Apparatus and method for airflow management and liquid entrapment in aerosol delivery systems

Abstract

An aerosol delivery device including a mouthpiece, a reservoir for containing aerosolizable material, and an aerosolization chamber. The aerosol delivery device features an aerosol tube connecting the mouthpiece to the aerosolization chamber and a heating element within the chamber to convert the material into aerosol. The device also has an air inlet and a selective flow portal located between the air inlet and the aerosolization chamber, which permits airflow into the chamber while preventing or inhibiting fluid flow out.

Description

APPARATUS AND METHOD FOR AIRFLOW MANAGEMENT AND LIQUIDENTRAPMENT IN AEROSOL DELIVERY SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 721,661, filed on November 18, 2024, and titled “APPARATUS AND METHOD FOR AIRLOW MANAGEMENT AND LIQUID ENTRAPMENT IN AEROSOL DELIVERY SYSTEMS,” and claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 661,625, filed on June 19, 2024, and titled “ORAL NICOTINE DISPENSING SYSTEM,” both of which are incorporated by reference herein in their entirety'.BACKGROUND

[0002] The issue of tobacco use and addiction is a pressing concern for regulatory bodies and public health organizations worldwide. Cessation and reduction of tobacco use is crucial for improving both individual and public health. It significantly reduces the risk of developing various diseases, including cardiovascular disease, chronic obstructive pulmonary disease (COPD), stroke, and several types of cancer, particularly lung cancer. Furthermore, tobacco cessation contributes to better quality of life, as individuals experience improved physical fitness, better taste and smell, and improved respiratory function. On a broader scale, smoking cessation reduces healthcare costs associated with treating smoking-related diseases, helps improve air quality, and reduces exposure to secondhand smoke, which can be harmful to non-smokers, especially children and pregnant women.

[0003] Tobacco-free nicotine alternatives are an important diversionary tool in smoking and tobacco cessation efforts. Among these, vaporizers and aerosol delivery' devices have enjoyed particular attention and success as an alternative nicotine delivery method. Such products may be desirable alternatives to those attempting to reduce or quit smoking because the provide the look and feel of a familiar device (i.e., a cigarette) while having a significantly more desirable safety' profile and reduced health risks, in comparison to traditional tobacco products. Aerosol delivery devices may be provided as a system with a disposable cartridge containing an aerosolizable material, coupled with a reusable base (including, e.g., electronic components of the device), or may be provided as disposable device with an integrated reservoir (i.e., the portion containing the aerosolizable material) and electronics.

[0004] In either configuration, conventional aerosol delivery devices have had persistent challenges in controlling fluid flow. For example, channels must be provided within the device for necessary' airflow to allow for user inhalation and provision of aerosols. However,such channels may also allow for liquid leaking and migration into undesirable locations, such as, e.g., excess liquid leaking from the aerosolization chamber and out of the device or into the base of the device, or aerosol condensate near a mouthpiece leaking out of the mouthpiece as liquid. Liquid migration into electrical components of the device may damage such components and make them inoperable. Further, liquid leakage can be troublesome and undesirable to a user, providing friction points and difficulties which may discourage users from their tobacco cessation efforts. Accordingly, solutions are needed for these issues, in order to provide safer nicotine alternatives in an easy and low-friction manner for adult consumers, in order to facilitate tobacco or smoking cessation.BRIEF SUMMARY

[0005] Provided herein is an aerosol delivery device configured to prevent leakage or migration of liquid from the aerosolization chamber. According to some aspects, the disclosed aerosol delivery device may include a mouthpiece, an aerosolization chamber, and an aerosol tube connecting these two parts. The device may also feature a heating element, or other aerosolization mechanism, within the aerosolization chamber to convert aerosolizable material into an aerosol. Additionally, the device may include an air inlet, through which air can be drawn into the aerosolization chamber, and a selective flow portal disposed between the air inlet and the aerosolization chamber, which allows for the flow of air into the aerosolization chamber while preventing the flow of liquid out of the aerosolization chamber. The disclosed aerosol delivery devices may include disposable aerosol delivery devices and cartridge / base systems.

[0006] An aerosol delivery device may include a mouthpiece, a reservoir with a chamber for holding aerosolizable material, and a base equipped with a power source. The device may also contain an aerosolization chamber and an aerosol tube facilitating fluid communication between the mouthpiece and the aerosolization chamber. Within the aerosolization chamber, a heating element may convert the aerosolizable material into an aerosol. The device may include an air inlet that connects the aerosolization chamber to the outside environment and features a selective flow portal. This portal may allow airflow into the aerosolization chamber via the air inlet but may block fluid from flowing out through the same path.

[0007] In some embodiments, the selective flow portal is a duckbill valve with a first and second flap that define a slit between them. The flaps of the duckbill valve are made of materials such as rubber, artificial elastomer, or silicone.

[0008] In specific configurations, the aerosolization chamber is formed by a reservoir base coupled with a vapor channel seal. The air inlet might be a single opening in the bottomsurface of the reservoir base, and the duckbill valve could be positioned within this inlet. Alternatively, the slit of the valve is aligned flush with the interior of the aerosolization chamber. Additionally, a wick may be partially placed within the aerosolization chamber, with the chamber featuring multiple liquid feed channels connecting to the reservoir chamber. The wick extends through these channels into the reservoir chamber.

[0009] A cartridge intended for use with an aerosol delivery7device may feature a mouthpiece, a reservoir with a chamber for aerosolizable material, and an aerosolization chamber. An aerosol tube may establish fluid communication between the mouthpiece and aerosolization chamber. Like the delivery device, it may include a heating element within the aerosolization chamber to convert the material into an aerosol, an air inlet, and a selective flow portal to manage airflow.

[0010] In some versions, the cartridge’s flow portal is also a duckbill valve with flaps that form a slit. The cartridge's aerosolization chamber could be defined by a reservoir base with a vapor channel seal, with the air inlet placed as an opening in the bottom surface of this base. Within the inlet, the duckbill valve might be placed, with its slit flush with the aerosolization chamber's interior. The cartridge may also include a wick that partially resides within the aerosolization chamber and traverses liquid feed channels to extend into the reservoir chamber.TERMS AND DEFINITIONS

[0011] As used in the specification and the appended claims, the singular forms “a,” “an,'’ “the” and the like include plural referents unless the context clearly dictates otherwise. Also, while reference may be made herein to quantitative measures, values, geometric relationships or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to engineering tolerances or the like.

[0012] As used herein, “active ingredient” refers to a chemical component that is biologically active and is responsible for the intended therapeutic effects or desired outcomes of a formulation, such as a pharmaceutical product, agricultural product, personal care item, or stimulant product. As used herein, the “active ingredient” may comprise or consist of nicotine. As used herein, “excipient” refers to refers to an inactive substance formulated alongside the active ingredient, serving as the vehicle or medium for active ingredient delivery7. Excipients may help to stabilize, preserve, or enhance the absorption of the active ingredient, and can also improve product characteristics like taste, appearance, and consistency.

[0013] As used herein, "aerosol’7refers to a liquid-in-gas suspension, a vapor, a mist, a steam, or similar. The aerosol may include at least one of an active ingredient and an excipient. As used herein, “aerosolizable material” refers to a material, preferably a liquid, capable of being converted into an aerosol by the aerosol delivery device. The aerosolizable material may include at least one of an active ingredient and an excipient.

[0014] As used herein, “aerosol delivery device” refers a device that generates aerosol such that a user may draw in the aerosol. As used herein, “aerosol delivery' devices” include vaporizers. Electronic Nicotine Delivery Systems (ENDS), inhalers, nebulizers, e-cigarettes, and / or other oral drug delivery devices.

[0015] As used herein, “base” refers to a portion of an aerosol delivery' device, not containing aerosolizable material and containing, e.g.. a power source and other electronic components. A base may be reusable and used in conjunction with a disposable cartridge, or may be disposable and be used integrated with a reservoir in a disposable aerosol delivery device.

[0016] As used herein, “cartridge” refers to a disposable portion of an aerosol delivery device, configured to hold aerosolizable material, and configured to be discarded and replaced when the aerosolizable material has been consumed.

[0017] As used herein, “disposable aerosol delivery device” refers to an aerosol delivery device which is configured to be disposed of in its entirety' (i.e., as opposed to disposal of only a cartridge) when the aerosolizable material is consumed. All components of a disposable aerosol delivery device are typically secured together such that they are not separable during normal use.

[0018] As used herein, “fluid” refers to a substance that flows freely, taking the shape of its container. As used herein, “fluid” may refer to either a gas or a liquid. As used herein, “fluid communication” refers to having a pathway or connection through which a fluid may flow or be transported.

[0019] As used herein, “mouthpiece” refers to an element that a user may touch with their teeth, lips, or both when drawing in aerosol from an aerosol delivery' device.

[0020] As used herein, “reservoir” refers to a portion of an aerosol delivery device configured to contain an aerosolizable material (whether in a cartridge or in a disposable aerosol delivery device.

[0021] As used herein, “first end” refers to an end furthest away from the mouthpiece (typically, adjacent the base) of an aerosol delivery device. “Second end" refers to an end of an aerosol delivery device opposite the first end, along a longitudinal axis (typically, at ordireclty adjacent to. the mouthpiece. "‘Forward” refers to a location closer to the second end.■‘Behind” refers to a location to the first end.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0022] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0023] FIG. 1 illustrates selective flow portals in accordance with certain embodiments.

[0024] FIG. 2 illustrates components of an aerosol deliver)’ device in accordance with one embodiment.

[0025] FIG. 3 illustrates components of an aerosol deliver)' device in accordance with one embodiment.

[0026] FIG. 4 illustrates components of an aerosol deliver)' device in accordance with one embodiment.

[0027] FIG. 5A illustrates components of an aerosol delivery device in accordance with one embodiment.

[0028] FIG. 5B illustrates components of an aerosol delivery device in accordance with one embodiment.

[0029] FIG. 6A illustrates a selective flow portal in accordance with one embodiment.

[0030] FIG. 6B illustrates a selective flow portal in accordance with one embodiment.

[0031] FIG. 6C illustrates a selective flow portal in accordance with one embodiment.

[0032] FIG. 7 illustrates a cross-section of components of an aerosol delivery device in accordance w ith one embodiment.

[0033] FIG. 8 illustrates a cartridge of an aerosol delivery device in accordance with one embodiment.

[0034] FIG. 9 illustrates a cross-section of components of an aerosol delivery device in accordance with one embodiment.

[0035] FIG. 10 illustrates a cross-section of components of an aerosol delivery device in accordance with one embodiment.

[0036] FIG. 11 A illustrates components of an aerosol deliver)' device in accordance with one embodiment.

[0037] FIG. 1 IB illustrates components of an aerosol delivery device in accordance with one embodiment.

[0038] FIG. I IC illustrates components of an aerosol delivery device in accordance with one embodiment.

[0039] FIG. 12 illustrates a cross-section of components of an aerosol delivery device in accordance with one embodiment.

[0040] FIG. 13A illustrates a cross-section of components of an aerosol delivery' device in accordance with one embodiment.

[0041] FIG. 13B illustrates a cartridge of an aerosol delivery device in accordance with one embodiment.DETAILED DESCRIPTION

[0042] A persistent issue with conventional aerosol delivery' devices is leakage of the liquid (i.e., vaporizable material) from a cartridge or a disposable aerosol delivery device. Such leakage may be caused by one or more of improper tolerances of the components, issues during manufacturing assembly, or changes in temperature / pressure. For the latter, this may lead to excessive wicking of aerosolizable material from the reservoir chamber storing into the aerosolization chamber. This may result in unwanted liquid discharge from the cartridge or reservoir air intake openings (which in most constructions need to exist to enable an airflow for the user to inhale). These problems may be further exacerbated by temperature and pressure variations during transportation and storage, causing liquid volumes to expand or contract in a fixed volume compartment.

[0043] Accordingly, provided herein are mechanisms that selectively permit air passage while preventing liquid flow through a portal. Suitable examples of such portals include various valve types, such as duck bill valves, umbrella valves, diaphragm valves, hopper valves, leaf valves, ball check valves, disc valves, and tilting disc valves. Additionally, or alternatively, employing hydrophobic filters — such as hydrophobic membrane filters or silicone pinhole membranes — can further enhance the solution. Other filter materials may also be incorporated for effective management of liquid and air flow.

[0044] The disclosed solutions and mechanisms may be implemented in disposable aerosol delivery devices and cartridge / base systems, certain examples of which are disclosed in more detail in, e.g., U.S. Pat. App. Ser. No. 18 / 370,272, filed on September 19, 2023, and titled “RIDGED MOUTHPIECE FOR AEROSOL DELIVERY DEVICES," and in U.S. Pat. App. No. 18 / 211,706. filed on June 20, 2023. and titled "APPARATUS AND METHOD FOR AEROSOL DELIVERY," the entirety of which are hereby incorporated by reference in its entirety. In general, the present disclosure provides an aerosol delivery device configured to prevent leakage or migration of liquid from the aerosolization chamber. According to someaspects, the disclosed aerosol delivery- device may include a mouthpiece, an aerosolization chamber, and an aerosol tube connecting these two parts. The device may also feature a reservoir capable of containing an aerosolizable material, and a heating element (or other aerosolization mechanism) within the aerosolization chamber to convert aerosolizable material into an aerosol. Additionally, the device may include an air inlet, through which air can be drawn into the aerosolization chamber, and a selective flow portal disposed between the air inlet and the aerosolization chamber, which allows for the flow of air into the aerosolization chamber while preventing the flow of liquid out of the aerosolization chamber.

[0045] Whether a disposable or a cartridge / base system, an aerosol delivery device may ty pically include an outer body, a base disposed at a first end of the device, and a mouthpiece disposed at a second end of the device, along a longitudinal axis. Typically, the base may include many (if not all) of the electrical components of the device. Between the base and the mouthpiece, an aerosol delivery device may include a reservoir configured to hold an aerosolizable material, an aerosolization chamber containing an aerosolization mechanism configured to convert the aerosolizable material into an aerosol, a liquid feel channel in fluid communication with the reservoir and the aerosolization chamber, an aerosol tube in fluid communication with the aerosolization chamber and the mouthpiece, and an air inlet in fluid communication with the aerosolization chamber and an outside environment, to provide airflow to the aerosolization chamber.

[0046] In conventional devices, the air inlet may typically be a site of liquid leakage, e.g., when excess liquid is drawn into the aerosolization chamber via the liquid feed channel. Because the air inlet must be maintained in an open state to allow airflow into the device in order to generate an aerosol, excess liquid may equally flow out of the air inlet. However, in the disclosed devices, a selective flow portal is provided between the aerosolization chamber and the air inlet, the selective flow portal being configured to allow air flow into the chamber but to prevent fluid flow out of the chamber.

[0047] The outer body may include all or part of any of the external surfaces of the aforementioned components. As used herein, an "outer body" is a container configured to encapsulate one or more internal elements. Internal elements may include, e.g., the aerosolization mechanism, a power source, a control circuit, a reservoir chamber, a vapor tube, and fluid flow channels. The outer body may include any suitable material or combination of materials. For instance, the outer body may include at least one of a metal, such as, e.g., aluminum, steel, or the like; a plastic, such as, e.g., polyvinyl chloride (PVC), high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), or the like; a ceramic; a composite material; a fiberglass; or hemp fiber. The outer body may bemanufactured according to any suitable method or combination of methods, including, e.g., casting; molding; subtractive processes such as machining, computer numerical control (CNC) machining, or the like; additive processes such as fused deposition printing, powerbinder printing, selective laser sintering, stereolithography, or the like; lamination; coating; finishing; painting; polishing; engraving; anodization; assembly of parts through adhesion, engineering fits, fastening, fusing or the like; or any combination thereof.

[0048] The base of an aerosol delivery' device may typically include most, or all, of the electrical components of the device. For example, the base may include, at minimum, a power source for the device and may additionally include, e.g., one or more of a control circuit, a processing circuit, or the like. As used herein, a "power source" is an element configured to provide electric power to a circuit, device, or both. The power source may include, e.g., a battery containing one or more cell chemistries such as, without limitation, lithium cobalt oxide (LCO), lithium nickel cobalt aluminum oxide (NCA), lithium nickel manganese cobalt oxide (NMC), lithium iron phosphate (LFP), and the like. In some instances, the power source may be rechargeable. In some cases, a power source may be electrically connected to and configured to transmit power to, any one or more of a plurality of electronic devices or components within the aerosol delivery device which require electricity to operate such as, e.g., a processing circuit, a control circuit, and / or any computing device described herein. In some cases, transmitting electric power may include using one or more continuous conductors, such as a continuous conductive wire. As used in this disclosure, a "continuous conductor" is an electrical conductor, without any interruption, made from electrically conducting material. Electrically conductive material may include any material that is conductive to electrical current and may include, as a nonlimiting example, various metals such as copper, steel, or aluminum, carbon conducting materials, or any other suitable conductive material.

[0049] In some cases, the base may additionally include a control circuit configured to control a status of a component of an aerosol delivery' device. A control circuit may be implemented, e.g., as an application-specific integrated circuit (ASIC), a reconfigurable hardware circuit such as a field-programmable gate array (FPGA). as a microprocessor, microcontroller, an analog circuit such as without limitation an operational amplifier circuit, or as any other circuit capable of generating a signal. In some embodiments, without limitation, a control circuit may be further configured to control other elements, components, and / or devices the aerosol delivery device, such as at least one of the aerosolization mechanism or the power source. For instance, the control circuit may be configured to direct,control, or otherwise regulate the output of electric power from the power to other components that require electric power input such as, without limitation, the aerosolization mechanism.

[0050] Further, in some instances, the base may include a processing circuit configured to perform processing and / or memory functions. The processing circuit may be configured to carry out any processing steps described in this disclosure. Processing circuit may include any computing device as described in this disclosure, including without limitation a microcontroller, microprocessor, digital signal processor (DSP) and / or system on a chip (SoC). Processing circuit may interface or communicate with one or more additional devices as described below in further detail via a network interface device.

[0051] In some embodiments, the base may include a charging connector, which may include a circuit or circuit element by means of which electric power may be transferred from an external power source to a power source of the aerosol delivery device. For instance, e.g., the charging connector may include an inductive charging coil whereby electrical power is transferred to the inductive charging coil using a varying exterior magnetic field supplied by another device or a conductive connection from the aerosol delivery device to an external device or power source. For example, the conductive connection may include two or more charge contacts, which may be constructed of conductive material and accessible from an outside environment such as the first end. Charge contacts may be electrically connected to the power source of the aerosol delivery device by any suitable connection such as charging pins which may contact one or more conductive elements including springs, clips, and / or a printed circuit board (PCB). Charging pins may include male and / or female connectors; for instance, charging pins may include a "plug" that projects from the outer body and may include holes into which a plug or one or more projecting conducting pins may be inserted. Additionally, or alternatively, charging connector on back end may include a magnetic contact.

[0052] In some embodiments, the base may include additional electrical components such as a biometric sensor, a radiofrequency chip such as an NFC or RFID chip, a printed circuit board ("PCB"), a pressure sensor, a light element, or similar.

[0053] In either disposable or cartridge / base type devices, the device may include a reservoir. In disposable devices, the reservoir may be integrated with and / or permanently coupled to the base, such that the reservoir and base are not separated during normal use. In contrast, in cartridge / base systems, the reservoir may be part of the cartridge which may be normally separable from the base. In either instance, the reservoir may include an outer body defining an interior reservoir chamber configured to contain an aerosolizable material.According to some embodiemnts. the reservoir may be made of durable (PCTG) plastic, resistant to impact, corrosion, and heat, preventing contamination of the aerosolizable material. In some instances, the reservoir may be fully recyclable.

[0054] The aerosolizable material may include an active ingredient, including, e.g., pharmaceutical chemicals, recreational chemicals, flavor-bearing chemicals, and the like. The active ingredient may be extracted, without limitation, from plant material, and / or a botanical, such as tobacco or other herbs or blends. In a preferred embodiment, the active ingredient comprises or consists of nicotine. In some cases, aerosolizable material may additionally include an excipient, such as a humectant. As used herein, a "humectant" is a substance used to keep things moist. The humectant may attract and retain moisture in the air by absorption, allowing the water to be used by other substances. The humectant may include, one or more of propylene glycol, sugar polyols such as glycerol, glycerin, honey and the like thereof.

[0055] According to some embodiments, the reservoir (or alternatively, any other component of the aerosol delivery' device) may include a status indicator located on a surface of outer body. As used herein, a "status indicator" is an element that continuously or intermittently indicates a status of an aerosol delivery device, or any component thereof. A status may include, without limitation, an internal state of a processing circuit, a state of a power source, a state of an aerosol generation mechanism and the like. In some embodiments, the status indicator may include a passive status indicator, wherein the passive status indicator may be a status indicator with physical configurations on the outer body which enable one or more indications of current apparatus state. In anon-limiting example, passive status indicator may be located on a surface of the outer body, e.g., of the reservoir, where at least a portion of the surface is transparent and / or hollow window. The window may allow a user to observe elements, components, or otherwise devices inside outer body, such as a liquid fill level.

[0056] The aerosolization chamber may house an aerosolization mechanism, and may be located in one or more of the reservoir, the base, or any other component of the aerosol delivery device. The aerosolization chamber may include or be formed of any suitable material, such as silicone, plastic, or the like. The aerosolization mechanism may include one or more of a heating element, a wick, a nebulizer, a heating chip made of glass, a heating chip made of crystal, a heating chip made of metal, or the like. The aerosolization chamber may include at least one air inlet, configured to provide airflow from an outside environment, through the aerosolization chamber to produce an aerosol, which is then directed through the vapor tube to the mouthpiece. According to some aspects, the vapor tube may include or be formed of one or more of silicone, plastic, or metal. According to some embodiments, the vapor tube may be continuously formed and permanently attached to at least one of theaerosolization chamber and / or the mouthpiece, while in alternative embodiments, the vapor tube may be a separate component which may be inserted into, snapped onto, or otherwise non-permanently coupled with the aerosolization chamber and / or the mouthpiece. The aerosolization chamber may additionally include a liquid feed channel, such as one liquid feed channel, two liquid feed channels, or two to four liquid feed channels, configured to provide aerosolizable material from the reservoir to the aerosolization chamber. When too much aerosolizable material is provided from the reservoir the aerosolization chamber via the liquid feed channel, e.g., when the aerosolizable liquid is provided at a faster rate than it is consumed (i.e., converted into an aerosol), the excess liquid may leak out of the air inlet.

[0057] In order to prevent and / or to mitigate such leakage, the disclosed aerosol delivery devices may include a selective flow portal provided between, or at the point of, the air inlet into the aerosolization chamber. The selective flow portal may be configured to allow for the necessary fluid flow of air into the aerosolization chamber, while simultaneously preventing or obstructing passage for fluid (e g., aerosolizable material) from the aerosolization chamber out of the air inlet. According to some aspects, the selective flow portal may be a directional flow portal. That is, a directional flow portal may allow for fluid flow (either liquid or air) in one direction while preventing or inhibiting fluid flow (either liquid or air) in the opposite direction. As shown in FIG. 1 , examples of directional flow portals may include leaflet valves, ball valves, umbrella valves, diaphragm valves, check valves, tilting disc valves, and similar. In some aspects, the selective flow portal may include a material selective flow portal, configured to allow passage of certain materials (e.g., air) while preventing passage of other materials (e.g.. liquids). Examples of material selective flow portals may include hydrophobic filters, low porosity materials, cottons, capillary plugs, or similar.

[0058] According to some aspects, the selective flow portal, e.g., the directional flow portal or valve, may incorporate or be formed of at least one of electroactive polymers (EAPs) or dielectric elastomers. These materials can alter their shape, size, or mechanical properties when subjected to an electric field. Notably, according to some embodiments, the stiffness of the selective flow portal or its components (e.g., a valve leaflet, the flap in a duckbill valve, etc.) may be a critical parameter, as it may governs the ease with which, e.g., a valve opens in response to a user's inhalation or the pressure dynamics within the system. For instance, a valve embedded with EAPs or dielectric elastomers can be designed to be sufficiently stiff to resist a user’s inhalation, effectively blocking airflow under normal conditions. However, when an electrical signal from the vaporizer is activated — such as by passing a certain voltage — the apparent stiffness of the valve may decrease, allowing the valve to open and permitting airflow when desired.

[0059] This mechanism may be integrated with user verification actions, such as inserting a genuine cartridge into a vaporizer base, through a cartridge identifier, via either a resistancebased method or a chip in the cartridge. According to other embodiments, the user verification action may include performing an unlocking command linked to biometric verification methods like fingerprint scanning or other biometric identification techniques to confirm the user's identity or age. Certain examples of such verification methods and devices are disclosed in more detail in, e.g., U.S. Pat. App. No. 18 / 211,706, filed on June 20, 2023, and titled "APPARATUS AND METHOD FOR AEROSOL DELIVERY." U.S. Pat. App. No. 18 / 211,726, filed on June 20, 2023. and titled "APPARATUS AND METHOD FOR UNIQUE INDENTIF1CAT1ON OF AN OBJECT USING NEAR-F1ELD COMMUNICATION (NFC)." U.S. Pat. App. No. 18 / 918,246, filed on October 17, 2024, and titled "APPARATUS AND METHOD FOR BIOMETRIC ACCESS CONTROL," U.S. Pat. App. Ser. No. 18 / 410,193, filed on January 11, 2024, and titled “APPARATUS AND METHOD FOR PREVENTING YOUTH ACCESS AND COUNTERFEIT AEROSOL DELIVERY,’7each of which is hereby incorporated by reference in its entirety.

[0060] Through this approach, the selective flow portal may remain sealed against unauthorized inhalation / airflow or unauthorized use until authorization steps are completed, only after which an appropriate electrical signal unlocks the user-responsive inhalation process.

[0061] The mouthpiece may be provided at the second end of the aerosol delivery device, such as, e.g., at an opposite end to the base. The mouthpiece may include an opening through which a user inhales vapor. For example, the mouthpiece may include one or more apertures through which vapor may be drawn when a user inhales, optionally a passage through which vapor passes to the aperture, one or more inlets to permit passage of air through the mouthpiece, and / or any other suitable feature. In some cases, the passage and / or the inlet of the mouthpiece may be provided by or may be continuous with the vapor tube. The mouthpiece may be tapered or otherwise shaped to fit in a user's mouth with ease and comfort.

[0062] According to some aspects, the disclosed aerosol delivery device may be a disposable aerosol delivery device. As exemplified in FIG. 2, the disposable aerosol delivery device may include a base 206 and a reservoir 208. Although not shown, the disposable aerosol delivery device may include a mouthpiece at a second end of the device. In some embodiments, mouthpiece may be located on an opposite end to the base. The mouthpiece may include an element of the device through which a user inhales an aerosol. In some embodiments, the mouthpiece may include one or more apertures through which vapor may be drawn when a user inhales, a passage through which vapor passes to the aperture, one or more inlets topermit passage of air through mouthpiece, and / or any other suitable feature. The mouthpiece may be tapered or otherwise shaped to fit in a user's mouth with ease and comfort.

[0063] The base 206 may be disposed directly adj acent a first end 202 of the device and may include at least a power source, and optionally, additional electrical components as described above. Both the base 206 and the reservoir 208 may have external surfaces defined by outer body 212. According to some aspects, outer body 212 may be capped by a body base 210 at first end 202. In some cases, body base 210 may include a body base seal (not shown), wherein the body base seal is a component that seals the connection between outer body 212 and body base 210, preventing leaks and ensuring proper functioning of the device. According to some embodiments, body base 210 may include a base plug (not shown) to a PCB (not shown), wherein the base plug may include, e.g., a transmitter, a separate PCB, a pressure sensor, a light element, and / or the like. For instance, base plug may include a separate PCB with integrated pressure sensor. According to another example, base plug may also include a base light, wherein the base light may be consistent with a status indicator, as described above. Additionally, or alternatively, the base plug may include a lighting scheme, wherein the lighting scheme may include one or more openings that allow light to shine through. In some cases, lighting scheme may include an opening in a shape of a logo or a shape of an initial of company producing the aerosol delivery device.

[0064] According to some embodiments, reservoir 208 may include a reservoir chamber 220 configured to hold an aerosolizable material, a reservoir fill port 228, a channel 214. a vapor tube 216, a vapor channel seal 222, a reservoir base 224, an aerosolization chamber 218, and an air inlet. Channel 214 is a pathway or a passage through which an aerosol may flow. Channel 214 may also be encased by a cotton absorption pad (not shown), centered around channel 214. Channel 214 may either be molded into the reservoir 208 as an extension of a vapor tube 216 or they may be separate components. Vapor tube 216 may either be molded as part of reservoir 208 or be a separate component, optionally made of a different material, and inserted later on. Vapor tube 216's function may be to transport an aerosol from the aerosolization chamber 218 to user. Air for generation of an aerosol may be provided to the aerosolization chamber 218 via an air inlet in fluid communication with the aerosolization chamber 218. According to the present disclosure, a selective flow portal 100 may be disposed between an outside environment and the aerosolization chamber 218, along an air flow path form the outside environment to the aerosolization chamber 218 via the air inlet. The disclosed selective flow portal 100 may allow for passage of air into the aerosolization chamber 218, while prevent leaking of liquid out of the aerosolization chamber 218 via the air inlet.

[0065] According to some aspects, reservoir 208 may include a reservoir fill port 228, wherein the reservoir fill port 228 may include a small opening on reservoir 208 and / or outer body 212 of the device that allows the user to fill reservoir 208 with a user-preferred aerosolizable material. In some cases, reservoir fill port 228 may be located on the top (i.e., nearer the second end) of reservoir 208 and be covered by or stoppered by a reservoir fill port seal (not shown). As described herein, a "reservoir fill port seal" is a seal that prevents aerosolizable material from leaking out of a reservoir fill port. In some cases, the reservoir fill port seal may include a removable cap or plug. Once reservoir 208 is filled, the reservoir fill port seal may be placed into reservoir fill port 228, sealing the reservoir fill port 228 and preventing liquid from leaking out.

[0066] Reservoir 208 may additionally be in fluidic communication with aerosolization chamber 218 which may include an aerosolization mechanism such as, e.g., a heating coil (i.e., a wire coil that heated to convert the aerosolizable material to an aerosol). A vapor channel seal 222 may be placed at the base of vapor tube 216 and may partially define the aerosolization chamber 218 to assist controlling of wicking and liquid flow into the aerosolization chamber 218. According to some aspects, the vapor channel seal 222 may couple with reservoir base 224 to define the aerosolization chamber 218 therein. Vapor channel seal 222 and reservoir base 224 may snap together, may be adhered together, or secured together by any other suitable means. A "vapor channel seal," as described herein, is a sealing component that ensures an airtight seal and leak-proof seal within vapor path or airway.

[0067] According to some embodiments, the aerosolization chamber may contain an aerosolization mechanism, such as a heating element. In some embodiments, the aerosolization chamber may also include a wick 226. such as a cotton wick which may help to direct aerosolizable material into the aerosolization chamber 218 and ensure that the aerosolizable material comes into contact with the aerosolization mechanism. The wick 226 may absorb aerosolizable material and direct it from the reservoir chamber 220 through a liquid feed channel to the aerosolization chamber, where it may be converted into an aerosol, which may be then inhaled by the user.

[0068] As exemplified in an exploded view in FIG. 3, in a disposable aerosol delivery device 200, the base 206 may be permanently coupled with the reservoir 208. As such, the base 206 and reservoir 208 may not be separable during normal usage. Base 206 and reservoir 208 may be permanently coupled by any suitable means including, e.g., adhesives, snapping, detent features, sealing, soldering, or the like. As shown in the exploded view in FIG. 3, reservoir 208 and base 206 may be connected by an electrical contact 302. The disclosed electricalcontact may include one electrical contact or a plurality of electrical contacts such as, e.g., two electrical contacts, or two to four electrical contacts. Such electrical contacts may include one or more of pins, electrodes, wires, conductive strips, foils, printed electrodes, or the like. According to some embodiments, as shown in FIG. 3, electrical contact 302 may extend from reservoir 208 to make physical contact with, and thereby establish electrical communication with, the electrical systems and circuits of the base. According to some embodiments, the electrical contact 302 be electrically connected to the aerosolization mechanism, e.g., the heating element, and may serve to connect the aerosolization mechanism to the power source in the base 206. According to some embodiments, a reservoir battery seal 304 may be disposed in between reservoir 208 and base 206 (i.e., under reservoir base 224 and above base 206), wherein the reservoir battery seal 304 may serve as a secondary protection for the power source and electrical systems, preventing aerosolizable material from leaking out through reservoir base 224 and into power source 380. Such leaking may additionally be mitigated by the disclosed selective flow portal 100. fitted between the air inlet and the aerosolization chamber 218.

[0069] As shown in FIG. 4. according to some embodiments, aerosolization chamber 218 may be insertable into and housed within reservoir 208, nearer the second end of the aerosol delivery device. As depicted in more detail in the exploded view shown in FIGS. 5A-B, the aerosolization chamber 218 may be defined by a reservoir base 224 coupled to a vapor channel seal 222. According to some embodiments, the aerosolization chamber 218 may include an aerosolization chamber seal 506 disposed between the reservoir base 224 and the vapor channel seal 222. The aerosolization chamber seal 506 may formed of rubber, silicone, an elastomer, or any other suitable material, such that it may be configured to provide a tight and resilient seal between the reservoir base 224 and the vapor channel seal 222 so as to prevent leakage of fluids therefrom. The aerosolization chamber 218 may contain an aerosolization mechanism 508. such as a heating element 510. According to an exemplary embodiment, this may be a heating coil, as shown in FIG. 5B. According to some embodiments, the aerosolization chamber 218 may house a wick 226, configured to direct aerosolizable material from the reservoir chamber 220 into the aerosolization chamber 218.

[0070] According to some aspects, the wick 226 may extend through a liquid feed channel 512. According to some embodiments, the liquid feed channel 512 may be formed as a hole, aperture, channel, or other passage into the aerosolization chamber. In some embodiments, the liquid feed channel 512 may be formed in the reservoir base 224 or the vapor channel seal 222. In other embodiments, the liquid feed channel 512 may be formed at the coupling point between the reservoir base 224 and the vapor channel seal 222, as shown in FIGS. 5A-B.

[0071] According to some aspects, the aerosolization chamber 218 may include an air inlet 504. According to some embodiments, as shown in FIG. 5B, the air inlet 504 may be formed in the reservoir base 224. Additionally or alternatively, one or more air inlets 504 may be formed in the vapor channel seal 222 and / or in other components of the aerosolization chamber, so long as the air inlet 504 defines a passage from an outside environment into the aerosolization chamber 218. According to a preferred embodiment, as shown in FIG. 5B, the air inlet may be formed as a cylindrical opening provided in the center of the reservoir base 224, behind the heating element 510. According to the present disclosure, a selective flow portal 100 may be provided between the air inlet 504 and the aerosolization chamber, or along the air inlet 504. According to one example, as shown in FIG. 5B, the selective flow portal 100 may be a duckbill valve 602. According to some aspects, the aerosolization chamber 218 may additionally be provided with an aerosolization chamber cap 502 fitted to the reservoir base 224. In some embodiments, the aerosolization chamber cap 502 may be fitted behind the air inlet 504 and the selective flow portal 100.

[0072] While air for generation of an aerosol may be provided to the aerosolization chamber 218 via air inlet 504 in fluid communication with the aerosolization chamber 218, the air inlet 504 may also allow for undesirable leakage of liquids out of the same opening. According to the present disclosure, a selective flow portal 100 may be disposed between an outside environment and the aerosolization chamber 218, along an air flow path form the outside environment to the aerosolization chamber 218 via the air inlet. The disclosed selective flow' portal 100 may allow for passage of air into the aerosolization chamber 218, while prevent leaking of liquid out of the aerosolization chamber 218 via the air inlet. According to some aspects, the selective flow' portal may be a directional flow portal configured to preferentially allow fluid flow' in a single direction. In some aspects, the selective flow' portal may include a material selective flow portal, configured to allow passage of certain materials (e.g., air) while preventing passage of other materials (e.g., liquids).

[0073] Among the directional flow portals, as illustrated in FIGS. 6A-C, a duckbill valve 602 may be used as the selective flow portal 100. According to some aspects, duckbill valve 602 may include a valve base 604 configured to couple the duckbill valve 602 with an opening, such as the air inlet, or with a channel, pipe, tube, or the like. The duckbill valve 602 may be secured to the opening, channel, or the like via a threaded connection, a snap, a seal, an adhesive, or the like. The duckbill valve 602 may include flaps 606, such as a first flap 606a and a second flap 606b, defining a slit 608 therebetween. According to some embodiments, at least the flaps 606 of the duckbill valve 602 may be formed of a flexible material, such as a rubber, an artificial elastomer, a silicone, or the like. In its natural state.the flaps 606 of the valve may have a flattened shape in which slit 608 is closed. However, when pressure is applied upstream (or conversely, negative pressure is formed downstream, such as when a user inhales), the flaps 606 may expand and the slit 608 may open, allowing for fluid flow through the valve in a flow direction 610. Conversely, when this pressure differential is no longer present, the natural pressure downstream of the valve may cause the flaps 606 to flatten again, closing slit 608 and preventing flow in a direction opposite to the chosen flow direction (i.e., the inhibited direction 612). Thereby, the duckbill valve 602 may allow for air intake when a user inhales, while preventing undesirable outflow of fluid such as, e.g., excess aerosolizable material.

[0074] In order to implement a duckbill valve 602 as the selective flow portal 100 between the air inlet and the aerosolization chamber in an aerosol delivery' device, it may be important to provide a valve having the appropriate dimensions to respond to the pressure differentials created when a user inhales, while preventing, e.g.. undesirable opening of the valve during pressure differentials that may be created inadvertently when the device is subjected to temperature changes during manufacturing, shipping, or storage. According to some embodiments, the duckbill valve 602 may have a slit 608 having a length of 1.0 mm to 3.0 mm, 1.0 mm to 2.0 mm. 1.0 mm to 1.40 mm, 1.1 mm to 1.3 mm. or most preferably 1.15 mm to 1.25 mm. The duckbill valve may further have a height 614 from the base to the slit of 2.50 mm to 3.50 mm, 2.60 to 3.30 mm, 2.70 mm to 3.20 mm, 2.80 mm to 3.10 mm, or most preferably 2.90 to 3.0 mm.

[0075] The duckbill valve 602 disclosed herein may be equally applied to any cartridge / based system as disclosed herein. Similarly, rather than a duckbill valve 602, the selective flow portal 100 in either a disposable aerosol delivery' device or a cartridge / base system may be one or more of a flapper valve, a leaflet valve, a ball check valve, an umbrella valve, a diaphragm valve, a disc valve, a tilting disc valve, a high density polyethylene ("HDPE") spunlace membrane disc, a hydrophobic membrane filter, a silicon pinhole membrane, a wicking material, a or a cotton disc or plug.

[0076] According to one exemplary embodiment, as shown in FIG. 7. the selective flow portal 100, e.g., the duckbill valve 602, may be placed inside the air inlet 504 disposed in a bottom surface of the reservoir base, the bottom surface being the surface disposed nearest the base. According to an exemplary embodiment, the air inlet 504 may be formed as a cylindrical opening in the reservoir base 224. In some embodiments, the air inlet 504 may be fitted within the air inlet 504 such that it sits flush with an interior surface of the aerosolization chamber 218. This configuration may be advantageous in that if may allow for control of fluid flow in and out of the aerosolization chamber 218, without the selective flow portal 100intruding into the aerosolization chamber 218. However, in alternative embodiments, the selective flow portal may be fitted to either end of the air inlet 504, i.e., extending into the heating chamber or disposed outside of the reservoir base 224, i.e., behind the reservoir base.

[0077] According to some aspects, the disclosed aerosol delivery device may be a cartridge / base system, certain examples of which are disclosed in more detail in, e.g., U.S. Pat. App. Ser. No. 18 / 410,193, filed on January 11, 2024, and titled ‘ APPARATUS AND METHOD FOR PREVENTING YOUTH ACCESS AND COUNTERFEIT AEROSOL DELIVERY / ’ which is incorporated by reference herein in its entirety. Such systems may have a base including any one or more of the features and electrical components disclosed above with respect to disposable systems. Further, such systems may include a cartridge, as exemplified in FIG. 8, having at least an outer body 212, a reservoir 208, an aerosolization chamber, an aerosolization mechanism, a mouthpiece 802, a vapor tube, a liquid feed channel, and an air inlet 504, according to any of the disclosures above. However, in such systems, the cartridge may be separable from the base during normal usage. For example, the cartridge may be disposed of when the aerosolizable material is consumed and replaced with a new cartridge which is then coupled to the base.

[0078] Conventional cartridges may suffer from the leakage problems disclosed above, wherein excess aerosolizable material fed to the aerosolization chamber via the liquid feed channel may leak out of the air inlet, thereby causing inconvenience to a user and waste of aerosolizable material as well as potential damage to electrical components housed within the base. Accordingly, the disclosed cartridges may include a selective flow portal disposed at, in, forward of, or behind the air inlet. The selective flow portal may be any of the selective flow portals disclosed herein, such as, e.g., any one or more of those disclosed in FIG. 1.

[0079] According to some aspects, among the directional flow portals, as exemplified in FIG. 9, the selective flow portal 100 may comprise or consist of an umbrella valve 902. The umbrella valve 902 may have a shaft 904, a sealing flange 906, and a retention flange 908. The sealing flange 906 may be disposed forward along the shaft 904 from the retention flange 908. As illustrated in FIG. 9, umbrella valve 902 may be disposed partially within a retention channel 910 such that the retention flange 908 and a portion of the shaft are disposed within the retention channel 910, and the sealing flange 906 is disposed outside of the retention channel 910. The retention channel 910 may have a diameter or cross-section corresponding to the diameter or cross section of the retention flange 908, and may have a retention lip 912 providing a diameter smaller than the retention flange 908.

[0080] According to some embodiments, the shaft 904 may have a constant diameter or cross-section (i.e., it may be cylindrical, rectangular, or the like), while in other embodiments, it may have a non-constant diameter or cross-section (e.g., if may have a pyramid or wedge shape, may be curved or contoured, etc.).

[0081] In it's neutral state, the sealing flange 906 may cover and provide a seal over an air inlet 504, such as, e.g., one air inlet, two air inlets, two to six, or two to four air inlets. Accordingly, in its neutral state, no fluid may pass in or out of the air inlet. However, when pressure is applied upstream (or conversely, negative pressure is formed downstream, such as when a user inhales), the valve may flex upstream or translate upstream along the shaft, allowing for fluid flow through the air inlet 504 from an outside environment into the aerosolization chamber. Conversely, when this pressure differential is no longer present, the natural pressure downstream of the valve may cause the sealing flange 906 to close over the air inlet 504, thereby preventing flow in a direction opposite (i.e., out of the aerosolization chamber). Thereby, the umbrella valve 902 may allow for air intake when a user inhales, while preventing undesirable outflow of fluid such as, e.g., excess aerosolizable material. The umbrella valve 902 disclosed herein may be equally applied to any disposable aerosol delivery device as disclosed herein.

[0082] According to some aspects, among the directional flow portals, as exemplified in FIG. 10, the selective flow portal 100 may comprise or consist of a poppet valve 1002. The poppet valve 1002 may have an o-ring 1004. a shaft 904, a flex arm 1006, and a poppet 1008. The poppet valve 1002 may be self-retained by means of the o-ring 1004 securing the shaft 904 and flex arms 1006 within the reservoir base 224. As air is drawn through the mouthpiece by the user the poppet 1008 and shaft 904 may translate inward allowing air to enter the aerosolization chamber 218 through the air inlet 504. Air may pass through the reservoir base 224 in one or more air inlets 504 (a circumferential opening depicted in this image around the full diameter of the valve). The valve is neutrally in the closed state as the flex arms 1006 attached to the shaft 904 wish to maintain a straight orientation and force the o-ring 1004 into the chamfered opening of the reservoir base 224, thus creating a fluid seal. The flex arms 1006 may be molded as part of the shaft 904. insert molded as a spring steel component, or may be assembled to the post.

[0083] Accordingly, in its neutral state, no fluid may pass in or out of the air inlet 504. However, when pressure is applied upstream (or conversely, negative pressure is formed downstream, such as when a user inhales), the valve may flex upstream or translate upstream along the shaft, allowing for fluid flow through the air inlet 504 from an outside environment into the aerosolization chamber. Conversely, when this pressure differential is no longerpresent, the natural pressure downstream of the valve may cause the sealing flange 906 to close over the air inlet 504, thereby preventing flow in a direction opposite (i.e., out of the aerosolization chamber). Thereby, the poppet valve 1002 may allow for air intake when a user inhales, while preventing undesirable outflow of fluid such as, e.g., excess aerosolizable material. The poppet valve 1002 disclosed herein may be equally applied to any disposable aerosol delivery device as disclosed herein.

[0084] According to some aspects, among the directional flow portals, as exemplified in FIGS. 11A-C, the selective flow portal 100 may comprise or consist of a check valve 1102. The check valve 1102 may have a ball 1104 and a spring retention arm 1106. The ball may be disposed within, or at the internal edge (i.e., internal to the aerosolization chamber) of the air inlet 504. The ball may have a diameter that corresponds to, or is greater than, the diameter of the air inlet 504, at least at the internal edge 1110, such that the ball 1104 may seal the air inlet 504 when contacting the air inlet 504. According to some aspects, a funneled surface 1108 may be provided at an internal edge 1110 of the air inlet 504, the funneled surface 1108 having a larger diameter forward of the internal edge 1110, such that the ball 1104 may provide a seal at the internal edge 1110, but may not seal the air inlet 504 as it moves forward of the internal edge 1110.

[0085] A spring retention arm 1106 may be disposed to provide a constant force against the ball 1104 to seal it against the air inlet 504. The spring retention arm 1106 may be formed of spring steel, or any other suitably flexible material. Alternatively, the spring retention arm 1106 may include any feature able to store potential energy (e.g., a spring, a plastic snap arm, compressed rubber, or similar). The spring retention arm 1106 may be retained by the adjacent components (i.e., such as a crossbar 1112), by additional components not shown, or by some other method (example: adhesive, heat staking, snap retention, or other).

[0086] Accordingly, in its neutral state, no fluid may pass in or out of the air inlet 504 as the spring retention arm 1106 may pin the ball 1104 against the air inlet 504. However, when pressure is applied upstream (or conversely, negative pressure is formed downstream, such as when a user inhales), the spring retention arm 1106 may flex upstream, allowing the ball to translate upstream, breaking the seal against the air inlet 504, allowing for fluid flow through the air inlet 504 from an outside environment into the aerosolization chamber. Conversely, when this pressure differential is no longer present, the natural pressure downstream of the valve may cause the ball 1104 to seal back against the air inlet 504. thereby preventing flow in a direction opposite (i.e., out of the aerosolization chamber). Thereby, the check valve 1102 may allow for air intake when a user inhales, while preventing undesirable outflow of fluidsuch as, e.g., excess aerosolizable material. The check valve 1102 disclosed herein may be similarly applied to any disposable aerosol delivery' device as disclosed herein.

[0087] According to some aspects, among material selective flow portals, as exemplified in FIG. 12, the selective flow portal 100 may comprise or consist of a hydrophobic filter 1202. They hydrophobic filter 1202 may comprise one or more of a polytetraflyoroethylene ("PTFE"), a polypropylene ("PP"), a polyvinylidene fluoride ("PVDF"), an expanded PTFE, a silicone coated fabric (either woven or nonwoven), a wax coated fabric (either woven or nonwoven), a microporous PP film, a nonwoven PP fabric with a hydrophobic surface treatment, or similar. They hydrophobic filter 1202 may be disposed inside the air inlet 504, e.g., by means of a press fit, or by other retention means, such as a holder, a clip, a bracket, etc.

[0088] Due to its hydrophobic nature, hydrophobic filter 1202 may prevent or inhibit passage for aqueous compositions, such as the aerosolizable material. However, due to its porosity, the hydrophobic filter 1202 may allow for passage of air when sufficient pressure differentials are provided.

[0089] Accordingly, no aerosolizable material may pass in or out of the air inlet 504 due to the hydrophobic filter blocking air inlet 504 (or, such passage may be significantly inhibited). However, when pressure is applied upstream (or conversely, negative pressure is formed downstream, such as when a user inhales), the pressure differential may allow for air flow through the air inlet 504 from an outside environment into the aerosolization chamber. Thereby, the hydrophobic filter 1202 may allow for air intake when a user inhales, while preventing undesirable outflow of fluid such as, e.g., excess aerosolizable material. The hydrophobic filter 1202 disclosed herein may be similarly applied to any disposable aerosol delivery device as disclosed herein.

[0090] According to some aspects, among material selective flow portals, as exemplified in FIGS. 13A-B, the selective flow portal 100 may comprise a capillary 1302, or a plurality of capillaries, such as 2 to 50 capillaries, 4 to 25 capillaries, 5 to 20 capillaries, or 5 to 15 capillaries. The capillary 1302 may be disposed inside the air inlet 504, e.g., a plug containing the capillary 1302 may be disposed within a larger pre-formed air inlet 504 by means of a press fit, or by other retention means, such as a holder, a clip, a bracket, etc. Additionally or alternatively, the capillary may be molded into the plug or added via a post molding process (e.g., by melting, laser etching, drilling, or the like). Additionally, the capillary may be formed by any suitable method such as micro molding, extrusion, sintering, or post processing. The capillary 1302, e.g., capillary tubes, or intricate pathways with appropriate ratios of diameterto length may prevent liquid egress from the air inlet 504 but may allow air to be passed through the orifices during inhalation.

[0091] Accordingly, no aerosolizable material may pass in or out of the air inlet 504 due to the capillary plug blocking air inlet 504 (or, such passage may be significantly inhibited). However, when pressure is applied upstream (or conversely, negative pressure is formed downstream, such as when a user inhales), the pressure differential may allow for air flow through the air inlet 504 from an outside environment into the aerosolization chamber. Thereby, the capillary 1302 may allow for air intake when a user inhales, while preventing undesirable outflow of fluid such as, e.g., excess aerosolizable material. The capillary 1302 or capillary plug disclosed herein may be similarly applied to any disposable aerosol delivery device as disclosed herein.

[0092] As described herein, the devices, systems, and methods can provide several significant advantages and benefits over other devices, systems, and methods for aerosol delivery' and aerosol delivery' devices, currently available in the art. However, the recited advantages are not meant to be limiting in any way, as one skilled in the art will appreciate that other advantages may also be realized upon practicing the present disclosure. It will be appreciated, moreover, that other applications for the disclosed cans are also possible and considered to fall within the scope of the present disclosure.

[0093] Furthermore, those skilled in the relevant art will recognize that changes can be made to the described embodiments while still obtaining the beneficial results. It will also be apparent that some of the advantages and benefits of the described embodiments can be obtained by selecting some of the features of the embodiments without utilizing other features, and that features from one embodiment may be combined with features from other embodiments in any appropriate combination. For example, any individual or collective features of method embodiments may be applied to apparatus, product or system embodiments, and vice versa. Accordingly, those who work in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances, and are a part of the disclosure. Thus, the present disclosure is provided as an illustration of the principles of the embodiments and not in limitation thereof, since the scope of the invention is to be defined by the claims.LISTING OF DRAWING ELEMENTS100 selective flow portal200 disposable aerosol delivery devicefirst end second end base reservoir body base outer body channel vapor tube aerosolization chamber reservoir chamber vapor channel seal reservoir base wick reservoir fill port electrical contact reservoir battery' seal aerosolization chamber cap air inlet aerosolization chamber seal aerosolization mechanism heating element liquid feed channel602 duckbill valve604 valve base606 flap606a first flap606b second flap608 slit610 flow direction612 inhibited direction614 height802 mouthpiece804 cartridge902 umbrella valve904 shaft906 sealing flange908 retention flange910 retention channel912 retention lip1002 poppet valve1004 o-ring1006 flex arm1008 poppet1102 check valve1104 ball1106 spring retention arm1108 funneled surface1110 internal edge1112 crossbar1202 hydrophobic filter1302 capillary

Claims

CLAIMSWhat is claimed is:

1. An aerosol delivery device, comprising: a mouthpiece; a reservoir comprising a reservoir chamber configured to contain an aerosolizable material; a base comprising a power source; an aerosolization chamber; an aerosol tube providing in fluidic communication between the mouthpiece and the aerosolization chamber; a heating element disposed within the aerosolization chamber, and configured to convert the aerosolizable material into an aerosol; an air inlet in fluid communication with the aerosolization chamber and an outside environment; and a selective flow portal disposed between the outside environment and the aerosolization chamber, configured to allow airflow into the aerosolization chamber via the air inlet while preventing fluid flow out of the aerosolization chamber via the air inlet.

2. The aerosol delivery device of claim 1, wherein the selective flow portal is a duckbill valve comprising a first flap and a second flap, defining a slit therebetween.

3. The aerosol delivery' device of claim 2, wherein the slit has a length within a range of 1.10 mm to 1.30 mm.

4. The aerosol delivery device of claim 2, wherein the duckbill valve has a height within a range of 2.50 mm to 3.50 mm.

5. The aerosol delivery device of claim 2, wherein the first and second flap are made of a rubber, an artificial elastomer, or a silicone.

6. The aerosol delivery device of claim 2, wherein the aerosolization chamber is defined by a reservoir base coupled to a vapor channel seal.

7. The aerosol delivery device of claim 6, wherein the air inlet is a single air inlet formed as an opening in the bottom surface of the reservoir base, the bottom surface being the surface of the reservoir base disposed closest to the base.

8. The aerosol delivery device of claim 7, wherein the duckbill valve is disposed within the air inlet.

9. The aerosol delivery device of claim 8, wherein the slit sits flush with an interior surface of the aerosolization chamber.

10. The aerosol delivery' device of claim 1, further comprising a wick disposed partially within the aerosolization chamber, wherein the aerosolization chamber comprises a plurality of liquid feed channels in fluid communication with the reservoir chamber and the aerosolization chamber, and the wick extends out of the aerosolization chamber through the liquid feed channels and into the reservoir chamber.

11. A cartridge for an aerosol delivery device, comprising: a mouthpiece; a reservoir comprising a reservoir chamber configured to contain an aerosolizable material; an aerosolization chamber; an aerosol tube providing in fluidic communication between the mouthpiece and the aerosolization chamber; a heating element disposed within the aerosolization chamber, and configured to convert the aerosolizable material into an aerosol; an air inlet; and a selective flow portal disposed between the air inlet and the aerosolization chamber, configured to allow airflow into the aerosolization chamber while preventing fluid flow out of the aerosolization chamber.

12. The cartridge of claim 11, wherein the selective flow portal is a duckbill valve comprising a first flap and a second flap, defining a slit therebetween.

13. The cartridge of claim 12, wherein the slit has a length within a range of 1.10 mm and 1.30 mm.

14. The cartridge of claim 12, wherein the duckbill valve has a height within a range of 2.50 mm to 3.50 mm.

15. The cartridge of claim 12, wherein the first and second flap are made of a rubber, an artificial elastomer, or a silicone.

16. The cartridge of claim 12, wherein the aerosolization chamber is defined by a reservoir base coupled to a vapor channel seal.

17. The cartridge of claim 16, wherein the air inlet is a single air inlet formed as an opening in the bottom surface of the reservoir base, the bottom surface being the surface of the reservoir base configured to be disposed closest to a base of the aerosol delivery device when the cartridge is coupled to the base.

18. The cartridge of claim 17, wherein the duckbill valve is disposed within the air inlet.

19. The cartridge of claim 18, wherein the slit sits flush with an interior surface of the aerosolization chamber.

20. The cartridge of claim 19, further comprising a wick disposed partially within the aerosolization chamber, wherein the aerosolization chamber comprises a plurality of liquid feed channels in fluid communication with the reservoir chamber and the aerosolization chamber, and the wick extends out of the aerosolization chamber through the liquid feed channels and into the reservoir chamber.

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