RU2836813C2 - Aerosol delivery device - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: present invention relates to aerosol delivery devices and, in particular, to an aerosol delivery device comprising a reservoir and a spraying unit, which can use electrical energy to evaporate an aerosol precursor composition to form an aerosol. Aerosol delivery device comprises: a casing defining an outer wall, and also including a power supply and a control component; mouthpiece part; part in the form of a container, which includes a reservoir configured to contain a liquid composition; and a spraying unit configured to evaporate the liquid composition for generating an aerosol. Spraying unit comprises a vibration unit, which includes a mesh plate, and a pump unit configured to transfer a portion of the liquid composition from the reservoir to the mesh plate, and wherein the pump assembly is configured to spray the liquid composition directly onto the mesh plate or onto a liquid transfer member which is configured to deliver at least a portion of the liquid composition to the mesh plate.

EFFECT: broader functional capabilities.

9 cl, 17 dwg

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority and benefit from U.S. Provisional Patent Application No. 62/851,318, entitled Reservoir Configuration for Aerosol Delivery Device, filed May 22, 2019, which is incorporated herein by reference in its entirety.

AREA OF TECHNOLOGY

The present invention relates to aerosol delivery devices and, in particular, to an aerosol delivery device comprising a reservoir and a spray unit that can use electrical energy to vaporize an aerosol precursor composition to form an aerosol. In various embodiments, the aerosol precursor composition, which may include materials and/or components that may be made or obtained from tobacco or otherwise contain tobacco or other plants, may include natural or synthetic components including flavors, and/or may include one or more medical components, is vaporized by the spray unit to obtain an inhalable substance for human consumption.

LEVEL OF TECHNOLOGY

Over the years, a variety of smoking devices have been proposed as an improvement or alternative to smoking products that require the combustion of tobacco. It is understood that many of these devices have been designed to provide the sensations associated with smoking cigarettes, cigars, or pipes, but without delivering significant amounts of the incomplete combustion and pyrolysis products that result from the combustion of tobacco. To this end, a variety of smoking products, aroma generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a vaporizable material or attempt to provide the sensations of smoking cigarettes, cigars, or pipes without significantly burning tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generating sources disclosed in the art, as described in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Application Publication No. 2013/0255702 to Griffith Jr. et al., and U.S. Patent Application Publication No. 2014/0096781 to Sears et al., which are incorporated herein by reference in their entireties. Also see, for example, the various types of electrically powered smoking articles, aerosol delivery devices, and sources referenced by trademark and trade information source in U.S. Patent Application Publication No. 2015/0216232 to Bless et al., which is incorporated herein by reference in its entirety.

However, it is preferable to provide an aerosol delivery device with improved functionality. In this regard, it is preferable to provide an aerosol delivery with advantageous elements.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

In various embodiments of the present disclosure, an aerosol delivery device is provided. The present disclosure includes, without limitation, the following exemplary embodiments.

An exemplary embodiment 1: An aerosol delivery device comprising a casing forming an outer wall and also including a power source and a control component, a mouthpiece portion, a container portion which includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit which includes a mesh plate, and the reservoir is configured to rotate relative to the position of the aerosol delivery device.

Exemplary Embodiment 2: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mesh plate is substantially planar.

Exemplary embodiment 3: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the mesh plate is convex with respect to the reservoir.

Exemplary Embodiment 4: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibrating assembly further includes a piezoelectric component attached to and substantially surrounding the mesh plate.

Exemplary embodiment 5: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibration unit is configured to be positioned near a closed portion of the reservoir.

Exemplary embodiment 6: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibration assembly is located near the open portion of the reservoir.

Exemplary embodiment 7: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the reservoir is substantially spherical.

Exemplary embodiment 8: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the reservoir is substantially cylindrical.

Exemplary embodiment 9: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the reservoir is rotatable about one axis.

Exemplary embodiment 10: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, further comprising an intermediate frame configured to connect a reservoir to a housing, wherein the intermediate frame is configured to rotate relative to the housing about a first axis, and the reservoir is configured to rotate relative to the intermediate frame about a second axis, wherein the first and second axes are substantially perpendicular.

An exemplary embodiment 11: An aerosol delivery device comprising a housing that forms an outer wall and also includes a power source and a control component, a mouthpiece portion, a container portion that includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit that includes a mesh plate and a perforated shutter element having a plurality of openings formed therein, wherein the perforated shutter element is located near the mesh plate and between the liquid composition and the mesh plate.

Exemplary embodiment 12: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the perforated shutter element is substantially parallel to the mesh plate.

Exemplary embodiment 13: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, further comprising a chamber formed between the mesh plate and the perforated shutter member.

Exemplary embodiment 14: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the plurality of openings of the perforated shutter element are truncated cone shaped.

Exemplary embodiment 15: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the small ends of the plurality of apertures are located closest to the mesh plate.

Exemplary embodiment 16: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the surface of the perforated shutter element is coated with a coating.

Exemplary embodiment 17: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the coating comprises a hydrophobic/oleophobic coating.

Exemplary embodiment 18: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibrating assembly also includes a piezoelectric component attached to and substantially surrounding the mesh plate.

Exemplary embodiment 19: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mesh plate is substantially planar.

Exemplary embodiment 20: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the mesh plate is convex with respect to the reservoir.

An exemplary embodiment 21: An aerosol delivery device comprising a housing forming an outer wall and also including a power source and a control component, a mouthpiece portion, a container portion which includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit which includes a mesh plate and also includes a liquid transfer element, one end of which is located near the mesh plate.

Exemplary embodiment 22: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the liquid transfer element comprises a single layer of a single material.

Exemplary embodiment 23: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the liquid transfer element comprises a plurality of layers of a single material.

Exemplary embodiment 24: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the liquid transfer element comprises a plurality of layers.

Exemplary embodiment 25: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the liquid transfer element comprises at least one of the following: a polymeric material, a polymeric fibrous material, a cotton material, a silk material, a silica fiber material, a particulate material, a synthetic fibrous material, a natural fibrous material, and a ceramic material.

Exemplary embodiment 26: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibrating assembly further includes a piezoelectric component attached to and substantially surrounding the mesh plate.

Exemplary embodiment 27: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mesh plate is substantially planar.

Exemplary embodiment 28: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the mesh plate is convex with respect to the reservoir.

Exemplary embodiment 29: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the aerosol delivery device comprises a housing that defines an outer wall and also includes a power source and a control component, a mouthpiece portion, a container portion that includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit that includes a mesh plate, and a pump unit configured to transfer a portion of the liquid composition from the reservoir to the mesh plate.

Exemplary embodiment 30: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the pump unit is configured to deliver the liquid composition to the mesh plate on demand.

Exemplary embodiment 31: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the pump unit uses one or more nozzles to transfer the liquid composition to the mesh plate.

Exemplary embodiment 32: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the pump assembly comprises at least one of the following: a dispensing mechanism, a membrane device, and a peristaltic device.

Exemplary embodiment 33: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the dispensing mechanism comprises a shape memory mechanism.

Exemplary embodiment 34: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibrating assembly also includes a piezoelectric component attached to and substantially surrounding the mesh plate.

Exemplary embodiment 35: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mesh plate is substantially planar.

Exemplary embodiment 36: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the mesh plate is convex with respect to the reservoir.

An exemplary embodiment 37: An aerosol delivery device comprising a housing forming an outer wall and also including a power source and a control component, a mouthpiece portion, a container portion that includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit that includes a mesh plate, and a pump unit configured to move a portion of the liquid composition from the reservoir to the mesh plate.

Exemplary embodiment 38: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the pump assembly comprises a compressor.

Exemplary embodiment 39: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the pump assembly includes one or more nozzles.

Exemplary embodiment 40: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the pump assembly uses compressed gas to move the liquid composition toward the mesh plate.

Exemplary embodiment 41: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the compressed gas comprises at least one of the following: air, carbon dioxide (CO2), and nitrogen (N2).

Exemplary embodiment 42: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibrating assembly also includes a piezoelectric component attached to and substantially surrounding the mesh plate.

Exemplary embodiment 43: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mesh plate is substantially planar.

Exemplary embodiment 44: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the mesh plate is convex with respect to the reservoir.

An exemplary embodiment 45: An aerosol delivery device comprising a housing forming an outer wall and also including a power source and a control component, a mouthpiece portion, a container portion that includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit that includes a mesh plate, and the reservoir comprises a U-shaped tube comprising a first portion of the reservoir, a second portion of the reservoir, and a third portion of the reservoir, wherein the third portion of the reservoir is located near the spray unit, and the second portion of the reservoir connects the first portion of the reservoir to the third portion of the reservoir.

Exemplary embodiment 46: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the first reservoir portion has a larger diameter than the diameter of the second and third reservoir portions.

Exemplary embodiment 47: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, further comprising a weight configured to apply a downward force to the liquid composition in the first portion of the reservoir.

Exemplary embodiment 48: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the weight comprises at least one of a weighted disk and a weighted ball.

Exemplary embodiment 49: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the weight further comprises an active component configured to apply a downward force to the weight.

Exemplary embodiment 50: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the reservoir is positioned at an angle relative to the longitudinal axis of the aerosol delivery device.

Exemplary embodiment 51: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mouthpiece portion is located on one side of the body of the aerosol delivery device so as to facilitate use of the device in particular orientations.

Exemplary embodiment 52: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the vibrating assembly also includes a piezoelectric component attached to and substantially surrounding the mesh plate.

Exemplary embodiment 53: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the mesh plate is substantially planar.

Exemplary embodiment 54: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein at least a portion of the mesh plate is convex with respect to the reservoir.

An exemplary embodiment 55: An aerosol delivery device comprising a housing that forms an outer wall and also includes a power source and a control component, a mouthpiece portion, a container portion that includes a reservoir configured to contain a liquid composition, and a spray unit configured to evaporate the liquid composition to generate an aerosol, wherein the spray unit comprises a vibration unit that includes a mesh plate, wherein the reservoir comprises a substantially cylindrical tube, and also comprises a weight containing an active component configured to apply a downward force to the liquid composition in a first portion of the reservoir.

Exemplary embodiment 56: An aerosol delivery device according to any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the active component comprises a spring.

These and other features, aspects and advantages of the present disclosure will become apparent from reading the following detailed description with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more features or elements disclosed in this invention, regardless of whether such features or elements are intentionally combined or otherwise set forth in a particular embodiment described herein. This invention is intended to be read as a whole, so that any individual features or elements of the invention in any of its aspects and embodiments should be considered as intended, namely, as combinable, unless the context of the invention clearly dictates otherwise.

It should be understood, therefore, that this disclosure is provided only for the purpose of briefly describing some exemplary embodiments so as to provide a basic understanding of some aspects of the invention. Accordingly, it should be understood that the exemplary embodiments described above are examples only and should not be construed as in any way narrowing the scope or spirit of the invention. Other exemplary embodiments, aspects and advantages will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of some of the exemplary embodiments described.

BRIEF DESCRIPTION OF DRAWINGS

To facilitate understanding of aspects of the invention, reference is now made to the accompanying drawings, which are not necessarily drawn to scale and in which like elements have like reference numbers. The drawings are provided by way of example to facilitate understanding of aspects of the present disclosure and should not be considered as limiting the present disclosure.

Fig. 1 is a schematic perspective view of an aerosol delivery device comprising a cartridge and a control unit, the cartridge and control unit being shown in a connected configuration according to an exemplary embodiment of the present disclosure;

Fig. 2 is a schematic front cross-sectional view of an aerosol delivery device comprising a cartridge and a control unit, wherein the cartridge and control unit are shown in a disconnected configuration according to an exemplary embodiment of the present disclosure;

Fig. 3 is a perspective view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 4A is a schematic side view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 4B is a schematic side view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 4C is a schematic side view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 4D is a schematic side view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 4E is a schematic side view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 4F is a schematic side view of a portion of a spray assembly according to an exemplary embodiment of the present disclosure;

Fig. 5 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 6 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 7 is a schematic perspective view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 8A is a schematic top view of a portion of a reservoir assembly configured to hold a liquid composition and a spray assembly configured to generate an aerosol from the liquid composition, according to exemplary embodiments of the present disclosure;

Fig. 8B is a schematic top view of a portion of a reservoir assembly configured to hold a liquid composition and a spray assembly configured to generate an aerosol from the liquid composition, according to exemplary embodiments of the present disclosure;

Fig. 8C is a schematic top view of a portion of an aerosol delivery device comprising a reservoir assembly configured to hold a liquid composition and a spray assembly configured to generate an aerosol from the liquid composition, according to exemplary embodiments of the present disclosure;

Fig. 9 is a schematic perspective view of various portions of an aerosol delivery device comprising a reservoir configured to hold a liquid composition and a spray assembly configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 10 is a schematic cross-sectional top view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 11 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 12 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 13 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 14 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 15A is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 15B is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 16 is a schematic side view of various portions of an aerosol delivery device comprising a reservoir configured to hold a liquid composition and a spray assembly configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

Fig. 17 is a schematic side view of a portion of a reservoir configured to hold a liquid composition and a spray unit configured to generate an aerosol from the liquid composition, according to an exemplary embodiment of the present disclosure;

IMPLEMENTATION OF THE INVENTION

The present disclosure is described in more detail below with reference to exemplary embodiments thereof. These exemplary embodiments are described in such a way that the present disclosure thoroughly, completely and fully conveys the scope of the invention to a person skilled in the art. Of course, the present invention can be implemented in many different forms and should not be considered as limited to the embodiments described herein; rather, these embodiments are presented in such a way that the present invention satisfies the relevant legal requirements. In this description and in the appended claims, grammatical constructions indicating the singular also mean the plural, unless the context of the invention clearly dictates otherwise.

As described below, embodiments of the present disclosure relate to aerosol delivery devices or vaporization devices, wherein these terms are used interchangeably herein. Aerosol delivery devices according to the present disclosure use electrical energy to vaporize a material (preferably without burning the material to any significant extent and/or without significantly chemically changing the material) to form an inhalable substance; and the components of such devices are in the form of articles that are most preferably sufficiently compact to be considered portable devices. In other words, use of components of some aerosol delivery devices does not result in the formation of smoke, i.e., from by-products of combustion or pyrolysis of tobacco, but rather, use of these preferred systems results in the formation of vapors formed during the vaporization of an aerosol precursor composition. In some examples, components of aerosol delivery devices can be characterized as electronic cigarettes, and these electronic cigarettes most preferably include tobacco and/or components derived from tobacco, and thus deliver components derived from tobacco in the form of an aerosol. Other examples include devices for delivering tetrahydrocannabinol (THC), cannabidiol (CBD), herbal remedies, medicinal drugs and/or other active ingredients.

Aerosol generating devices of certain preferred aerosol delivery devices can provide a variety of sensations (e.g., inhalation and exhalation rituals, types of tastes and aromas, organoleptic effects, physical sensation, rituals of use, visual cues such as those provided by a visible aerosol, and the like) of smoking a cigarette, cigar, or smoking pipe that are caused by lighting and burning tobacco (and then inhaling the tobacco smoke) without significantly burning any of their components. For example, a user of an aerosol generating device according to the present disclosure can hold and use the device in a manner similar to a smoker using a traditional type of smoking article, by drawing on one end of the device to inhale the aerosol generated by the device, by taking or making draws at selected intervals, and the like.

The aerosol delivery devices of the present disclosure may also be characterized as vapor-generating articles or drug delivery articles. Thus, such articles or devices may be adapted to deliver one or more substances (e.g., flavoring agents and/or pharmaceutical active ingredients) in a form or state suitable for inhalation. For example, the inhalable substances may be substantially in the form of a vapor (e.g., a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, the inhalable substances may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is intended to refer to vapors, gases, and aerosols of a form or type that are suitable for inhalation by a person, whether or not they are visible and whether or not they have a shape that can be considered "smoke-like."

The aerosol delivery devices of the present disclosure most preferably comprise some combination of a power source (e.g., an electrical power source), at least one control component (e.g., means for actuating, controlling, regulating, and stopping the supply of power, such as by controlling the flow of electric current from the power source to other components of the article - such as a microcontroller or a microprocessor), a spray unit, a liquid composition (e.g., typically a liquid aerosol precursor composition capable of forming an aerosol, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece or mouthpiece region for allowing a puff to be taken through the aerosol delivery device to inhale the aerosol (e.g., a defined air flow path through the article such that the generated aerosol can be expelled therefrom after a puff has been taken).

The alignment of the components within the aerosol delivery device may vary. In particular embodiments, the aerosol precursor composition may be located between two opposite ends of the device (e.g., within a cartridge reservoir, which in certain circumstances is replaceable and disposable or reusable). However, other configurations are not excluded. In general, the components are arranged relative to each other such that energy from the spray unit vaporizes the aerosol precursor composition (as well as one or more flavors, medications, and the like, which may also be provided for delivery to the user) and forms an aerosol for delivery to the user. When the spray unit vaporizes 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 above terms are to be considered interchangeable, so that forms of the said term such as "to release, release, releases or released" include forms such as "to form or create, formation or creation, forms or creates and formed or created". In particular, the inhalable substance is released in the form of a vapour or aerosol or a mixture thereof.

More specific formats, configurations and arrangements of components in aerosol delivery devices according to the present invention will be apparent in light of the further disclosure of the invention presented below. In addition, the selection and arrangement of various components of aerosol delivery devices may be understood by considering commercially available electronic aerosol delivery devices, such as those representative products referenced in the "Background of the Invention" section of this disclosure.

Fig. 1 shows an aerosol delivery device comprising a cartridge and a control unit, wherein the cartridge and the control unit are shown in a connected configuration, according to an exemplary embodiment of the present disclosure. In particular, Fig. 1 shows a schematic perspective view of an aerosol delivery device 100 comprising a cartridge 104 and a control unit 102. As shown in the drawing, the cartridge 104 can be aligned to be operated with the control unit 102 permanently or with the ability to be disconnected. In some embodiments, for example, the cartridge and the control unit can comprise one part, while in other embodiments (such as the illustrated embodiment), the connection therebetween can be detachable, such that, for example, the control unit can be reused with one or more additional cartridges, which can be disposable and/or reusable. In various embodiments, various means of interaction can be used to connect the cartridge and the control unit. For example, in some embodiments, the cartridge and the control unit may be connected by one or more of a locking fit interaction, a press fit interaction, a threaded interaction, and a magnetic interaction. It should be noted that the components shown in this and other figures are a typical example of components that may be present in the control unit and/or the cartridge and are not intended to limit the scope of the control unit and/or the cartridge components covered by this disclosure.

Fig. 2 shows a schematic front sectional view of an aerosol delivery device 100, in which the cartridge 104 and the control unit 102 of Fig. 1 are shown in a disconnected configuration. In various embodiments, the aerosol delivery device 100 may have different shapes. For example, in some embodiments (such as the illustrated embodiment), the aerosol delivery device 100 may be substantially rod-shaped or substantially tubular in shape or substantially cylindrical in shape. However, in other embodiments, other shapes and sizes are possible (e.g., rectangular, oval, hexagonal, prismatic, regular or irregular polygonal shapes, disc-shaped, cuboid, polyhedral shapes, or the like). In still other embodiments, the cartridge and the control unit may have different shapes.

In the illustrated embodiment, the control unit 102 and the cartridge 104 include components configured to facilitate mechanical interaction therebetween. Although various other configurations are possible, the control unit 102 of the illustrated embodiment includes a connector 124 that defines a cavity 125 therein. Similarly, the cartridge 104 includes a base 140 configured to interact with an interface 124 of the control unit 102. An interface and a base that may be suitable for use in accordance with the present disclosure are described in U.S. Patent Application Publication No. 2014/0261495 to Novak et al., the disclosure of which is incorporated herein by reference.

However, it should be noted that in other embodiments, various other structures, shapes and/or components may be used to connect the control unit and the cartridge. For example, in some embodiments, the control unit and the cartridge may be connected to each other by means of a press-fit or interference fit connection, such as, for example, embodiments in which the control housing includes a chamber configured to receive at least a portion of the cartridge, or embodiments in which the cartridge includes a chamber configured to receive at least a portion of the control unit. In other embodiments, the cartridge and the control unit may be connected to each other by means of a screw thread connection. In still other embodiments, the cartridge and the control unit may be connected to each other by means of a bayonet connection. In still other embodiments, the cartridge and the control unit may be connected by means of a magnetic connection. In various embodiments, after the connection, an electrical connection may be created between the cartridge and the control unit for electrically connecting the cartridge (and its components) to the battery and/or via the control component of the control unit. Such an electrical connection may exist due to one or more components of the connecting elements. In this way, the corresponding electrical contacts in the cartridge and the control unit can be substantially aligned after connection to ensure electrical connection.

In particular embodiments, control unit 102 and/or cartridge 104 may be disposable or reusable. For example, in some embodiments, the control unit may have a replaceable battery or a rechargeable battery and thus may be combined with any type of recharging technology, including connection to a wall charger, connection to a vehicle charger (e.g., cigarette lighter socket, USB port, etc.), connection to a computer, any of which may include a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type C), connection to a USB connector (e.g., USB 2.0, 3.0, 3.1, USB Type C, which may be implemented in a wall electrical outlet, an electronic device, a vehicle, etc.), connection to a photovoltaic cell (sometimes referred to as a solar photovoltaic cell) or to a solar panel of solar photovoltaic cells, or to a wireless charger, such as a charger that uses inductive wireless charging (including, for example, wireless charging in accordance with with the QJ wireless charging standard developed by the Wireless Power Consortium (WPC)) or a wireless radio frequency (RF) charger and connecting to an array of external cell(s), such as a power bank, to charge the device via a USB connector or a wireless charger. Examples of inductive wireless charging systems are described in U.S. Patent Application Publication No. 2017/0112196 to Sur et al., which is incorporated herein by reference in its entirety. In additional embodiments, the power source may also include a capacitor. Capacitors may discharge faster than batteries and may be charged between puffs, allowing the battery to discharge into the capacitor at a slower rate. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), may be used separately from or in combination with the battery. When used separately, the supercapacitor may be charged before each use of the product. Thus, the device may also include a charging component that can be attached to the smoking article between uses to replenish the supercapacitor. Examples of energy sources that include supercapacitors are described in U.S. Patent Application Publication No. 2017/0112191 to Sur et al., which is incorporated herein by reference in its entirety.

As shown in the drawing, the control unit 102 may be formed from a control unit housing 101, which includes a control component 106 (for example, a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller, and the like), a flow sensor 108, a battery 110, and a light-emitting diode (LED) 112, and these components may be aligned in various ways. Some examples of types of electronic components, their structures and configurations, their features, and their general methods of operation are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent No. 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., U.S. Patent No. 8,205,622 to Pan, U.S. Patent Application Publication No. 2009/0230117 to Fernando et al., U.S. Patent Application Publication No. 2014/0060554 to Collet et al. etc., in U.S. Patent Application Publication No. 2014/0270727 to Ampolini et al., and in U.S. Patent Application Publication No. 2015/0257445 to Henry et al., the disclosure of which is incorporated herein by reference in its entirety. Some examples of batteries that may be applicable to the present disclosure are described in U.S. Patent Application Publication No. 2010/0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety. In some embodiments, additional indicators (e.g., a haptic feedback component, an audible feedback component, or the like) may be included in addition to or as an alternative to the LED. Additional representative types of components that provide visual signals or indicators, such as light emitting diode components, and their construction and use are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al., 8,499,766 to Newton, and 8,539,959 to Scatterday, and in U.S. Patent Application Publication No. 2015/0020825 to Galloway et al. and in U.S. Patent Application Publication No. 2015/0216233 to Sears et al., which are incorporated herein by reference in their entireties. It should be understood that not all of the illustrated elements may be required in various embodiments. For example, in some embodiments, the LED may be omitted or may be replaced with another indicator, such as a vibration indicator. Similarly, the flow sensor can be replaced by a manual actuator, such as one or more manually operated push buttons.

In the embodiment shown, the cartridge 104 may be formed from a cartridge housing 103, which may form a liquid reservoir 144 configured to contain a liquid composition 145. In some embodiments, the liquid reservoir may be part of the cartridge housing (such as, for example, comprising a molded element of the cartridge housing), while in other embodiments, the liquid reservoir may comprise a separate part. In some embodiments, the liquid reservoir may be disposable. In other embodiments, the liquid reservoir may be reusable. In various embodiments, the liquid composition contained in the liquid reservoir 144 may comprise an aerosol precursor composition. Some examples of types of substrates, reservoirs, or other components for supporting a liquid composition are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Application Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various absorbent materials, as well as the design and operation of these absorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety.

In some embodiments, the reservoir may be made of a polymeric material, which in additional embodiments of the invention may be at least partially transparent or translucent. In some embodiments, such materials may include, but are not limited to, polycarbonate, acrylic, polyethylene terephthalate (PET), amorphous copolyester (PETG), polyvinyl chloride (PVC), liquid silicone rubber (LSR), cyclic olefin copolymers, polyethylene (PE), ionomer resin, polypropylene (PP), fluorinated ethylene propylene (FEP), styrene methyl methacrylate (SMMA), styrene acrylonitrile resin (SAN), polystyrene, acrylonitrile butadiene styrene (ABS), and combinations thereof. In other embodiments, the reservoir may be made of another material, which may be at least partially transparent or translucent. Such materials may include, for example, glass or ceramic materials.

In some embodiments, the aerosol precursor composition may comprise nicotine, which may be present in various concentrations. The source of nicotine may vary, and the nicotine included in the aerosol precursor composition may be from a single source or a combination of two or more sources. For example, in some embodiments, the aerosol precursor composition may comprise nicotine obtained from tobacco. In other embodiments, the aerosol precursor composition may include nicotine obtained from other organic plant sources, such as, for example, non-tobacco plant sources, including plants of the Solanaceae family. In other embodiments, the aerosol precursor composition may comprise synthetic nicotine. In some embodiments, the nicotine included in the aerosol precursor composition may be obtained from non-tobacco plant sources, such as other members of the Solanaceae family.

In some embodiments, the aerosol precursor composition may additionally or alternatively contain alcohol, other botanicals, other medicinal substances, or may contain tetrahydrocannabinol (THC), cannabidiol (CBD), or other active ingredients, or some combination thereof.

In some embodiments, the aerosol precursor composition may comprise tobacco or tobacco-derived components. In one respect, the tobacco may be in the form of tobacco pieces or pieces, such as finely ground, shredded, or powdered tobacco strip. Tobacco balls, pellets, or other solid forms may be included, such as described in US Patent Application Publication No. 2015/0335070 to Sears et al., the disclosure of which is incorporated herein by reference in its entirety. In another respect, the tobacco may be in the form of an extract, such as a spray-dried extract, that includes many of the water-soluble components of tobacco. Alternatively, the tobacco extracts may be in the form of relatively high nicotine extracts that also contain minor amounts of other extracted components derived from tobacco. In another respect, the components derived from tobacco may be provided in a relatively pure form, such as certain flavoring agents that are derived from tobacco. On the one hand, the component that is obtained from tobacco and that can be used in a highly purified or substantially pure form is nicotine (e.g., pharmaceutical grade nicotine, USP/EP nicotine, etc.). In other embodiments, only non-tobacco materials can form the aerosol precursor composition. In some embodiments, the aerosol precursor composition can include nicotine extracted from tobacco with tobacco or non-tobacco flavors and/or nicotine not extracted from tobacco with tobacco or non-tobacco flavors.

In the illustrated embodiment, the liquid composition, sometimes referred to as an aerosol precursor composition, a vapor precursor composition, or an "e-liquid," may comprise various components, which may include, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, and/or flavorings. Representative types of aerosol precursor components and compositions are also known and characterized in U.S. Patent No. 7,217,320 to Robinson and in U.S. Patent Application Publication Nos. 2013/0008457 to Zheng et al.; 2013/0213417 to Chong; and 2014/0060554 to Collett et al.; 2015/0020823 to Lipowicz et al.; and No. 2015/0020830 to Koller, and WO 2014/182736 to Bowen et al., the disclosures of which are incorporated herein by reference in their entireties. Other aerosol precursors that may be used include aerosol precursors that are included in the VUSE® products of R. J. Reynolds Vapor Company, the BLU™ products of Fontem Ventures B.V., the MISTIC MENTHOL product of Mistic Ecigs, the MARK TEN products of Nu Mark LLC, the JUUL product of Juul Labs, Inc., and the VYPE products of CN Creative Ltd. Also desirable are the so-called "smoke juices" for electronic cigarettes that are available from Johnson Creek Enterprises LLC. Other additional examples of aerosol precursor compositions are sold under the trade names BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, MITTEN VAPORS, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR and JIMMY THE JUICE MAN.

The amount of aerosol precursor included in the aerosol delivery system is such that the aerosol generating device has acceptable sensory and desired performance characteristics. For example, it is particularly preferred that a sufficient amount of aerosol forming material (e.g., glycerin and/or propylene glycol) is used to ensure the generation of a visible primary aerosol, which in many ways resembles the appearance of tobacco smoke. The amount of aerosol precursor within the aerosol generating system may depend on factors such as the number of puffs desired on the aerosol generating device. In one or more embodiments, about 1 ml or more, about 2 ml or more, about 5 ml or more, or about 10 ml or more of the aerosol precursor composition may be included.

In some examples described above, the aerosol precursor composition comprises a glycerin-based liquid. However, in other embodiments, the aerosol precursor composition may be an aqueous liquid. In some embodiments, the aqueous liquid may be comprised of more than about 80% water. For example, in some embodiments, the percentage of water in the aqueous liquid may be in the range of about 90% to about 93%, inclusive. In some embodiments, the aqueous liquid may include up to about 10% propylene glycol. For example, in some embodiments, the percentage of propylene glycol in the aqueous liquid may be in the range of about 4% to about 5%, inclusive. In some embodiments, the aqueous liquid may contain up to about 10% flavoring. For example, in some embodiments, the percentage of flavoring(s) of the aqueous liquid may be in the range of about 3% to about 7%, inclusive. In some embodiments, the aqueous liquid may contain up to about 1% nicotine. For example, in some embodiments, the percentage of nicotine in the aqueous liquid may be in the range of about 0.1% to about 0.3%, inclusive. In some embodiments, the aqueous liquid may contain up to about 10% cyclodextrin. For example, in some embodiments, the percentage of cyclodextrin in the aqueous liquid may be in the range of about 3% to 5%, inclusive. In still other embodiments, the aerosol precursor composition may be a combination of a glycerin-based liquid and an aqueous liquid. For example, some embodiments may contain up to about 50% water and less than about 20% glycerin.

The remaining components may include one or more of propylene glycol, flavourings, nicotine, cyclodextrin and the like. Some examples of aqueous liquid compositions that may be suitable are disclosed in GB 1817863.2, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817864.0, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817867.3, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817865.7, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817859.0, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817866.5, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817861.6, filed on 1 November 2018, entitled Gel and Crystalline Powder; GB 1817862.4, filed on 1 November 2018, entitled Aerosolisable Formulation; GB 1817868.1, filed on 1 November 2018, entitled Aerosolisable Formulation; and GB 1817860.8, filed on 1 November 2018, entitled Aerosolisable Formulation, each of which is incorporated herein by reference in its entirety.

As noted above, in various embodiments, the liquid composition may include a flavoring agent. In some embodiments, the flavoring agent may be pre-mixed with the liquid. In other embodiments, the flavoring agent may be delivered separately downstream of the atomizer as a primary or secondary flavoring agent. Still other embodiments may combine a pre-mixed flavoring agent with a downstream flavoring agent. As used herein, the term "flavoring agent" refers to compounds or components that can be atomized and delivered to the user and that convey sensory sensations in terms of taste and/or aroma. Examples of flavoring agents include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (such as apple, cherry, strawberry, peach, and citrus flavors including lime and lemon, mango and other citrus flavors), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hips, mate, gaiusa, honeybush, rooibos, amaretto, mojito, californica, ginseng, chamomile, turmeric, bacopa monnieri, ginkgo biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarola, cocoa, licorice, and flavoring agents and additives of the type and nature traditionally used to flavor cigarette, cigar, and pipe tobacco. Other examples include flavors derived from or imitating Burley, Oriental, flue-cured tobacco, and the like. Syrups, such as high fructose corn syrup, may also be used. Examples of plant-derived compositions that may be useful are described in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012/0152265 to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such additional components will vary depending on factors such as the sensory characteristics desired in a smoking article, and the present disclosure is intended to cover any such additional components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972), and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entirety. It should be noted that reference to a flavoring agent need not be limited to any one flavoring agent as described above, and may in fact be a combination of one or more flavoring agents.

Referring again to Fig. 2, the fluid reservoir 144 of the illustrated embodiment may be in fluid communication with (either directly or through one or more additional components) at least a portion of the spray assembly 115. As will be described in more detail below, in some embodiments, the fluid reservoir 144 may comprise an independent container (e.g., formed by walls that are substantially impermeable to the liquid composition), which in some embodiments may be configured to rotate relative to the housing of the aerosol delivery device (e.g., the housing of the control unit and/or the housing of the cartridge unit). In some embodiments, the walls of the fluid reservoir may be flexible and/or collapsible, while in other embodiments, the walls of the fluid reservoir may be substantially rigid. In some embodiments, the fluid reservoir may be substantially sealed to prevent the liquid composition from escaping therefrom, except for any specific openings or channels specifically designed to allow the liquid composition to pass, such as through one or more transfer elements, as otherwise described herein.

Electrical connection 116 connects the spray unit 115 to the control component 106 and/or the battery 110. In the illustrated embodiment, the spray unit 115 is connected to the base 140 of the cartridge 104, which, when assembled with the control unit 102, provides an electrical connection to the control component 106 and/or the battery 110. As indicated above, the spray unit 115 is configured to be electrically connected to the battery 110 and/or the control component 106. Thus, the spray unit 115 of the illustrated embodiment can be powered by the battery 110 and/or the control component 106 (for example, in order to vibrate a component of the spray unit at a relatively high speed). In various embodiments, the spray unit 115 may be fluidly connected to a portion of the liquid composition such that the spray unit 115 forms an aerosol from the liquid composition in contact. In various embodiments, the spray unit may be directly fluidly connected to a portion of the liquid composition or indirectly fluidly connected to a portion of the liquid composition, such as via a liquid transfer element. In various embodiments, the liquid transfer element may have a single layer or multiple layers and may be made of a single material or multiple materials. In various embodiments, the liquid transfer element may be of any shape and may be a porous, semi-porous, or non-porous absorbent/adsorbent material.

For example, in some embodiments, the fluid transfer element may be made of fibrous materials (e.g., organic cotton, acetyl cellulose, regenerated cellulose fabric, fiberglass), polymers, silk, particles, porous ceramics (e.g., aluminum oxide, silicon dioxide, zirconium, SiC, SiN, AIN, and the like), porous metals, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, porous polymers, or the like. In some embodiments, the fluid transfer element may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). The pores may be nanopores, micropores, macropores, or combinations thereof. As further described herein, some embodiments of the present disclosure may in particular relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. In some embodiments, the liquid transfer element may be a substantially solid non-porous material, such as a polymer or dense ceramics or metals, configured to direct liquid through openings or gaps without necessarily relying on capillary action. Such a solid body may be used in combination with a porous absorbent pad. The absorbent pad may be formed from silica fibers, organic cotton, viscose fibers, cellulose acetate, regenerated cellulose fabric, highly porous ceramic or metal mesh, etc. Some representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014/0261487 to Chapman et al., 2014/0059780 to Davis et al., and U.S. Patent Application Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, the liquid transfer element may be formed partially or completely of a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Publication No. 2017/0188626 to Davis et al. and U.S. Patent Application Publication No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

In various embodiments, the end of the liquid transfer element can be configured to be positioned near the mesh plate and between the mesh plate and the liquid composition in the reservoir in such a way that the liquid transfer element acts as a secondary reservoir that absorbs or adsorbs liquid from the reservoir in such a way that the mesh plate is in contact with the liquid composition even if there is no more liquid in the reservoir. In this way, the liquid transfer element is configured to facilitate contact between the liquid composition and the spray unit.

In some embodiments, the liquid composition may be passed through a component of the spray assembly, which results in the formation of a plurality of aerosol particles. Similarly, in other embodiments, vibration of the component of the spray assembly may create ultrasonic waves within the liquid composition and/or surface acoustic waves in the liquid composition, which result in the formation of an aerosol on the surface of the liquid composition. As will be described in more detail below, in some embodiments, the liquid composition may be applied and/or transferred to a component of the spray assembly to create an aerosol.

In the illustrated embodiment, the control unit housing 101 includes an air inlet 118, which may comprise an opening in the housing near the interface element 124, allowing air from the environment to pass into the control unit housing 101, where it then passes through the cavity 125 of the interface element 124, and ultimately into or around the spray unit 115, where it can be mixed with the vaporizable aerosol precursor composition to contain the aerosol that is delivered to the user. It should be noted that in other embodiments, the air inlet 118 is not limited to being on or near the control unit housing 101. For example, in some embodiments, the air inlet may be formed through the cartridge housing 103 (e.g., in such a way that it does not enter the control unit 102) or some other part of the aerosol delivery device 100. In the embodiment shown, the mouthpiece portion, which includes the opening 128, may be located in the housing 103 of the cartridge (e.g., at the mouthpiece end 104 of the cartridge) to allow the generated aerosol to exit the cartridge 104, e.g., for delivery to a user who puffs on the mouthpiece end of the cartridge 104.

In various embodiments, the cartridge 104 may also include at least one electronic component 150, which may comprise an integrated circuit, a memory component, a sensor, or the like, although such a component need not be included. In those embodiments of the invention that include such a component, the electronic component 150 may be configured to communicate with the control component 106 and/or with an external device via wired or wireless means. In various embodiments, the electronic component 150 may be located anywhere in the cartridge 104 or its base 140. Some examples of electronic/control components that may be applicable to the present disclosure are described in U.S. Patent Application Publication No. 2019/0014819 to Sur, which is incorporated herein by reference in its entirety. Although the illustrated embodiment shows the control component 106 and the flow sensor 108 separately, it should be noted that in some embodiments the control component and the flow sensor may be combined in the form of an electronic circuit board with the air flow sensor attached directly thereto. In some embodiments the air flow sensor may comprise its own circuit board or other main element to which it may be attached. In some embodiments a flexible circuit board may be used. The flexible circuit board may be formed in various shapes, including substantially tubular shapes. Configurations of a printed circuit board and a pressure sensor are described, for example, in US Patent Application Publication No. 2015/0245658 to Worm et al., the disclosure of which is incorporated herein by reference. Additional types of sensing and detecting mechanisms, their structures and configurations, their components, and general methods of operation are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr., U.S. Patent No. 5,372,148 to McCafferty et al., and PCT Publication No. WO 2010/003480 to Flick, which are incorporated herein by reference in their entireties.

In some embodiments, when a user takes a puff on the article 100, an air flow can be detected by the sensor 108, and the atomization unit 115 can be activated, which can vaporize the liquid composition. As noted above, in some embodiments, taking a puff on the mouth end of the article 100 causes air from the environment to enter the air intake 118 and pass through the cavity 125 in the interface element 124 and the base 140. In the cartridge 104, the drawn air is mixed with the generated vapor to form an aerosol. The aerosol is entrained, aspirated or otherwise diverted from the atomization unit 115 and from the mouth opening 128 at the mouth end of the article 100. As noted, in other embodiments, in the absence of an air flow sensor, the atomization unit 115 can be manually activated, for example, by means of a push button (not shown). In addition, in some embodiments, the air intake may occur through the cartridge or between the cartridge and the control unit. It should be noted that in some embodiments, one or more components may be provided between the spray unit and the opening in the mouth end of the article. For example, in the illustrated embodiment, the heating component 147 is located downstream of the spray unit 115. In various embodiments, the heating component may comprise any device configured to increase the temperature of the resulting aerosol, including, for example, one or more heating components in the form of a coil, ceramic heating components, and the like.

In some embodiments, one or more input elements may be included in the aerosol delivery device (and may replace or supplement the air flow sensor, pressure sensor, or hand button). In various embodiments, an input element may be included to allow a user to control functions of the device and/or to output information to the user. Any component or combination of components may be used as an input for controlling a function of the device. For example, one or more push buttons may be used as described in U.S. Patent Application Publication No. 2015/0245658 to Worm et al., which is incorporated herein by reference in its entirety. Similarly, a touch screen may be used as described in U.S. Patent Application Ser. No. 14/643,626, filed March 10, 2015 to Sears et al., which is incorporated herein by reference in its entirety. As a further example, components configured to recognize gestures based on predetermined movements of the aerosol delivery device may be used as an input device. See US Patent Application Publication No. 2016/0158782 to Henry et al., which is incorporated herein by reference in its entirety. As another example, a capacitive sensor may be implemented on an aerosol delivery device to allow a user to provide input, such as by touching a surface of the device on which the capacitive sensor is implemented.

In some embodiments, the data input element may comprise a computer or a computing device, such as a smartphone or a tablet. In particular, the aerosol delivery device may be connected to the computer or other device via wires, such as by using a USB cord or a similar protocol. The aerosol delivery device may also communicate with the computer or other device acting as the data input device via wireless communication. See, for example, the systems and methods for controlling a device via a read request, as described in U.S. Patent Application Publication No. 2016/0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference in its entirety. In such embodiments, an application or other computer program may be used in conjunction with a computer or other computing device to input control commands to the aerosol delivery device, wherein such control commands include, for example, the ability to form an aerosol of a certain composition by selecting the nicotine content and/or the content of additional flavors to be included.

Other features, controls, or components that may be included in the aerosol delivery systems of the present disclosure are described in U.S. Patent No. 5,967,148 to Harris et al., U.S. Patent No. 5,934,289 to Watkins et al., U.S. Patent No. 5,954,979 to Counts et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,402,976 to Fernando et al., U.S. Patent Application Publication No. 2010/0163063 to Fernando et al., U.S. Patent Application Publication No. 2013/0192623 to Tucker et al., U.S. Patent Application Publication No. 2013/0298905 to Leven et al., U.S. Patent Application Publication No. 2013/0180553 to Kim et al., U.S. Patent Application Publication No. 2014/0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014/0261495 to Novak et al., and U.S. Patent Application Publication No. 2014/0261408 to DePiano et al., which are incorporated herein by reference in their entireties.

In various embodiments, the nebulization assembly may comprise a plurality of different components or devices configured to form an aerosol from the liquid composition. For example, in some embodiments, the nebulization assembly may comprise a jet nebulizer assembly that may be configured to use compressed air to form an aerosol. In other embodiments, the nebulization assembly may comprise an ultrasonic assembly that may be configured to use the generation of ultrasonic waves within the liquid composition to form an aerosol. In other embodiments, the nebulization assembly may comprise a vibrating mesh assembly that may comprise a piezoelectric material (e.g., a piezoelectric ceramic material) that may be attached to and/or substantially surround a mesh plate (e.g., a perforated plate) that vibrates within the liquid composition or near the surface of the liquid composition to form an aerosol. In other embodiments, the nebulization assembly may comprise a surface acoustic wave (SAW) assembly or a Roley wave assembly that may use surface wave characteristics to form an aerosol on the surface of the liquid composition. It should be noted that for the purposes of the present application, the ultrasonic unit may be any unit designed to generate ultrasonic waves within the liquid composition. In some embodiments, for example, a vibrating mesh unit may also operate as an ultrasonic unit.

An example of a spray assembly of one embodiment is shown in Fig. 3. In particular, Fig. 3 shows a spray assembly 215 that includes a piezoelectric ring 217 attached to a mesh plate 219 and substantially surrounding it. In some embodiments, additional components may be included. For example, in some embodiments, a support component may be included that is located on the side of the mesh plate opposite the vibrating component (e.g., such that the mesh plate is clamped between the support component and the vibrating component). Although other configurations are possible, in some embodiments, the support component may include a support ring. In various embodiments, the support component may be made of any suitable material, including, without limitation, polymeric, metallic and/or ceramic materials. Thus, in some embodiments, the support component may increase the durability of the mesh plate. In some embodiments, the support component may be replaceable, while in other embodiments, the support component may be attached to the mesh plate and/or the vibrating component. In some embodiments, an auxiliary component may be used, located between the mesh plate and the vibration component. Although other configurations are possible, in some embodiments, the auxiliary component may comprise an auxiliary ring. In various embodiments, the auxiliary component may be made of any suitable material, including, without limitation, polymeric, metallic and/or ceramic materials. Thus, the auxiliary component may facilitate interfacial contact of the components. In some embodiments, the auxiliary component may be replaceable, while in other embodiments, the auxiliary component may be attached to the mesh plate and/or the vibration component.

In various embodiments, the vibration component and the mesh plate can be permanently attached to each other, for example, by fastening the components together with an adhesive, such as, for example, epoxy or other adhesive, or by ultrasonic welding, mechanical fasteners and the like. It should be noted that although the illustrated embodiment describes a vibration component in the form of a piezoelectric ring, in other embodiments, the vibration component should not be limited to a ring-shaped object. For example, in some embodiments, the piezoelectric component can have a rectangular, oval, hexagonal, triangular and regular or irregular polygon shape. In various embodiments, the mesh plate can have a variety of different configurations. For example, in some embodiments, the mesh plate can have a substantially flat profile. In other embodiments, the mesh plate can have a substantially dome-shaped shape, which can be concave or convex with respect to the liquid composition. In other embodiments, the mesh plate can comprise a substantially flat portion and a dome-shaped portion. In various embodiments, the mesh plate may be made of a variety of different materials. In some embodiments, the mesh plate may be made of a metallic material, such as, but not limited to, stainless steel, palladium-nickel, or titanium. In other embodiments, the mesh plate may be made of a polymer material, such as, for example, a polyimide polymer. In still other embodiments, the mesh plate may be made of a combination of materials.

In various embodiments, the design of the spray assembly may vary. For example, Figs. 4A-4F show exemplary embodiments of various spray assemblies. In particular, Fig. 4A shows a spray assembly comprising a piezoelectric ring 217A attached to and substantially surrounding a mesh plate 219A. Fig. 4B shows a spray assembly comprising a mesh plate 219A located between two portions of the piezoelectric ring 217A. Fig. 4C shows a spray assembly comprising a piezoelectric ring 217C attached to and substantially surrounding a mesh plate 219C, wherein at least a portion of the mesh plate 219C is curved. In Fig. 4D shows a spray unit comprising a mesh plate 219D located between two parts of a piezoelectric ring 217D, wherein at least a part of the mesh plate 219D is curved. Fig. 4E shows a spray unit comprising a piezoelectric ring 217E attached to one side of the mesh plate 219E and substantially surrounding it, wherein the other side of the mesh plate 219E comprises a metal ring 221E substantially surrounding and attached to it. Fig. 4F shows a spray unit comprising a mesh plate 219F, one side of which includes a metal ring 221 F substantially surrounding and attached to it, wherein the mesh plate 219F and the metal ring 221F are located between two parts of the piezoelectric ring 217F.

Referring again to Fig. 3, the mesh plate 219 includes a plurality of perforations. In some embodiments, the perforations may be formed by circular openings in the surfaces of the plate. In other embodiments, the perforations may be formed by non-circular openings in the surfaces of the plate, such as, for example, oval, rectangular, triangular, regular or irregular polygonal openings. In various embodiments, the perforations may be created using a variety of different methods, including, without limitation, using a laser (e.g., a femtosecond laser) or by electrodeposition (e.g., lithography) or by using ion or electron beams with high or low energy. In various embodiments, the shapes formed through the plate by the perforations may vary. For example, in some embodiments, the shapes formed through the plate by the perforations may be substantially cylindrical. In other embodiments, the shapes formed through the plate by the perforations may be substantially conical (e.g., have a truncated conical shape forming smaller openings on one surface of the plate and larger openings on the opposite surface of the plate). In other embodiments, the shapes formed through the plate by the perforations may be tetragonal or pyramidal. It is believed that in some embodiments, substantially conical shapes may increase the performance of the mesh in atomizing the liquid composition. Although any orientation of the mesh plate may be used, in some embodiments with perforations forming substantially conical shapes through the plate, the larger openings may be located near the surface of the liquid composition, and the smaller openings may form an aerosol exit region. In some embodiments with perforations forming substantially conical shapes, the smaller openings may have a size in the range of about 1 micron to about 10 microns inclusive, with an average size of about 2 microns to about 5 microns. In other embodiments, the smaller openings may have a size in the range of about several hundred nanometers to about 4 microns, with an average size of about 2 microns to about 3.1 microns. In other embodiments, the smaller openings may have a size in the range of about several hundred nanometers to about 2 microns, with an average size of about 1 micron. In some embodiments, the larger openings may have a size in the range of about 10 microns to about 60 microns inclusive, with an average size of about 20 microns to about 30 microns. In other embodiments, the larger openings may have a size in the range of about 5 microns to about 20 microns inclusive, with an average size of about 10 microns. In some embodiments, the size of the perforations may be substantially uniform over the entire perforated portion of the plate; however, in other embodiments, the size of the perforations may vary. Thus, the formed aerosol may have aerosol droplets of different sizes. For example, in some embodiments, the perforations may be larger in one part of the plate and smaller in another part of the plate. Such parts may include, for example, the center of the plate and the periphery of the plate or alternating rings that extend radially from the center of the plate.

In various embodiments, the mesh plate may have any number of perforations. In some embodiments, for example, the number of perforations in the mesh plate may be in the range from about 200 to about 6000 inclusive, wherein the average number of perforations is from about 1100 to about 2500. In other embodiments, the number of perforations in the mesh plate may be in the range from about 400 to about 1000 inclusive. In various embodiments, the thickness of the piezoelectric ring and the thickness of the mesh plate may vary. For example, in some embodiments, the thickness of the mesh plate may be in the range from several microns to several millimeters. In various embodiments, the overall diameter of the mesh plate may vary. For example, in some embodiments, the overall diameter of the mesh plate may be in the range from about several millimeters to about 30 millimeters inclusive. In some embodiments, the outer diameter of the piezoelectric ring may be larger than the overall diameter of the mesh plate. In other embodiments, the outer diameter can have substantially the same size as the overall diameter of the mesh plate. In various embodiments, the diameter of the perforated region can be smaller than the overall diameter of the mesh plate. For example, in some embodiments, the diameter of the perforated region can be in the range from about 1 millimeter to about 20 millimeters inclusive, on average from about 4 millimeters to about 12 millimeters. In some embodiments, the inner diameter of the piezoelectric ring can be larger than the diameter of the perforated region of the mesh plate. In other embodiments, the inner diameter of the piezoelectric ring can be substantially the same or smaller than the diameter of the perforated region of the mesh plate. In some embodiments, the thickness of the piezoelectric ring can be in the range from several hundred microns to tens of millimeters inclusive. For example, in some embodiments, the thickness of the piezoelectric ring can be less than 1 millimeter.

In various embodiments, the piezoelectric ring may be made of a piezoceramic material. In general, piezoceramic materials have piezoelectric properties (e.g., ferroelectric properties), while they are designed to change shape to a small extent (e.g., 1-2 μm) when exposed to an electrical stimulus. This occurs due to a shift in the crystal structure of piezoceramic materials (e.g., from orthorhombic to cubic, or hexagonal to cubic, etc.). With regard to the piezoceramic ring, such a change in shape leads to internal deformation and, therefore, shrinkage of the disk, which leads to bending of the disk due to its rigid structure. Since the ring is attached to the mesh plate, the bending of the ring is transferred to the mesh material. When the electric current is disconnected from the piezoelectric ring, the ring and the mesh plate return to their original shape and position. Thus, a continuous change in shape and position will lead to an oscillatory motion that can be used as a vibration source. In various embodiments, the frequency of the piezoelectric ring may be in the range of several Hz to several MHz. For example, in some embodiments, the frequency of the piezoelectric ring is in the range of about 50 kHz to about 150 kHz inclusive, with an average value in one embodiment of about 110 kHz, and in another embodiment of about 113 kHz, and in another embodiment of about 117 kHz, in another embodiment of about 130 kHz, in another embodiment of about 150 kHz, in another embodiment of about 170 kHz, and in another embodiment of about 250 kHz. In other embodiments, the frequency of the piezoelectric ring is in the range of about 1 MHz to about 5 MHz inclusive, with an average value of about 3 MHz to about 3.5 MHz.

In various embodiments of the present disclosure, various piezoelectric materials are possible, including natural or synthetic materials. Some non-limiting examples of natural piezoelectric materials include, for example, quartz, berlinite (AIPO ₄ ), sucrose, Rochelle salt, topaz, tourmaline minerals, lead titanate (PbTiO ₃ ), and collagen. Some non-limiting examples of synthetic materials include, for example, (La ₃ Ga ₅ SiO ₁₄ ), gallium phosphate, gallium orthophosphate (GaPC ₄ ), lithium niobate (LiNbO ₃ ), lithium tantalate (LiTaO ₃ ), AIN, ZnO, barium titanate (BaTiO ₃ ), lead zirconate titanate (Pb[Zr _x Ti _1-x ]O ₃ ) (also known as PZT), potassium niobate (KNbO ₃ ), sodium tungstate (Na ₂ WO ₃ ), Ba ₂ NaNb ₅ O ₅ , Pb ₂ KNb ₅ O ₁₅ , zinc oxide (ZnO), sodium potassium niobate (K,Na)NbO ₃ ) (also known as NKN), bismuth ferrite (BiFeO ₃ ), sodium niobate NaNbO ₃ , barium titanate (BaTiO ₃ ), bismuth titanate Bi ₄ Ti ₃ O ₁₂ , sodium titanate and sodium bismuth titanate NaBi(TiO ₃ ) ₂ . In other embodiments, polymers having piezoelectric characteristics can be used, including, but not limited to, polyvinylidene fluoride (PVDF).

In various embodiments, the mesh plate 219 of the spray unit 215 can be in contact with at least a portion of the liquid composition and/or can be located near at least a portion of the liquid composition and/or can receive (e.g., via a delivery mechanism) at least a portion of the liquid composition. Thus, the resulting vibration of the plate forms an aerosol from the liquid composition in contact. In particular, the liquid composition is passed through a plurality of perforations, which leads to the formation of a plurality of aerosol particles. Similarly, in other embodiments, such as, for example, embodiments in which the mesh plate is immersed in the liquid composition, the vibration of the plate creates ultrasonic waves within the liquid composition, which lead to the formation of an aerosol on the surface of the liquid composition. As will be described in more detail below, in other embodiments, the liquid composition can be applied and/or transferred to the spray unit to create an aerosol.

Another example of a spray unit of one embodiment is shown in Fig. 5. In particular, Fig. 5 shows a spray unit 315 that comprises a piezoelectric ring 317 attached to a mesh plate 319 and substantially surrounding it. As shown in the drawing, the spray unit 315 is located near one end of a reservoir 344 containing a liquid composition 345. The mesh plate 319 of the shown embodiment comprises two parts, an outer part 319A that is substantially flat and an inner part 319B that is dome-shaped. In the shown embodiment, the inner dome-shaped portion 319B of the mesh plate 319 is configured to interact with the liquid composition 345 and has a convex configuration with respect to the reservoir 344 (and the liquid composition 345). In the embodiment shown, the mesh plate 319 includes a plurality of perforations 360 that have a substantially conical shape. In particular, the plurality of perforations 360 include a larger end 360A, configured to be located near the point of coupling with the liquid composition 345, and a smaller end 360B, through which the formed aerosol passes.

In various embodiments, it is advantageous to facilitate contact (e.g., maintain or promote contact) between the liquid composition and the spray unit. In accordance with these lines, Fig. 6 shows a schematic side view of a portion of a reservoir 444 containing a liquid composition 445 and a spray unit 415 configured to form an aerosol from the liquid composition according to an exemplary embodiment of the present disclosure, and Fig. 7 shows a schematic perspective view of a portion of a reservoir 444 containing a spray unit 415 (with the liquid composition having been removed for clarity of illustration). In the embodiment shown, the reservoir 444 has a substantially hollow spherical shape; however, in other embodiments, other shapes are possible, including, for example, a substantially hollow cylindrical shape, a substantially hollow prismatic shape, a substantially hollow cuboid shape, or any other shape configured to contain a liquid composition. Regardless of the shape of the reservoir, in various embodiments the reservoir may be located in various positions within the housing of the aerosol delivery device.

In some embodiments, the reservoir may be made of a polymeric material, which in additional embodiments of the invention may be at least partially transparent or translucent. In some embodiments, such materials may include, but are not limited to, polycarbonate, acrylic, polyethylene terephthalate (PET), amorphous copolyester (PETG), polyvinyl chloride (PVC), liquid silicone rubber (LSR), cyclic olefin copolymers, polyethylene (PE), ionomer resin, polypropylene (PP), fluorinated ethylene propylene (FEP), styrene methyl methacrylate (SMMA), styrene acrylonitrile resin (SAN), polystyrene, acrylonitrile butadiene styrene (ABS), and combinations thereof. In other embodiments, the reservoir may be made of another material, which may be at least partially transparent or translucent. Such materials may include, for example, glass or ceramic materials.

In the illustrated embodiment, the reservoir 444 comprises an opening 446 near its upper end. In various embodiments, the opening 446 can be used to fill the reservoir 444 with a liquid composition 445. In the illustrated embodiment, the opening 446 can be closed by a reservoir lid 448, which in some embodiments can include a plurality of openings and/or can be substantially gas-permeable to allow the generated aerosol to exit the reservoir. Although in other embodiments the spray unit can be located in other locations within the reservoir, the spray unit 415 of the illustrated unit is located opposite the opening 446 of the reservoir 444 near its bottom. In the illustrated embodiment, the reservoir 444 also comprises an electrical connection 416 that extends to the spray unit 415 and electrically connects (either directly or indirectly through one or more additional components) the spray unit 415 to the control component and/or the battery. In various embodiments, electrical connection 416 may extend inside and/or outside tank 444.

In various embodiments, the reservoir according to the present disclosure may be configured to freely or otherwise rotate, for example, by active control, relative to the position of the aerosol delivery device. As shown in the drawings, the reservoir 444 of the illustrated embodiment is configured to rotate about one axis (axis 450) by means of a pair of rotation elements 452 that are attached to the aerosol delivery device (not shown). In various embodiments, the rotation elements 452 may be attached to the housing of the cartridge, or to the housing of the control unit, or to any other component of the aerosol delivery device that allows the reservoir to rotate relative to it. In various embodiments, the rotation elements may comprise a plurality of different components configured to rotate the reservoir relative to the aerosol delivery device, including, for example, carrier elements, pins configured to rotate in corresponding locks or holes, and the like. In some embodiments, the rotation elements 452 may facilitate an electrical connection between the electrical connection 416 and the battery and/or the control component.

In various embodiments, the rotation of the reservoir 444 of the shown embodiment is configured to facilitate contact between the liquid composition 445 and the spray unit 415, regardless of the position of the aerosol delivery device. To facilitate contact between the liquid composition 445 and the spray unit 415 of the shown embodiment, the lower end of the reservoir 444 (for example, a portion of the reservoir 444 near the spray unit 415) of the shown embodiment is weighted relative to the upper end. In various embodiments, weighing the reservoir can be accomplished in a variety of different ways. For example, in some embodiments, the liquid composition itself can provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In other embodiments, the spray unit can provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In other embodiments, weight can be added to the reservoir near the spray unit to allow rotation of the reservoir relative to the aerosol delivery device. In still other embodiments of the invention, the reservoir itself may be configured (e.g., by providing additional material near the spray unit) to provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In some embodiments, the reservoir may be configured to actively rotate relative to the aerosol delivery device. For example, in some embodiments, the reservoir may be actively rotated relative to the position of the aerosol delivery device using, for example, electromagnetic means. Such embodiments may include a reservoir that is configured to rotate within another portion (e.g., a substantially spherical reservoir configured to rotate within another substantially spherical portion) in the presence of a hydraulic fluid.

Some additional examples of reservoir configurations are shown in Figs. 8A-8C, which illustrate a sequence of top schematic views of portions of reservoirs and spray units of various aerosol delivery devices according to example embodiments of the present disclosure. In particular, Fig. 8A shows a substantially cylindrical reservoir 544 (containing a spray unit 515 located near its lower end) configured to rotate about an axis 550 by means of rotation elements 552, although in other embodiments the reservoir may have any shape. Fig. 8B shows a substantially cuboid reservoir 644 (which contains a spray unit 615 located near its lower end) configured to rotate about an axis 650 by means of rotation elements 652, although in other embodiments the reservoir may have any shape. And Fig. 8C shows an aerosol delivery device 700 of a substantially oval shape, having a substantially cylindrical reservoir 744 (which contains a spraying unit 715 located near its lower end), configured to rotate about an axis 750 through rotation elements 752. In Fig. 8C, the reservoir 744 is located near the side of the aerosol delivery device 700 closest to the opening 728 in the aerosol delivery device through which the aerosol is delivered to the user. By forming the aerosol delivery device as such and by positioning the opening 728 of the mouthpiece portion at this location, the reservoir 744 of the illustrated embodiment can promote contact between the liquid composition in the reservoir 744 and the spraying unit 715 regardless of the position of the aerosol delivery device and by rotating the reservoir 744 about the axis 750.

It should be noted that although in some embodiments the aerosol delivery device according to the present disclosure may comprise separate cartridge and control unit components, and the reservoir may or may not be reusable, in other embodiments the aerosol delivery device according to the present invention may comprise a single housing, and the reservoir may or may not be reusable. For example, Fig. 9 shows an aerosol delivery device according to another example embodiment of the present disclosure. In particular, Fig. 9 shows a schematic perspective view of an aerosol delivery device 800. As shown in the figure, the aerosol delivery device 800 does not include a separate cartridge and control units, but rather these components are combined into a single housing having a common housing 805. As shown in the figure, the housing 805 includes a mouthpiece portion having an opening 828. The aerosol delivery device 800 of the illustrated embodiment also includes a reservoir 844 having a substantially spherical shape. In the illustrated embodiment, the reservoir 844 includes an opening 846 near its upper end. In various embodiments, the opening 846 can be used to fill the reservoir 844 with a liquid composition. In the illustrated embodiment, the opening 846 can be closed by a reservoir lid 848. Although in other embodiments the spray unit can be located in other locations within the reservoir, the spray unit 815 of the illustrated unit is located opposite the opening 846 of the reservoir 844 near its lower part. In the illustrated embodiment, the reservoir 844 also includes an electrical connection (not shown) that connects the spray unit 815 (either directly or indirectly through one or more additional components) to the control component and/or the battery. In various embodiments, the electrical connection can extend inside and/or outside the reservoir 844. In some embodiments, the rotation elements 852 can facilitate the electrical connection between the spray unit 815 and the battery and/or the control component.

In various embodiments, the reservoir according to the present invention may be configured to freely or otherwise rotate, for example, by active control, relative to the position of the aerosol delivery device. As shown in the drawings, the reservoir 844 of the illustrated embodiment is configured to rotate about one axis (axis 850) by a pair of rotation elements 852 that are attached to the aerosol delivery device 800. In various embodiments, the rotation elements 852 may be attached to the housing 805 or any component of the aerosol delivery device, which will allow the reservoir to rotate relative to it. In various embodiments, the rotation elements may comprise a plurality of different components configured to rotate the reservoir relative to the aerosol delivery device, including, for example, carrier elements, pins configured to rotate in corresponding locks or holes, and the like.

In various embodiments, the rotation of the reservoir 844 of the shown embodiment is configured to facilitate contact between the liquid composition and the spray unit 815, regardless of the position of the aerosol delivery device. To facilitate contact between the liquid composition and the spray unit 815 of the shown embodiment, the lower end of the reservoir 844 (for example, a portion of the reservoir 844 near the spray unit 815) of the shown embodiment is weighted relative to the upper end. In various embodiments, the weighting of the reservoir can be accomplished in a variety of different ways. For example, in some embodiments, the liquid composition itself can provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In other embodiments, the spray unit can provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In other embodiments, weight can be added to the reservoir near the spray unit to allow rotation of the reservoir relative to the aerosol delivery device.

In still other embodiments of the invention, the reservoir itself may be configured (e.g., by providing additional material near the spray unit) to provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In some embodiments, the reservoir may be configured to actively rotate relative to the aerosol delivery device. For example, in some embodiments, the reservoir may be actively rotated relative to the position of the aerosol delivery device using, for example, electromagnetic components. Such embodiments may include a reservoir that is configured to rotate within another portion (e.g., a substantially spherical reservoir configured to rotate within another substantially spherical portion) in the presence of a hydraulic fluid.

Although in some embodiments the rotation of the reservoir may occur by rotation about one axis relative to the aerosol delivery device, in other embodiments the rotation of the reservoir may occur about two axes relative to the aerosol delivery device. A schematic example of such an embodiment is shown in Fig. 10. In particular, Fig. 10 is a schematic top sectional view of a portion of the reservoir 944 and the spray assembly 915 of the aerosol delivery device according to another example embodiment of the present disclosure. Although in other embodiments the spray assembly may be located at other locations within the reservoir, the spray assembly 915 of the shown assembly is located near the bottom of the reservoir 944. In the shown embodiment, the reservoir 944 also comprises an electrical connection (not shown) that connects the spray assembly 915 (either directly or indirectly through one or more additional components) to the control component and/or the battery. In various embodiments, the electrical connection may extend inside and/or outside the reservoir 944. In some embodiments, the pivot members may facilitate the electrical connection between the spray assembly 815 and the battery and/or the control component.

In various embodiments, the reservoir according to the present disclosure may be configured to freely or otherwise rotate (e.g., by active control) relative to the position of the aerosol delivery device. As shown in the drawing, the embodiment of Fig. 10 includes an intermediate frame 960 configured to rotate relative to the housing 905 of the aerosol delivery device about a first axis (axis 950A) via a pair of first rotation elements 952A. In various embodiments, the first rotation elements 952A may be attached to the housing 905 or any component of the aerosol delivery device, which will allow the intermediate frame 960 to rotate relative to it. In various embodiments, the first rotation elements may comprise a plurality of different components configured to rotate the intermediate frame relative to the aerosol delivery device, including, for example, bearing elements, pins configured to rotate in corresponding locks or holes, and the like.

In addition, in the illustrated embodiment, the reservoir 944 is configured to rotate relative to the intermediate frame 960 about a second axis (axis 950B) by means of a pair of second rotation elements 952B. In the illustrated embodiment, the second axis 950B is substantially perpendicular to the first axis 950A. In various embodiments, the second rotation elements may comprise a plurality of different components configured to rotate the intermediate frame relative to the aerosol delivery device, including, for example, bearing elements, pins configured to rotate in corresponding locks or holes, and the like. In various embodiments, the second rotation elements may be the same or different from the first rotation elements. In the illustrated embodiment, the reservoir 944 has a substantially hollow spherical shape; however, in other embodiments, other shapes are possible, including, for example, a substantially hollow cylindrical shape, a substantially hollow prismatic shape, a substantially hollow cuboid shape, or any other shape configured to contain a liquid composition. Regardless of the shape of the reservoir, in various embodiments, the reservoir can be located in various positions within the housing of the aerosol delivery device.

In various embodiments, the rotation of the reservoir 944 of the illustrated embodiment is configured to facilitate contact between the liquid composition and the spray unit 915, regardless of the position of the aerosol delivery device. To facilitate contact between the liquid composition and the spray unit 915 of the illustrated embodiment, the lower end of the reservoir 944 (for example, a portion of the reservoir 944 near the spray unit 915) of the illustrated embodiment is weighted relative to the upper end. In various embodiments, the weighting of the reservoir can be accomplished in a variety of different ways. For example, in some embodiments, the liquid composition itself can provide sufficient weight to enable rotation of the reservoir relative to the aerosol delivery device. In other embodiments, the spray unit can provide sufficient weight to enable rotation of the reservoir relative to the aerosol delivery device.

In other embodiments, weight may be added to the reservoir near the spray unit to allow rotation of the reservoir relative to the aerosol delivery device. In still other embodiments of the invention, the reservoir itself may be configured (for example, by providing additional material near the spray unit) to provide sufficient weight to allow rotation of the reservoir relative to the aerosol delivery device. In some embodiments, the reservoir may be configured to actively rotate relative to the aerosol delivery device. For example, in some embodiments, the reservoir may be actively rotated relative to the position of the aerosol delivery device using, for example, electromagnetic means. Such embodiments may include a reservoir that is configured to rotate within another part (for example, a substantially spherical reservoir configured to rotate within another substantially spherical part) in the presence of a hydraulic fluid.

Another embodiment of the present disclosure is shown in Fig. 11. In particular, Fig. 11 shows a schematic side view of a portion of a reservoir 1044 configured to hold a liquid composition (not shown) and a spray unit 1015 configured to generate an aerosol from the liquid composition, according to another exemplary embodiment of the present disclosure. In the illustrated embodiment, the reservoir 1044 and the spray unit 1015 are configured to be used in combination with an aerosol delivery device. In the illustrated embodiment, the spray unit 1015 comprises a vibrating mesh unit that comprises a piezoelectric disk or ring 1017 attached to and substantially surrounding a mesh plate 1019. In various embodiments, an electrical connection (not shown) connects the spray unit 1015 to a control component and/or a battery of the aerosol delivery device. Thus, the spray assembly 1015 of the embodiment shown may be powered by a battery and/or a control component for vibrating the mesh plate 1019 at a relatively high speed. The resulting vibration of the plate generates an aerosol from the liquid composition in contact. Additional reference is made to the discussion of the components of the vibrating mesh assembly and variations described above.

In the illustrated embodiment, the spraying unit 1015 further includes a perforated shutter element 1062 located near the mesh plate 1019, between the liquid composition and the mesh plate 1019. In the illustrated embodiment, the perforated shutter element 1062 is substantially parallel to the mesh plate 1019 such that a small chamber 1064 is formed between the mesh plate 1019 and the perforated shutter element 1062. In various embodiments, the perforated shutter element 1062 defines a plurality of openings 1066 configured to allow the liquid composition to pass through them. In the illustrated embodiment, the openings 1066 are configured to facilitate the passage of the liquid composition from the reservoir 1044 into the small chamber 1064 between the mesh plate 1019 and the perforated shutter element 1062.

As shown in the drawing, each of the openings 1066 of the illustrated embodiment has a truncated conical shape (see detailed information), with the small end of the opening located closest to the mesh plate 1019. Thus, the openings 1066 can act similar to a single directional valve, in which the liquid composition is allowed to pass through the perforated shutter element 1062 into the chamber 1064 in one direction and is prevented from moving back through the perforated shutter element 1062 in the opposite direction. It should be noted that in other embodiments, the openings can have other configurations and/or other shapes. For example, in other embodiments, the plurality of openings can have a tetragonal, pyramidal or cylindrical shape. In some embodiments, at least a portion of the perforated shutter element 1062 can include one or more coating materials. For example, in the illustrated embodiment, the side of the perforated shutter element 1062 closest to the chamber 1064 includes a hydrophobic/oleophobic coating. Due to the configuration of the reservoir 1044 and the spray assembly 1015, the illustrated embodiment allows the aerosol delivery device to be used at a variety of angles and orientations.

Another embodiment of the present disclosure is shown in Fig. 12. In particular, Fig. 12 shows a schematic side view of a portion of a reservoir 1144 configured to hold a liquid composition (not shown) and a spray assembly 1115 configured to generate an aerosol from the liquid composition according to another example embodiment of the present disclosure. In the illustrated embodiment, the reservoir 1144 and the spray assembly 1115 are configured to be used in combination with an aerosol delivery device. In the illustrated embodiment, the spray assembly 1115 comprises a vibrating mesh assembly that includes a piezoelectric disk or ring 1117 attached to and substantially surrounding a mesh plate 1119. In various embodiments, an electrical connection (not shown) connects the spray assembly 1115 to a control component and/or a battery of the aerosol delivery device. Thus, the spray assembly 1115 of the embodiment shown may be powered by a battery and/or a control component for vibrating the mesh plate 1119 at a relatively high speed. The resulting vibration of the plate generates an aerosol from the liquid composition in contact. Additional reference is made to the discussion of the components of the vibrating mesh assembly and variations described above.

The illustrated embodiment also comprises a liquid transfer element 1168, one end of which is located near the mesh plate 1119. In the illustrated embodiment, the liquid transfer element 1168 is located between the liquid composition in the reservoir 1144 and the mesh plate 1119. In some embodiments, the liquid transfer element may occupy a part or substantially the entire reservoir. In various embodiments, the liquid transfer element may have a single layer or multiple layers and may be made of a single material or multiple materials. In various embodiments, the liquid transfer element may be of any shape and may be a porous, semi-porous or non-porous absorbent/adsorbent material. In other embodiments, a second liquid transfer element may be present, located between the first liquid transfer element and the liquid reservoir, wherein the second liquid transfer element is configured to transfer liquid from the liquid reservoir to the first liquid transfer element. Thus, the first liquid transfer element may not be in direct contact with the liquid in the liquid reservoir. In various embodiments, the second liquid transfer element may be made of the same material or a material that is different from the first liquid transfer element, and may have a shape that is the same or different from the shape of the first liquid transfer element.

For example, in some embodiments, the fluid transfer element may be made of fibrous materials (e.g., organic cotton, acetyl cellulose, regenerated cellulose fabric, fiberglass), polymers, silk, particles, porous ceramics (e.g., aluminum oxide, silicon dioxide, zirconium, SiC, SiN, AIN, and the like), porous metals, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, porous polymers, or the like. In some embodiments, the fluid transfer element may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). The pores may be nanopores, micropores, macropores, or combinations thereof. As further described herein, some embodiments of the present disclosure may in particular relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. In some embodiments, the liquid transfer element may be a substantially solid non-porous material, such as a polymer or dense ceramics or metals, configured to direct liquid through openings or gaps without necessarily relying on capillary action. Such a solid body may be used in combination with a porous absorbent pad. The absorbent pad may be formed from silica fibers, organic cotton, viscose fibers, cellulose acetate, regenerated cellulose fabric, highly porous ceramic or metal mesh, etc. Some representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014/0261487 to Chapman et al., 2014/0059780 to Davis et al., and U.S. Patent Application Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, the liquid transfer element may be formed partially or completely of a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Publication No. 2017/0188626 to Davis et al. and U.S. Patent Application Publication No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

In various embodiments, the end of the liquid transfer element is configured to be positioned near the mesh plate and between the mesh plate and the liquid composition in the reservoir in such a way that the liquid transfer element acts as a secondary reservoir that absorbs or adsorbs liquid from the reservoir in such a way that at least part of the liquid composition is supplied to the mesh plate, even if there is no more liquid in the reservoir. Thus, the liquid transfer element is configured to facilitate the delivery of the liquid composition to the spray unit.

Another embodiment of the present disclosure is shown in Fig. 13. In particular, Fig. 13 shows a schematic side view of a portion of a reservoir 1244 configured to hold a liquid composition (not shown) and a spray assembly 1215 configured to generate an aerosol from the liquid composition, according to another example embodiment of the present disclosure. In the illustrated embodiment, the reservoir 1244 and the spray assembly 1215 are configured to be used in combination with an aerosol delivery device. In the illustrated embodiment, the spray assembly 1215 comprises a vibrating mesh assembly that comprises a piezoelectric disk or ring 1217 attached to and substantially surrounding a mesh plate 1219. In various embodiments, an electrical connection (not shown) connects the spray assembly 1215 to a control component and/or a battery of the aerosol delivery device. Thus, the spray assembly 1215 of the illustrated embodiment may be powered by a battery and/or a control component for vibrating the mesh plate 1219 at a relatively high speed. Since at least a portion of the liquid composition is supplied to the mesh plate 1219, the resulting vibration of the plate generates an aerosol from the contacting liquid composition. Additional reference is made to the discussion of the components of the vibrating mesh assembly and variations described above.

In the illustrated embodiment, the spraying assembly 1215 also includes a micropump assembly 1260. In various embodiments, the micropump assembly 1260 is configured to transfer a portion of the liquid composition from the reservoir 1244 to the mesh plate 1219. In some embodiments, the delivery of the liquid composition to the mesh plate 1219 may occur automatically. In other embodiments, the delivery of the liquid composition to the mesh plate 1219 may occur on demand, such as by control from a control component. In some embodiments, the micropump assembly may apply droplets of the liquid composition directly to the mesh plate. In other embodiments, the micropump assembly may spray (e.g., via one or more nozzles) droplets of the liquid composition onto the mesh plate. In yet other embodiments, the micropump assembly may apply or spray droplets of the liquid composition onto a liquid transfer element that may deliver at least a portion of the liquid composition to the mesh plate, as described with reference to Fig. 12 above. In various embodiments, a micropump assembly may comprise any mechanical or non-mechanical pump configured to pump fluid from one location to another. Non-limiting examples of micropump assemblies include metering mechanisms (such as, for example, shape memory dispensing mechanisms), diaphragm devices, peristaltic devices, or microfluidic systems using lab-on-a-chip (LOC) or lab-on-a-disk (LOD) technology. Such devices may be configured to automatically transfer fluid or may be configured to initially transfer based on one or more stimuli, such as manual force or pressure, and the like. Some examples of shape memory dispensing mechanisms are described in U.S. Patent No. 10,080,388 to Sebastian et al., which is incorporated herein by reference in its entirety.

Another embodiment of the present disclosure is shown in Fig. 14. In particular, Fig. 14 shows a schematic side view of a portion of a reservoir 1344 configured to hold a liquid composition (not shown) and a spray assembly 1315 configured to generate an aerosol from the liquid composition according to another example embodiment of the present disclosure. In the illustrated embodiment, the reservoir 1344 and the spray assembly 1315 are configured to be used in combination with an aerosol delivery device. In the illustrated embodiment, the spray assembly 1315 comprises a vibrating mesh assembly that includes a piezoelectric disk or ring 1317 attached to and substantially surrounding a mesh plate 1319. In various embodiments, an electrical connection (not shown) connects the spray assembly 1315 to a control component and/or a battery of the aerosol delivery device. Thus, the spray assembly 1315 of the illustrated embodiment may be powered by a battery and/or a control component for vibrating the mesh plate 1319 at a relatively high speed. Since at least a portion of the liquid composition is supplied to the mesh plate 1319, the resulting vibration of the plate generates an aerosol from the contacting liquid composition. Additional reference is made to the discussion of the components of the vibrating mesh assembly and variations described above.

In the illustrated embodiment, the spray assembly 1315 also includes a micropump assembly 1362. In various embodiments, the micropump assembly 1362 is configured to move a portion of the liquid composition (e.g., in the form of fine particles or a small stream) from the reservoir 1344 to the surface of the mesh plate 1319. In some embodiments, the micropump assembly may comprise a microcompressor. In some embodiments, the micropump assembly may use compressed gas (e.g., air, carbon dioxide ( _CO2 ), nitrogen (N2), etc.) to help move the liquid composition toward the surface of the mesh plate. In some embodiments, the micropump assembly may comprise one or more nozzles.

Other embodiments of the present disclosure are shown in Fig. 15A and 15B. In particular, Fig. 15A and 15B show schematic side views of a portion of a reservoir 1444A, 1444B configured to hold a liquid composition 1445A, 1445B, and a spray assembly 1415A, 1415B configured to generate an aerosol from the liquid composition according to other example embodiments of the present disclosure. In the embodiments shown, the reservoirs 1444A, 144B and the spray assemblies 1415A, 1415B are configured to be used in combination with an aerosol delivery device. In the illustrated embodiment, each atomization unit 1415A, 1415B comprises a vibrating mesh unit that comprises a piezoelectric disk or ring 1417A, 1417B attached to and substantially surrounding a mesh plate 1419A, 1419B. In various embodiments, an electrical connection (not shown) connects each atomization unit 1415A, 1415B to a control component and/or a battery of the aerosol delivery device. Thus, the atomization units 1415A, 1415B of the illustrated embodiments can be powered by a battery and/or a control component for vibrating the mesh plates 1419A, 1419B at a relatively high speed. The resulting vibration of the plates generates a corresponding aerosol from the liquid composition in contact. Additional reference is made to the discussion of the components of the vibrating mesh unit and variations described above.

In the illustrated embodiment, the reservoirs 1444A, 1444B comprise substantially U-shaped tubes and include respective first reservoir portions 1447A, 1447B, second reservoir portions 1449A, 1449B and third reservoir portions 1451A, 1451B. In the illustrated embodiments, the first reservoir portions 1447A, 1447B and third reservoir portions 1451A, 1451B are substantially straight, and the second reservoir portions 1449A, 1449B that connect the first reservoir portions 1447A, 1447B to the third reservoir portions 1451A, 1451B are substantially curved. In the embodiment shown in Fig. 15A, the diameters of the first part 1447A of the tank, the second part 1449A of the tank and the third part 1451A of the tank are substantially the same. However, in other embodiments, the diameters may differ. For example, in the embodiment shown in FIG. 15B, the diameters of the second part 1449B of the tank and the third part 1451B of the tank are substantially the same and are smaller than the diameter of the first part 1447B of the tank.

In each of the illustrated embodiments, the reservoirs 1444A, 1444B include respective weights 1464A, 1464B that apply a downward force to the liquid composition in the first portions 1447A, 1447B of the reservoir. In various embodiments, the weight may comprise any device configured to increase the pressure on the liquid composition, including, for example, weighted disks or balls. Thus, even when the level of the liquid composition in the reservoirs 1444A, 1444B decreases, contact is maintained between the liquid composition and the mesh plates 1419A, 1419B.

Another embodiment of the present disclosure is shown in Fig. 16. In particular, Fig. 15 shows a schematic side view of a portion of a reservoir 1544 configured to hold a liquid composition (not shown) and a spray assembly 1515 configured to generate an aerosol from the liquid composition according to another example embodiment of the present disclosure. In the embodiments shown, the reservoir 1544 and the spray assembly 1515 are configured to be used in combination with an aerosol delivery device such as those described above. In the embodiment shown, the spray assembly 1515 comprises a vibrating mesh assembly that includes a piezoelectric disk or ring 1517 attached to and substantially surrounding a mesh plate 1519. In various embodiments, an electrical connection (not shown) connects the spray assembly 1515 to a control component and/or a battery of the aerosol delivery device. Thus, the spray assembly 1515 of the embodiments shown may be powered by a battery and/or a control component for vibrating the mesh plate 1519 at a relatively high speed. The resulting vibration of the plate generates an aerosol from the liquid composition in contact. Additional reference is made to the discussion of the components of the vibrating mesh assembly and variations described above.

In the illustrated embodiment, the reservoir 1544 comprises a substantially U-shaped tube and includes a first reservoir portion 1547, a second reservoir portion 1549 and a third reservoir portion 1551. In the illustrated embodiments, the first reservoir portion 1547 and the third reservoir portion 1551 are substantially straight, and the second reservoir portion 1519, which connects the first reservoir portion 1547 to the third reservoir portion 1551, is substantially curved. In the embodiment shown in Fig. 16, the diameters of the first reservoir portion 1547, the second reservoir portion 1549 and the third reservoir portion 1551 are substantially the same. However, in other embodiments, the diameters may differ.

In the illustrated embodiment, the reservoir 1544 includes a weight 1564 that applies a downward force to the liquid composition in the first portions 1547 of the reservoir. In various embodiments, the weight may comprise any device configured to increase pressure on the liquid composition, including, for example, weighted disks or balls. Thus, even when the level of the liquid composition in the reservoir 1544 decreases, the contact between the liquid composition and the mesh plates 1519 is maintained. In addition, in the illustrated embodiment, the U-shaped reservoir is positioned at an angle relative to the longitudinal axis 1550 of the body 1505 of the aerosol delivery device in such a way that the contact between the liquid composition and the mesh plate 1519 is maintained. In addition, in the illustrated embodiment, the mouthpiece portion 1509 (which forms the opening 1528 through which the aerosol exits) is positioned on one side of the body 1505 of the aerosol delivery device in order to encourage the use of the device in specific orientations.

Another embodiment of the present disclosure is shown in Fig. 17. In particular, Fig. 17 shows a schematic side view of a portion of a reservoir 1644 configured to hold a liquid composition (not shown) and a spray assembly 1615 configured to generate an aerosol from the liquid composition according to another example embodiment of the present disclosure. In the illustrated embodiment, the reservoir 1644 and the spray assembly 1615 are configured to be used in combination with an aerosol delivery device. In the illustrated embodiment, the spray assembly 1615 comprises a vibrating mesh assembly that includes a piezoelectric disk or ring 1617 attached to and substantially surrounding a mesh plate 1619. In various embodiments, an electrical connection (not shown) connects the spray assembly 1615 to a control component and/or a battery of the aerosol delivery device. Thus, the spray assembly 1615 of the embodiments shown may be powered by a battery and/or a control component for vibrating the mesh plate 1619 at a relatively high speed. The resulting vibration of the plate generates an aerosol from the liquid composition in contact. Additional reference is made to the discussion of the components of the vibrating mesh assembly and variations described above.

In the illustrated embodiment, the reservoir 1644 comprises a substantially U-shaped tube and includes a first reservoir portion 1647, a second reservoir portion 1649 and a third reservoir portion 1651. In the illustrated embodiments, the first reservoir portion 1647 and the third reservoir portion 1651 are substantially straight, and the second reservoir portion 1619, which connects the first reservoir portion 1647 to the third reservoir portion 1651, is substantially curved. In the embodiment shown in Fig. 17, the diameters of the first reservoir portion 1647, the second reservoir portion 1649 and the third reservoir portion 1651 are substantially the same. However, in other embodiments, the diameters may differ.

In the illustrated embodiment, the reservoir 1644 includes a weight 1664 that applies a downward force to the liquid composition in the first portions 1647 of the reservoir. As noted above, in various embodiments, the weight may comprise any device configured to increase the pressure on the liquid composition. In some embodiments, such as the illustrated embodiment, the weight may also comprise an active component configured to actively apply pressure to the liquid composition in the reservoir. In various embodiments, the active component may be any device configured to actively apply a force to the liquid composition in the reservoir. In the illustrated embodiment, the active component comprises a spring 1665 that applies additional force to the weight 1664. In other embodiments, the active component may comprise an electromechanical device, such as, for example, an actuator or a piston, which in some embodiments may include feedback control. In various embodiments, the active component can be selected based on the properties of the liquid composition (e.g., viscosity, density, etc.) and/or the mesh size and/or the vibration frequency of the vibration unit. It should also be noted that in other embodiments, the reservoir having the active component can be substantially cylindrical in shape.

Although in some embodiments of the present disclosure the cartridge and the control unit may be provided together as a single aerosol delivery device, these components may be provided separately as a whole. For example, the present invention also encompasses a disposable unit for use with a reusable unit. In particular embodiments, such a disposable unit (which may be a cartridge, as shown in the accompanying drawings) may be configured to cooperate with a reusable unit (which may be a control unit, as shown in the accompanying drawings). In still other configurations, the cartridge may comprise a reusable unit, and the control unit may comprise a disposable unit.

Although some of the drawings described herein illustrate the cartridge and control unit in an operational state, it is understood that the cartridge and control unit may exist as individual components. Accordingly, any discussion herein with respect to components in combination should also be understood as referring to the control unit and cartridge as individual and separate components.

According to another aspect, the present invention can be directed to kits that provide various components as described herein. For example, a kit can comprise a control unit with one or more cartridges. The kit can also comprise a control unit with one or more charging components. The kit can also comprise a control unit with one or more batteries. The kit can also comprise a control unit with one or more cartridges and one or more charging components and/or one or more batteries. In additional embodiments, the kit can comprise a plurality of cartridges. The kit can also comprise a plurality of cartridges and one or more batteries and/or one or more charging components. In the above embodiments, the cartridges or control units can be equipped with a heating element included therein. The kits according to the invention can also comprise a case (or other packaging, carrying or storage component) in which one or more additional components of the kit are placed. The case can be a reusable hard or soft container. In addition, the case can simply be a box or other packaging structure.

Many modifications and other embodiments of the disclosure may be apparent to those skilled in the art upon review of the present invention as described in the above descriptions and accompanying drawings. It should therefore be noted that the present disclosure should not be limited to the specific embodiments described herein, and that modifications and other embodiments are included within the scope of protection of the appended claims. Although specific terms are used in this application, they are used in a general and descriptive sense only and not for purposes of limitation.

Claims (13)

1. An aerosol delivery device comprising: a casing that forms the outer wall and also includes a power source and a control component; a mouthpiece; a container-shaped portion that includes a reservoir configured to contain a liquid composition; and a spray unit configured to evaporate a liquid composition to generate an aerosol, wherein the spraying unit comprises a vibration unit that includes a mesh plate, and a pump unit configured to transfer a portion of the liquid composition from the reservoir to the mesh plate, and wherein the pump unit is configured to spray the liquid composition directly onto the mesh plate or onto a liquid transfer element that is configured to deliver at least a portion of the liquid composition to the mesh plate. 2. An aerosol delivery device according to claim 1, wherein the pump unit is configured to deliver the liquid composition on demand. 3. An aerosol delivery device according to claim 1, wherein one or more nozzles are used in the pump unit for delivering the liquid composition. 4. The aerosol delivery device of claim 1, wherein the pump unit comprises at least one of the following: a dispensing mechanism, a membrane device, and a peristaltic device. 5. An aerosol delivery device according to claim 4, wherein the dispensing mechanism comprises a shape memory mechanism. 6. The aerosol delivery device of claim 1, wherein the vibrating assembly further includes a piezoelectric component attached to and surrounding the mesh plate. 7. The aerosol delivery device of claim 1, wherein the mesh plate is flat. 8. The aerosol delivery device of claim 1, wherein at least a portion of the mesh plate is convex with respect to the reservoir. 9. The aerosol delivery device of claim 1, wherein the pump unit comprises a micropump unit.