0039] Example 14: An aerosol delivery device as described in any preceding or subsequent embodiment, wherein a bubble jet head is coupled to a distal end of the reservoir.

[0040] Example 15: An aerosol delivery device as described in any preceding or subsequent embodiment, wherein a bubble jet head is coupled to the side of the reservoir.

[0041] Example 16: An aerosol delivery device of any preceding or subsequent embodiment, wherein the bubble jet head and nebulizer are positioned between the reservoir and the mouthpiece.

[0042] Example 17: The aerosol delivery device of any preceding or subsequent embodiment, wherein the reservoir is located between the mouthpiece and the nebulizer and bubble jet head.

[0043] Example 18: The aerosol delivery device of any preceding or subsequent embodiment, further comprising a cartridge having a base and a control body having a coupler, the base configured to engage with the coupler to provide a mechanical and electrical connection between the cartridge and the control body.

[0044] Example 19: A storage section; a bubble jet head including an ejection heating element configured to dispense an aerosol precursor composition from a reservoir; a nebulizer comprising a vaporizing heating element configured to heat an aerosol precursor composition dispensed by the bubble jet head to generate an aerosol; The bubble jet head and the atomizer are connected to each other via a housing portion, A combined dispenser / atomizer assembly, wherein the housing is configured to be received within an outer body of an aerosol delivery device.

[0045] Example 20: A combined dispenser / atomizer assembly as described in any preceding or subsequent embodiment, wherein the thermal mass of the exhaust heating element is less than the thermal mass of the vaporizing heating element.

[0046] Example 21: The bubble jet head further comprises a precursor inlet and a precursor nozzle; The combined dispenser / atomizer assembly of any preceding or subsequent embodiment, wherein the atomizer further comprises an aerosol outlet.

[0047] Example 22: A combined dispenser / atomizer assembly as described in any preceding or subsequent embodiment, wherein the area of ​​the aerosol outlet is greater than the area of ​​the precursor nozzle.

[0048] Example 23: A combined dispenser / atomizer assembly as described in any preceding or subsequent embodiment, wherein the exhaust heating element, the precursor nozzle, and the vaporization heating element are axially aligned.

[0049] Example 24: The combined dispenser / atomizer assembly of any preceding or subsequent embodiment, wherein the housing defines at least one of a precursor inlet, a precursor nozzle, and an aerosol outlet.

[0050] Example 25: A method for aerosolization in an aerosol delivery device, comprising: directing an airflow from a controller having a power source through a cartridge having a reservoir; Dispensing an aerosol precursor composition from a reservoir through a bubble jet head; heating in a nebulizer an aerosol precursor composition dispensed from a reservoir by a bubble jet head.

[0051] Example 26: The method of aerosolization of any preceding or subsequent embodiment, wherein dispensing the aerosol precursor composition and heating the aerosol precursor composition comprises independently applying power from a power source to a bubble jet head and a nebulizer.

[0052] Example 27: A method of aerosolization as described in any preceding or subsequent embodiment, wherein dispensing the aerosol precursor composition and heating the aerosol precursor composition comprises applying power to a bubble jet head followed by directing power to a nebulizer.

[0053] Example 28: The method of aerosolization of any preceding or subsequent embodiment, further comprising preheating the aerosol precursor composition with a bubble jet head prior to dispensing the aerosol precursor composition.

[0054] Example 29: The method of aerosolization of any preceding or subsequent embodiment, further comprising detecting a temperature of the aerosol precursor composition, and wherein preheating the aerosol precursor composition comprises preheating the aerosol precursor composition to a desired temperature.

[0055] Example 30: A method of aerosolization as described in any preceding or subsequent embodiment, wherein preheating the aerosol precursor composition comprises applying a relatively smaller pulse width or pulse amplitude of power to the bubble jet head compared to dispensing the aerosol precursor composition.

[0056] These and other features, aspects, and advantages of the present disclosure will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, and any combination of two, three, four, or more features or elements described in this disclosure, whether or not such features or elements are expressly combined in the description of a particular embodiment herein. The present disclosure is intended to be read in its entirety such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, should be considered as intended to be combinable, unless the context clearly dictates otherwise. [Brief description of the drawings]

[0057] Having thus described the present disclosure in the foregoing general terms, reference is now made to the accompanying drawings, which are not necessarily to scale.

[0058] [Figure 1] 1 illustrates an exploded view of a control according to an exemplary embodiment of the present disclosure. [Diagram 2] FIG. 1 shows an exploded view of an aerosol delivery device including a combined dispenser / atomizer assembly with a standard bubble jet head according to an exemplary embodiment of the present disclosure. [Diagram 3] 3 shows a modified cross-sectional view through the aerosol delivery device of FIG. 2 illustrating airflow through the aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 4] 3 shows a modified cross-sectional view through the combined dispenser / atomizer assembly of the aerosol delivery device of FIG. 2 according to an exemplary embodiment of the present disclosure. [Diagram 5] 3 shows a modified perspective cross-sectional view through the aerosol delivery device of FIG. 2 at the combined dispenser / atomizer assembly and reservoir, according to an exemplary embodiment of the present disclosure. [Figure 6]FIG. 3 shows a modified cross-sectional view through the aerosol delivery device of FIG. 2 illustrating the generation of vapor, according to an exemplary embodiment of the present disclosure. [Figure 7] FIG. 13 shows a cross-sectional view through an additional embodiment of an aerosol delivery device including an integrated dispenser / atomizer combination assembly, according to an exemplary embodiment of the present disclosure. [Figure 8] 8 shows a cross-sectional view through the aerosol delivery device of FIG. 7, illustrating airflow through the aerosol delivery device, according to an exemplary embodiment of the present disclosure. [Figure 9] 8 shows a cross-sectional view through a combined dispenser / atomizer assembly of the aerosol delivery device of FIG. 7, according to an exemplary embodiment of the present disclosure. [Figure 10] 8 shows an enlarged cross-sectional view through the combined dispenser / atomizer assembly of the aerosol delivery device of FIG. 7, according to an exemplary embodiment of the present disclosure. [Figure 11] FIG. 8 shows a partial cross-sectional view through the aerosol delivery device of FIG. 7 showing the production of vapor, according to an exemplary embodiment of the present disclosure. [Figure 12] 13 shows a cross-sectional view through an aerosol delivery device including a combined dispenser / atomizer assembly including a flexible circuit according to an additional exemplary embodiment of the present disclosure. [Figure 13] 13 shows an enlarged partial cross-sectional view through the aerosol delivery device of FIG. 12 at a combined dispenser / atomizer assembly according to an exemplary embodiment of the present disclosure. [Figure 14] FIG. 13 shows a modified cross-sectional view through the aerosol delivery device of FIG. 12 illustrating airflow through the aerosol delivery device, according to an exemplary embodiment of the present disclosure. [Figure 15] FIG. 13 shows a partial cross-sectional view through an aerosol delivery device, substantially similar to the aerosol delivery device of FIG. 12, except that the aerosol delivery device includes an integrated dispenser / nebulizer combination assembly, according to an additional exemplary embodiment of the present disclosure. [Figure 16] 13 shows a cross-sectional view through an aerosol delivery device including a combined dispenser / atomizer assembly positioned between a reservoir and a mouthpiece, according to a further exemplary embodiment of the present disclosure. [Figure 17] FIG. 17 shows an enlarged partial cross-sectional view through the aerosol delivery device of FIG. 16, illustrating the airflow through the aerosol delivery device, according to an exemplary embodiment of the present disclosure. [Figure 18] 13 shows a cross-sectional view through an aerosol delivery device including a combined dispenser / atomizer assembly coupled to the side of a reservoir, according to an additional exemplary embodiment of the present disclosure. [Figure 19] FIG. 19 shows a modified enlarged partial cross-sectional view of the aerosol delivery device of FIG. 18 illustrating airflow through the aerosol delivery device, according to an exemplary embodiment of the present disclosure. [Figure 20] FIG. 1 shows a partial schematic diagram of an aerosol delivery device in which the respective exhaust and heating surfaces of the bubble jet head and nebulizer are oriented at a non-zero angle relative to the longitudinal axis of the aerosol delivery device, according to an additional exemplary embodiment of the present disclosure. [Figure 21] 13 shows a cross-sectional view through an aerosol delivery device including a combined dispenser / atomizer assembly in which airflow occurs through the center, according to an additional exemplary embodiment of the present disclosure. [Figure 22] FIG. 22 shows an enlarged cross-sectional view through the aerosol delivery device of FIG. 21 illustrating the airflow through the aerosol delivery device according to an exemplary embodiment of the present disclosure. [Diagram 23] 22 is a schematic diagram showing an enlarged exploded view of the combined dispenser / atomizer assembly of the aerosol delivery device of FIG. 21 according to an exemplary embodiment of the present disclosure. [Figure 24] FIG. 13 illustrates a perspective view of a substantially conical atomizer defining an internal heating surface according to an additional exemplary embodiment of the present disclosure. [Diagram 25] FIG. 13 illustrates a perspective view of a substantially conical atomizer defining an outer heated surface according to an additional exemplary embodiment of the present disclosure. [Figure 26] 13 illustrates an exploded view of a combined dispenser / sprayer assembly including a reinforcing member according to an additional exemplary embodiment of the present disclosure. [Figure 27] 27 illustrates a reverse view of the combined dispenser / sprayer assembly of FIG. 26 with the reinforcing member in an assembled configuration, according to an exemplary embodiment of the present disclosure. [Figure 28A]FIG. 27 illustrates an enlarged cross-sectional view through the sprayer of the combined dispenser / sprayer assembly of FIG. 26, in which the sprayer defines a perforated heated surface, according to an additional exemplary embodiment of the present disclosure. [Figure 28B] FIG. 27 illustrates an enlarged cross-sectional view through the sprayer of the combined dispenser / sprayer assembly of FIG. 26, in which the sprayer defines a partially porous heated surface, according to an additional exemplary embodiment of the present disclosure. [Figure 28C] FIG. 27 illustrates an enlarged cross-sectional view through the sprayer of the combined dispenser / sprayer assembly of FIG. 26, in which the sprayer defines a fully porous heated surface, according to an additional exemplary embodiment of the present disclosure. [Figure 29] 13 shows a cross-sectional view through an aerosol delivery device in which a combined dispenser / atomizer assembly is positioned within a control body, according to a further exemplary embodiment of the present disclosure. [Diagram 30] 13 shows a cross-sectional view through an aerosol delivery device including a regulator, a dispenser and nebulizer cartridge, and a reservoir cartridge according to an additional exemplary embodiment of the present disclosure. [Diagram 31] 13A-13C are schematic diagrams illustrating a method for aerosolization in an aerosol delivery device according to an additional exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0059] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. In fact, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein, but rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural variations unless the context clearly dictates otherwise.

[0060] As described below, embodiments of the present disclosure relate to aerosol delivery systems, devices, and components therefor. Aerosol delivery systems according to the present disclosure use electrical energy to heat materials to form inhalable substances (preferably without burning the materials to any significant extent), and the components of such systems most preferably have the form of an article that is small enough to be considered a handheld device. That is, the use of the components of the preferred aerosol delivery systems does not result in the production of smoke in the sense that the aerosol is primarily due to by-products of tobacco combustion or pyrolysis, rather, the use of these preferred systems results in the production of vapor due to the volatilization or vaporization of certain components incorporated therein. In preferred embodiments, the components of the aerosol delivery systems can be characterized as electronic cigarettes, and these electronic cigarettes most preferably incorporate tobacco and / or tobacco-derived components to deliver tobacco-derived components in aerosol form.

[0061] The aerosol-generating components of certain preferred aerosol delivery systems may provide many of the perceptions (e.g., inhalation and exhalation habits, taste or flavor variety, organoleptic effects, physical sensations, usage habits, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used in ignition and combustion of tobacco (and thereby inhalation of tobacco smoke), without burning any components of the tobacco to any significant extent. For example, a user of an aerosol-generating component of the present disclosure may hold and use the component, draw on one end of the component to inhale the aerosol generated by the component, take puffs or sucks at selected time intervals, etc., in much the same way that a smoker uses a conventional type of smoking article.

[0062] The aerosol delivery system of the present disclosure may also be characterized as being a suitable vapor product or drug delivery article. Thus, such an article or device may be adapted to provide one or more substances (e.g., flavors and / or pharma- ceutical active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance that is in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas).

[0063] The aerosol delivery system of the present disclosure most preferably comprises some combination of a power source (i.e., a power source), at least one control component (e.g., a means for starting, controlling, regulating, and / or stopping the power supplied for heat generation, such as by controlling the current flow from the power emission unit to other components of the aerosol generating component), a heater or heat generating component (e.g., an electrical resistance heating element and associated components commonly referred to as providing an "atomizer"), and an aerosol precursor (e.g., a composition that is generally a liquid capable of generating an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), as well as a mouth region or tip that allows for drawing on the aerosol delivery device for aerosol inhalation (e.g., a defined airflow path through the aerosol generating component such that the generated aerosol may be drawn therefrom when drawn on by a user).

[0064] More specific forms, configurations, and arrangements of components within the aerosol delivery systems of the present disclosure will become apparent in view of the further disclosure provided below. In addition, the selection and arrangement of various aerosol delivery system components can be understood upon review of commercially available electronic aerosol delivery devices, such as the representative products referenced in the Background section of this disclosure.

[0065] The arrangement of the components within the aerosol delivery device may vary. In certain embodiments, the aerosol precursor composition may be located near an end of the article (e.g., in a cartridge that may be replaceable and disposable in certain circumstances) that may be configured to be positioned proximal to the mouth of the user to maximize delivery of the aerosol to the user. However, other configurations are not excluded. In general, the components may be configured relative to one another such that heat from the heating element may volatilize the aerosol precursor composition (as well as one or more flavorants, agents, etc. that may also be provided for delivery to the user) to form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, emitted, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are meant to be interchangeable, with references to release, releasing, releases, or released including form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapour or an aerosol, or a mixture thereof.

[0066] The aerosol delivery device incorporates a battery or other power source to provide sufficient current to provide various functionalities to the article, such as powering the heater, powering the control system, powering the indicators, etc. The power source may take on a variety of embodiments. The power source is preferably capable of delivering sufficient power to rapidly heat the heating element to provide aerosol formation and power the article for the desired period of use. The power source is preferably sized to conveniently fit within the aerosol delivery device so that the aerosol delivery device can be easily handled, and in addition, the power source is preferably sufficiently lightweight so as not to impair the desired smoking experience.

[0067] The aerosol delivery device may include a cartridge and a control body that may be permanently or removably aligned in a functional relationship. Various embodiments of engagement between the cartridge and the control body may be used, such as, for example, threaded engagement, press-fit engagement, interference fit, magnetic engagement, etc. The aerosol delivery device may be substantially rod-shaped, substantially tubular, or substantially cylindrical in shape in some embodiments when the cartridge and control body are in an assembled configuration.

[0068] In certain embodiments, one or both of the cartridge and the controller may be referred to as being disposable or as being reusable. For example, the controller may have a replaceable or rechargeable battery and thus may be combined with any type of recharging technology, including connection to a typical AC electrical outlet, connection to a car charger (i.e., cigarette lighter receptacle), connection to a computer via a Universal Serial Bus (USB) cable, or the like. Additionally, in some embodiments, the cartridge may comprise a single-use cartridge, as disclosed in U.S. Patent Publication No. 2014 / 0060555 to Chang et al., which is incorporated herein by reference in its entirety.

[0069] In some embodiments, the cartridge may include a base that may include anti-rotation features that substantially prevent relative rotation between the cartridge and the control body, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., the entirety of which is incorporated herein by reference.

[0070] The aerosol delivery device may include components configured to hold an aerosol precursor composition. The aerosol precursor composition, also referred to as a vapor precursor composition, may include various components, including, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extract, and / or flavorants. Various components that may be included in the aerosol precursor composition are described in U.S. Patent No. 7,726,320 to Robinson et al., which is incorporated herein by reference in its entirety. Additional representative types of aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., PCT Publication No. WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988), the disclosures of which are incorporated herein by reference in their entireties.

[0071] Various heater components may be used in the aerosol delivery device. In various embodiments, one or more microheaters or similar solid heaters may be used. Microheater embodiments that may be utilized are further described herein. Additional microheaters and nebulizers incorporating microheaters suitable for use in the devices of the present disclosure are described in U.S. Patent Publication No. 2014 / 0060554 to Collett et al., which is incorporated herein by reference in its entirety. In some embodiments, the heating element may be formed by wrapping a wire around a liquid transport element, as described in U.S. Patent Application Publication No. 2014 / 0157583 to Ward et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the wire may define a variable coil spacing, as described in U.S. Patent Application Publication No. 2014 / 0270730 to DePiano et al., which is incorporated herein by reference in its entirety. Various embodiments of materials configured to generate heat when an electric current is applied through the material may be used to form a resistive heating element. Exemplary materials from which the wire coils can be formed include Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi 2 ), molybdenum silicide (MoSi), and aluminum-doped molybdenum disilicide (Mo(Si,Al) 2), graphite and graphite-based materials, and ceramics (e.g., ceramics having positive or negative temperature coefficients). In further embodiments, stamped heating elements may be used in the atomizer, as described in U.S. Patent Application Publication No. 2014 / 0270729 to DePiano et al., which is incorporated by reference herein in its entirety. In addition to the above, additional exemplary heating elements, and materials for use therein, can be found in U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 ... Sprinkel et al., and U.S. Patent No. 5,311,621 to DePiano et al. No. 5,228,460 to Jr. et al., U.S. Patent No. 5,322,075 to Deevi et al., U.S. Patent No. 5,353,813 to Deevi et al., U.S. Patent No. 5,468,936 to Deevi et al., U.S. Patent No. 5,498,850 to Das, U.S. Patent No. 5,659,656 to Das, U.S. Patent No. 5,498,855 to Deevi et al., U.S. Patent No. 5,530,225 to Hajaligol, U.S. Patent No. 5,665,262 to Hajaligol, U.S. Patent No. 5,573,692 to Das et al., and U.S. Patent No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties. Additionally, in other embodiments, chemical heating may be used. Various additional examples of heaters and materials used to form the heaters are described in U.S. Patent Publication No. 2014 / 0060554 to Collett et al., which is incorporated by reference herein as noted above.

[0072] In some embodiments, the aerosol delivery device of the present disclosure may include a controller and a cartridge. When the controller is coupled to the cartridge, an electrical control component in the cartridge may form an electrical connection with the controller. Thus, the controller may use the electrical control component to determine whether the cartridge is authentic and / or perform other functions. Additionally, various examples of electronic control components and functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference in its entirety.

[0073] During use, a user may suck on the mouthpiece of the cartridge of the aerosol delivery device. This may draw air through an opening in the control body or cartridge. For example, in one embodiment, the opening may be defined between the connector and the outer body of the control body, as described in U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al., the entirety of which is incorporated herein by reference. However, air flow may be received through other parts of the aerosol delivery device in other embodiments.

[0074] A sensor in the aerosol delivery device (e.g., an inhalation or flow sensor in the controller) can sense inhalation. When inhalation is sensed, the controller can direct current through a circuit to the heater. In this manner, the heater can vaporize the aerosol precursor composition, and the mouthpiece can allow air and entrained vapor (i.e., the components of the aerosol precursor composition in an inhalable form) to pass from the cartridge to a consumer who inhales it.

[0075] Various other details regarding components that may be included in the cartridge are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated by reference in its entirety. In this regard, FIG. 7 shows an enlarged exploded view of the base and control component terminals, FIG. 8 shows an enlarged perspective view of the base and control component terminals in an assembled configuration, FIG. 9 shows an enlarged perspective view of the base, control component terminals, electronic control component, and heater terminal of the sprayer in an assembled configuration, FIG. 10 shows an enlarged perspective view of the base, sprayer, and control component in an assembled configuration, FIG. 11 shows an opposite perspective view of the assembly of FIG. 10, FIG. 12 shows an enlarged perspective view of the base, sprayer, flow tube, and reservoir substrate in an assembled configuration, FIG. 13 shows a perspective view of the base and outer body in an assembled configuration, FIG. 14 shows a perspective view of the cartridge in an assembled configuration, FIG. 15 shows a first partial perspective view of a connector for the cartridge and control of FIG. 14, and FIG. 16 shows a perspective view of the cartridge and control of FIG. FIG. 17 shows a perspective view of a cartridge including a base with an anti-rotation mechanism, FIG. 18 shows a perspective view of a control body including a coupler with an anti-rotation mechanism, FIG. 19 shows the arrangement of the cartridge of FIG. 17 with the control body of FIG. 18, FIG. 20 shows an aerosol delivery device including the cartridge of FIG. 17 and the control body of FIG. 18, accompanied by a modified view of the aerosol delivery device showing engagement of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body, FIG. 21 shows a perspective view of a base with an anti-rotation mechanism, FIG. 22 shows a perspective view of a coupler with an anti-rotation mechanism, and FIG. 23 shows a cross-sectional view of the base of FIG. 21 and the coupler of FIG. 22 in an engaged configuration.

[0076] The various components of the aerosol delivery device according to the present disclosure can be selected from those described in the art and commercially available. See, for example, the reservoir and heater system for controllably delivering multiple aerosolizable materials in an electronic smoking article disclosed in U.S. Patent Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0077] In the present disclosure, FIG. 1 shows an exploded view of a control 300 of an aerosol delivery device according to one exemplary embodiment. As shown, the control 300 may include a connector 302, an outer body 304, a sealing member 306, an adhesive member 308 (e.g., KAPTON® tape), a flow sensor 310 (e.g., an inhalation sensor or pressure switch), a control component 312, a spacer 314, a power source 316 (e.g., a battery that may be rechargeable), a circuit board with an indicator 318 (e.g., a light-emitting diode (LED)), a connector circuit 320, and an end cap 322. An example of a power source is described in U.S. Patent Application Publication No. 2010 / 0028766 by Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety. An exemplary mechanism that may provide inhalation actuation capability includes a silicon sensor, model 163PC01D36, manufactured by the MicroSwitch division of Honeywell, Inc. (Freeport, Ill.). Further examples of demand-activated electrical switches that can be used in the heating circuit according to the present disclosure are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Further descriptions of current regulation circuits and other control components, including microcontrollers, that can be useful in the present aerosol delivery device are provided in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875, all 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., and U.S. Patent No. 7,040,314 to Nguyen et al., all of which are incorporated herein by reference in their entirety. See also the control scheme described in U.S. Patent Application Publication No. 2014 / 0270727 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0078] In one embodiment, the indicator 318 may comprise one or more light emitting diodes. The indicator 318 communicates with the control component 312 through the connector circuit 320 and may illuminate while a user draws on a cartridge connected to the connector 302, for example, as detected by the flow sensor 310. The end cap 322 may be adapted to make visible the illumination provided thereunder by the indicator 318. In this manner, the indicator 318 may illuminate during use of the aerosol delivery device to mimic a lit end of a smoking article. However, in other embodiments, the indicator 318 may be provided in various numbers, may take different shapes, and may even be an opening in the outer body (such as to emit a sound when such an indicator is present).

[0079] Additional components may also be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor associated with the mouthpiece of the device to detect the user's lip action associated with taking a puff and then trigger heating; U.S. Patent No. 5,372,148 to McCafferty et al. discloses an inhalation sensor for controlling energy flow to a heat load array in response to a pressure drop through the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device including an identification device that detects non-uniformity in infrared transmittance of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with multiple differential phase shifts; and U.S. Patent No. 5,934,220 to Watkins et al. discloses a method for controlling a power supply in a smoking device. No. 289 discloses photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for modifying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses certain battery configurations for use within smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interfacing means for smoking devices that facilitate charging and allow computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for smoking devices; and WO 2010 / 003480 by Flick discloses a fluid flow sensing system that indicates inhalation within an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.Further examples of components related to electronic aerosol delivery articles and disclosing materials or components that may be used in the articles include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. No. 6,872,471 to Hon, U.S. Pat. No. 6,7 ... Nos. 8,156,944 and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al. and U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon, U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al., U.S. Patent Application Publication Nos. 2009 / 0260643 to Oglesby et al., U.S. Patent Application Publication Nos. 2009 / 0260644 to Oglesby et al., U.S. Patent Application Publication Nos. 2009 / 0260642 to Oglesby ...2 to Oglesby et al., U.S. Patent Application Publication Nos. 2009 / 0260642 to Oglesby et al., U.S. Patent Application Publication Nos. 2009 / 0260642 to Oglesby et al., U.S. Patent Application Publication Nos. 2009 / 0260642 to Oglesby et al., U.S. Patent Application Publication Nos. 2009 / 02606 US Patent Application Publication No. 2010 / 0024834 to Glesby et al., US Patent Application Publication No. 2010 / 0307518 to Wang, US Patent Application Publication No. 2014 / 0261408 to DePiano et al., WO 2010 / 091593 to Hon, and WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. The various materials disclosed by the aforementioned documents may be incorporated into the present device in various embodiments, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0080] Thus, exemplary embodiments of the aerosol delivery device are described above. However, the present disclosure provides various other embodiments of the aerosol delivery device. As described below, such aerosol delivery devices may include different configurations of components for storing, delivering, and / or vaporizing the aerosol precursor composition. Some of the components of the aerosol delivery device may be substantially similar to the components described above, so details regarding these components and their functions will not be repeated or will only be briefly described. However, it should be understood that the description of the components provided above is equally applicable to the embodiments of the aerosol delivery device described below, unless otherwise stated.

[0081] In this regard, Fig. 2 shows an exploded view of an aerosol delivery device 1200 according to an additional exemplary embodiment of the present disclosure. As shown, the aerosol delivery device 1200 may include a controller 1202 and a cartridge 1204. The controller 1202 may include an end cap 1206, a circuit board with an indicator 1208 (e.g., a light emitting diode (LED)), a connector circuit 1209, a power source 1210 (e.g., a battery, which may be rechargeable), a flow sensor 1212, a coupler 1214, and an outer body 1216 (which may include one or more inlet holes 1233). The cartridge 1204 may include a base 1218, a combined dispenser / atomizer assembly 1220, a reservoir 1222, a lid 1224, a mouthpiece 1226, and an outer body 1228.

[0082] 3 shows a modified cross-sectional view through the aerosol delivery device 1200 of FIG. 2. As shown in the figure, the base 1218 of the cartridge 1204 can be configured to engage the coupler 1214 of the regulator 1202 to form a mechanical and electrical connection therebetween. The connection between the base 1218 of the cartridge 1204 and the coupler 1214 of the regulator 1202 can be releasable, for example, so that the cartridge can be replaced once the aerosol precursor composition 1246 (see FIG. 6) contained within the cartridge is consumed. Although FIG. 2 shows the wire 1230 as being coupled to the base 1218, in some embodiments, the wire can actually be coupled to the coupler 1214 to enable a releasable connection between the cartridge 1204 and the regulator 1202.

[0083] 3 further illustrates the flow path of air through the aerosol delivery device 1200 when a user draws on the mouthpiece 1226. As shown, airflow or flow of ambient air 1232 may enter the aerosol delivery device 1200 through one or more inlet holes 1233 and travel proximate to or past the flow sensor 1212. The air 1232 may then travel through at least one connector hole 1261 in the connector 1214 and at least one base hole 1263 in the base 1218, around the combined dispenser / atomizer assembly 1220 and the reservoir 1222 (e.g., via one or more aerosol delivery holes 1265 defined in the outer body 1228 or the space between the reservoir and the outer body), and exit the mouthpiece 1226.

[0084] The inlet hole 1233 may be defined in the outer body 1216 of the control body 1202 such that the flow sensor 1212, which may also be positioned in the control body, may detect the flow of the air 1232. The control body 1202 may be reusable, while the cartridge 1204 may be disposable. In this regard, while certain components in the cartridge 1204 may degrade or wear out, the flow sensor 1212 and other components in the control body may maintain full functionality even with repeated use. In this manner, positioning the flow sensor 1212 in the control body 1202 and providing a corresponding flow path for the air 1232 through the control body, or otherwise providing fluid communication between the air moving through the aerosol delivery device 1200 and the flow sensor, may reduce the cost of the cartridge 1204 by reducing the number and types of components received in the cartridge. In this regard, while in this embodiment and other embodiments disclosed herein, airflow is generally described as occurring through the control body, in additional embodiments, a pressure tap can be used to allow a flow sensor in the control body to detect airflow through the cartridge without substantially any airflow through the control body, as described, for example, in U.S. patent application Ser. No. 14 / 193,961 to Worm et al., filed Feb. 28, 2014, which is incorporated by reference in its entirety.

[0085] The lid 1224 and the combined dispenser / sprayer assembly 1220 may be coupled to opposing ends of the reservoir 1222. In this manner, the lid 1224 and the combined dispenser / sprayer assembly 1220 may enclose the reservoir 1222 and retain the aerosol precursor composition 1246 (see FIG. 6) therein. However, when the flow sensor 1212 detects inhalation, the combined dispenser / sprayer assembly 1220 may be actuated such that the aerosol precursor composition 1246 (see FIG. 6) is controllably dispensed from the reservoir 1222.

[0086] In this regard, Figure 4 illustrates a partial cross-sectional view through a combined dispenser / atomizer assembly. As shown, in one embodiment, combined dispenser / atomizer assembly 1220 may include a bubble jet head 1234 and an atomizer 1238 fixedly coupled thereto. As described in detail below, bubble jet head 1234 may be configured to dispense aerosol precursor composition 1246 from reservoir 1222 (see, e.g., Figure 6). Further, atomizer 1238 may be configured to heat aerosol precursor composition 1246 to generate an aerosol or vapor 1248 (see Figure 6).

[0087] The bubble jet head 1234 may include one or more precursor inlets 1245, one or more precursor channels 1235, one or more first or exhaust heating elements 1240, one or more precursor nozzles 1242, and a wafer, substrate, or housing 1241 associated therewith. In some embodiments, the housing 1241 may include silicon, ceramic, graphite, or other low thermal conductivity and / or insulating material. The precursor inlets 1245, precursor channels 1235, and / or precursor nozzles 1242 may be defined by holes in the housing 1241 in some embodiments. Alternatively, the precursor inlets, precursor channels, and / or precursor outlets may comprise separate elements coupled to the housing. Additionally, the exhaust heating elements 1240 may be positioned within one or more first or exhaust chambers 1237, which may be defined by the housing 1241 of the bubble jet head 1234. In some embodiments, the bubble jet head 1234 may comprise a standard inkjet printer head (e.g., a standard bubble jet print head sold by ImTech of Corvallis, Oregon, or a 45 style jet head sold by Hewlett Packard of Palo Alto, California).

[0088] The nebulizer 1238 may be positioned relative to the bubble jet head 1234 to receive the aerosol precursor composition 1246 dispensed from the reservoir 1222 (see FIG. 6). In some embodiments, the nebulizer 1238 may be fixedly coupled to the bubble jet head 1234 such that the combined dispenser / nebulizer assembly 1220 may be inserted as a unit into the outer body 1228 of the cartridge 1204 (see, e.g., FIG. 3) rather than being inserted separately into the outer body. By way of example, the combined dispenser / nebulizer assembly 1220 may be engaged with the reservoir 1222 and the combined assembly may be inserted into the outer body 1228 (see, e.g., FIG. 3). Additionally, the fixed coupling of the bubble jet head 1234 to the nebulizer 1238 may allow precise positioning of these two components relative to one another such that the dispensed aerosol precursor composition 1246 (see FIG. 6) is received in place on the nebulizer for nebulization.

[0089] As shown in FIG. 4, in one embodiment, the bubble jet head 1234 may be fixedly coupled to the atomizer 1238 via one or more spacers 1236. Specifically, the atomizer 1238 may include a wafer, substrate, or housing 1243 that is coupled to a housing 1241 of the bubble jet head 1234 via the spacer 1236. In some embodiments, the housing 1243 may include silicon, ceramic, graphite, or other non-conductive and / or insulating materials. The spacer 1236 may be configured to provide a gap between the bubble jet head 1234 and the atomizer 1238. In some embodiments, the gap may be about 1 mm to about 10 mm, more preferably about 1 mm to about 3 mm, to reduce splashing of the aerosol precursor composition. However, in other embodiments, a gap defining a different dimension may be used. In this regard, the gap between the bubble jet head 1234 and the nebulizer 1238 can be selected or adjusted based on the droplet distribution pattern associated with the ejection of the aerosol precursor composition from the bubble jet head to precisely deliver the aerosol precursor composition to the heated surface of the nebulizer (e.g., to prevent pooling of the aerosol precursor composition on one or more portions of the nebulizer, to provide a thin, uniform film of the aerosol precursor composition across the heated surface of the nebulizer, and / or to target specific areas of the nebulizer). The nebulizer 1238 can further include one or more second or vaporizing heating elements 1244. For example, each of the vaporizing heating elements 1244 can be associated with a respective ejection heating element 1240 and each nozzle 1242.

[0090] The bubble jet head 1234 may be coupled to or otherwise positioned in fluid communication with the reservoir 1222. For example, as shown in FIG. 5, in some embodiments, the bubble jet head 1234 may be coupled to a distal end 1222A of the reservoir 1222 to block an opening 1222′ to the reservoir and retain an aerosol precursor composition 1246 (see FIG. 6) therein as described above. Thus, a precursor inlet 1245 in the bubble jet head 1234 may be in fluid communication with the reservoir 1222 such that the precursor channel 1235 may direct the aerosol precursor composition 1246 (see FIG. 6) to an exhaust chamber 1237 in which an exhaust heating element 1240 is positioned.

[0091] Coupling the bubble jet head 1234 to the distal end 1222A of the reservoir 1222 can be advantageous in that it provides a relatively simple mechanism for attachment and fluid connection. In this regard, the reservoir 1222 can define a hollow, substantially cylindrical configuration and the distal end 1222A can define a substantially planar configuration such that the bubble jet head 1234 can be coupled (e.g., glued, adhered, or welded) to the distal end 1222A of the reservoir 1222 to seal the reservoir and provide fluid communication between the reservoir and the bubble jet head.

[0092] In this manner, the bubble jet head 1234 can receive the aerosol precursor composition 1246 (see FIG. 6) from the reservoir 1222. In some embodiments, as shown in FIG. 5, the reservoir 1222 can include a reservoir substrate 1239 configured to direct the aerosol precursor composition 1246 (see FIG. 6) to the bubble jet head 1234. In this regard, the reservoir substrate 1239 can include any material configured to wick or otherwise transport the aerosol precursor composition 1246 (see FIG. 6) to the bubble jet head 1234, such as, for example, cellulose acetate, polyethylene terephthalate (PET), or any polymeric material, whether woven or nonwoven, and whether fibrous or non-fibrous. Additionally, in other embodiments, the reservoir substrate 1239 can include one or more non-polymeric materials, such as those that can be fabricated as open-cell foams, etc. (e.g., ceramic foams, carbon foams, sintered glass), to define a porous medium that provides wicking channels. In this manner, by using the reservoir substrate 1239, the aerosol precursor composition 1246 (see FIG. 6) can be directed to the bubble jet head 1234 regardless of the orientation of the aerosol delivery device 1200 (see, e.g., FIG. 2), such that the aerosol delivery device does not need to be oriented in a particular manner during use. In some embodiments, the reservoir substrate can occupy only a portion of the longitudinal length of the reservoir. For example, the reservoir substrate can be positioned only proximal to the distal end of the reservoir to which the bubble jet head is attached. This configuration can provide substantially the same benefits as described above, since movement of the aerosol delivery device can cause the aerosol precursor composition to contact the reservoir substrate while reducing the volume within the reservoir occupied by the reservoir substrate to allow for an increase in the fluid volume within the reservoir.

[0093] The precursor nozzle 1242 may initially prevent the aerosol precursor composition 1246 (see FIG. 6 ) from traveling through the rest of the combined dispenser / sprayer assembly 1220. In this regard, the precursor nozzle 1242 may be appropriately dimensioned to resist flow therethrough, e.g., due to surface tension. Alternatively or additionally, negative pressure within the reservoir (e.g., created by a spring and piston within the reservoir or as a result of applying negative pressure to the reservoir prior to sealing it) may resist passive leakage of the aerosol precursor composition out of the reservoir and through the bubble jet head.

[0094] However, when inhalation is detected by the flow sensor 1212, the bubble jet head 1234 can direct the aerosol precursor composition 1246 (see FIG. 6) in the reservoir 1222 towards the atomizer 1238. Specifically, as described and illustrated in more detail below with respect to alternative embodiments of the present disclosure, electrical current from the power source 1210 (see, e.g., FIG. 2) can be directed to the exhaust heating element 1240 to heat the aerosol precursor composition 1246 (see FIG. 6) received through the precursor inlet 1245 and the precursor channel 1235, resulting in the formation of vapor bubbles that can expel droplets of the aerosol precursor composition through the precursor nozzle 1242 towards the atomizer 1238.

[0095] Current from the power source 1210 (see, e.g., FIG. 2) may be applied to the vaporization heating element 1244 prior to, simultaneously with, or after applying current to the exhaust heating element 1240. However, delaying the application of current to the vaporization heating element 1244 until after the exhaust heating element 1240 receives the current may help prevent wasting energy. In this regard, some of the heat generated by the vaporization heating element 1244 before the aerosol precursor composition 1246 (see FIG. 6) contacts the vaporization heating element may be unnecessarily transferred to surrounding portions of the aerosol delivery device 1200 or to the air within the aerosol delivery device, rather than being applied to the aerosol precursor composition as desired.

[0096] In one embodiment, multiple walls defined by the housing 1241 of the bubble jet head 1234, the spacer 1236, and / or the housing 1243 of the nebulizer 1238 may cooperate to define a second or vaporization chamber 1247 (see, e.g., FIG. 4) into which the vaporization heating element 1244 is positioned and into which the aerosol precursor composition 1246 (see FIG. 6) is delivered. Thus, problems with the aerosol precursor composition 1246 (see FIG. 6) being directed into the air 1232 and thus to the user without being vaporized may be avoided. In this regard, the aerosol precursor composition 1246 may be directed into contact with the vaporization heating element 1244 in the vaporization chamber 1247 to ensure its vaporization before being directed into the flow of the air 1232 through the aerosol delivery device 1200. As shown in FIG. 6, the flow of air 1232 may extend generally around the combined dispenser / atomizer assembly 1220, rather than flowing between the bubble jet head 1234 and the atomizer 1238, so that the air flow does not direct the aerosol precursor composition away from the atomizer before atomization. Note that if the aerosol precursor composition is directed into the air without being vaporized, it may separate from the air and accumulate in the aerosol delivery device at locations outside the reservoir. This may result in undesirable leakage of fluid from the aerosol delivery device. Alternatively or additionally, liquid aerosol precursor composition may reach the mouth of the user, causing an undesirable taste or sensation.

[0097] Thus, droplets of aerosol precursor composition 1246 ejected from nozzle 1242 can be vaporized by vaporizing heating element 1244 of nebulizer 1238 to generate aerosol or vapor 1248 (see FIG. 6). As shown in FIG. 6, vapor 1248 generated by vaporizing heating element 1244 can then exit combined dispenser / nebulizer assembly 1220 and mix with air 1232, traveling therewith to mouthpiece 1226. In this manner, bubble jet head 1234 can be used to precisely dispense aerosol precursor composition 1246 (see FIG. 6) to nebulizer 1238, which may provide an advantage in ensuring a consistent amount of aerosol is delivered with each puff of aerosol delivery device 1200, as compared to embodiments of aerosol delivery devices that rely on passive aerosol precursor composition delivery mechanisms, such as wicks.

[0098] The power delivered from the power supply 1210 to the bubble jet head 1234 and the atomizer 1238 can be controlled in one or more ways. For example, the power delivered to the bubble jet head 1234 can be controlled independently to the atomizer 1238 in one or more ways. Additionally, pulse width and / or pulse amplitude modulation can be used to provide appropriate amounts of current to the bubble jet head 1234 and the atomizer 1238. Relatively larger pulse widths and / or amplitudes can be used to generate relatively larger amounts of heat. In this regard, the exhaust heating element 1240 can have a relatively lower thermal mass and can be configured to heat the aerosol precursor composition 1246 to a relatively lesser extent than the vaporization heating element 1244, rather than completely vaporizing the aerosol precursor composition (as occurs in the atomizer 1238) in order to exhaust and dispense the aerosol precursor composition. In this regard, while the exhaust of the aerosol precursor composition may involve vaporization, only a small portion of the aerosol precursor composition is vaporized such that one or more droplets of the aerosol precursor composition are exhausted from the chamber, and the vaporization occurs within the substantially enclosed exhaust chamber 1237. In contrast, the vaporization heating element may be configured to vaporize the entirety of the aerosol precursor composition directed thereto. Thus, to heat the exhaust heating element 1240 to a relatively lesser extent than the vaporization heating element 1244, a relatively smaller pulse width and / or amplitude of power may be directed to the exhaust heating element as compared to the pulse width and / or amplitude of the power directed to the vaporization heating element. Additionally, the application of power to the vaporization heating element 1244 may be delayed relative to the application of power to the exhaust heating element 1240 such that energy is not wasted in the vaporization heating element prior to the exhaust of the aerosol precursor composition.

[0099] As noted above, in one embodiment, the bubble jet head may comprise a substantially conventional bubble jet head, such as an inkjet head used in a printer. However, the inkjet head may be modified for use in the aerosol delivery device of the present disclosure. For example, the number of precursor nozzles and precursor inlets leading thereto may be adjusted, the diameter and / or shape of the precursor inlets and / or precursor nozzles may be adjusted, the dimensions of the exhaust heating elements in the bubble jet head may be adjusted, the heat output by the exhaust heating elements may be adjusted, the pulse width of the power applied to the exhaust heating elements in the bubble jet head may be adjusted, and / or various other features may be adjusted. These modifications may accommodate the difference in viscosity of the aerosol precursor composition relative to the ink, as well as the goal of directing the aerosol precursor composition to an atomizer to vaporize the aerosol precursor composition, as opposed to printing the ink on a substrate such as paper.

[0100] The present disclosure provides various additional embodiments of an aerosol delivery device that includes a bubble jet head configured to dispense an aerosol precursor composition to a nebulizer. For the sake of brevity, the description of certain features and components of the aerosol delivery device described above will not be repeated in greater detail below. However, it should be understood that the description provided above is applicable to the embodiments of the aerosol delivery device described below, except where otherwise indicated.

[0101] 7 shows a cross-sectional view through an aerosol delivery device 1300 according to an additional exemplary embodiment of the present disclosure. As shown, the aerosol delivery device 1300 may include a controller 1302 and a cartridge 1304. The controller 1302 may include an end cap 1306, a flow sensor 1308, a power source 1310 (e.g., a battery, which may be rechargeable), a coupler 1312 defining at least one coupler hole 1361, and an outer body 1314. As described elsewhere herein, the controller may additionally include a circuit board with an indicator (e.g., a light emitting diode (LED)) and connector circuitry. The cartridge 1304 may include a base 1316 defining at least one base hole 1363, a combined dispenser / atomizer assembly 1318, a reservoir 1320, a lid 1322 sealing the reservoir, a mouthpiece 1324, and an outer body 1326 defining one or more aerosol delivery holes 1365. The base 1316 of the cartridge 1304 may be configured to engage a coupler 1312 of the control body 1302 to form a mechanical and electrical connection therebetween, which connection may be releasable to allow replacement of the cartridge.

[0102] 8 shows a cross-sectional view through the aerosol delivery device 1300 illustrating the flow path of air through the aerosol delivery device when a user draws on the mouthpiece 1324. As shown, airflow or flow of ambient air 1328 may enter the aerosol delivery device 1300 through one or more inlet holes 1331 and move past or proximate to the flow sensor 1308 and around the power source 1310. Although the ambient air 1328 is shown flowing around the power source 1310, in other embodiments the air may not flow past the power source and / or the flow sensor may be located in an alternative location. Additionally, the inlet holes 1331 may be located in various alternative locations and defined within other components, such as between the power source 1310 and the coupler 1312 within the outer body 1314 of the control body 1302. Air 1328 can flow from the control body 1302, through a hole 1361 in the connector 1312, into and through a base hole 1363 in the base 1316, around the combined dispenser / atomizer assembly 1318 and reservoir 1320 (e.g., via an aerosol delivery hole 1365 defined in the outer body 1326 or between the reservoir and the outer body), and out the mouthpiece 1324.

[0103] When the flow sensor 1308 detects inhalation, a combined dispenser / atomizer assembly 1318 may be initiated. In this regard, as shown in the partial cross-sectional view of FIG. 9, the combined dispenser / atomizer assembly 1318 may receive an aerosol precursor composition 1330 from a reservoir 1320 and generate an aerosol or vapor 1332. More specifically, as shown in the enlarged partial cross-sectional view of FIG. 10, the combined dispenser / atomizer assembly 1318 may include a wafer, substrate, or housing 1333 defining at least one precursor inlet 1334 through which the aerosol precursor composition 1330 is received. The aerosol precursor composition 1330 may then travel through one or more precursor channels 1335 to one or more precursor nozzles 1336. In some embodiments, the precursor inlet 1334, the precursor channels 1335, and / or the precursor nozzles 1336 may be defined by the housing 1333. Alternatively, the precursor inlet, precursor channel, and / or precursor outlet may comprise separate components coupled to the reservoir. A precursor nozzle 1336 leading to the combined dispenser / sprayer assembly may initially prevent the aerosol precursor composition 1330 from moving through the remainder of the combined dispenser / sprayer assembly 1318. In this regard, the precursor nozzle 1336 may be appropriately dimensioned to resist flow therethrough, e.g., due to surface tension. Alternatively or additionally, the aerosol precursor composition may be exposed to negative pressure within the reservoir, as described above, to reduce the likelihood of fluid leakage through the combined dispenser / sprayer assembly.

[0104] However, when flow sensor 1308 (see, e.g., FIG. 8) detects inhalation in aerosol delivery device 1300, electrical current can be directed from power source 1310 (see, e.g., FIG. 8) to one or more first or exhaust heating elements 1338 positioned within first or exhaust chamber 1339 defined by housing 1333. This can cause exhaust heating elements 1338 to heat aerosol precursor composition 1330 such that it boils and vapor bubbles 1340 form. Each of the vapor bubbles 1340 expands very rapidly, creating a pressure pulse that then expels droplets 1342 of aerosol precursor composition 1330 through each of precursor nozzles 1336. After application of power to exhaust heating elements 1338 ceases, the vapor bubbles 1340 collapse as the aerosol precursor composition 1330 and vapor bubbles 1340 cool. The surface tension and surface energy associated with the aerosol precursor composition 1330 at the precursor nozzle 1336 and capillary forces resulting from the interaction of the aerosol precursor composition with the microfluidic channels defined by the precursor inlet 1334, the precursor channel 1335, and the precursor nozzle can direct more of the aerosol precursor composition from the reservoir toward the exhaust heating element 1338 so that it replenishes the exhaust chamber 1337 and the exhaust cycle can be repeated. Thus, the use of a separate valve may not be required to dispense the aerosol precursor composition 1330. In this manner, the combined bubble jet head / dispenser 1318 can include a bubble jet head 1350 including the exhaust heating element 1338, the precursor inlet 1334, the precursor channel 1335, and the precursor nozzle 1336.

[0105] 10, the droplets 1342 of the aerosol precursor composition 1330 may be ejected through the precursor nozzle 1336 toward one or more second or vaporization heating elements 1344. In this regard, each ejection heating element 1338 of each portion of the combined dispenser / sprayer assembly 1318, the precursor nozzle 1336, and the vaporization heating element 1344 may be axially aligned such that the aerosol precursor composition 1330 is ejected onto the vaporization heating element. The vaporization heating element 1344 may be positioned within the second or vaporization chamber 1346 defined by the housing 1333 and into which the droplets 1342 of the aerosol precursor composition 1330 are delivered. Each of the vaporization heating elements 1344 may be associated with each of the ejection heating elements 1338 and the precursor nozzle 1336. This allows droplets 1342 of the aerosol precursor composition 1330 ejected from the precursor nozzle 1336 to be vaporized by a vaporization heating element 1344 to produce a vapor 1332 (see, for example, FIG. 9).

[0106] In this regard, the exhaust heating element 1338 may have a relatively lower thermal mass and may be configured to heat the aerosol precursor composition 1330 to a relatively lesser extent as compared to the vaporization heating element 1344. The vapor 1332 (see, e.g., FIG. 9 ) generated by the vaporization heating element 1344 may then exit the combined dispenser / atomizer assembly 1318 through one or more aerosol outlets 1348, which may be defined by a housing 1333 at a second chamber 1346. To exit the vapor 1332 through the aerosol outlets 1348 rather than traveling in the reverse direction through the precursor nozzle 1336, the aerosol outlets may define an area larger than that of the precursor nozzle. Furthermore, by providing a relatively larger area for the aerosol outlet 1348 and / or a relatively larger volume for the second chamber 1346, problems with the aerosol precursor composition 1330 rapidly expanding into vapor 1332 (see, e.g., FIG. 9 ) and causing damage to the combined dispenser / atomizer assembly 1318 can be avoided.

[0107] 11, the vapor 1332 can mix with the air 1328 and travel therewith toward the mouthpiece 1324 (see, e.g., FIG. 8). For example, the vapor 1332 and air 1328 can travel through an aerosol delivery hole 1365 defined in the outer body 1326 of the cartridge 1304. As described above, the aerosol precursor composition can be discharged into the vaporization chamber 1346 and vaporized therein. This can avoid issues with directing the aerosol precursor composition into the air 1328 (see, e.g., FIG. 8) without first being nebulized.

[0108] 7-11 may thus be an integrated unit (e.g., provided as a silicon chip) including both a bubble jet head 1350 (e.g., including an exhaust heating element 1338, a precursor inlet 1334, a precursor channel 1335, and a precursor nozzle 1336) and a sprayer 1352 (e.g., including an aerosol outlet 1348 and a vaporization heating element 1344) fixedly coupled to one another via a housing 1333 configured to be received within an outer body 1326 of a cartridge 1304 (see, e.g., FIG. 8). In contrast, the combined dispenser / sprayer assembly 1220 shown in FIGS. 2-6 may include a standard bubble jet head 1234 (e.g., an inkjet printer bubble jet head) fixedly coupled to a sprayer 1238 (e.g., via a spacer 1236) and which may be modified to function as a dispenser for dispensing an aerosol precursor composition to the sprayer.

[0109] 12 shows a cross-sectional view through an aerosol delivery device 1400 according to an additional exemplary embodiment of the present disclosure. As shown, the aerosol delivery device 1400 may include a controller 1402 and a cartridge 1404, shown in a separated configuration. The controller 1402 may include an end cap 1406, a circuit board with an indicator 1408 (e.g., a light emitting diode (LED)), a connector circuit 1409, a power source 1410 (e.g., a battery that may be rechargeable), a flow sensor 1411 (e.g., an inhalation sensor or pressure switch), a coupler 1412, wiring 1413, and an outer body 1414. The cartridge 1404 may include a base 1416, a combined dispenser / atomizer assembly 1418, a reservoir 1420, a lid 1422 that seals the reservoir, a mouthpiece 1424, and an outer body 1426. The base 1416 of the cartridge 1404 may be configured to engage the coupler 1412 of the control body 1402 to form a mechanical and electrical connection therebetween, which connection may be releasable to allow replacement of the cartridge.

[0110] 13 shows an enlarged partial cross-sectional view of an aerosol delivery device 1400 in which a controller 1402 and a cartridge 1404 are coupled to one another. As shown, a combined dispenser / atomizer assembly 1418 can include a bubble jet head 1450 and an atomizer 1452. The bubble jet head 1450 and the atomizer 1452 can include any of the bubble jet head and atomizer components and features described elsewhere herein.

[0111] 13, the bubble jet head 1450 and the sprayer may be coupled via a flexible circuit 1453. Specifically, the flexible circuit 1453 may be electrically coupled to the base 1416 such that the dispenser / sprayer assembly 1418 is electrically connected to the cartridge 1402 through the base and connector 1412. The flexible circuit 1453 may additionally electrically couple the bubble jet head 1450 to the sprayer 1452 such that power may be directed to the bubble jet head and the sprayer in the manner described elsewhere herein.

[0112] Further, in some embodiments, the flexible circuit can mechanically couple the bubble jet head 1450 to the sprayer 1452 such that the bubble jet head and the sprayer are fixedly coupled to one another. In this regard, the flexible circuit 1453 can include a high temperature polyamide substrate or other flexible, non-conductive material on which a circuit is printed, etched, or otherwise formed. Further, in some embodiments, the combined dispenser / sprayer assembly 1418 can be coupled to the reservoir 1420, and then the assembly can be inserted into the outer body 1426 of the cartridge 1404. In this regard, the mechanical coupling between the bubble jet head 1450 and the sprayer 1452 via the flexible circuit 1453 can enable insertion in this manner. Further, the flexible circuit 1453 can be configured to flex, for example, so that the combined dispenser / sprayer assembly 1418 can be pressed against the base 1416 to define a desired gap or separation between the bubble jet head 1450 and the sprayer 1452. In this regard, for example, the flexible circuit 1453 may initially position the bubble jet head 1450 and the sprayer 1452 at a relatively large separation, and the flexible circuit may bend during assembly, e.g., as a result of contact with the base 1416, to define the desired separation.

[0113] 13, in some embodiments, the outer body 1414 of the control body 1402 may define one or more inlet holes 1431, the coupler 1412 may define at least one coupler hole 1427, the base 1416 may define at least one base hole 1429, and the outer body 1426 of the cartridge 1404 may define at least one aerosol delivery hole 1465, which may allow air to flow through the aerosol delivery device 1400. In this regard, FIG. 14 depicts a cross-sectional view through the aerosol delivery device 1400 illustrating the flow path of air through the aerosol delivery device when a user draws on the mouthpiece 1424. As shown, airflow or flow of ambient air 1428 may enter the aerosol delivery device 1400 through an inlet hole 1431, which may be defined in the outer body 1414 of the control body 1402, and travel past or proximate to the flow sensor 1411. The air 1428 may flow from the control body 1402, through the coupler 1412 at the coupler hole 1427 (see FIG. 13), through a base hole 1429 defined in the base 1416 of the cartridge 1404, through and / or around the combined dispenser / atomizer assembly 1418, around the reservoir 1420 (e.g., through an aerosol delivery hole 1465 defined in the outer body 1426 or between the reservoir and the outer body, as shown in FIG. 15), and out the mouthpiece 1424. It should be noted that although the aerosol delivery holes 1465 are shown as defining a non-linear flow path, in other embodiments the aerosol delivery holes may define a linear flow path (e.g., extending parallel to the longitudinal length of the cartridge) to simplify manufacture of the cartridge and provide a flow path with a smaller pressure drop.

[0114] Specifically, air 1428 may travel through the base 1416 via at least one base hole 1429 (see FIG. 13). As shown in FIG. 13, the base hole 1429 may be positioned proximate to the radially outer edge of the base 1412. This allows air 1428 to enter the cartridge proximate to the inner surface of the outer body 1426, as shown in FIG. 14. Air 1428 may flow around and partially through the combined dispenser / atomizer assembly 1418 between the bubble jet head 1450 and the atomizer 1452 (see FIG. 13).

[0115] When the flow sensor 1411 detects inhalation, the combined dispenser / nebulizer assembly 1418 may be triggered such that the bubble jet head 1450 ejects the aerosol precursor composition from the reservoir 1420 towards the nebulizer 1452 (see FIG. 13). While the above configuration of the flow of at least a portion of the air 1428 through the combined dispenser / nebulizer assembly 1418 may result in the aerosol precursor composition being ejected into the air 1428 stream prior to nebulization, the base hole 1429 may be used to adjust the flow of air through the combined dispenser / nebulizer assembly such that substantially all of the aerosol precursor composition is entrained in the air in liquid form and then may contact the nebulizer 1452 (see FIG. 13) and be nebulized, rather than potentially separating from the air. Further, a portion of the air 1428 can flow around, rather than through, the combined dispenser / atomizer assembly 1418 such that the air flow can be distributed over a relatively large area, thereby defining a relatively low velocity through the combined dispenser / atomizer assembly that may not significantly affect the dispensing of the aerosol precursor composition onto the atomizer 1452 (see FIG. 13). Additionally, the flexible circuit 1453 and / or the bubble jet head 1450 and atomizer 1452 housing can define a vaporization chamber that further resists directing the aerosol precursor composition into the air 1428 flow without being atomized. In some embodiments, the atomizer can be moved downstream of the bubble jet head to account for the movement of the aerosol precursor composition caused by the air flow. After atomization, the air and vapor can move around the reservoir 1422 and out the mouthpiece 1424 to the user. It should be noted that embodiments of the aerosol delivery device including a flex circuit can be configured to avoid problems associated with the liquid aerosol precursor composition being entrained in the air rather than vaporized. In this regard, for example, the bubble jet head and the nebulizer can be spaced relatively close to one another, and the nebulizer can be heated to a temperature such that the aerosol precursor composition can be nebulized without contacting the nebulizer.

[0116] As described above, the flexible circuit 1453 may be used to establish mechanical and electrical connections between the bubble jet head 1450 and the sprayer 1452 of the combined dispenser / sprayer assembly 1418. However, the flexible circuit 1453 may also be configured to electrically connect the combined dispenser / sprayer assembly 1418 and the power source 1410 within the cartridge through the connector 1412 and the base 1416. In this regard, the combined dispenser / sprayer assemblies of various other embodiments may be electrically connected to one or more other components of the aerosol delivery device via the flexible circuit.

[0117] For example, Figure 15 shows a partial cross-sectional view of an embodiment of an aerosol delivery device 1400' that is substantially similar to the aerosol delivery device 1400 of Figures 12-14. However, as shown, the aerosol delivery device 1400' of Figure 15 may include a combined dispenser / atomizer assembly 1418' that includes a shared wafer, substrate, or housing 1433' in which both the bubble jet head and the atomizer are housed. In this respect, for example, the combined dispenser / atomizer assembly 1418' of Figure 15 may be substantially similar to the combined dispenser / atomizer assembly 1318 of Figure 9. In this embodiment, a flexible circuit 1453 may be used to provide electrical connections to the combined dispenser / atomizer assembly, regardless of whether the bubble jet head and the atomizer are located in separate housings or a shared housing. It should also be noted that the use of a combined dispenser / sprayer assembly 1418' including a bubble jet head and sprayer in a shared housing 1433' that is impermeable to flowing air can avoid any problems associated with the liquid precursor composition being transported by the air flow without spraying.

[0118] 16 illustrates a cross-sectional view through an aerosol delivery device 1500 according to an additional exemplary embodiment of the present disclosure. As shown, the aerosol delivery device 1500 can include a control body 1502 and a cartridge 1504, shown in a separated configuration. In this regard, a base 1516 of the cartridge 1504 can be configured to engage a coupler 1512 of the control body 1502 to form a mechanical and electrical connection therebetween, which can be releasable to allow replacement of the cartridge.

[0119] The control 1502 may include an end cap 1506, a circuit board with an indicator 1508 (e.g., a light emitting diode (LED)), a connector circuit 1509, a power source 1510 (e.g., a battery, which may be rechargeable), a flow sensor 1511 (e.g., an inhalation sensor or pressure switch), a coupler 1512, wiring 1513, and an outer body 1514. The cartridge 1504 may include a base 1516, a combined dispenser / atomizer assembly 1518, a reservoir 1520, a mouthpiece 1524, an insulator 1555, and an outer body 1526. In the embodiment shown, the coupler 1516 defines a lid 1522 that seals the reservoir 1520. In this regard, sealing one end of the reservoir 1520 with the coupler 1516 may simplify assembly of the cartridge 1504. However, in other embodiments, the lid may include a separate component from the coupler.

[0120] 17 shows an enlarged partial cross-sectional view of an aerosol delivery device 1500 in which a controller 1502 and a cartridge 1504 are coupled to one another. As shown, a combined dispenser / nebulizer assembly 1518 can include a bubble jet head 1550 and a nebulizer 1552, which can be fixedly coupled to one another (e.g., by one or more spacers). The bubble jet head 1550 and the nebulizer 1552 can include any of the bubble jet head and nebulizer components and features described elsewhere herein.

[0121] 17 further illustrates the flow path of air through the aerosol delivery device 1500 when a user inhales on the mouthpiece 1524. As shown, airflow, i.e., a flow of ambient air 1528, enters the aerosol delivery device 1500 through one or more inlet holes 1531, which may be defined in the outer body 1514 of the control body 1502, and may travel past or proximate to the flow sensor 1511. Air 1528 can flow from the control body 1502, through at least one connector hole 1561 defined in the connector 1512, through one or more base holes 1529 defined in the base 1516 of the cartridge 1504, around the reservoir 1520 (e.g., through one or more air delivery channels 1565 defined in the outer body 1526 or between the reservoir and the outer body), around and partially through the combined dispenser / sprayer assembly 1518, and out the mouthpiece 1524.

[0122] As a result of this configuration, some or all of the air 1528 can flow laterally throughout the cartridge 1504, through the combined dispenser / nebulizer assembly 1518, and between the bubble jet head 1550 and the nebulizer 1552. When the flow sensor 1511 detects inhalation, the combined dispenser / nebulizer assembly 1518 can be actuated such that the bubble jet head 1550 ejects the aerosol precursor composition from the reservoir 1520 toward the nebulizer 1552.

[0123] While the above configuration of at least a portion of the flow of air 1528 through the combined dispenser / sprayer assembly 1518 may result in the aerosol precursor composition being exhausted into the flow of air 1528 prior to spraying, the use of one or more base holes 1529 may adjust the flow of air through the combined dispenser / sprayer assembly such that substantially all of the aerosol precursor composition may be entrained in liquid form with the air and then contacted and sprayed by the sprayer 1552 (see FIG. 13 ) rather than potentially separating from the air. Additionally, a portion of the air 1528 may flow around, rather than through, the combined dispenser / sprayer assembly 1518 such that the flow of air may be distributed over a relatively large area, thereby defining a relatively low velocity through which the flow of air through the combined dispenser / sprayer assembly may not affect to any significant extent the dispensing of the aerosol precursor composition onto the sprayer 1552 (see FIG. 13 ). Additionally, as described above, one or more spacers and / or the housing of the bubble jet head 1550 and the nebulizer 1552 may define a vaporization chamber that further resists directing the aerosol precursor composition into the stream of air 1528 without being nebulized, and / or the nebulizer may be positioned downstream of the bubble jet head to account for movement of the aerosol precursor composition caused by the air stream. After nebulization, the air and vapor may travel around the reservoir 1522 and out the mouthpiece 1524 to the user.

[0124] It should be noted that in the aerosol delivery devices 1200, 1300, 1400 of Figures 2-15, the reservoir is located between the mouthpiece and the combined dispenser / atomizer assembly, which may include a bubble jet head and an atomizer. This configuration may be desirable in that it positions the atomizer distally from the mouthpiece so that the user's mouth does not come into contact with the heated surface. In contrast, the combined dispenser / atomizer assembly 1518 of the aerosol delivery device 1500 of Figures 16 and 17 is located between the reservoir 1520 and the mouthpiece 1524. This configuration may be preferable in that the aerosol generated by the atomizer may only have to travel a relatively short distance to the mouthpiece 1524, such that the possibility of the aerosol precursor composition condensing and exiting the air 1528 after vaporization is reduced. 16, the aerosol delivery device 1500 may further include an insulator 1555 to keep the mouthpiece 1524 and / or the outer body 1526 cool to the touch in areas that a user may contact with their lips. The insulator 1555 may include any embodiment of an insulating material such as a plastic, fiberglass, or phenolic material. Additionally, the insulator 1555 may be positioned proximate to or define one or both of the outer body 1526 and the mouthpiece 1524, or a portion thereof.

[0125] 18 illustrates a cross-sectional view through an aerosol delivery device 1600 according to an additional exemplary embodiment of the present disclosure. As shown, the aerosol delivery device 1600 can include a control body 1602 and a cartridge 1604, shown in a coupled configuration. In this regard, a base 1616 of the cartridge 1604 can be configured to engage a coupler 1612 of the control body 1602 to form a mechanical and electrical connection therebetween, which can be releasable to allow replacement of the cartridge.

[0126] The control 1602 may include an end cap 1606, a circuit board with an indicator 1608 (e.g., a light emitting diode (LED)), a connector circuit 1609, a power source 1610 (e.g., a battery, which may be rechargeable), a flow sensor 1611 (e.g., an inhalation sensor or pressure switch), a coupler 1612, wiring 1613, and an outer body 1614. The cartridge 1604 may include a base 1616, a combined dispenser / atomizer assembly 1618, a reservoir 1620, a mouthpiece 1624, and an outer body 1626. In the embodiment shown, the coupler 1616 defines a lid 1622 that seals the reservoir 1620. In this regard, sealing one end of the reservoir 1620 with the coupler 1616 may simplify assembly of the cartridge 1604. However, in other embodiments, the lid may include a separate component from the coupler.

[0127] 19 shows an enlarged partial cross-sectional view of an aerosol delivery device 1600 in which a controller 1602 and a cartridge 1604 are coupled to one another. As shown, a combined dispenser / atomizer assembly 1618 can include a bubble jet head 1650 and an atomizer 1652, which can be fixedly coupled to one another (e.g., by one or more spacers 1636). The bubble jet head 1650 and the atomizer 1652 can include any of the bubble jet head and atomizer components and features described elsewhere herein.

[0128] As further shown in FIG. 18, the outer body 1614 of the control body 1602 may define one or more inlet holes 1631, and the coupler 1612 may define at least one coupler hole 1661, the base 1616, and at least one base hole 1629, which may allow airflow through the aerosol delivery device 1600. In this regard, FIG. 19 further illustrates the flow path of air through the aerosol delivery device 1600 when a user inhales on the mouthpiece 1624. As shown, airflow, i.e., a flow of ambient air 1628, may enter the aerosol delivery device 1600 through the inlet hole 1631, which may be defined in the outer body 1614 of the control body 1602, and travel past or proximate to the flow sensor 1611. Air 1628 can flow from the control body 1602, through a connector hole 1661 defined in the connector 1612, through the base 1616 of the cartridge 1604 via a base hole 1629, between the reservoir 1620 and the outer body 1626, around and partially through the combined dispenser / atomizer assembly 1618, and out the mouthpiece 1624. When the flow sensor 1611 detects inhalation, the combined dispenser / atomizer assembly 1618 can be actuated such that the bubble jet head 1650 ejects the aerosol precursor composition from the reservoir 1620 towards the atomizer 1652.

[0129] While the above configuration of the flow of at least a portion of the air 1628 through the combined dispenser / atomizer assembly 1618 may result in the aerosol precursor composition being exhausted into the flow of air 1628 prior to atomization, the use of at least one base hole 1629 may adjust the flow of air through the combined dispenser / atomizer assembly such that substantially all of the aerosol precursor composition may be entrained in the air in liquid form and then contacted and atomized by the atomizer 1652, rather than potentially separating from the air. Additionally, a portion of the air 1628 may flow around, rather than through, the combined dispenser / atomizer assembly 1618 such that the flow of air may be distributed over a relatively large area, thereby defining a relatively low velocity through which the flow of air through the combined dispenser / atomizer assembly may not affect to any significant extent the dispensing of the aerosol precursor composition onto the atomizer 1652. Additionally, as described above, the spacer 1636 and / or the bubble jet head 1650 and vaporizer 1652 housing may define a vaporization chamber that further resists directing the aerosol precursor composition into the air 1628 stream without being atomized, and / or the vaporizer may be positioned downstream of the bubble jet head to account for movement of the aerosol precursor composition caused by the air stream. After atomization, the air and vapor may travel around the reservoir 1620 and out the mouthpiece 1624 to the user.

[0130] 18 and 19, the combined dispenser / atomizer assembly may be positioned proximal to the mouthpiece 1624, which may provide benefits in terms of avoiding condensation of vaporized aerosol precursor condensate within the aerosol delivery device, as described above. As further described above, insulation may be used proximal to the mouthpiece to reduce the amount of heat transferred to the user's lips. As further shown in FIG. 19, in some embodiments, the combined dispenser / atomizer assembly 1618 may be coupled to a side 1655 of the reservoir 1620. This configuration may allow for a substantially longitudinal flow through the combined dispenser / atomizer assembly 1618 to the mouthpiece 1624. In this regard, the heating surface of the nebulizer 1652 (e.g., comprising the outer surface of the vaporizing heating element described above) and the exhaust surface of the bubble jet head 1650 (e.g., comprising the precursor nozzle) may be oriented substantially parallel to the longitudinal axis of the outer body 1626 of the cartridge 1604 and the longitudinal axis of the aerosol delivery device 1600 as a whole. This allows a flow of air 1628 to occur between the parallel planes defined by the bubble jet head 1650 and the nebulizer 1652 such that the flow of air and aerosol may proceed in a substantially linear manner to the mouthpiece 1624.

[0131] In contrast, the embodiments of the aerosol delivery devices 1200, 1300, 1400, 1500 described above include embodiments of the combined dispenser / nebulizer assembly in which the heating surface of the nebulizer and the discharge surface of the bubble jet head are attached to the distal end of the reservoir in a manner that is oriented substantially perpendicular to the outer body of the cartridge and the longitudinal axis of the aerosol delivery device as a whole. Although attaching the combined dispenser / nebulizer assembly to the distal end of the reservoir provides a simplified configuration of the aerosol delivery device, this configuration may result in a non-linear airflow path through the aerosol delivery device. For example, as shown in FIG. 14, when the bubble jet head and the nebulizer are oriented perpendicular to the longitudinal axis of the aerosol delivery device, the air may make one or more sharp turns to enter and / or exit the combined dispenser / nebulizer assembly. These sharp turns may unnecessarily increase the pressure drop associated with the use of the aerosol delivery device, which may result in a relatively greater effort being required to inhale it. Furthermore, sharp turns in the airflow path or downstream of the combined dispenser / atomizer assembly can be detrimental in that such changes can cause the aerosol to condense back into liquid form as a result of impacting with surrounding structures within the aerosol delivery device (e.g., the outer body of the cartridge). It may therefore be desirable to use an airflow path that is generally oriented parallel to the longitudinal axis of the cartridge and does not include sharp turns. In this regard, the aerosol delivery device 1600 shown in Figures 18 and 19 is configured to avoid the above problems. However, it is also noted that using a bubble jet head and atomizer oriented such that their respective discharge and heating surfaces are substantially perpendicular to the longitudinal axis of the cartridge, as described in the embodiment of the aerosol delivery device of Figures 2-17, can be desirable in that such a configuration can define a relatively slower airflow flowing therethrough, which can result in improved atomization of the aerosol precursor composition.

[0132] Although the bubble jet head and nebulizer of the aerosol delivery device of Figures 18 and 19 are shown as configured with their respective ejection and heating surfaces oriented substantially parallel to the longitudinal axis of the cartridge and the aerosol delivery device as a whole, certain embodiments of an aerosol delivery device including a bubble jet head and nebulizer in which the respective ejection and heating surfaces are oriented at a non-zero angle relative to the longitudinal axis of the outer body may still provide many of the benefits described above with respect to the aerosol delivery device 1600 of Figures 18 and 19. In this regard, Figure 20 shows a partial schematic view of an aerosol delivery device 1700 including a combined dispenser / nebulizer assembly 1718 in which the respective ejection and heating surfaces of the bubble jet head 1750 and nebulizer 1752 of the device are oriented at a non-zero angle relative to the longitudinal axis 1770 of the aerosol delivery device. However, the angles between these surfaces and the longitudinal axis 1770 are relatively small (e.g., less than about 45 degrees) such that the pressure drop caused by turns in the flow path of the air 1728 before it exits the mouthpiece 1724 is reduced as compared to otherwise similar embodiments of an aerosol delivery device that define sharper turns in the flow path. Additionally, the relatively small angles between the exhaust and heating surfaces of the bubble jet head 1750 and the atomizer 1752 and the longitudinal axis 1770 may also help to avoid problems with vaporization and condensation of the aerosol after introduction into the air 1728 flow, since the air and aerosol leaving the combined dispenser / atomizer assembly can exit therefrom smoothly without making sharp turns.

[0133] 21 illustrates a cross-sectional view through an aerosol delivery device 1800 according to an additional exemplary embodiment of the present disclosure. As shown, the aerosol delivery device 1800 can include a control body 1802 and a cartridge 1804, shown in a coupled configuration. In this regard, a base 1816 of the cartridge 1804 can be configured to engage a coupler 1812 of the control body 1802 to form a mechanical and electrical connection therebetween, which can be releasable to allow replacement of the cartridge.

[0134] The control 1802 may include an end cap 1806, a circuit board with an indicator 1808 (e.g., a light emitting diode (LED)), a connector circuit 1809, a power source 1810 (e.g., a battery, which may be rechargeable), a flow sensor 1811 (e.g., an inhalation sensor or pressure switch), a coupler 1812, wiring 1813, and an outer body 1814. The cartridge 1804 may include a base 1816, a combined dispenser / atomizer assembly 1818, a reservoir 1820, a mouthpiece 1824, and an outer body 1826. In the embodiment shown, the coupler 1816 defines a lid 1822 that seals the reservoir 1820. In this regard, sealing one end of the reservoir 1820 with the coupler 1816 may simplify assembly of the cartridge 1804. However, in other embodiments, the lid may include a separate component from the coupler.

[0135] 22 shows an enlarged partial cross-sectional view of an aerosol delivery device 1800 in which a controller 1802 and a cartridge 1804 are coupled to one another. As shown, a combined dispenser / atomizer assembly 1818 can include a bubble jet head 1850 and an atomizer 1852, which can be fixedly coupled to one another (e.g., by one or more spacers 1836). The bubble jet head 1850 and the atomizer 1852 can include any of the bubble jet head and atomizer components and features described elsewhere herein.

[0136] 21 and 22 further illustrate the flow path of air through the aerosol delivery device 1800 when a user draws on the mouthpiece 1824. As shown in FIG. 21, airflow or flow of ambient air 1828 may enter the aerosol delivery device 1800 through one or more inlet holes 1831, which may be defined in the outer body 1814 of the control body 1802, and may travel past or proximate to the flow sensor 1811. As shown in FIG. 22, the air 1828 may flow from the control body 1802, through a coupler inlet 1861 defined in the coupler 1812, into the base 1816 of the cartridge 1804, through the reservoir 1820, through the combined dispenser / atomizer assembly 1818, and out the mouthpiece 1824.

[0137] Specifically, air 1828 may travel through the base 1816 via at least one base hole 1829. Additionally, the reservoir 1820 may define a channel 1854 extending therethrough. In this regard, the reservoir 1820 may define an elongated annular configuration such that the aerosol precursor enclosed therein is separated from the channel 1854 (e.g., by an interior wall of the reservoir defining the channel). The channel 1854 may direct the flow of air 1828 to the combined dispenser / atomizer assembly 1818. In this regard, the bubble jet head 1850 may include an airflow hole 1856, and the atomizer 1852 may include an aerosol delivery hole 1858 configured to direct the flow of air 1828 therethrough. In the embodiment shown, the base holes 1829, the channels 1854 through the reservoir 1820, the airflow holes 1856 through the bubble jet head 1850, and the aerosol delivery holes 1858 through the atomizer 1852 are linearly aligned along a longitudinal axis extending through the cartridge 1804 such that the flow of air 1828 travels along a substantially linear path, thereby avoiding problems with increasing the pressure drop of the aerosol delivery device 1800 and causing condensation. The aerosol delivery device 1800 may be further configured to avoid the creation of condensation as a result of the combined dispenser / atomizer assembly 1818 being positioned between the reservoir 1820 and the mouthpiece 1824. As described above, insulation may be used to reduce heat transfer to the mouthpiece and outer body.

[0138] 23 shows a schematic close-up exploded view of the proximal cartridge 1804 of the combined dispenser / sprayer assembly 1818. As shown, the reservoir 1820, bubble jet head 1850, and sprayer 1852 may be configured to dispense and spray the aerosol precursor composition in a radial or annular manner. In this regard, as shown generally, the precursor inlet, precursor channel, exhaust heating element, and / or precursor nozzle of the bubble jet head 1850 may be positioned annularly at a plurality of radial positions 1860 about an airflow hole 1856 extending through the bubble jet head. Similarly, the vaporization heating element 1862 of the sprayer 1852 may extend substantially radially and annularly about an aerosol delivery hole 1858 extending through the sprayer. This configuration may allow the aerosol precursor composition to be dispensed and sprayed around, rather than in, the positive flow of air 1828 through the aerosol delivery device 1800 to avoid introducing liquid aerosol precursor composition into the airflow. This configuration can also promote a substantially linear flow of air 1828 so as to combine the benefits of the aerosol delivery devices described above.

[0139] In the embodiments of the aerosol delivery device described above, the nebulizer is generally described as defining a substantially planar heating surface on which the vaporization heating element(s) are positioned. In this regard, the bubble jet head defines an ejection surface on which the precursor nozzle is positioned, which is also generally planar and parallel to the heating surface of the nebulizer. This causes the bubble jet head to eject the aerosol precursor composition substantially perpendicular to the heating surface of the nebulizer. However, various other configurations of the nebulizer may be used.

[0140] For example, Figure 24 shows a nebulizer 1900 according to an alternative embodiment of the present disclosure. The nebulizer 1900 may be used in conjunction with any of the combined dispenser / nebulizer assemblies described elsewhere herein. For example, the nebulizer 1900 may be used in place of the nebulizer 1852 of the combined dispenser / nebulizer assembly 1818 of the aerosol delivery device of Figures 21-23.

[0141] As shown, the nebulizer 1900 can include an inner heated surface 1902 that is non-planar. Specifically, the nebulizer 1900 and the nebulizer inner heated surface 1902 can be substantially conical (e.g., defining a hollow frusto-conical configuration as shown). In this regard, the nebulizer 1900 can be configured to receive a flow 1904 of air and aerosol precursor composition therethrough such that the nebulizer inner heated surface 1902 receives the flow 1904 of air and aerosol precursor composition thereover.

[0142] This allows the heated surface 1902 to atomize the aerosol precursor composition. For example, multiple vaporizing heating elements 1906 may be positioned on the inner heated surface 1902. By way of further example, in some embodiments, the heating elements may be arranged in a spiral on the inner heated surface 1902. This configuration may advantageously contact a majority of the aerosol precursor composition that is directed through the nebulizer 1900. This allows a flow of air and aerosol 1908 to exit the nebulizer 1900.

[0143] FIG. 25 illustrates an alternative embodiment of a nebulizer 2000 that may be used in place of the nebulizer 1852 of the combined dispenser / nebulizer assembly 1818 of the aerosol delivery device of FIGS. 21-23. The nebulizer 2000 may include an outer heating surface 2002. As shown, in addition to the outer heating surface 2002, the nebulizer 2000 as a whole may define a substantially conical configuration. In this embodiment, a stream 2004 of air and aerosol precursor composition may be directed toward a narrow end of the nebulizer 2000. This allows the aerosol precursor composition to be vaporized by one or more vaporizing heating elements 2006 positioned on the outer heating surface 2002 to generate a stream 2008 of air and aerosol. The vaporizing heating elements 2006 may be arranged in a spiral on the outer heating surface 2002 to advantageously heat and vaporize the aerosol precursor composition.

[0144] It should also be noted that while the use of multiple evaporative heating elements 1906, 2006 has been generally described above, in other embodiments, a single evaporative heating element may be used. For example, the evaporative heating element may comprise a single continuous embedded or printed filament in the heating surface. As a further example, the single continuous filament may define a helical configuration as described above (e.g., on the inner heating surface in the sprayer shown in FIG. 24 or on the outer heating surface in the sprayer shown in FIG. 25). The use of a single continuous filament in the evaporative heating element may be preferred in that it may simplify the construction of the sprayer.

[0145] Thus, in some embodiments, the heated surface of the nebulizer may define a non-planar configuration. The use of a nebulizer including a non-planar heated surface may enable a variety of alternative flow configurations through the aerosol delivery device. Specifically, the substantially conical nebulizers of Figs. 24 and 25 may each be configured to focus and distribute air and aerosol while still providing a substantially straight airflow path with minimal pressure drop associated with inhalation in the aerosol delivery device. In these and other embodiments of the combined dispenser / nebulizer, the bubble jet head may direct the aerosol precursor composition at a non-perpendicular angle to the heated surface of the nebulizer. By avoiding directing the aerosol precursor composition perpendicular to the heated surface of the nebulizer, problems with splashing of the aerosol precursor composition may be avoided. In this regard, the splashed aerosol precursor composition may be deflected back toward the bubble jet head, which may clog the bubble jet head. 24 embodiment of the atomizer 1900, any splattered aerosol precursor composition may be retained within the atomizer and contact another portion of the inner heated surface 1902 such that the splattered aerosol precursor is still vaporized due to the inner heated surface of the atomizer defining the chamber. Various other embodiments of frustoconical atomizers are described in U.S. Patent Application Serial No. 14 / 329,334 to Taluskie et al., filed July 11, 2014, which is incorporated herein by reference in its entirety.

[0146] 26 shows an exploded view of an alternative embodiment of a combined dispenser / atomizer assembly 2100 that may be included in the embodiments of the aerosol delivery device disclosed herein. As shown, the combined dispenser / atomizer assembly 2100 may include a bubble jet head 2102 and an atomizer 2104. Details regarding the bubble jet head embodiment are described above and will not be repeated in their entirety. Briefly, however, the bubble jet head 2102 may include a wafer, substrate, or receptacle 2106 that may define at least one precursor inlet 2108 (see FIG. 27) configured to receive an aerosol precursor composition from a reservoir, and at least one precursor nozzle 2110 configured to dispense the aerosol precursor composition to the atomizer 2104.

[0147] Further, the sprayer 2104 may comprise a wafer, substrate, or housing 2112. Additionally, as shown, in some embodiments, the sprayer 2104 may further comprise a strengthening member 2114. The strengthening member 2114 may be configured to support and provide structural stability to the housing 2112 of the sprayer 2104. For example, as shown in FIG. 27, the strengthening member 2114 may be coupled to the housing 2112 of the sprayer 2104 such that the housing is supported. Specifically, the strengthening member 2114 may be coupled to a back surface of the housing 2112, and the at least one evaporative heating element 2116 is coupled to an opposing front surface of the housing.

[0148] In this regard, the reinforcing member may be configured to provide rigidity, support, and structure to the nebulizer 2014 without substantially increasing the thermal mass of the nebulizer. It may be desirable to provide a nebulizer 2104 with a relatively low thermal mass such that the nebulizer may rapidly heat up to a temperature sufficient to vaporize the aerosol precursor composition upon application of an electric current thereto. Thus, the nebulizer 2104 may heat up rapidly when a user draws on the associated aerosol delivery device.

[0149] Positioning the reinforcing member 2114 opposite the vaporizing heating element 2116 allows the reinforcing member to avoid direct contact with the heating element, reducing heat transfer to the reinforcing member. Additionally, as shown in FIG. 26, the reinforcing member 2114 may define a cutout 2118. The cutout 2118 may further reduce the thermal mass of the sprayer 2104 while still allowing the reinforcing member 2114 to provide improved strength to the sprayer. In this regard, the cutout may be centrally positioned such that the reinforcing member defines a frame that extends around the outer edge of the housing 2112. This configuration results in only a relatively small loss of the moment of inertia of the reinforcing member 2114 while also positioning its mass away from the vaporizing heating element 2116, further reducing heat transfer to the reinforcing member. Additionally, the reinforcing member 2114 may include plastic, ceramic, glass, or other embodiments of insulating and non-conductive materials configured to avoid thermal and electrical transfer to the material.

[0150] As shown in FIG. 27, the sprayer 2104 may further comprise one or more conductive pads 2120. The conductive pads 2120 may be configured to contact and conduct electrical current to the evaporative heating element 2116. However, to prevent the conductive pads 2120 from unnecessarily generating heat, the conductive pads may comprise a material and / or configuration (e.g., thicker gauge) that defines a lower resistance than the material of the evaporative heating element 2116. For example, the conductive pads 2120 may comprise silver-palladium and the evaporative heating element 2116 may comprise platinum. As a further example, in some embodiments, the conductive pads 2120 may comprise silver-palladium and the evaporative heating element 2116 may comprise a silver-palladium compound that defines a relatively greater resistance. However, as may be appreciated, a variety of other materials may be used in other embodiments, including, for example, gold, silver, platinum, palladium, tungsten, and combinations thereof. The materials defining the conductive pads and the vaporizing heating element may be selected to define a desired resistance as well as suitable bonding characteristics with respect to other portions of the housing and / or vaporizer.

[0151] In some embodiments, the sprayer 2104 can be configured to fixedly engage the bubble jet head 2102 via the post 2103 (see FIG. 27). In this regard, as shown in FIG. 26, the housing 2112 and / or the reinforcing member 2114 can define recesses 2122a, 2122b configured to engage the post 2103. In some embodiments, the post 2103 can electrically couple the bubble jet head 2102 to the sprayer 2104. Thus, for example, the conductive pad 2120 can be positioned proximate to the recesses 2122a, 2122b defined in the sprayer 2104 such that an electrical connection can be established therebetween.

[0152] As noted above, it may be desirable to avoid splashing of the aerosol precursor composition dispensed onto the nebulizer. Accordingly, embodiments of the aerosol delivery device of the present disclosure may include additional or alternative features configured to mitigate splashing of the aerosol precursor composition and to perform other functions. In this regard, Figures 28A-C show enlarged partial views of an embodiment of the nebulizer 2104 of Figures 26 and 27 in which the heated surface of the nebulizer is textured rather than smooth. However, it should be noted that such texturing may be used in any of the nebulizers described herein.

[0153] Specifically, FIG. 28A illustrates an embodiment of a sprayer 2104A in which the heated surface 2124A is perforated. In other words, the heated surface 2124A defines a substantially regular pattern of protrusions and recesses. FIG. 28B illustrates an embodiment of a sprayer 2104B in which the heated surface 2124B is partially porous. In this regard, the topography of the heated surface 2124B may be substantially similar to the topography of a closed-cell foam. FIG. 28C illustrates an embodiment of a sprayer 2104C in which the heated surface 2124C is completely porous. In this regard, the topography of the heated surface 2102C may be substantially similar to the topography of an open-cell foam or sintered material.

[0154] In some embodiments, the heating surfaces 2124A-C may be defined by or coated with a passivation layer positioned on its exterior surface (e.g., on top of the housing 2112 and the vaporizing heating element 2116). In this regard, the passivation layer is configured to prevent oxidation, catalytic reactions, and various other chemical reactions from occurring in the vaporizer when the aerosol precursor composition 2128 is dispensed thereon. For example, the passivation layer may include aluminum oxide, glass, or a ceramic material that may be splashed or otherwise deposited onto the housing 2112 and the vaporizing heating element 2116.

[0155] The use of a textured heated surface can reduce the aerosol precursor composition's tendency to splatter due to the textured heated surface capturing stray aerosol precursor composition such that it is less likely to stray back to the bubble jet head. Additionally, the use of a textured heated surface can increase the effective area of ​​the heated surface over which the aerosol precursor composition is directed. In this way, heat can be transferred to the aerosol precursor composition more efficiently, improving the vaporization of the aerosol precursor composition.

[0156] In some embodiments, the heating surface may include a wicking or absorbing layer, which may optionally define a textured surface and may be configured to reduce splashback and heat loss, and perform other functions described below. The absorbing layer, which may include alumina paper in some embodiments, may be positioned outside the passivation layer and configured to receive the aerosol precursor composition. This may allow the aerosol precursor composition to saturate the layer as heat is applied to the aerosol precursor composition absorbed within the absorbing layer. In this embodiment, the bubble jet head may replenish the aerosol precursor composition within the absorbing layer as it is vaporized. In this regard, the absorbing layer may be at least partially saturated with the aerosol precursor composition before it is subjected to the suction of the aerosol delivery device, such that the aerosol may be generated more rapidly.

[0157] Although certain embodiments of the atomizer are described above, it should be noted that various other embodiments of the atomizer may be used to vaporize the aerosol precursor composition in the embodiments of the aerosol delivery device provided herein. Such atomizers may include areal heaters, wire-wound surfaces, microheaters (e.g., embedded on a chip), glass plates, lasers, resistive heaters, and heaters of any other shape and embodiment. For example, in one embodiment, a vaporization heating element may be associated with each precursor nozzle and each exhaust heating element of the bubble jet head, respectively. However, in other embodiments, multiple precursor nozzles and multiple exhaust heating elements (e.g., all of the precursor nozzles and exhaust heating elements of the bubble jet head) may exhaust the aerosol precursor composition onto a single vaporization heating element to vaporize the aerosol precursor composition. Furthermore, the materials used in the exhaust heating element and the vaporization heating element may be different. For example, the materials described above with respect to the wire coil heating element may be used. Various other materials that may be used in the exhaust heating element and the vaporization heating element, as well as the various other heating elements described herein, may include platinum or platinum coated materials, and resistive inks (e.g., printed on ceramic materials).

[0158] In another embodiment, the housing of one or both of the bubble jet head and the nebulizer may comprise a silicon chip. In this embodiment, one or both of the vaporization heating element and the exhaust heating element may comprise doped silicon of the silicon chip. In other words, a portion of the silicon chip may define a resistive circuit configured to generate heat for exhausting or vaporizing the aerosol precursor composition.

[0159] In an embodiment of an aerosol delivery device that includes a bubble jet head, it may be desirable to reduce the viscosity of the aerosol precursor composition to facilitate dispensing of droplets of the aerosol precursor composition, as described above. Thus, in one embodiment, the aerosol precursor composition may be preheated. For example, the aerosol precursor composition may be preheated using an exhaust heating element prior to heating the aerosol precursor composition to such an extent that vapor bubbles form and droplets of the aerosol precursor composition are expelled through the precursor nozzle. Such preheating may involve applying a pulsed current to the exhaust heating element. In this regard, a relatively smaller pulse width of power may be applied to the exhaust heating element of the bubble jet head during preheating of the aerosol precursor composition compared to the pulse width of the power applied to the exhaust heating element of the bubble jet head during dispensing of the aerosol precursor composition. In another embodiment, the aerosol precursor composition may be diluted (e.g., with water) to reduce its viscosity. Thus, the use of a bubble jet head with the aerosol precursor composition may be facilitated in either or both of these ways. In one embodiment, the viscosity of the aerosol precursor composition may initially define a range of about 5 to about 400 centipoise at 20° C. However, the viscosity of the aerosol precursor composition may be reduced through either dilution (e.g., via water) or preheating, or both, to define a viscosity of less than about 100 centipoise at 20° C. In comparison, inks used in inkjet printers may generally define a relatively lower viscosity (e.g., about 10 to about 40 centipoise at 20° C.).

[0160] In the embodiments provided herein, the combined dispenser / atomizer assembly is generally described as being located within the cartridge. However, in other embodiments, the bubble jet head and / or atomizer may be located within the control body. For example, in one embodiment, the bubble jet head may be located within the control body and configured to eject the aerosol precursor composition toward the atomizer in the cartridge. In this embodiment, the aerosol precursor composition may be directed from a reservoir in the cartridge to the bubble jet head in the control body and back to the atomizer in the cartridge. In another embodiment, the bubble jet head may be located within the cartridge and configured to eject the aerosol precursor composition from a reservoir in the cartridge toward the atomizer in the control body.

[0161] 29 illustrates an alternative embodiment of the aerosol delivery device 2200 in which the combined dispenser / atomizer assembly is positioned within a control body. As shown, the aerosol delivery device 2200 may include a control body 2202 and a cartridge 2204, which are shown in a separated configuration. In this regard, a base 2216 of the cartridge 2204 may be configured to engage a coupler 2212 of the control body 2202 to form a mechanical and electrical connection therebetween, which may be releasable to allow replacement of the cartridge.

[0162] The control body 2202 may include an end cap 2206, a circuit board with an indicator 2208 (e.g., a light emitting diode (LED)), a connector circuit 2209, a power source 2210 (e.g., a battery, which may be rechargeable), a flow sensor 2211 (e.g., an inhalation sensor or pressure switch), a coupler 2212, wiring 2213, a combined dispenser / sprayer assembly 2218, and an outer body 2214. In some embodiments, the control body 2202 may further include a mounting plate 2219, and the combined dispenser / sprayer assembly 2218 may be attached between the mounting plate and the coupler 2212. In the embodiment shown, the bubble jet head 2250 of the combined dispenser / sprayer assembly 2218 may be coupled to the connector 2212, the sprayer 2252 of the combined dispenser / sprayer assembly may be coupled to the mounting plate 2219, and the bubble jet head may be coupled to the sprayer via a flexible circuit 2253.

[0163] The cartridge 2204 may include a base 2216, a reservoir 2220, a lid 2222 sealing the reservoir, a mouthpiece 2224, and an outer body 2226. When the cartridge 2204 is coupled to the control body 2202, the reservoir 2220 may be in fluid communication with the bubble jet head 2250. In this regard, the reservoir 2220 may define an outlet 2256. In some embodiments, the base 2216 may also define an outlet 2258 that may align with the outlet 2256 to the reservoir 2220. One or both of the outlets 2256, 2258 may be initially sealed to retain the aerosol precursor composition within the reservoir 2220. In this regard, by way of example, a foil or plastic seal may cover the outlets 2256, 2258. However, when the base 2216 of the cartridge 2204 is engaged with the coupler 2212 of the control body 2202, the seal may be broken (e.g., by piercing the seal). This allows the bubble jet head 2250 to be positioned proximal to the coupler 2212, such that the bubble jet head can receive the aerosol precursor composition transported from the reservoir 2220 through the outlets 2256, 2258 and through the inlet 2260 at the coupler. This allows the bubble jet head 2250 to dispense the aerosol precursor composition to the nebulizer 2252 to generate an aerosol. Air flow may enter through one or more inlet holes 2262 in the outer body 2214 of the control body 2202, travel through the mounting plate holes 2261 defined in the mounting plate 2219, and travel through and / or around the combined dispenser / nebulizer assembly 2218. The combined air and aerosol can thereby be directed through the connector hole 2267 defined in the connector 2212, the base hole 2263 defined in the base 2216, and through the aerosol delivery hole 2265 defined in the outer body 2226 (or between the reservoir and the outer body) to the mouthpiece 2224.

[0164] 30 illustrates an alternative embodiment of the aerosol delivery device 2300 in which the combined dispenser / sprayer assembly is positioned within a separate dispenser / sprayer body. As shown, the aerosol delivery device 2200 may include a controller 2302, a dispenser / sprayer cartridge 2303, and a reservoir cartridge 2304, shown in a separate configuration. In this regard, the base 2316 of the reservoir cartridge 2304 may be configured to engage a coupler 2364 of the dispenser / sprayer cartridge 2303, and the base 2366 of the dispenser / sprayer cartridge may be configured to engage a coupler 2312 of the controller 2302 to form a mechanical and electrical connection therebetween, which may be releasable to allow replacement of the dispenser / sprayer cartridge and / or the reservoir cartridge.

[0165] The control 2302 may include an end cap 2306, a circuit board with an indicator 2308 (e.g., a light emitting diode (LED)), a connector circuit 2309, a power source 2310 (e.g., a battery, which may be rechargeable), a flow sensor 2311 (e.g., an inhalation sensor or pressure switch), a coupler 2312, and wiring 2313. The dispenser / sprayer cartridge 2303 may include an outer body 2371, a base 2366, a coupler 2364, and a combined dispenser / sprayer assembly 2318. As shown, in one embodiment, the combined dispenser / sprayer assembly 2318 may be positioned between and coupled to the base 2366 and the coupler 2364. Specifically, the combined dispenser / sprayer assembly 2318 may include a bubble jet head 2350 and a sprayer 2352, which may be connected via a flexible circuit 2353. In one embodiment, the bubble jet head 2350 may be attached to a coupler 2364 and the sprayer 2352 may be attached to a base 2366 of the dispenser / sprayer cartridge 2303 .

[0166] The reservoir cartridge 2304 may include a base 2316, a reservoir 2320, a lid 2322 sealing the reservoir, a mouthpiece 2324, and an outer body 2326. When the reservoir cartridge 2304 is coupled to the dispenser / atomizer cartridge 2303, the reservoir 2320 may be in fluid communication with the bubble jet head 2350. In this regard, the reservoir 2320 may define an outlet 2356. In some embodiments, the base 2316 of the reservoir cartridge 2304 may also define an outlet 2358 that may align with the outlet 2356 to the reservoir. One or both of the outlets 2356, 2358 may be initially sealed to retain the aerosol precursor composition within the reservoir 2320. In this regard, by way of example, a foil or plastic seal may cover the outlets 2356, 2358. However, when the base 2316 of the reservoir cartridge 2304 is engaged with the connector 2364 of the dispenser / atomizer cartridge 2303, the seal may be broken (e.g., by piercing the seal), thereby positioning the bubble jet head 2350 proximate the connector 2364 of the dispenser / atomizer cartridge 2303 such that the bubble jet head can receive the aerosol precursor composition transported from the reservoir 2320 through the outlets 2356, 2358 and through the inlet 2360 at the connector of the dispenser / atomizer assembly. This allows the bubble jet head 2350 to dispense the aerosol precursor composition to the atomizer 2352 to generate an aerosol.

[0167] The air flow may enter through one or more inlet holes 2362 in the outer body 2314 of the control body 2302, thereby being directed through at least one coupler hole 2361 defined in the coupler 2312 of the control body, through at least one base hole 2363 defined in the base 2366, and through and / or around the aerosol dispenser / atomizer assembly 2318. The combined air and aerosol may then travel through a coupler hole 2365 defined in the coupler 2364 of the dispenser / atomizer cartridge 2303, through a base hole 2367 defined in the base 2316 of the reservoir cartridge 2304, through a vapor delivery hole 2369 defined in the outer body 2326 of the reservoir cartridge (or between the reservoir and the outer body) to the mouthpiece 2324.

[0168] Thus, various alternative location configurations can be used for the components of the aerosol delivery device described herein. As noted above, in one embodiment, the combined dispenser / sprayer assembly can be located within the control body (see, e.g., FIG. 29). This configuration can be desirable in that the combined dispenser / sprayer assembly can have a useful life that exceeds the useful life of the reservoir. However, in another embodiment, the combined dispenser / sprayer assembly can be received within a separate dispenser / sprayer cartridge (see, e.g., FIG. 30). This configuration can be desirable in that the combined dispenser / sprayer can have a useful life that exceeds the useful life of the reservoir, but the useful life of the combined dispenser / sprayer assembly can be less than the useful life of the power supply and other components of the control body, and vice versa. Furthermore, this configuration may allow for the substitution of alternative embodiments of the combined dispenser / nebulizer assembly or controller, allowing the aerosol delivery device to be customized to suit the user's preferences (e.g., by using a bubble jet head configured to generate larger or smaller amounts of aerosol per inhalation, or by using a controller with a larger battery).

[0169] In embodiments of the aerosol delivery device that include a bubble jet head, the bubble jet head has generally been described as being fixedly coupled to a nebulizer that vaporizes the aerosol precursor composition. For example, in one embodiment (see, e.g., Figures 2-6), the bubble jet head is coupled to the nebulizer via a spacer. In another embodiment (see, e.g., Figures 7-11), the bubble jet head is fixedly coupled to the nebulizer via a shared housing. In an additional embodiment, the bubble jet head is coupled to the nebulizer via a flexible circuit, and one or both of the nebulizer and bubble jet head are coupled to a structure that surrounds the combined dispenser / nebulizer assembly (see, e.g., Figures 12-15). However, in another embodiment, the bubble jet head may be separate from and aligned with the nebulizer. This allows the space between the bubble jet head and the nebulizer to be tailored for the particular design of the bubble jet head, the viscosity of the aerosol precursor composition, and various other factors.

[0170] Additionally, in some embodiments, the sprayer and / or bubble jet head may be configured to perform a cleaning cycle (e.g., by generating heat to remove residual aerosol precursor composition therefrom) either automatically (e.g., after a certain number of users) or manually when so instructed by a user. This may be particularly useful in embodiments where the bubble jet head and / or sprayer is positioned within a controller or dispenser / sprayer cartridge and is therefore configured to be reused with multiple reservoirs.

[0171] The aerosol delivery devices described herein may avoid certain problems associated with conventional aerosol delivery devices that use a wick to direct the aerosol precursor composition to the atomizer. In this regard, the use of a wick may cause separation of the components of the aerosol precursor composition. Furthermore, using a wick to transport the aerosol precursor composition from the substrate to the heating element may lead to leakage. Thus, the embodiments of the aerosol delivery devices disclosed herein may provide these and / or other advantages, including those described above with respect to superior control over the dispensed amount of the aerosol precursor composition. In addition, the bubble jet heads and atomizers described herein may require less energy to dispense and atomize the aerosol precursor composition than the fluid delivery and vaporization mechanisms of other embodiments. Furthermore, the use of the bubble jet head may allow for its customization (e.g., at the factory or by the end user). For example, the frequency and / or duration of dispensing by the bubble jet head may be adjusted to meet the preferences of the user. Thus, for example, an aerosol delivery device may be configured to vaporize a relatively smaller or larger amount of the aerosol precursor composition per inhalation on the aerosol delivery device, and such changes may be made without requiring changes to the hardware of the aerosol delivery device. In this regard, such changes may be implemented by changes to software or electronic settings.

[0172] It should be noted that although the aerosol delivery devices disclosed herein are generally described as including a cartridge (e.g., a replaceable cartridge) and a controller (e.g., a reusable controller), various other embodiments may be used. For example, in other embodiments, the aerosol delivery device may include three or more parts (e.g., as described above with reference to FIG. 30). In an additional embodiment, the aerosol delivery device may define a unitary, one-piece construction. Thus, any of the aerosol delivery devices disclosed herein may be configured within one or more outer bodies in any of a variety of ways.

[0173] Various embodiments of the nebulizer and vaporizing heating element are described herein. As can be appreciated, various other embodiments of the nebulizer and vaporizing heating element may be used in other embodiments. By way of example, in some embodiments, the nebulizer may include a coil heater that may receive the aerosol precursor composition dispensed by the bubble jet head.

[0174] Furthermore, the specific configuration of the bubble jet head relative to the atomizer may vary. For example, in one embodiment, the combined dispenser / atomizer assembly may include a housing having a first channel extending therethrough. The bubble jet head and atomizer may be coupled to either side of the first channel such that the bubble jet head may dispense the aerosol precursor composition onto the atomizer. For example, a second channel defined within the housing may supply the aerosol precursor composition to the bubble jet head. The resulting vapor may exit the housing in which the bubble jet head and atomizer are received via the first channel.

[0175] In an additional embodiment, a method for aerosolization in an aerosol delivery device is provided. As shown in Figure 31, the method may include directing an airflow from a controller with a power source through a cartridge with a reservoir in step 2402. Further, the method may include dispensing the aerosol precursor composition from the reservoir via a bubble jet head in step 2404. The method may additionally include heating the aerosol precursor composition dispensed from the reservoir by the bubble jet head in a nebulizer in step 2406.

[0176] In some embodiments of the method, dispensing the aerosol precursor composition in step 2404 and heating the aerosol precursor composition in step 2406 include independently applying power from a power source to a bubble jet head and a nebulizer. Additionally, dispensing the aerosol precursor composition in step 2404 and heating the aerosol precursor composition in step 2406 may include directing power to the nebulizer after applying power to the bubble jet head. The method may further include preheating the aerosol precursor composition with the bubble jet head prior to dispensing the aerosol precursor composition in step 2406. Additionally, the method may include detecting a temperature of the aerosol precursor composition, and preheating the aerosol precursor composition includes preheating the aerosol precursor composition to a desired temperature. Preheating the aerosol precursor composition may include applying a relatively smaller pulse width of power to the bubble jet head compared to dispensing the aerosol precursor composition.

[0177] Numerous modifications and other embodiments of the present disclosure will come to mind for those skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. It is therefore 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 have been employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A composite assembly for vaporizing an aerosol precursor composition in an aerosol delivery device, the composite assembly comprising: a plurality of walls forming a vaporization chamber configured to receive a liquid in a first portion of the composite assembly and configured to dispense a liquid to a second portion of the composite assembly where the liquid is vaporized; a bubble jet unit for transferring liquid to the vaporization chamber; A composite assembly comprising:

2. The composite assembly of claim 1 , wherein the composite assembly is coupled to a liquid reservoir that contains a liquid.

3. The composite assembly of claim 1 , wherein said first portion of said composite assembly is said bubble jet unit.

4. The composite assembly of claim 1 , wherein the first portion of the composite assembly includes one or more ejection elements.

5. The composite assembly of claim 4 , wherein the first portion of the composite assembly defines one or more liquid channels for passing liquid to a second portion of the composite assembly.

6. The composite assembly of claim 5 , wherein the one or more drainage elements are positioned within the one or more liquid channels.

7. The composite assembly of claim 4 , wherein the one or more ejection elements are configured to dispense liquid as droplets onto a second portion of the composite assembly.

8. The composite assembly of claim 7 , wherein the one or more exhaust elements comprise one or more heaters.

9. The composite assembly of claim 7 , wherein the composite assembly comprises one or more nozzles configured to pass droplets from a first portion to a second portion.

10. 7. The composite assembly of claim 6, wherein positioning of the one or more ejection elements within the one or more liquid channels has the effect of both directing liquid through the one or more liquid channels and ejecting liquid to a second portion of the composite assembly.

11. The composite assembly of claim 1 , wherein a second portion of said composite assembly defines said vaporization chamber.

12. 12. The composite assembly of claim 11, wherein the second portion of the composite assembly comprises one or more vaporization elements positioned within the vaporization chamber, the one or more vaporization elements configured to vaporize liquid dispensed from the first portion of the composite assembly.

13. The composite assembly of claim 12 , wherein the one or more vaporizing elements comprise one or more heating elements.

14. The composite assembly of claim 11 , wherein the composite assembly comprises one or more outlets from a vaporization chamber for exiting an aerosol or vapor.

15. The composite assembly of claim 1 , wherein the composite assembly comprises one or more micro-heaters.

16. The composite assembly of claim 1 , wherein the composite assembly is configured to be electrically connected to a power source.

17. The composite assembly of claim 1 , wherein the composite assembly is configured for insertion into an outer body of an aerosol delivery device.

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