Aerosol delivery device including control unit, sprayer unit, and cartridge, and related methods.

Abstract

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

Description

Technical Field

[0001] The present disclosure relates to aerosol delivery devices such as electronic cigarettes, and more particularly to aerosol delivery devices including an atomizer. The atomizer may be configured to heat an aerosol precursor composition that can be made from tobacco, derived from tobacco, or otherwise incorporate tobacco to form an inhalable substance for human intake.

Background Art

[0002] Over the years, many devices have been proposed as improved or alternative smoking products that require the combustion of tobacco for use. Many of these devices are designed to provide the sensations associated with smoking a cigarette, cigar, or pipe, but are said to deliver no significant incomplete combustion and pyrolysis products resulting from the combustion of tobacco. For this purpose, many alternative smoking products, aroma generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or provide the smoking sensation of a cigarette, cigar, or pipe without significantly burning the tobacco. See, for example, the various alternative smoking products, aerosol delivery devices, and heat sources described in the background art of Collett et al.'s U.S. Patent No. 8,881,737, Griffith Jr. et al.'s U.S. Patent Application Publication No. 2013 / 0255702, Sebastian et al.'s U.S. Patent Application Publication No. 2014 / 0,000,638, Sears et al.'s U.S. Patent Application Publication No. 2014 / 0,096,781, Ampolini et al.'s U.S. Patent Application Publication No. 2014 / 0,096,782, and Davis et al.'s U.S. Patent Application Publication No. 2015 / 0,059,780, which are hereby incorporated by reference in their entirety. Also, see, for example, the various embodiments of products and heating configurations described in the background art sections of Counts et al.'s U.S. Patent No. 5,388,594 and Robinson et al.'s U.S. Patent No. 8,079,371, which are hereby incorporated by reference in their entirety.

Prior Art Documents

Patent Documents

[0003] [Patent Document 1] U.S. Patent No. 8,881,737 [Patent Document 2] U.S. Patent Application Publication No. 2013 / 0255702 [Patent Document 3] U.S. Patent Application Publication No. 2014 / 0000638 [Patent Document 4] U.S. Patent Application Publication No. 2014 / 0096781 [Patent Document 5] U.S. Patent Application Publication No. 2014 / 0096782 [Patent Document 6] U.S. Patent Application Publication No. 2015 / 0059780 [Patent Document 7] U.S. Patent No. 5,388,594 [Patent Document 8] U.S. Patent No. 8,079,371 [Overview of the project] [Problems that the invention aims to solve]

[0004] However, it may be desirable to provide aerosol delivery devices with alternative configurations. Therefore, advances in aerosol delivery devices may be desirable. [Means for solving the problem]

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

[0006] Exemplary Implementation Embodiment 1: Aerosol delivery device comprising a cartridge comprising a control body, a sprayer body including a sprayer, and a reservoir configured to contain an aerosol precursor composition, and a valve assembly configured to distribute the aerosol precursor composition to the sprayer body when the cartridge is engaged with the sprayer body, wherein the valve assembly includes a distribution seal and a reservoir seal, the control body is configured to engage releasably with the sprayer body, the sprayer body is configured to engage releasably with the cartridge, and the sprayer is configured to receive current from the control body and receive the aerosol precursor composition from the cartridge to produce an aerosol.

[0007] Exemplary Implementation 2: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, wherein the cartridge comprises one or more airflow openings extending from the atomizer body to the mouthpiece, and the airflow openings are configured to guide aerosols through them. Exemplary Implementation 3: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, wherein at least one of the airflow openings penetrates a valve assembly. Exemplary Implementation 4: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, wherein the valve assembly defines a distribution capillary, and the valve assembly further comprises a first plate and a second plate arranged adjacent to each other with a space defined between them, and the distribution capillary extends through the first plate to the space between the first plate and the second plate. Exemplary Implementation Configuration 5: An aerosol delivery device in any of the aforementioned exemplary implementation configurations, or any combination of any of the aforementioned exemplary implementation configurations, in which a gap is defined between the radial outer edge of the first plate and the radial outer edge of the second plate and the inner surface of the reservoir.

[0008] Exemplary Implementation 6: An aerosol delivery device of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, wherein the sprayer body further comprises a nozzle configured to penetrate a reservoir seal and engage with a distribution seal. Exemplary Implementation 7: An aerosol delivery device of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, wherein the valve assembly further comprises a frame, and the reservoir seal is molded into the frame. Exemplary Implementation 8: An aerosol delivery device of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, wherein the sprayer comprises a liquid transport element comprising a porous monolith. Exemplary Implementation 9: An aerosol delivery device of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, wherein the sprayer further comprises a heating element comprising a wire at least partially embedded in the liquid transport element. Exemplary Implementation 10: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, further comprising a liquid transport element defining a tube, and a sprayer further comprising a capillary rod configured to penetrate the liquid transport element and guide an aerosol precursor composition through it. Exemplary Implementation 11: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, in which a control body further comprises a microphone, the microphone configured to detect user aspiration onto a cartridge.

[0009] Exemplary Implementation 12: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, wherein the sprayer comprises an outer body, a terminal base, a flow guide, and a liquid transport element comprising a porous monolith, and the sprayer chamber is made up of the flow guide, a terminal base, and the inner surface of the liquid transport element. Exemplary Implementation 13: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, wherein the flow guide comprises a central inlet air channel configured such that air entering through the inlet air channel is guided by a transition barrier through one or more radial inlet air holes, a transition barrier, and one or more radial inlet air holes. Exemplary Implementation 14: An aerosol delivery device of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, wherein the flow guide further comprises one or more inlet liquid flow chambers configured to deliver an aerosol precursor composition to a liquid transport element. Exemplary Implementation Configuration 15: An aerosol delivery device in any of the above-described exemplary implementation configurations, or any combination of any of the above-described exemplary implementation configurations, wherein the outer body includes one or more vapor openings, and the flow guide further includes one or more radial inlet vapor openings, one or more radial vapor channels, one or more vertical vapor openings of the flow guide, and one or more vapor openings of the outer body, so that an aerosol is guided to one or more vapor channels of a cartridge.

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

[0011] Exemplary Implementation 17: An aerosol delivery device operating method of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, further comprising: a valve assembly defining a distribution capillary, and guiding the aerosol precursor composition out of the cartridge through the valve assembly, between a first plate and a second plate positioned adjacent to each other with a defined space between them, and out of the space through a distribution capillary penetrating the first plate. Exemplary Implementation 18: An aerosol delivery device operating method of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, further comprising: guiding the aerosol precursor composition out of the cartridge through the valve assembly, and engaging the nozzle of the sprayer body with the valve assembly. Exemplary Implementation 19: An aerosol delivery device operating method of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, further comprising: engaging the nozzle with the valve assembly, and guiding the nozzle through the reservoir seal of the valve assembly. Exemplary Implementation Configuration 20: A method for operating an aerosol delivery device of any of the above-described exemplary implementation configurations, or any combination of any of the above-described exemplary implementation configurations, further comprising engaging a nozzle with a valve assembly in a distribution capillary tube with a distribution seal of the valve assembly.

[0012] Exemplary Implementation 21: An aerosol delivery device operating method of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, comprising receiving an aerosol precursor composition into a sprayer body, or guiding an aerosol precursor composition between a nozzle and a capillary rod. Exemplary Implementation 22: An aerosol delivery device operating method of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, comprising guiding an aerosol precursor composition into a sprayer within a sprayer body, or guiding an aerosol precursor composition between the capillary rod of the sprayer and a liquid transport element. Exemplary Implementation 23: An aerosol delivery device operating method of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, further comprising guiding an aerosol through one or more airflow openings penetrating a cartridge. Exemplary Implementation 24: An aerosol delivery device operating method of any of the aforementioned exemplary implementations, or any combination of any of the aforementioned exemplary implementations, comprising guiding an aerosol through one or more airflow openings penetrating a cartridge, or guiding an aerosol through a valve assembly.

[0013] Exemplary Implementation 25: An aerosol delivery device operating method of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, comprising guiding an aerosol precursor composition into a sprayer within the sprayer body through one or more radial flow openings in the outer body of the sprayer and through one or more inlet liquid channels in the flow guide of the sprayer. Exemplary Implementation 26: An aerosol delivery device operating method of any of the above-described exemplary implementations, or any combination of any of the above-described exemplary implementations, further comprising guiding an aerosol into one or more vapor channels of a cartridge through one or more radial inlet vapor holes, one or more radial vapor channels and one or more vertical vapor holes of the flow guide and one or more vapor openings of the outer body of the sprayer.

[0014] These and other features, aspects and advantages of the Disclosure will become apparent upon reading the following detailed description, along with the accompanying drawings which are briefly described below. The Disclosure includes any combination of two, three, four, or more features or elements described herein, whether such features or elements are expressly combined in the specific exemplary implementations described herein or otherwise enumerated. The Disclosure is intended to be read as a whole, i.e., as combinable, in any aspect or exemplary implementation, unless the context of the Disclosure clearly indicates otherwise.

[0015] Therefore, it will be understood that this summary is provided solely for the purpose of summarizing some exemplary implementations in order to provide a basic understanding of some aspects of this disclosure. Accordingly, it will be understood that the above exemplary implementations are merely examples and should not be construed as narrowing the scope or spirit of this disclosure. Other exemplary implementations, aspects and advantages will become apparent from the following detailed description, along with the accompanying drawings illustrating the principles of some of the described exemplary implementations.

[0016] This disclosure uses the general terminology described above, and the attached drawings will be referenced below, although these drawings are not necessarily drawn to scale. [Brief explanation of the drawing]

[0017] [Figure 1] The image shows a side view of an aerosol delivery device comprising a cartridge and a control unit in an assembled configuration according to an exemplary embodiment of the present disclosure. [Figure 2] The control unit shown in Figure 1 is shown in an exploded configuration according to an exemplary embodiment of the present disclosure. [Figure 3] The cartridge shown in Figure 1 is shown in a disassembled configuration according to an exemplary embodiment of the present disclosure. [Figure 4]A perspective view of an aerosol delivery device including a cartridge, a nebulizer body, and a control body in a separated configuration according to an exemplary embodiment of the present disclosure is shown. [Figure 5] An exploded view of the cartridge of FIG. 4 including a reservoir and a valve assembly according to an exemplary embodiment of the present disclosure is shown. [Figure 6] A perspective view of the filling of the reservoir of FIG. 5 according to an exemplary embodiment of the present disclosure is shown. [Figure 7] A perspective view of the valve assembly of FIG. 5 according to an exemplary embodiment of the present disclosure is shown. [Figure 8] An exploded view of the nebulizer body of FIG. 4 including an outer body, a nebulizer, and a coupler according to an exemplary embodiment of the present disclosure is shown. [Figure 9] An exploded view of the nebulizer of FIG. 8 according to an exemplary embodiment of the present disclosure is shown. [Figure 10] An exploded view of the coupler and terminals of the nebulizer body of FIG. 4 according to an exemplary embodiment of the present disclosure is shown. [Figure 11] A perspective view of the coupler and terminals of FIG. 10 in an assembled configuration according to an exemplary embodiment of the present disclosure is shown. [Figure 12] A partially assembled partial exploded view of a part of the nebulizer body of FIG. 4 according to an exemplary embodiment of the present disclosure is shown. [Figure 13] A modified cross-sectional view of the aerosol delivery device of FIG. 4 according to an exemplary embodiment of the present disclosure is shown. [Figure 14] A modified cross-sectional view of the aerosol delivery device of FIG. 4 in the cartridge according to an exemplary embodiment of the present disclosure is shown. [Figure 15] An enlarged view of region Z of FIG. 14 according to an exemplary embodiment of the present disclosure is shown. [Figure 16] A perspective end view of the cartridge of FIG. 4 according to an exemplary embodiment of the present disclosure is shown. [Figure 17] A schematic illustration of a method of operating an aerosol delivery device according to an exemplary embodiment of the present disclosure is shown. [Figure 18] A cartridge and a nebulizer are shown according to an additional exemplary embodiment of the present disclosure. [Figure 19] Figure 18 shows the sprayer in an assembled configuration according to an exemplary embodiment of the present disclosure. [Figure 20] Figure 18 shows the sprayer in an exploded configuration according to an exemplary embodiment of the present disclosure. [Figure 21] An exemplary embodiment of the present disclosure shows a cartridge for use with the sprayer shown in Figure 18. [Figure 22] Figure 21 shows a bottom view of the cartridge according to an exemplary embodiment of the present disclosure. [Figure 23] The liquid transport element and heating element for use with the sprayer shown in Figure 18 are shown according to exemplary embodiments of the present disclosure. [Figure 24] An exemplary embodiment of the present disclosure shows a flow guide for use with the sprayer shown in Figure 18. [Figure 25] Figure 24 shows a cross-sectional view of a flow guide according to an exemplary embodiment of the present disclosure. [Figure 26] Figure 18 shows a partial cross-sectional view of the sprayer according to an exemplary embodiment of the present disclosure. [Figure 27] Figure 18 shows different partial cross-sectional views of the sprayer according to an exemplary embodiment of the present disclosure. [Figure 28] Figure 23 shows a partial front view of the cartridge according to an exemplary embodiment of the present disclosure. [Modes for carrying out the invention]

[0018] This disclosure is described in further detail below with reference to its exemplary embodiments. These exemplary embodiments are described so as to ensure that this disclosure is thorough and complete and fully conveys the scope of this disclosure to those skilled in the art. In fact, this disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided so as to satisfy the applicable legal requirements of this disclosure. The singular forms “a,” “an,” and “the” as used herein and in the appended claims include multiple variations unless otherwise explicitly indicated in the context.

[0019] This disclosure provides a description of an aerosol delivery device. The aerosol delivery device may use electrical energy to heat a material (preferably without significantly burning the material) to form an inhalable substance. It is most preferable that such an article be small enough to be considered a “handheld” device. The aerosol delivery device may provide some or all of the sensation of smoking a cigarette, cigar or pipe (e.g., the form of inhalation and exhalation, the type of taste or flavor, the sensory effect, the physical sensation, the form of use, the visual stimulation as provided by a visible aerosol, etc.) without substantially burning any component of the article or device. The aerosol delivery device may not produce smoke in the sense of an aerosol resulting from a byproduct of the combustion or pyrolysis of tobacco, but rather, the article or device most preferably produces vapor (including vapor in an aerosol that may be considered a visible aerosol, which may be considered as a smoke-like substance) resulting from the volatilization or vaporization of certain components of the article or device, although in other embodiments the aerosol may be invisible. In a very preferred embodiment, the aerosol delivery device may incorporate tobacco and / or tobacco-derived components. Thus, aerosol delivery devices can be characterized as electronic smoking products such as e-cigarettes.

[0020] While the system is generally described herein in relation to embodiments relating to aerosol delivery devices such as so-called "electronic cigarettes," it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with various articles. For example, the descriptions provided herein may be used in combination with embodiments of relevant packaging for conventional smoking products (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and any of the products disclosed herein. Therefore, it should be understood that the descriptions of mechanisms, components, features, and methods disclosed herein are discussed merely as examples relating to embodiments of aerosol delivery devices and may be embodied and used in various other products and methods.

[0021] The aerosol delivery devices of this disclosure can also be characterized as vapor products or pharmaceutical delivery articles. Such articles or devices can therefore be configured to deliver one or more substances (e.g., flavors and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension or droplets of fine solid particles in a gas). For clarity, the term “aerosol” as used herein means including vapors, gases and aerosols in forms or types suitable for human inhalation, whether visible or in a form that can be considered fuzzy.

[0022] The aerosol delivery device of the present disclosure may, when in use, be subject to many of the physical actions performed by an individual when using conventional types of smoking products (e.g., cigarettes, cigars, or pipes, which are used by lighting and inhaling a tobacco). For example, a user of the aerosol delivery device of the present disclosure may hold the item like a conventional type of smoking product, inhale one end of the item to inhale the aerosol produced by the item, and inhale at selected time intervals, and so on.

[0023] The aerosol delivery devices of this disclosure generally include a number of components housed within an outer shell or body. The overall design of the outer shell or body is modifiable, and the form or configuration of the outer body, which can define the overall dimensions and shape of the aerosol delivery device, is modifiable. Typically, an elongated body resembling the shape of a cigarette or cigar may be formed from a single, one-piece shell, or the elongated body may be formed from two or more separable parts. For example, an aerosol delivery device may have an elongated shell or body whose shape is substantially tubular and can resemble the shape of a conventional cigarette or cigar. However, in other embodiments, various other shapes and configurations may be used (e.g., rectangular or fob-shaped).

[0024] In one embodiment, all components of an aerosol delivery device are housed within a single outer body or shell. Alternatively, an aerosol delivery device may comprise two or more joined and separable shells. For example, an aerosol delivery device may have a control body at one end comprising a shell housing one or more reusable components (e.g., a rechargeable battery and various electronic devices for controlling the operation of the articles), and a detachably attached shell at the other end housing a disposable component (e.g., a disposable flavor-containing cartridge). More specific forms, configurations, and arrangements of components within a single-shell type unit or a multi-component separable-shell type unit will become apparent in light of further disclosures provided herein. Furthermore, by considering commercially available electronic aerosol delivery devices, various aerosol delivery device designs and component arrangements can be understood.

[0025] The aerosol delivery device of the present disclosure most preferably includes any combination of a drive source (i.e., a power source), at least one control component (means for operating, controlling, regulating and / or stopping power for heating, for example, by controlling the flow of current from the drive source to other components of the aerosol delivery device), a heater or heating element (e.g., an electrically resistive heating element or component commonly referred to as part of a “sprayer”), an aerosol precursor composition (e.g., a liquid that can produce an aerosol when sufficiently heated, such as components commonly referred to as “smoke juice”, “e-liquid”, and “e-juice”), and a mouthpiece end region or tip (e.g., a defined airflow path through the article such that the generated aerosol can be drawn out therefrom by suction) that allows the aerosol delivery device to be inhaled for aerosol inhalation.

[0026] The alignment of components within the aerosol delivery device of this disclosure is modifiable. In certain embodiments, the aerosol precursor composition may be positioned near the end of the aerosol delivery device, thereby being positioned close to the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heating element may be positioned close enough to the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorings, pharmaceuticals, etc., that may be offered for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, the aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the terms herein are paraphrasable to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, inhalable substances are released in the form of vapors, aerosols, or mixtures thereof, and such terms are used interchangeably herein unless otherwise specified.

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

[0028] More specific forms, configurations, and arrangements of components within the aerosol delivery apparatus of this disclosure will become apparent in light of further disclosures provided below. Furthermore, by considering commercially available electronic aerosol delivery apparatuses, the selection of various aerosol delivery apparatus components can be understood. Furthermore, by considering commercially available electronic aerosol delivery apparatuses, the arrangement of components within an aerosol delivery apparatus can also be understood. Examples of commercially available products that may include such components, methods of operation, materials contained therein, and / or other attributes thereof are described in U.S. Patent Application No. 15 / 222,615 filed on 28 July 2016, which is incorporated herein by reference in its entirety.

[0029] Figure 1 shows one exemplary embodiment of the aerosol delivery device 100. In particular, Figure 1 shows the aerosol delivery device 100 including a control body 200 and a cartridge 300. The control body 200 and the cartridge 300 may be permanently or removablely aligned in a functional relationship. Various mechanisms may connect the cartridge 300 to the control body 200 to provide screw engagement, press-fit engagement, interlocking fit, magnetic engagement, etc. In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped, substantially tubular, or substantially cylindrical when the cartridge 300 and the control body 200 are in an assembled configuration. However, as described above, in other embodiments, various other configurations such as square or fob-shaped may be used. Furthermore, although the aerosol delivery device is generally described herein as resembling the dimensions and shape of a conventional smoking product, in other embodiments, different configurations and a large-capacity reservoir which may be called a “tank” may be used.

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

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

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

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

[0034] Further components may be used in the aerosol delivery apparatus of this disclosure. For example, U.S. Patent No. 5,154,192 by Sprinkel et al. discloses an indicator for smoking products; U.S. Patent No. 5,261,424 by Sprinkel, Jr. discloses a piezoelectric sensor that may be associated with the mouthpiece end of a device for detecting the movement of a user's lips associated with inhalation and subsequently causing heating of the heating device; U.S. Patent No. 5,372,148 by McCafferty et al. discloses a smoke inhalation sensor for controlling the energy flow to a heating load array in response to a pressure drop through a mouthpiece; U.S. Patent No. 5,967,148 by Harris et al. discloses a receptacle in a smoking device including a discriminator for detecting non-uniformity of the infrared transmittance of an inserted component and a controller for executing a detection routine when the component is inserted into the receptacle; U.S. Patent No. 6,040,560 by Fleischhauer et al. describes a defined, executable drive cycle having multiple differential phases; and U.S. Patent No. 5,934,289 by Watkins et al. The U.S. Patent No. 5,954,979 by Counts et al. discloses means for changing the inhalation resistance through a smoking device; the U.S. Patent No. 6,803,545 by Blake et al. discloses specific battery configurations for use in a smoking device; the U.S. Patent No. 7,293,565 by Griffen et al. disclose various charging systems for use with a smoking device; the U.S. Patent No. 8,402,976 by Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; the U.S. Patent No. 8,689,804 by Fernando et al. discloses an identification system for a smoking device; and the International Publication No. 2010 / 003480 by Flick discloses a fluid flow sensing system indicating smoke inhalation using an aerosol generation system. All of the aforementioned disclosures are incorporated herein by reference in their entirety.Additional examples of components relating to electronic aerosol delivery articles and disclosed materials or components that may be used herein include U.S. Patent No. 4,735,217 by Gerth et al., U.S. Patent No. 5,249,586 by Morgan et al., U.S. Patent No. 5,666,977 by Higgins et al., U.S. Patent No. 6,053,176 by Adams et al., U.S. Patent No. 6,164,287 by White, U.S. Patent No. 6,196,218 by Voges, U.S. Patent No. 6,810,883 by Felter et al., U.S. Patent No. 6,854,461 by Nichols, U.S. Patent No. 7,832,410 by Hon, U.S. Patent No. 7,513,253 by Kobayashi, U.S. Patent No. 7,896,006 by Hamano, U.S. Patent No. 6,772,756 by Shayan, and U.S. Patent No. U.S. Patent Nos. 8,156,944 and 8,375,957, U.S. Patent No. 8,794,231 by Thorens et al., U.S. Patent No. 8,851,083 by Oglesby et al., U.S. Patent Nos. 8,915,254 and 8,925,555 by Monsees et al., and U.S. Patent No. 9,220,302 by DePiano et al., and Hon's U.S. Patent Application Publication No. 2006 / 01 References include U.S. Patent Publication No. 96518 and U.S. Patent Application Publication No. 2009 / 0188490, U.S. Patent Application Publication No. 2010 / 0024834 by Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 by Wang, International Publication No. 2010 / 091593 by Hon, and International Publication No. 2013 / 089551 by Foo, each of which is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed in the aforementioned documents may be incorporated into the apparatus, and each of the aforementioned disclosures is incorporated herein by reference in its entirety.

[0035] Figure 3 shows a disassembled configuration of the cartridge 300 of the aerosol delivery device 100 (see Figure 1). As shown, the cartridge 300 may comprise, according to exemplary embodiments of the present disclosure, a base 302, control component terminals 304, electronic components 306, flow guide 308, sprayer 310, reservoir 312 (e.g., reservoir substrate), outer body 314, mouthpiece 316, label 318, and first and second heating terminals 320, 321.

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

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

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

[0039] Reservoir 312 may be configured to hold the aerosol precursor composition. Typical types of aerosol precursor components and formulations are also described and characterized in U.S. Patent No. 7,726,320 by Robinson et al., U.S. Patent No. 8,881,737 by Collett et al., U.S. Patent No. 9,254,002 by Chong et al., and U.S. Patent Publication No. 2013 / 0008457 by Zheng et al., U.S. Patent Publication No. 2015 / 0020823 by Lipowicz et al., and U.S. Patent Publication No. 2015 / 0020830 by Koller, and International Publication No. 2014 / 182736 by Bowen et al., and these disclosures are incorporated herein by reference. Other aerosol precursors that may be used include those incorporated into RJReynolds Vapor Company's VUSE(R) products, Lorillard Technologies' BLU products, Mistic Ecigs' MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. So-called “smoke juice” for e-cigarettes, available from Johnson Creek Enterprises LLC, is also desirable. Embodiments of foaming materials may be used in conjunction with aerosol precursors, as described, for example, in Hunt et al.'s U.S. Patent Application Publication 2012 / 0055494, which is incorporated herein by reference. Furthermore, the use of foaming materials is described, for example, in U.S. Patent No. 4,639,368 by Niazi et al., U.S. Patent No. 5,178,878 by Wehling et al., U.S. Patent No. 5,223,264 by Wehling et al., U.S. Patent No. 6,974,590 by Pater et al., U.S. Patent No. 7,381,667 by Bergquist et al., U.S. Patent No. 8,424,541 by Crawford et al., U.S. Patent No. 8,627,828 by Strickland et al., and U.S. Patent No. 9,307,787 by Sun et al., as well as in U.S. Patent Publication No. 2010 / 0018539 by Brinkley et al. and International Publication No. 97 / 06786 by Johnson et al., all of which are incorporated herein by reference.Further descriptions relating to embodiments of the aerosol precursor composition, including a description of tobacco or tobacco-derived components contained in the aerosol precursor composition, are described in U.S. Patent Application No. 15 / 216,582 and U.S. Patent Application No. 15 / 216,590, both filed on 21 July 2016 by Davis et al., and are incorporated herein by reference in their entirety.

[0040] The reservoir 312 may comprise multiple layers of nonwoven fibers formed in the shape of a tube surrounding the inside of the outer body 314 of the cartridge 300. Thus, for example, the reservoir 312 can adsorb and retain liquid components. The reservoir 312 is fluidly connected to the liquid transport element 324. Thus, the liquid transport element 324 may be configured to transport the liquid from the reservoir 312 to the heating element 326 via capillary action or other liquid transport mechanism.

[0041] As illustrated, the liquid transport element 324 may be in direct contact with the heating element 326. As further shown in Figure 3, the heating element 326 may comprise a wire defining a plurality of coils wound around the liquid transport element 324. In some embodiments, the heating element 326 may be formed by winding a wire around the liquid transport element 324, as described in U.S. Patent No. 9,210,738 of Ward et al., which is incorporated herein by reference in its entirety. Furthermore, in some embodiments, the wire may define a variable coil spacing, as described in U.S. Patent No. 9,277,770 of DePiano et al., which is incorporated herein by reference in its entirety. The heating element 326 may be formed using various embodiments of a material configured to generate heat when an electric current is applied. Examples of materials that may form wire coils include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)2), graphite and graphite-based materials, as well as ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics).

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

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

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

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

[0046] A sensor within the aerosol delivery device 100 (for example, a flow sensor 210 in the control unit 200, see Figure 2) may detect fumes. When fumes are detected, the control unit 200 may conduct an electric current to the heating element 326 through a circuit including a first heating terminal 320 and a second heating terminal 321. Thus, the heating element 326 may vaporize the aerosol precursor composition that has been guided from the reservoir 312 to the aerosolization zone by the liquid transport element 324. In this way, the mouthpiece 326 may pass air and entrained vapors (i.e., components of the aerosol precursor composition in an inhalable form) from the cartridge 300 toward the consumer who inhales it.

[0047] Various other details regarding components that may be included in cartridge 300 are described, for example, in U.S. Patent Application Publication 2014 / 0261495 by DePiano et al., which is incorporated herein by reference in its entirety. Additional components that may be included in cartridge 300, and related details are described, for example, in U.S. Patent Application Publication 2015 / 0335071 by Brinkley et al., filed on 23 May 2014, which is incorporated herein by reference in its entirety.

[0048] Various components of the aerosol delivery apparatus described herein may be selected from components described in the Art and commercially available. For example, see the reservoir and heater system for controllable delivery of multiple aerosolizable materials in an e-smoking product disclosed in U.S. Patent Application Publication No. 2014 / 0000638 by Sebastian et al., which is incorporated entirely herein by reference.

[0049] In another embodiment, the cartridge may be substantially entirely formed from one or more carbon materials, which may offer advantages in terms of biodegradability and the absence of wires. In this regard, the heating element may comprise a carbon foam, the reservoir may comprise a carbonized fabric, and graphite may be used to form electrical connections with power and control components. Exemplary embodiments of carbon-based cartridges are described in U.S. Patent Application Publication 2013 / 0255702 by Griffith et al., which is incorporated in its entirety herein by reference.

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

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

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

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

[0054] Figure 5 shows an exploded view of the cartridge 500. As shown, the cartridge 500 may include a reservoir 502 and a valve assembly 504. The reservoir 502 may be configured to contain an aerosol precursor composition 506. In some embodiments, the reservoir 502 may be made of a translucent or transparent material so that the user can see the amount of aerosol precursor composition 506 remaining in it. The aerosol precursor composition 506 may be dispensed into the reservoir 502 or otherwise guided. For example, as shown in Figure 6, a filling needle 508 may be guided into the reservoir 502 and the aerosol precursor composition 506 may be dispensed from there.

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

[0056] In some embodiments, the valve assembly 504 may be attached to the reservoir 504. For example, the valve assembly 504 may be ultrasonically welded to the reservoir 502. As can be understood, various other mechanisms and techniques, such as the use of adhesives, may be used to engage with and hold the valve assembly 504 to the reservoir 502. However, the use of ultrasonic welding may be preferred in that it can provide an airtight seal without requiring additional components or materials to form the seal. This can prevent the valve assembly 504 from being nondestructively removed from the reservoir 502, and as a result, the reservoir cannot be refilled, as will be described in more detail below.

[0057] Figure 7 shows an enlarged view of the valve assembly 504. As shown, the valve assembly 504 may include a frame 510. As described above, the base 512 of the frame 510 may be ultrasonically welded to the inner surface of the reservoir 502 to form a cartridge 500 (see, for example, Figure 5). Furthermore, the frame 510 may include at least one connector portion 514, a first plate 516, a second plate 518, and at least one spacer 520. The connector portion 514 may extend from the base 512 to the first plate 516. The first plate 516 and the second plate 518 may be arranged adjacent to each other with a defined space between them. In this regard, the spacer 520 may extend between the first plate 516 and the second plate 518, separating them so that the first plate and the second plate are separated. The distributing capillary 522 may extend through the first plate 516 to the space defined between the first plate and the second plate 518.

[0058] Furthermore, the valve assembly 504 may include one or more seals. In particular, the valve assembly 504 may include a reservoir seal 524. The reservoir seal 524 may be configured to seal against the inside of the reservoir 502 to seal the aerosol precursor composition 506 in the reservoir (see, for example, Figure 5). The reservoir seal 524 may be molded into the frame 510 (for example, by insert molding).

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

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

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

[0062] Regarding additional components of the aerosol delivery device 400 (see Figure 4), the sprayer body 600 is shown in a partially disassembled configuration in Figure 8. As illustrated, the sprayer body 600 may include an outer body 602. The outer body 602 may be configured to engage with the base 604. For example, the outer body 602 may comprise a metallic material (e.g., stainless steel) that can be pressed against the base 604, which may comprise a plastic material. When the outer body 602 engages with the base 604, various other components of the sprayer body 600 may be substantially enclosed within it.

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

[0064] The heating element 610 may include a wire that can be wound around the liquid transport element 608. In some embodiments, the wire may include titanium, Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)2), graphite and graphite-based materials, ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics), tungsten and tungsten alloys, or any other suitable material as described elsewhere in this specification. The use of tungsten and tungsten alloys may be desirable in that these materials can specify a coefficient of thermal expansion suitable for use with many of the ceramics that may be used in the liquid transport element 608.

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

[0066] The sprayer 606 may further comprise a capillary rod 612. In this regard, the liquid transport element 608 may define a tube. In other words, the liquid transport element 608 may include an opening that penetrates it longitudinally. Thereafter, the capillary rod 612 may extend longitudinally through the liquid transport element 608. Thus, the capillary rod 612 may be configured to guide the aerosol precursor composition through the liquid transport element 608. In this regard, the distance between the capillary rod 612 and the inner surface of the liquid transport element 608 may define a capillary channel through which the aerosol precursor composition is guided. The aerosol precursor composition may then be drawn substantially radially outward through the liquid transport element 608 during the operation of the heating element 610.

[0067] The sprayer body 600 (see Figure 4) may further include a first sprayer seal 614 shown in Figure 9. The first sprayer seal 614 may engage with a first end of a liquid transport element 608 and a first end of a capillary rod 612 that can define a head 616. This allows the liquid transport element 608 to be sealed to the head 616 of the capillary rod 612, preventing leakage of the aerosol precursor composition between them.

[0068] Figure 10 shows an exploded view of the base 604 and a number of terminals configured to engage with the base. The terminals include a first heating terminal 618, a second heating terminal 620, and an electronic component terminal 622. The electronic component terminal 622 may engage with an electronic component 624 that verifies that the sprayer body 600 (see, for example, Figure 8) is genuine and / or provides other functions as described elsewhere in this specification.

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

[0070] As shown in Figure 12, the first clip 626 and the second clip 628 may be aligned so that the liquid transport element 608 can be received and held in place within them. In this regard, the liquid transport element 608 may be inserted from the side through the openings of each clip 626, 628 and engaged with them. The first clip 626 and the second clip 628 can contact the opposing ends of the heating element 610, and as a result, current can be guided through them via the first heating terminal 618 and the second heating terminal 620. In some embodiments, the clips 626, 628 may be welded (e.g., laser welded) to the heating element 610 to provide a secure connection with it. For example, a laser beam may be guided to each of the clips 626, 628, thereby forming the clip and heating element 610 at the weld.

[0071] The sprayer body 600 (see, for example, Figure 4) may further include a second sprayer seal 630 and a sprayer body seal 632. As shown in Figure 8, the sprayer body seal 632 may extend over the liquid transport element 608 and heating terminals 618, 620 and engage with the base 604. As further shown in Figure 8, the second sprayer seal 630 may be configured to engage with the second end of the liquid transport element 608. This allows the sprayer body seal 632 to extend over the liquid transport element 608 and the first and second heating terminals 618, 620 so as not to detach the liquid transport element from the first clip 626 (see, for example, Figure 12). Similarly, the second sprayer seal 630 may extend over the liquid transport element 608 and the second heating terminal 620 so as not to detach the liquid transport element from the second clip 628 (see, for example, Figure 12). Therefore, the liquid transport element 608 may remain engaged with the heating terminals 618 and 620.

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

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

[0074] The operation of the aerosol delivery device 400 will be described in more detail below. As shown in Figure 13, the sprayer body 600 may be engaged with the control body 200. Furthermore, the cartridge 500 may be engaged with the sprayer body 600 such that the sprayer body is positioned between the control body and the cartridge 500. However, as can be understood, the sprayer body 600, the control body 200 and the cartridge 500 may be arranged in different ways in other embodiments.

[0075] The connection between the control body 200 and the sprayer body 600 via the first and second heating terminals 618, 620 and the electronic component terminal 622 (see, for example, Figure 10) allows the control body 200 to conduct current to the sprayer 606 when smoke extraction using the aerosol delivery device 400 is detected. In this regard, the longitudinal end of the cartridge 500 opposite the sprayer body 600 may define a mouthpiece 528. When a user inhales through the mouthpiece 528, air 223 may be drawn in through an air intake 224 which may be defined between the coupler 202 and the outer body 204 of the control body 200. The air 223 drawn in through the air intake 224 may be drawn in through the coupler 202 of the control body 200 and then drawn into the spray cavity 638 of the sprayer body 600 through the base 604 and the sprayer body seal 632. Furthermore, the air 223 can cool the electronic components 624 (see, for example, Figure 10) as it passes through the base 604, thereby reducing the risk of temperature-related degradation.

[0076] Because an O-ring 640 is included on its outer surface that can engage with and seal the inner surface of the reservoir 502 of the cartridge 500, air 223 can be drawn in through the air intake 224, as opposed to passing through the connection between the cartridge 500 and the sprayer body 600. Furthermore, the reservoir 502 may define a retaining element 530 on its inner surface that can engage with a recess 642. This allows the sprayer body 600 to maintain a secure engagement with the cartridge 500. This air can be combined in the spray cavity 638 with the air received through the air intake 224 to the extent that it enters the aerosol delivery device 400 between the control body 200 and the sprayer body 600, rather than passing through the air intake 224.

[0077] The retaining arm 530 and recess 642 may provide additional or alternative functions. In this regard, in some embodiments, engagement between the retaining arm 530 and recess 642 may be required to enable operation of the device. For example, engagement between the retaining arm 530 and recess 642 may complete a circuit with an electronic component 624 (see, for example, Figure 10) required for operation of the aerosol delivery device.

[0078] When air is drawn in through the air intake 224, the flow sensor 210 (see Figure 2) may detect the draw-in. The control unit 200 may then conduct current to the sprayer 606 through the heating terminals 618, 620. As the sprayer 606 heats up, the aerosol precursor composition 506 can be vaporized in the sprayer. In this regard, the aerosol precursor composition 506 may be held in a precursor cavity 532 within the reservoir 502. The aerosol precursor composition 506 may be guided to the sprayer 606 through the valve assembly 504.

[0079] In this regard, the valve assembly 504 may be configured to distribute the aerosol precursor composition 506 to the sprayer body 600 when engaged with it. Otherwise, the valve assembly 504 may remain in a closed configuration to hold the aerosol precursor composition 506 in the reservoir 502. More specifically, the sprayer body 600 may include a nozzle 644. The nozzle 644 may be configured to engage with the valve assembly 504. In this regard, the nozzle 644 may penetrate the reservoir seal 524 and be configured to engage with the distribution seal 526. Thus, the aerosol precursor composition 506 held in the precursor cavity 532 may be guided through the valve assembly 504 to the nozzle 644.

[0080] As shown in Figures 14 and 15, the aerosol precursor composition 506 can flow into the space defined between the first plate 516 and the second plate 518 through the gap defined between the radial outer edges of the first plate 516 and the second plate 518 of the valve assembly 504 and the inner surface of the reservoir 502. More specifically, Figure 15 shows an enlarged view of region Z in Figure 14. As illustrated, the aerosol precursor composition 506 can be drawn between the first plate 516 and the second plate 518 by capillary action.

[0081] In some embodiments, the inner surfaces of the first plate 516 and the second plate 518 may be set at an angle to each other. In particular, the first plate 516 and the second plate 518 may be molded and configured such that their inner surfaces are furthest from each other when their outer edges are close together, and closest to each other when they are close to the distribution capillary 522. This allows the distance between the first plate 516 and the second plate to decrease from the outer edges of the plates toward their centers. For example, the inner surfaces of the first plate 516 and the second plate 518 may be set at an angle to each other, and in some embodiments, the angle may be about 1 to about 5 degrees. By configuring the first plate 516 and the second plate 518 in this way, a "ventilator" can be created to draw the aerosol precursor composition toward the distribution capillary 522. Therefore, the aerosol precursor composition can be drawn into the distribution capillary 522 (see, for example, Figure 13) defined through the first plate, resulting in a flow of the aerosol precursor composition toward it in any orientation in which the aerosol precursor composition contacts the first plate 516 and the second plate 518. Furthermore, the accompanying volume of the aerosol precursor composition 506 in the valve assembly 504 and the downstream components may allow for continuous operation (e.g., about 15-20 smoke inhalations) in any orientation before it becomes necessary to change the orientation of the aerosol delivery device 400 (see, for example, Figure 13) in a direction in which the aerosol precursor composition contacts the first plate 516 and the second plate 518.

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

[0083] As a result, as shown in Figure 13, the aerosol precursor composition 506 can be guided through the nozzle 644 to the liquid transport element 608. The aerosol precursor composition 506 can then be vaporized directly by the heating element 610 or via heating of the liquid transport element 608. Thus, the resulting vapor or aerosol 646 can be generated in the spray cavity 638 and subsequently guided to the user. In this regard, the outer body 602 of the sprayer unit 600 may include one or more airflow openings 648 that penetrate it and are in fluid communication with the spray cavity 638. Furthermore, one or more airflow openings 534 may be defined through the reservoir seal 524 of the valve assembly 504 and aligned with the airflow openings 648 that penetrate the outer body 602 of the sprayer unit 600.

[0084] Furthermore, the reservoir 502 may include one or more airflow openings 536 extending from the valve assembly 504 to the mouthpiece 528. The airflow openings 536 penetrating the reservoir 502 may be separated from the precursor cavity 532 into which the aerosol precursor composition 506 is received. In this regard, the airflow openings 536 may be defined circumferentially around the precursor cavity 532 through the material forming the reservoir 502. Thus, the aerosol 646 may be guided from the spray cavity 638 through the mouthpiece 528 to the user.

[0085] As described above with reference to Figure 13, the cartridge 500 may contain the aerosol precursor composition 506, and the sprayer body 600 may contain the sprayer 606. At the same time, the cost associated with using the aerosol delivery device 400 can be reduced by enabling the replacement of the cartridge 500 without requiring the replacement of the sprayer 606. In this regard, in some embodiments, the sprayer 606 may have a usable life configured to spray an amount of aerosol precursor composition 506 that can be contained in about 200 to about 300 cartridges 500 before replacement is required.

[0086] In contrast, the cartridge 500 may be configured to be discarded after the aerosol precursor composition 506 has been used up from it. In this regard, the cartridge 500 may be configured to prevent its refilling. Figure 16 shows a diagram of the cartridge 500 in the valve assembly 504. As shown, the reservoir seal 524 may define an orifice 538 configured to guide and receive the nozzle 644 of the sprayer body 600 (see, for example, Figure 13), as described above. As can be understood, a user may attempt to refill the reservoir 502 with the aerosol precursor composition using the orifice 538. However, the valve assembly 504 may be configured to resist refilling.

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

[0088] Furthermore, by using two or more projections 540 around the orifice 538, the width of any nozzle that can engage with the orifice 538 is restricted, further limiting the types of nozzles that can penetrate the orifice and / or form a surface seal with it. In some embodiments, the orifice may define a diameter of about 1 mm to about 3 mm, which may be too small to insert a standard e-liquid bottle nozzle or glass dropper tip. In addition, by using both the reservoir seal 524 and the dispensing seal 526, each formed from an elastic material and separated from each other, it may be difficult to refill the reservoir 502 using a subcutaneous injection needle.

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

[0090] Furthermore, as described above, the valve assembly 504 may be embedded in and attached to the reservoir 502 (for example, via ultrasonic welding). In this way, the valve assembly 504 cannot be removed from the reservoir 502 without damaging one or both of these components, thereby further resisting refilling of the cartridge 500. Moreover, considering that the sprayer 606 is contained in a separate sprayer body 600 (see, for example, Figure 13) rather than the cartridge 500, the cartridge may be priced relatively inexpensively, thereby mitigating cost savings as an incentive for users to refill the cartridge.

[0091] In additional embodiments, a method for operating an aerosol delivery device is provided. As shown in Figure 17, the method may include, in operation 702, introducing the aerosol precursor composition from the reservoir of the cartridge through a valve assembly to the outside of the cartridge. Introducing the aerosol precursor composition from the reservoir of the cartridge through the valve assembly to the outside of the cartridge in operation 702 may include introducing the aerosol precursor composition through a distributing capillary, a distributing seal in the distributing capillary, and a reservoir seal in the reservoir. Furthermore, the method may include, in operation 704, receiving the aerosol precursor composition into the sprayer body. The method may further include, in operation 706, introducing the aerosol precursor composition into the sprayer in the sprayer body. The method may further include, in operation 708, introducing an electric current from the control body to the sprayer to generate an aerosol.

[0092] In some embodiments, guiding the aerosol precursor composition out of the cartridge through the valve assembly in operation 702 may further include guiding the aerosol precursor composition out of the space between a first plate and a second plate that are positioned adjacent to each other with a defined space between them, and through a distributing capillary that penetrates the first plate. Guiding the aerosol precursor composition out of the cartridge through the valve assembly in operation 702 may further include engaging the nozzle of the sprayer body with the valve assembly. Engaging the nozzle with the valve assembly may include guiding the nozzle through the reservoir seal of the valve assembly. Engaging the nozzle with the valve assembly may further include engaging the nozzle with the distributing seal of the valve assembly in the distributing capillary.

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

[0094] As can be understood, the apparatus and methods of this disclosure may vary. In this regard, Figure 18 shows a cartridge 800 and sprayer 900 according to an additional exemplary embodiment of this disclosure. In particular, Figure 18 shows the cartridge 800 and sprayer 900 in an assembled configuration and engaged with each other. The sprayer 900 may be configured to engage with a control body, such as the control body 200 described above (see, for example, Figure 2). In this embodiment, it should be noted that the sprayer 900 may also comprise a sprayer body, and therefore the terms sprayer and sprayer body may be used interchangeably. Unless otherwise described and / or illustrated, the components of the aerosol delivery apparatus according to this embodiment may be substantially similar to or identical to the corresponding components described above.

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

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

[0097] Referring to Figure 20, the sprayer 900 may also include a terminal base 908. In various embodiments, the terminal base may be made of a plastic material including, but not limited to, silicone, thermoplastic polyurethane, or another elastic material. An exemplary commercially available material that can be used for the terminal base is TRITAN copolyester, sold by Eastman Chemical Company in Kingsport, Tennessee. In the illustrated embodiment, the first heating terminal 910 and the second heating terminal 912 penetrate the terminal base 908. In various embodiments, the first heating terminal 910 and the second heating terminal 912 may be insert-molded into the terminal base 908. Thus, the terminal base 908 may comprise an overmolded structure into which the first heating terminal 910 and the second heating terminal 912 are fixedly mounted.

[0098] Figures 21 and 22 show separate diagrams of the cartridge 800. As illustrated, the cartridge 800 may include an internal reservoir 802 and a central passage 804. The cartridge may also include a distribution valve 806 defined on the bottom surface of the cartridge 800, leading to a pair of vertical cartridge vapor channels 810, and a substantially circular vapor flow groove 808. Similar to the embodiments described above, the reservoir 802 may be configured to contain the aerosol precursor composition. In some embodiments, the cartridge 800 may include a translucent or transparent material so that the user can see the amount of aerosol precursor composition remaining in it. The aerosol precursor composition may be distributed into the reservoir 802 or otherwise guided. The valve 806 may seal the aerosol precursor composition in the reservoir 802. However, as described below, the valve 806 may allow the aerosol precursor composition to flow into the atomizer 900 when engaged with it.

[0099] Figure 23 shows an exemplary embodiment of the liquid transport element 914. Also shown are a heating element 926, a first heating terminal 910, and a second heating terminal 912 for use with the sprayer 900. Note that the terminal base 908 is not shown for simplification of the figure. In various embodiments, the liquid transport element 914 may comprise a porous monolith. For example, the liquid transport element 608 may comprise a ceramic. As shown, the heating element 926 may comprise a wire that can be wound around the inner surface of the liquid transport element 914. In some embodiments, the wire may comprise titanium, Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)2), graphite and graphite-based materials, ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics), tungsten and tungsten-based alloys, or any other suitable material as described elsewhere in this specification. The use of tungsten and tungsten alloys may be desirable in that these materials can specify a coefficient of thermal expansion suitable for use with many ceramics that may be used in liquid transport elements 914.

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

[0101] As described above, in some embodiments, the thermal bonding of the heating element 926 to the liquid transport element 914 may occur by embedding or partially embedding the heating element 926 into the liquid transport element 914. In other embodiments, the thermal bonding of the heating element to the liquid transport element may occur via "direct drawing," which may include computer-aided surface deposition of a specialized alloyed flowable metal onto a substrate. In other embodiments, the heating element may be bonded to the liquid transport element via plating, electroplating, direct deposition (e.g., sputtering) and / or other preferred methods.

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

[0103] In some embodiments, it may be desirable to reduce heat transfer from the heating element to the apparatus (most directly via the atomizer housing) and for the user thereof, and / or (as described in this invention with respect to air cooling of electrical components) to reduce thermal degradation of the apparatus, and / or to increase the efficiency of the heat generated by the heating element and applied to the aerosol precursor composition to bring about a mass transition of the precursor to aerosol or vapor (with associated efficiency benefits such as reduced power consumption and improved overall system efficiency). Therefore, in some embodiments, the external electrical connections are made of a material with a different thermal conductivity from the liquid transport element, which may create a thermal gradient across the liquid transport element where the thermal conductivity of the entire inner surface of the liquid transport element is greater than the thermal conductivity of the entire outer surface.

[0104] In some embodiments, the mass of the material can be used to increase the difference in the time delta of heat transfer through the liquid transport element. Furthermore, the properties of the liquid transport element can be selectively altered by utilizing many processes, including direct drawing and the processes described above. In addition, the application of co-processes or post-sintering processes that "dope" the surface of the material and penetrate to a selected depth of the substrate depending on the porosity of the substrate, material composition, process, and application is a possible approach. In various embodiments, conductive non-porous ceramic materials can also be used as liquid transport elements. In this regard, a thermal gradient exists throughout the cross-section of the liquid transport element, and there is a considerably high-temperature region throughout the inner surface of the liquid transport element, leading to a phase transition and mobilization of the precursor composition, while the outer surface of the liquid transport element remains relatively low-temperature, which can serve to insulate and isolate heat to the atomization chamber.

[0105] Alternatively, it may be desirable to simply insulate the direct area of ​​the external electrical connection that connects to the first and second heating terminals. In such embodiments, the external electrical connection can also function as a resistance heater itself. In this capability, the external electrical connection and the heating element may have different resistance characteristics so that the external electrical connection can help overcome the initial heat gradient required in the initial heating phase of the user operating process. In such embodiments, the external electrical connection may not reach the temperature required to activate the precursor. Rather, the external electrical connection may be heated to a temperature lower than that of the heating element. This can increase the vapor product over time by reducing the time delta from activation to aerosol generation. In this capability, the external electrical connection can also heat nearby precursors located within and adjacent to the liquid transport element by reducing the viscosity of the precursor, thereby promoting increased transport to the liquid transport element.

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

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

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

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

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

[0111] It should be noted that the "winding path" of the aerosol through the upper flange 925 of the flow guide 916 via the inlet steam vent 932, radial steam channel 934, and vertical steam vent 936 may have a functional roll that forms a series of impact surfaces configured to capture aerosol droplets outside the optimal range (i.e., relatively large). In this way, droplets with relatively large mass cannot remain trapped in the airflow as the path turns 90° through the inlet steam vent 932, radial steam channel 934, and vertical steam vent 936, and can therefore impact the upper flange 925, where they can flow back into the sprayer chamber 942.

[0112] Figure 28 shows the flow of steam or aerosol 646 through the cartridge 800 to the central passage 804. The circular steam channel 808 of the cartridge 800 is configured to substantially align with the multiple steam openings 924 of the outer body 920 of the sprayer 900 when the cartridge 800 is coupled to the sprayer 900. Thus, the steam or aerosol 646 flowing through the multiple steam openings 924 can be directed by the steam channel 808 into the vertical cartridge steam channel 810. As shown in the figure, the vertical steam channel 810 leads to the respective horizontal steam channels 812, which then lead to the central passage 804 of the cartridge 800.

[0113] As described above regarding additional implementation forms, the cartridge 800 may contain the aerosol precursor composition 506. At the same time, the cost associated with using the aerosol delivery device can be reduced by enabling the replacement of the cartridge 800 without requiring the replacement of the sprayer 900. In this regard, in some embodiments, the sprayer 900 may have a usable life configured to spray an amount of aerosol precursor composition 506 that can be contained in about 200 to about 300 cartridges 800 before replacement is required.

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

[0115] In this regard, the cartridge 800 may include one or more projections 816 extending inward toward the distribution seal 806 from a region adjacent to the vapor flow groove 808. As a result of the projections 816 projecting inward toward the distribution seal 806, it may be impossible for a bottle nozzle or glass dripper to form a face seal with respect to the distribution seal, and a face seal may be required to allow fluid flow through the distribution seal. In this regard, the distribution seal 806 may be closed in an unbiased configuration and define a valve that opens during engagement with the nozzle 922 when the cartridge 800 engages with the atomizer 900. As a result of resisting the formation of seals with respect to most bottle nozzles and glass drippers, the distribution seal 806 may resist refilling of the reservoir 802. Furthermore, by using two or more projections 816 around the orifice 814, the width of any nozzle that can engage with the orifice 806 may be restricted, further limiting the types of nozzles that can penetrate the orifice and / or form a face seal with it. In some embodiments, the orifice may define a diameter of about 1 mm to about 3 mm, which may be too small to insert a standard e-liquid bottle nozzle or glass dropper tip.

[0116] Those skilled in the art, who benefit from the teachings shown in the above description and the associated drawings, will likely envision many modifications and other embodiments of this disclosure. Therefore, it should be understood that this 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. While specific terms are used herein, they are used in a general and descriptive sense only and not for limitation.

Claims

1. Aerosol delivery device, Control unit and A sprayer unit equipped with a sprayer, It is a cartridge, A reservoir configured to contain an aerosol precursor composition, A valve assembly configured to distribute an aerosol precursor composition to the sprayer body when the cartridge is engaged with the sprayer body, A cartridge and a valve assembly comprising a distribution seal and a reservoir seal. Equipped with, The control unit is configured to releasably engage with the sprayer body, and the sprayer body is configured to releasably engage with the cartridge, and the control unit, sprayer body and cartridge are configured to have separate separable components. The sprayer is configured to receive an electric current from the control unit and an aerosol precursor composition from the cartridge to generate an aerosol. The valve assembly comprises a first plate, a second plate, and a spacer extending between the first plate and the second plate and separating them. Aerosol delivery device.

2. The aerosol delivery device according to claim 1, wherein the cartridge comprises one or more airflow openings extending from the sprayer body to the mouthpiece, and the airflow openings are configured to guide an aerosol through them.

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

4. The aerosol delivery device according to claim 1, wherein a valve assembly defines a distributing capillary, and the distributing capillary extends through a first plate into the space between the first plate and the second plate.

5. The aerosol delivery device according to claim 4, wherein a gap is defined between the radial outer edge of the first plate and the radial outer edge of the second plate and the inner surface of the reservoir.

6. The aerosol delivery device according to claim 1, further comprising a nozzle configured to extend through a reservoir seal and engage with a distribution seal, wherein the sprayer body is further a nozzle.

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

8. The aerosol delivery device according to claim 1, wherein the sprayer comprises a liquid transport element having a porous monolith.

9. The aerosol delivery device according to claim 8, further comprising a heating element having a wire at least partially embedded in a liquid transport element, the sprayer.

10. The aerosol delivery device according to claim 9, further comprising a liquid transport element defining a tube, and a sprayer configured to penetrate the liquid transport element and guide an aerosol precursor composition through it.

11. The aerosol delivery device according to claim 1, wherein the control unit further comprises a microphone, and the microphone is configured to detect user inhalation of the cartridge.

12. The aerosol delivery device according to claim 1, wherein the sprayer comprises an outer body, a terminal base, a flow guide, and a liquid transport element having a porous monolith, and the sprayer chamber is formed by the flow guide, the terminal base, and the inner surface of the liquid transport element.

13. The aerosol delivery device according to claim 12, wherein the flow guide includes a central inlet air channel, a transition barrier, and one or more radial inlet air holes configured such that air entering through the inlet air channel is guided by the transition barrier through one or more radial inlet air holes.

14. The aerosol delivery apparatus according to claim 13, further comprising one or more inlet liquid flow chambers configured to deliver an aerosol precursor composition to a liquid transport element.

15. The aerosol delivery device according to claim 14, wherein the outer body includes one or more vapor openings, and the flow guide includes one or more radial inlet vapor holes, one or more radial inlet vapor holes, and one or more vertical vapor holes, and the aerosol is guided through one or more radial inlet vapor holes, one or more radial vapor channels, one or more vertical vapor holes of the flow guide, and one or more vapor openings of the outer body to one or more vapor channels of the cartridge.

16. An aerosol delivery device, Control unit and A sprayer unit equipped with a sprayer, It is a cartridge, A reservoir configured to contain an aerosol precursor composition, A valve assembly configured to distribute an aerosol precursor composition to the sprayer body when the cartridge is engaged with the sprayer body, A cartridge and a valve assembly comprising a distribution seal and a reservoir seal. Equipped with, The control unit is configured to releasably engage with the sprayer body, and the sprayer body is configured to releasably engage with the cartridge, and the control unit, sprayer body and cartridge are configured to have separate separable components. The sprayer is configured to receive an electric current from the control unit and an aerosol precursor composition from the cartridge to generate an aerosol. The cartridge comprises one or more airflow openings extending from the atomizer body to the mouthpiece, and the airflow openings are configured to guide the aerosol through them. At least one of the airflow openings extends through the valve assembly, Aerosol delivery device.

17. The aerosol delivery device according to claim 16, wherein the sprayer body further comprises a nozzle configured to extend through the reservoir seal and engage with the distribution seal.

18. The aerosol delivery device according to claim 16, wherein the valve assembly further comprises a frame and a reservoir seal is molded into the frame.

19. The aerosol delivery device according to claim 16, wherein the control unit further comprises a microphone, and the microphone is configured to detect user inhalation of the cartridge.

20. An aerosol delivery device, Control unit and A sprayer unit equipped with a sprayer, It is a cartridge, A reservoir configured to contain an aerosol precursor composition, A valve assembly configured to distribute an aerosol precursor composition to the sprayer body when the cartridge is engaged with the sprayer body, A cartridge and a valve assembly comprising a distribution seal and a reservoir seal. Equipped with, The control unit is configured to releasably engage with the sprayer body, and the sprayer body is configured to releasably engage with the cartridge, and the control unit, sprayer body and cartridge are configured to have separate separable components. The sprayer is configured to receive an electric current from the control unit and an aerosol precursor composition from the cartridge to generate an aerosol. The sprayer has a liquid transport element comprising a porous monolith, The sprayer further comprises a heating element having a wire at least partially embedded in the liquid transport element, The liquid transport element defines a tube, and the sprayer further comprises a capillary rod configured to penetrate the liquid transport element and guide an aerosol precursor composition through it. Aerosol delivery device.

21. The aerosol delivery device according to claim 20, wherein the control unit further comprises a microphone, and the microphone is configured to detect user inhalation of the cartridge.

22. An aerosol delivery device, Control unit and A sprayer unit equipped with a sprayer, It is a cartridge, A reservoir configured to contain an aerosol precursor composition, A valve assembly configured to distribute an aerosol precursor composition to the sprayer body when the cartridge is engaged with the sprayer body, A cartridge and a valve assembly comprising a distribution seal and a reservoir seal. Equipped with, The control unit is configured to releasably engage with the sprayer body, and the sprayer body is configured to releasably engage with the cartridge, and the control unit, sprayer body and cartridge are configured to have separate separable components. The sprayer is configured to receive an electric current from the control unit and an aerosol precursor composition from the cartridge to generate an aerosol. The sprayer comprises an outer body, a terminal base, a flow guide, and a liquid transport element having a porous monolith, and the sprayer chamber is formed by the flow guide, the terminal base, and the inner surface of the liquid transport element. Aerosol delivery device.

23. The aerosol delivery device according to claim 22, wherein the flow guide includes a central inlet air channel, a transition barrier, and one or more radial inlet air holes configured such that air entering through the inlet air channel is guided by the transition barrier through one or more radial inlet air holes.

24. The aerosol delivery device according to claim 23, further comprising one or more inlet liquid flow chambers configured to deliver an aerosol precursor composition to a liquid transport element.

25. The aerosol delivery device according to claim 24, wherein the outer body includes one or more vapor openings, and the flow guide includes one or more radial inlet vapor holes, one or more radial inlet vapor holes, and one or more vertical vapor holes, and the aerosol is guided through one or more radial inlet vapor holes, one or more radial vapor channels, one or more vertical vapor holes of the flow guide, and one or more vapor openings of the outer body to one or more vapor channels of the cartridge.

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