Patent Description:
<CIT> discloses a fluid vaporization device. A vaporizer fluid is transported from a fluid reservoir to a vaporization chamber via wick element which extends into both the fluid reservoir and the vaporization chamber. The fluid in the vaporization chamber is then heated by activating a heating element which is disposed within the vaporization chamber. The heating step transforms the fluid stored in the wick element into a vapor, after which it is transported out of the vaporization device via a conduit.

Many smoking devices have been proposed through the years as improvements upon, or alternatives to, smoking products that require combusting tobacco for use. Many of those devices purportedly have been designed to provide the sensations associated with cigarette, cigar, or pipe smoking, but without delivering considerable quantities of incomplete combustion and pyrolysis products that result from the burning of tobacco. To this end, there have been proposed numerous smoking products, flavor generators, and medicinal inhalers that utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant degree. See, for example, the various alternative smoking articles, aerosol delivery devices and heat generating sources set forth in the background art described in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

Certain existing embodiments of aerosol delivery devices include a control body and a cartridge. A power source (e.g., a battery) may be positioned in the control body and an aerosol precursor composition may be positioned in the cartridge. However, the aerosol precursor composition may be prone to leak from the cartridge, particularly during filling of the cartridge. Thus, advances with respect to configurations of cartridges for aerosol delivery devices which resist leakage or otherwise improve performance thereof and methods of assembly thereof may be desirable.

The present disclosure relates to aerosol delivery devices which, in certain embodiments, may be characterized as electronic cigarettes. In one aspect a cartridge for an aerosol delivery device according to claim <NUM> is provided.

In an additional aspect a method for assembling a cartridge for an aerosol delivery device according to claim <NUM> is provided.

Further embodiments are defined by the dependent claims as appended.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below.

The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

Aerosol delivery devices according to the present disclosure may use electrical energy to heat a material (preferably without combusting the material to any significant degree) to form an inhalable substance; such articles most preferably being sufficiently compact to be considered "hand-held" devices. An aerosol delivery device may provide some or all of the sensations (e.g., inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical feel, use rituals, visual cues such as those provided by visible aerosol, and the like) of smoking a cigarette, cigar, or pipe, without any substantial degree of combustion of any component of that article or device. The aerosol delivery device may not produce smoke in the sense of the aerosol resulting from by-products of combustion or pyrolysis of tobacco, but rather, that the article or device most preferably yields vapors (including vapors within aerosols that can be considered to be visible aerosols that might be considered to be described as smoke-like) resulting from volatilization or vaporization of certain components of the article or device. In highly preferred embodiments, aerosol delivery devices may incorporate tobacco and/or components derived from tobacco. As such, the aerosol delivery device can be characterized as an electronic smoking article such as an electronic cigarette.

Aerosol delivery devices of the present disclosure also can be characterized as being vapor-producing articles or medicament delivery articles. Thus, such articles or devices can be adapted so as to provide one or more substances (e.g., flavors and/or pharmaceutical active ingredients) in an inhalable form or state. For example, inhalable substances can be substantially in the form of a vapor (i.e., a substance that is in the gas phase at a temperature lower than its critical point). Alternatively, inhalable substances can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term "aerosol" as used herein is meant to include vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not visible, and whether or not of a form that might be considered to be smoke-like.

Smoking articles of the present disclosure generally include a number of components provided within an outer shell or body. The overall design of the outer shell or body can vary, and the format or configuration of the outer body that can define the overall size and shape of the smoking article can vary. Typically, an elongated body resembling the shape of a cigarette or cigar can be a formed from a single, unitary shell; or the elongated body can be formed of two or more separable pieces. For example, a smoking article can comprise an elongated shell or body that can be substantially tubular in shape and, as such, resemble the shape of a conventional cigarette or cigar. In one embodiment, all of the components of the smoking article are contained within one outer body or shell. Alternatively, a smoking article can comprise two or more shells that are joined and are separable. For example, a smoking article can possess at one end a control body comprising a shell containing one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of that article), and at the other end and removably attached thereto a shell containing a disposable portion (e.g., a disposable flavor-containing cartridge). More specific formats, configurations and arrangements of components within the single shell type of unit or within a multi-piece separable shell type of unit will be evident in light of the further disclosure provided herein. Additionally, various smoking article designs and component arrangements can be appreciated upon consideration of the commercially available electronic smoking articles, such as those representative products listed in the background art section of the present disclosure.

Aerosol delivery devices of the present disclosure most preferably comprise some combination of a power source (i.e., an electrical power source), at least one control component (e.g., means for actuating, controlling, regulating and/or ceasing power for heat generation, such as by controlling electrical current flow from the power source to other components of the aerosol delivery device), a heater or heat generation component (e.g., an electrical resistance heating element or component commonly referred to as part of an "atomizer"), and an aerosol precursor composition (e.g., commonly a liquid capable of yielding an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid" and "e-juice"), and a mouthend region or tip for allowing draw upon the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the article such that aerosol generated can be withdrawn therefrom upon draw). Exemplary formulations for aerosol precursor materials that may be used according to the present disclosure are described in <CIT> and <CIT>.

Alignment of the components within the aerosol delivery device of the present disclosure can vary. In specific embodiments, the aerosol precursor composition can be located near an end of the aerosol delivery device which may be configured to be positioned proximal to the mouth of a user so as to maximize aerosol delivery to the user. Other configurations, however, are not excluded. Generally, the heating element can be positioned sufficiently near the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorants, medicaments, or the like that may likewise be provided for delivery to a user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof.

As noted above, the aerosol delivery device may incorporate a battery or other electrical power source (e.g., a capacitor) to provide current flow sufficient to provide various functionalities to the aerosol delivery device, such as powering of a heater, powering of control systems, powering of indicators, and the like. The power source can take on various embodiments. Preferably, the power source is able to deliver sufficient power to rapidly heat the heating element to provide for aerosol formation and power the aerosol delivery device through use for a desired duration of time. The power source preferably is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Additionally, a preferred power source is of a sufficiently light weight to not detract from a desirable smoking experience.

More specific formats, configurations and arrangements of components within the aerosol delivery device of the present disclosure will be evident in light of the further disclosure provided hereinafter. Additionally, the selection of various aerosol delivery device components can be appreciated upon consideration of the commercially available electronic aerosol delivery devices, such as those representative products listed in the background art section of the present disclosure. Further, the arrangement of the components within the aerosol delivery device can also be appreciated upon consideration of the commercially available electronic aerosol delivery devices, such as those representative products listed in the background art section of the present disclosure.

One example embodiment of an aerosol delivery device <NUM> according to the present disclosure is illustrated in <FIG>. As illustrated, the aerosol delivery device <NUM> may include a control body <NUM> and a cartridge <NUM>. In this regard, <FIG> illustrates the control body <NUM> and the cartridge <NUM> respectively in an assembled configuration, wherein the control body and the cartridge are coupled to one another. Various mechanisms may connect the control body <NUM> to the cartridge <NUM> to result in a threaded engagement, a press-fit engagement, an interference fit, a magnetic engagement, or the like.

The components of the control body <NUM> and the cartridge <NUM> may be formed from a variety of materials. For example, plastic (e.g., polycarbonate or acrylonitrile butadiene styrene (ABS)), metal (e.g., stainless steel or aluminum), paperboard, cardboard, ceramic, fiberglass, glass (e.g., a resilient glass), or a graphite composite may be employed to form components of the aerosol delivery device. Various other materials that may be employed in the aerosol delivery device are discussed below in particular reference to certain specified components thereof.

The aerosol delivery device <NUM> may be substantially rod-like, substantially tubular shaped, or substantially cylindrically shaped in some embodiments when the control body <NUM> and the cartridge <NUM> are coupled to one another. In this regard, in some embodiments it may be preferable to provide the aerosol delivery device <NUM> with a size, shape, and/or configuration resembling a smoking article such as a cigarette or cigar. Thus, in some embodiments the control body <NUM> and the cartridge <NUM> may be generally cylindrical and the aerosol delivery device <NUM> may define an elongated cylindrical configuration as a result of coupling therebetween. Accordingly, the typical size, shape and/or general appearance of the aerosol delivery device <NUM> may be comparable to commercially available electronic cigarettes.

In some embodiments the control body <NUM> and the cartridge <NUM> may define substantially the same longitudinal length. However, in other embodiments the control body <NUM> and the cartridge <NUM> may define differing longitudinal lengths. For example, a ratio of a longitudinal length of the cartridge <NUM> to a longitudinal length of the control body <NUM> may be from about <NUM>:<NUM> to about <NUM>:<NUM>, from about <NUM>:<NUM> to about <NUM>:<NUM>, or from about <NUM>:<NUM> to about <NUM>:<NUM>. In this regard, in some embodiments the dimensions of the cartridge <NUM> may be similar to that of a filter element and the dimensions of the control body <NUM> may be similar to that of a tobacco rod of a traditional cigarette. This configuration may provide adequate room in the control body <NUM> for an electrical power source, which may be included therein as discussed above and hereinafter.

In one embodiment the control body <NUM> and the cartridge <NUM> may be permanently coupled to one another in the configuration illustrated in <FIG>. Examples of aerosol delivery devices which may be configured to be disposable and/or which may include first and second outer bodies that are configured for permanent coupling are disclosed in <CIT>.

However, in another embodiment the control body <NUM> and the cartridge <NUM> may be configured to be separable. In this regard, <FIG> illustrates the control body <NUM> and the cartridge <NUM> in a decoupled configuration, wherein a side view of the cartridge and a sectional view through the control body are provided.

In specific embodiments, one or both of the control body <NUM> and the cartridge <NUM> may be referred to as being disposable or as being reusable. For example, the control body <NUM> may have a replaceable battery or a rechargeable battery and thus may be combined with any type of recharging technology, including connection to a typical alternating current electrical outlet, connection to a car charger (i.e., cigarette lighter receptacle), and connection to a computer, such as through a universal serial bus (USB) cable. Further, in some embodiments the cartridge <NUM> may comprise a single-use cartridge, as disclosed in <CIT>.

As illustrated in <FIG>, the control body <NUM> may comprise a plurality of components. For example, the control body <NUM> may include a coupler <NUM>, an outer body <NUM>, a flow sensor <NUM>, a control component 212an electrical power source <NUM> (e.g., a battery, which may be rechargeable), an indicator <NUM> (e.g., an LED indicator), and an end cap <NUM>. Various element that may be included in a control body are described in <CIT>.

The aerosol generating piece most preferably incorporates a sensor or detector for control of supply of electric power to the heat generation element when aerosol generation is desired (e.g., upon draw during use). As such, for example, there is provided a manner or method for turning off the power supply to the heat generation element when the aerosol generating piece is not be drawn upon during use, and for turning on the power supply to actuate or trigger the generation of heat by the heat generation element during draw. Additional representative types of sensing or detection mechanisms, structure and configuration thereof, components thereof, and general methods of operation thereof, are described in <CIT>; <CIT>; and <CIT>.

The aerosol generating piece most preferably incorporates a control mechanism for controlling the amount of electric power to the heat generation element during draw. Representative types of electronic components, structure and configuration thereof, features thereof, and general methods of operation thereof, are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>; <CIT> and <CIT>; and <CIT> and <CIT>.

Representative types of substrates, reservoirs or other components for supporting the aerosol precursor are described in <CIT>; and <CIT>; <CIT> and <CIT>.

Additionally, various wicking materials, and the configuration and operation of those wicking materials within certain types of electronic cigarettes, are set forth in <CIT>.

<FIG> illustrates the cartridge <NUM> in an exploded configuration. As illustrated, the cartridge <NUM> may comprise a base <NUM>, a control component terminal <NUM>, an electronic control component <NUM>, a flow director <NUM>, an atomizer <NUM>, a reservoir substrate <NUM>, an outer body <NUM>, a mouthpiece <NUM>, a label <NUM>, and first and second heating terminals 320a, 320b according to an example embodiment of the present disclosure. The atomizer <NUM> may comprise a liquid transport element <NUM> and a heating element <NUM>. The cartridge may additionally include a base shipping plug engaged with the base and/or a mouthpiece shipping plug engaged with the mouthpiece in order to protect the base and the mouthpiece and prevent entry of contaminants therein prior to use as disclosed, for example, in <CIT>. The description included hereinafter provides example configurations of the above-described components and methods of assembly thereof. However, it should be understood that the cartridge <NUM> may be assembled in a variety of manners and may include additional or fewer components in other embodiments. For example, although the cartridge <NUM> is generally described herein as including a reservoir substrate, in other embodiments the cartridge may hold an aerosol precursor composition therein without the use of a reservoir substrate (e.g., through use of a container or vessel that stores the aerosol precursor composition or direct storage therein). In some embodiments, an aerosol precursor composition may be within a container or vessel that may also include a porous (e.g., fibrous) material therein.

<FIG> illustrates a bottom perspective view of a back of the flow director <NUM> and the first and second heating terminals 320a, 320b, whereas <FIG> illustrates an opposing top perspective view of a front of the flow director and the heating terminals. As discussed hereinafter, the flow director <NUM> may be configured to direct a flow of air, which may be received from the control body <NUM>, to the heating element <NUM> of the atomizer <NUM> (which is further described in relation to <FIG>). Further, the first heating terminal 320a and the second heating terminal 320b (e.g., positive and ground terminals) are configured to engage opposing ends of the heating element <NUM> and form an electrical connection with the control body <NUM> when the cartridge <NUM> is connected thereto.

As illustrated in <FIG> and <FIG>, one or both of the heating terminals 320a, 320b may be coupled to the flow director <NUM>. In the illustrated embodiment the first and second heating terminals 320a, 320b extend through the flow director <NUM>. For example, one or both of the first and second heating terminals 320a, 320b may be molded into the flow director <NUM>. By way of further example, the heating terminals 320a, 320b may be insert molded into the flow director <NUM>. In this regard, in some embodiments the flow director <NUM> may comprise plastic or other material which may be shaped into a desired structure via a molding process.

Molding the heating terminals 320a, 320b into the flow director <NUM> may provide certain benefits. In this regard, molding the heating terminals 320a, 320b into the flow director <NUM> may allow for precise and secure placement of the heating terminals 320a, 320b with respect to one another and with respect to the flow director. Thereby, for example, a precise separation distance between the heating element terminals 320a, 320b may be set during the molding process and this separation distance may be maintained following the molding process by the resulting structure defined by the flow director <NUM>. Additionally, providing the heating terminals 320a, 320b in secure engagement with the flow director <NUM> may further facilitate manufacturing of the cartridge <NUM> by providing a relatively large structure which may be more easily grasped and manipulated during manufacture of the cartridge. In this regard, the cartridge <NUM> of the present disclosure may be formed using automated manufacturing techniques as disclosed, for example, in <CIT>.

Further, molding the heating terminals 320a, 320b into the flow director <NUM> may provide a seal between the heating terminals and the flow director. Thereby, fluid leakage between the heating terminals 320a, 320b and the flow director <NUM> may be substantially avoided. Thus, for example, leakage of aerosol precursor composition along the heating terminals 320a, 320b, which may otherwise occur during filing of the cartridge, may be substantially prevented. However, as may be understood, the heating terminals 320a, 320b may be sealed to the flow director <NUM> in other manners in embodiments in which the heating terminals are not molded into the flow director. For example, a sealant may be applied between the heating terminals 320a, 320b and the flow director <NUM> in embodiments in which the heating terminals extend through the flow director but are not molded therein.

In the illustrated embodiment the flow director <NUM> includes a base portion <NUM> and a longitudinal extension <NUM> extending therefrom. A through hole <NUM> may extend along the longitudinal length of the flow director <NUM> through the base portion <NUM> and the longitudinal extension <NUM>. In this regard, the longitudinal extension <NUM> may define a tube surrounding the through hole <NUM>. The through hole <NUM> may be configured to direct a flow of air, which may be received through the base <NUM> from the control body <NUM> or the coupler <NUM>, through the base portion <NUM> and the longitudinal extension <NUM> to the heating element <NUM> of the atomizer <NUM>. In this regard, in some embodiments the coupler <NUM> of the control body <NUM> (see, e.g., <FIG>) may define an inlet through which ambient air enters and travels to the base <NUM> of the cartridge as described, for example, in <CIT>, and <CIT>.

However, air may enter the cartridge in a variety of differing manners in other embodiments.

As illustrated, in some embodiments the heating elements may extend through the base portion <NUM> and the longitudinal extension <NUM>. The longitudinal extension <NUM> may include cutouts <NUM> defined therein at which the heating terminals 320a, 320b may be exposed. The cutouts <NUM> may allow for formation of the flow director <NUM> with less material and/or allow for grasping the heating terminals 320a, 320b during the molding process so as to allow for precise placement of the heating terminals within the flow director as described above.

The heating terminals 320a, 320b may extend out of the flow director <NUM> at opposing ends thereof. In this regard, the first heating terminal 320a may extend out of the longitudinal extension <NUM> to define a first tab 334a and the second heating terminal 320b may extend out of the longitudinal extension to define a second tab 334b. Accordingly, the heating element <NUM> (see, e.g., <FIG>) may be coupled (e.g., welded) to the heating terminals 320a, 320b such that current may be directed therethrough.

At an opposing end of the flow director <NUM>, the first heating terminal 320a may extend out of the base portion <NUM> to define a first end 336a and the second heating terminal 320b may extend out of the base portion <NUM> to define a second end 336b. The ends 336a, 336b of the heating terminals 320a, 320b may be configured to engage electrical contacts in the coupler <NUM> of the control body <NUM> (see, e.g., <FIG>). In some embodiments the electrical contacts in the coupler <NUM> may comprise circular metal bands of varying radii positioned at differing depths within the coupler as described in <CIT>.

<FIG> illustrates an enlarged perspective view of the base <NUM>. As illustrated, the base <NUM> defines a recess <NUM> configured to receive the electronic control component <NUM> therein. Additionally, the control component terminal <NUM> may be engaged with the base <NUM>. As illustrated, the control component terminal <NUM> may include one or more wings <NUM>. The wings <NUM> may be configured to engage a ledge <NUM> defined in the base <NUM> and/or walls extending perpendicularly thereto so as to securely hold the control component terminal <NUM> in the base and substantially prevent movement thereof.

A first end <NUM> of the control component terminal <NUM> may be configured to engage the electronic control component <NUM>. The control component terminal <NUM> may define a reverse bend <NUM> configured to engage a contact <NUM> (see, e.g., <FIG>) on the electronic control component <NUM>. In this regard, the first end <NUM> of the control component terminal <NUM> may extend downwardly and into the recess <NUM> such that the electronic control component <NUM> may be inserted following coupling of the control component terminal to the base <NUM> to provide a secure connection therebetween. For example, the reverse bend <NUM> may cause the control component terminal <NUM> to act as a spring that biases the first end <NUM> thereof into contact with the electronic control component <NUM>. However, in other embodiments the electronic control component <NUM> may be inserted into the base <NUM> before the control component terminal <NUM>.

<FIG> illustrates a top perspective view of the base <NUM> following insertion of the heating terminals 320a, 320b, wherein the flow director <NUM> is not shown for clarity purposes. As illustrated therein, the base <NUM> may additionally include a ledge <NUM> configured to support the electronic control component <NUM> thereon. In this regard, the flow director <NUM> includes one or more deformable ribs <NUM> (see, <FIG>) configured to engage the electronic control component <NUM> when the flow director is coupled to the base <NUM>. Accordingly, the deformable ribs <NUM> may engage the electronic control component <NUM> such that the electronic control component is tightly sandwiched between the deformable ribs <NUM> and the ledge <NUM> in the base <NUM>. Thus, the electronic control component <NUM> may be securely locked in place such that vibration may not cause the electronic control component to become loose or disconnect from the terminals in contact therewith.

Additionally, features may be provided that are configured to retain the control component terminal <NUM> in a desired position with respect to the electronic control component <NUM>. In this regard, as illustrated in <FIG> and <FIG>, the base may define a clip <NUM>. The clip <NUM> may be configured to define an interference fit relationship with respect to the control component terminal <NUM> such that the control component terminal is sandwiched between the clip <NUM> and the ledge <NUM>. Thus, the control component terminal <NUM> may be securely locked in place such that vibration may not cause the control component <NUM> to become loose or disconnect from the electronic control component <NUM>.

As further illustrated in <FIG>, the base <NUM> may define a plurality of apertures 350a-c extending therethrough. A first aperture 350a may be configured to receive the first heating terminal 320a, a second aperture 350b may be configured to receive the second heater terminal 350b, and a third aperture 350c may be configured to receive the control component terminal <NUM>. Accordingly, the control component terminal <NUM> may be inserted into the third aperture 350c, the first heating terminal 320a may be inserted into the first aperture 350a, and the second heating terminal 320b may be inserted into the second aperture 350b, as illustrated in <FIG>.

As the first heating terminal 320a and the second heating terminal 320b are respectively inserted into the first and second apertures 350a, 350b, the base <NUM> may slightly bend the heating terminals away from a central axis extending through the cartridge <NUM>. In this regard, the base <NUM> may define first and second protrusions 351a, 351b (see, <FIG>) respectively configured to bend the first and second heating terminals 320a, 320b outwardly. By bending the first and second heating terminals 320a, 320b in this manner, the ends 336a, 336b (see, e.g., <FIG>) of the heating terminals may be positioned and configured with a spring bias to securely engage electrical contacts in the coupler <NUM> of the control body <NUM> (see, e.g., <FIG>) and provided with a clearance for movement during engagement with the electrical contacts. Note that the particular direction in which the heating terminals are bent may vary depending on the configuration of the electrical contacts within the control body.

The first heating terminal 320a may define a ground protrusion <NUM>. The ground protrusion <NUM> may be configured to contact a ground terminal <NUM> on the electronic control component <NUM> so as to provide ground thereto. Accordingly, the ground protrusion <NUM> may engage the ground terminal <NUM> during insertion of the first heating terminal 320a into the first aperture 350a in the base <NUM>.

As noted above, the heating terminals 320a, 320b may be coupled to the flow director <NUM>. Thus, the flow director <NUM> may be engaged with the base <NUM> substantially simultaneously with inserting the heating terminals 320a, 320b through the first and second apertures 350a, 350b in the base to define the configuration illustrated in <FIG>. It may be important to provide a particular rotational alignment of the base <NUM> with respect to the flow director <NUM> about a longitudinal axis extending therethough. For example, a proper rotational alignment between the base <NUM> and the flow director <NUM> may ensure alignment of the heating terminals 320a, 320b in the first and second apertures 350a, 350b and proper alignment of the ground protrusion <NUM> with respect to the ground terminal <NUM>. Accordingly, the base <NUM> and/or the flow director <NUM> may include features configured to ensure proper rotational alignment therebetween.

In this regard, as illustrated in <FIG>, a notch <NUM> may be defined in the flow director <NUM>, for example in the base portion <NUM> thereof. Further an inwardly-extending protrusion <NUM> may be defined at the base <NUM>, as illustrated in <FIG> and <FIG>. Accordingly, the inwardly-extending protrusion <NUM> may engage the notch <NUM> to prevent rotation of the base <NUM> with respect to the flow director <NUM> and provide for alignment thereof. Additionally, the flow director <NUM> may include a flat cutout <NUM> (see, e.g., <FIG>) and the base <NUM> may include a corresponding flat extension <NUM> (see, e.g., <FIG> and <FIG>) configured to engage the flat cutout to prevent rotation of the base with respect to the flow director and provide for alignment thereof. However, as may be understood, the base <NUM> may be keyed to the flow director <NUM> in a variety of other manners to ensure rotational alignment thereof and prevent rotational movement therebetween.

In this regard, <FIG> illustrates the flow director <NUM> coupled to an inner end 302a of the base <NUM>. In some embodiments the base <NUM> may be sealed to the flow director <NUM>. Various embodiments of mechanisms and manners may be employed to seal the base <NUM> to the flow director <NUM>. For example, the base <NUM> may be welded to the flow director <NUM> or the base may be adhered to the flow director via a glue, adhesive, or sealant. With respect to welding, various embodiments of methods thereof may be employed depending on the particular materials from which the flow director <NUM> and the base <NUM> are formed. For example, arc welding, gas welding, resistance welding, energy beam welding, and solid-state welding may be employed. An example of a solid-state welding process is ultrasonic welding which uses ultrasonic vibrations to create a weld between two workpieces held together under pressure. Another example of a solid-state welding process is induction welding, which uses electromagnetic induction to heat workpieces. However, in embodiments in which the base <NUM> and the flow director <NUM> are formed from plastic or other non-ferromagnetic materials, the material may be implanting with metallic or ferromagnetic compounds, called susceptors in order to allow for induction welding thereof. As may be understood, these welding methods may provide a hermetic seal. However, as noted above, various other embodiments of coupling and sealing mechanisms and methods may be employed.

As described above, the heating terminals 320a, 320b and the control component terminal <NUM> may extend through respective apertures 350a-c in the base <NUM>. Thus, as illustrated in <FIG>, the ends 336a, 336b of the heating terminals 320a, 320b may be exposed at a connector end 302b of the base <NUM> in order to engage electrical contacts in the coupler <NUM> of the control body <NUM>. Further, the control component terminal <NUM> may extend from the electronic control component <NUM> through the third aperture 350c to a second end <NUM> positioned proximate the connector end 302b of the base <NUM>.

Thus, when the control body <NUM> is coupled to the cartridge <NUM>, the electronic control component <NUM> may form an electrical connection with the control body through the control component terminal <NUM>. For example, the second end <NUM> of the control component terminal <NUM> may engage an electrical contact in the coupler <NUM> of the control body <NUM> (see, e.g., <FIG>). The control body <NUM> may thus employ the electronic control component <NUM> to determine whether the cartridge <NUM> is genuine and/or perform other functions. Various examples of electronic control components and functions performed thereby are described in <CIT>. , Further, in some embodiments the base <NUM> may comprise anti-rotation features that substantially prevent relative rotation between the cartridge <NUM> and the control body <NUM> when coupled together as disclosed in <CIT>.

As illustrated in <FIG>, the atomizer <NUM> may couple to the heating terminals 320a, 320b. For example, the atomizer <NUM> may be coupled to the heating terminals 320a, 320b after the base <NUM> is coupled to the flow director <NUM>. Alternatively, the atomizer <NUM> may be coupled to the heating terminals 320a, 320b prior to coupling the flow director <NUM> to the base <NUM>. In this regard, by coupling the heating terminals 320a, 320b to the flow director <NUM>, the heating terminals may be securely retained at a desired separation distance, which may allow for coupling of the atomizer <NUM> thereto at any point in time.

As noted above, in one embodiment the atomizer <NUM> may include the liquid transport element <NUM> and the heating element <NUM>. The heating element <NUM> may be in direct contact with the liquid transport element <NUM> so as to directly apply heat thereto. Various embodiments of materials configured to produce heat when electrical current is applied therethrough may be employed to form the heating element <NUM>. Example materials from which the heating element <NUM> may be formed include Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi<NUM>), molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)<NUM>), graphite and graphite-based materials; and ceramic (e.g., a positive or negative temperature coefficient ceramic). Accordingly, regardless of the particular configuration of the heating element <NUM> and the material thereof, current supplied from the control body <NUM> through the heating terminals 320a, 320b may be employed to produce heat at the heating element.

As illustrated in <FIG>, in one embodiment the heating element <NUM> may comprise a wire defining a plurality of coils <NUM> wound about the liquid transport element <NUM>. In some embodiments the heating element <NUM> may be formed by winding the wire about the liquid transport element <NUM> as described in <CIT>. Further, in some embodiments the wire may define a variable coil spacing configured to provide a heating portion and contact portions for attachment to heating terminals, as described in <CIT>. Additionally, in some embodiments the heating portion of the heating element may define a variable coil spacing, as described in <CIT>.

However, various other embodiments of methods may be employed to form the heating element <NUM>, and various other embodiments of heating elements may be employed in the atomizer <NUM>. For example, a stamped heating element may be employed in the atomizer, as described in <CIT>. Various additional examples of heaters and materials employed to form heaters are described in <CIT> Additionally, in various embodiments, one or more microheaters or like solid state heaters may be used. Example embodiments of microheaters and atomizers incorporating microheaters suitable for use in the presently disclosed devices are described in <CIT>.

The heating element <NUM> may be coupled to the tabs 334a, 334b of the heating terminals 320a, 320b via a variety of methods. For example, the heating element <NUM> may be crimped to the tabs 334a, 334b of the heating terminals 320a, 320b. Alternatively, the heating element <NUM> may be soldered to the tabs 334a, 334b of the heating terminals 320a, 320b. In an additional embodiment the heating element <NUM> may be coupled to the tabs 334a, 334b of the heating terminals 320a, 320b via clips or other mechanical fasteners. In another example embodiment the heating element <NUM> may be welded (e.g., laser or resistance welded) to the tabs 334a, 334b of the heating terminals 320a, 320b, as described, for example, in <CIT>. However, as may be understood, the atomizer may be coupled to various other portions of the heating terminals and/or various other connection mechanisms (e.g., wires) and methods may be employed in other embodiments.

After coupling of the atomizer <NUM> to the heating terminals 320a, 320b, the reservoir substrate <NUM> may be positioned in contact with the liquid transport element <NUM> of the atomizer, as illustrated in <FIG>. For example, the reservoir substrate <NUM> may be wrapped at least partially about the liquid transport element <NUM>. Alternatively to wrapping the reservoir substrate around the liquid transport element, in another embodiment the liquid transport element may be positioned outside of, but still in contact with, the reservoir substrate. For example, the reservoir substrate may be wrapped around the flow director and the liquid transport element may be folded against the outer surface of the reservoir substrate.

The reservoir substrate <NUM> may comprise one or more layers of nonwoven fibers at least partially wrapped about the flow director <NUM>. Thereby, for example, the reservoir substrate <NUM> may be substantially formed into the shape of a tube. In some embodiments first and second ends 312a, 312b of the reservoir substrate <NUM> may be out of contact with one another such that a gap <NUM> is defined between the first and second ends thereof (see, <FIG>). However, in other embodiments the ends of the reservoir substrate <NUM> may overlap one another. Exemplary reservoir substrates formed of cellulose acetate fibers are described in <CIT>.

The aerosol precursor composition can be, for example, sorptively retained by the reservoir substrate <NUM>. The reservoir substrate <NUM> is in fluid connection with the liquid transport element <NUM> due to the contact therebetween. Thus, the liquid transport element <NUM> may be configured to transport liquid from the reservoir substrate <NUM> to the heating element <NUM> via capillary action or other liquid transport mechanisms. In this regard, so long as physical contact between the reservoir substrate <NUM> and the liquid transport element <NUM> is provided, the aerosol precursor component may be transferred therebetween due to wicking characteristics of the liquid transport element. Thus, the liquid transport element <NUM> need not be configured to extend along an entirety of a longitudinal length of the reservoir substrate <NUM> in some embodiments.

As illustrated, the reservoir substrate <NUM> may also be wrapped and extend at least partially around the flow director <NUM> in addition to the liquid transport element <NUM>. The flow director <NUM> may include particular features configured to facilitate wrapping of the reservoir substrate <NUM> thereabout and retention of the reservoir substrate in a selected position thereon. In this regard, as illustrated in <FIG>, the flow director <NUM> may include one or more protrusions <NUM> extending therefrom. As illustrated, in one embodiment the protrusions <NUM> may define a substantially conical configuration (e.g., a truncated conical configuration) in some embodiments. Thereby, the protrusions <NUM> may extend into the material defining the reservoir substrate <NUM> to provide for engagement therebetween. However, protrusions defining various other shapes configured to engage the reservoir substrate (e.g., a hook configuration) may be employed in other embodiments.

By providing engagement between the flow director <NUM> and the reservoir substrate <NUM>, the reservoir substrate may be securely coupled to the flow director, which may help to retain the reservoir substrate in a desired position. In this regard, the reservoir substrate <NUM> may otherwise be prone to movement during insertion of the flow director <NUM> and the reservoir substrate into the outer body <NUM>. In some embodiments the outer body <NUM> may be inserted over the reservoir substrate using a funnel-shaped tool as described, for example, in <CIT>.

<FIG> illustrates a partial sectional view through a first embodiment of the cartridge <NUM>' along line <NUM> - <NUM> from <FIG>, wherein the reservoir substrate (see, e.g., <FIG>) is hidden for clarity purposes, following coupling of the outer body <NUM> thereto. As illustrated, in some embodiments the outer body <NUM> may be directly coupled to the base <NUM>. As further illustrated in <FIG>, in some embodiments the outer body <NUM> may be directly coupled to the flow director <NUM>. In other words, the outer body <NUM> may directly contact the base <NUM> and the flow director <NUM>.

The flow director <NUM> and the outer body <NUM> may define a first compartment <NUM>. In particular, the flow director <NUM> may contact the outer body <NUM> such that the flow director and the outer body collectively define and at least partially surround the first compartment <NUM>. In some embodiments the first compartment <NUM> may be configured to receive the reservoir substrate <NUM>. Accordingly, the first compartment <NUM> may also be referred to as a reservoir compartment <NUM>. As illustrated, in some embodiments the reservoir compartment <NUM> may define a substantially annular configuration as a result of the reservoir compartment extending between the outer body <NUM>, which may define a tubular configuration, and the flow director <NUM>, which may extend along at least a portion of a length of the outer body proximate a center thereof.

The flow director <NUM> and the base <NUM> may define a second compartment <NUM>. In particular, the flow director <NUM> may contact (e.g., directly contact) the base <NUM> such that the flow director and the base collectively define and at least partially surround the second compartment <NUM>. The second compartment <NUM> may also be referred to as an electronics compartment <NUM> in embodiments in which one or more electronic components are at least partially received therein. For example, in the embodiment illustrated in <FIG>, the control component terminal <NUM> and the electronic control component <NUM> are received therein.

The first compartment <NUM> and the second compartment <NUM> are referred to hereinafter as the reservoir compartment <NUM> and the electronics compartment <NUM>. However, reference to the compartments <NUM>, <NUM> in this manner is provided for purposes of simplicity. In this regard, as noted above, in some embodiments the first compartment <NUM> may not include the reservoir substrate <NUM> and/or the second compartment <NUM> may not include electronic components such as the control component terminal <NUM> and the electronic control component <NUM>.

The flow director <NUM> may be coupled to the outer body <NUM> via a variety of manners and via a variety of mechanisms. Similarly the flow director <NUM> may be coupled to the base <NUM> in a variety of manners and via a variety of mechanisms. The mechanisms and manners of coupling employed may depend on the particular structural relationship of the flow director <NUM>, the outer body <NUM>, and the base <NUM> as well as the material compositions thereof.

In some embodiments the base <NUM>, the flow director <NUM>, and/or the outer body <NUM> may be configured to avoid leakage of fluid. In this regard, for example, leakage of the aerosol precursor composition out of the reservoir compartment <NUM> to an exterior environment may be undesirable. For example, such leakage may decrease the useable life of the cartridge by decreasing the amount of aerosol precursor composition available for vaporization. Additionally, leakage of the aerosol precursor composition from the reservoir compartment <NUM> into the electronics compartment <NUM> may be undesirable. In this regard, the aerosol precursor composition could damage the electronic control component <NUM> and/or leak along the control component terminal <NUM> to the control body <NUM> (see, e.g., <FIG>), which could also be damaged.

Accordingly, in order to avoid any such fluid leakage, the flow director <NUM> may seal against the outer body <NUM>. For example, in the embodiment illustrated in <FIG>, the base portion <NUM> of the flow director <NUM> seals against an inner surface 314c of the outer body <NUM>. As illustrated, in one embodiment the base portion <NUM> of the flow director <NUM> may define at least one deformable rib <NUM> configured to seal against an inner surface 314c of the outer body <NUM>. In this regard, each of the deformable ribs <NUM> may extend continuously around the perimeter of the base portion <NUM> of the outer body <NUM> and initially extend to an outer dimension (e.g., an outer diameter in embodiments in which the outer body is tubular) equal to, or slightly greater than an inner dimension (e.g., a diameter) of the outer body <NUM> at the inner surface 314c.

Thereby, the deformable ribs <NUM> may deform upon coupling of the outer body <NUM> to the flow director <NUM> to define a tight seal with the inner surface 314c of the outer body. For example, the outer body <NUM> may comprise a metal such as stainless steel and the flow director <NUM> may define a relatively softer material such as plastic that is configured to deform during insertion into the outer body. By sealing the flow director <NUM> against the inner surface 314c of the outer body <NUM>, leakage from the reservoir compartment <NUM> between the outer body and the flow director may be avoided.

In the illustrated embodiment the flow director <NUM> includes three deformable ribs <NUM>. However, in other embodiments the flow director <NUM> may include a plurality of deformable ribs <NUM> and particularly may include from one deformable rib to six deformable ribs. Use of multiple deformable ribs <NUM> at the flow director <NUM> may be desirable in that the additional deformable ribs may provide redundant protection in the event that the aerosol precursor composition leaks past a first deformable rib. However, as noted above, the flow director <NUM> may include a single deformable rib <NUM> in other embodiments.

Accordingly, the deformable ribs <NUM> at the base portion <NUM> of the flow director <NUM> may resist leakage of the aerosol precursor composition between the outer body <NUM> and the flow director. Further, as noted above, in some embodiments the base <NUM> may be sealed to the flow director <NUM> (e.g., welded thereto). Accordingly, in the event that the aerosol precursor leaks past the deformable ribs <NUM> at the base portion <NUM> of the flow director <NUM>, the seal between the flow director and the base <NUM> may prevent entry of the aerosol precursor composition into the electronics compartment <NUM>.

As further illustrated in <FIG>, the outer body <NUM> may couple to the base <NUM>. For example, the base <NUM> may be directly coupled to a first end 314a of the outer body <NUM>. In this regard, the base <NUM> may define at least one deformable rib <NUM> configured to seal against the inner surface 314c of the outer body <NUM>. By sealing the base <NUM> against the inner surface 314c of the outer body <NUM>, the base may further resist leakage of the aerosol precursor composition from the reservoir compartment <NUM>. In this regard, each deformable ribs <NUM> may extend continuously around the perimeter of the inner end 302a of the base <NUM> and initially extend to an outer dimension (e.g., an outer diameter in embodiments in which the outer body is tubular) equal to, or slightly greater than an inner dimension (e.g., a diameter) of the outer body <NUM> at the inner surface 314c.

Thereby, the deformable ribs <NUM> may deform upon coupling of the outer body <NUM> to the base <NUM> to define a tight seal with the inner surface 314c of the outer body. For example, the outer body <NUM> may comprise a metal such as stainless steel and the base <NUM> may define a relatively softer material such as plastic that is configured to deform during insertion of the inner end 302a into the outer body. By sealing the base <NUM> against the inner surface 314c of the outer body <NUM>, leakage from the reservoir compartment <NUM> between the outer body and the base may be avoided.

In the illustrated embodiment the base <NUM> includes two deformable ribs <NUM>. However, in other embodiments the base <NUM> may include a plurality of deformable ribs <NUM> and particularly may include from one deformable rib to six deformable ribs. Use of multiple deformable ribs <NUM> at the base <NUM> may be desirable in that the additional deformable ribs may provide redundant protection in the event that the aerosol precursor composition leaks past the base portion <NUM> of the flow director <NUM> and further leaks past a first deformable rib <NUM> of the base <NUM>. However, as noted above, the base <NUM> may include a single deformable rib <NUM> in other embodiments.

As may be understood, deformable ribs may alternatively or additionally be placed at the inner surface 314c of the outer body <NUM> in order to contact the flow director <NUM> and/or the base <NUM>. Accordingly, the deformable ribs <NUM> of the flow director <NUM> and the deformable ribs <NUM> of the base <NUM> and/or the outer body <NUM> may deform during the engagement therebetween such that a tight seal is formed between the outer body and the flow director and between the base and the flow director so as to resist fluid leakage as described above.

As further illustrated in <FIG>, in some embodiments the outer body <NUM> may be crimped so as to provide a secure coupling between the outer body and the base <NUM> and/or the flow director <NUM>. For example, in the illustrated embodiment the outer body <NUM> may be crimped proximate the first end 314a to define a crimp <NUM> extending into a groove <NUM> defined in and at least partially extending around the perimeter of the inner end 302a of the base <NUM>. Thereby, engagement between the crimp <NUM> and the groove <NUM> may secure the outer body <NUM> to the base <NUM> and may further resist leakage by ensuring a tight seal against one or more of the deformable ribs <NUM>, <NUM>. In some embodiments, in order to facilitate crimping of the outer body <NUM>, the outer body may comprise a metal that is relatively ductile, such as stainless steel. Use of stainless steel may also be beneficial in that it may resist corrosion. However, various other embodiments of materials that are relatively ductile may be employed.

By sealing the reservoir compartment <NUM> in one or more manners, fluid leakage from the reservoir compartment to the electronics compartment <NUM> may be avoided. In this regard, by positioning the control component terminal <NUM> in the electronics compartment <NUM>, the control component terminal may not extend into the reservoir compartment <NUM>. Thereby, leakage of aerosol precursor composition along the control component terminal <NUM>, which may otherwise occur in instances in which the cartridge is overfilled or filled at a rate that exceeds a rate of absorption of the reservoir substrate <NUM>, may be avoided. Further, sealing the reservoir compartment <NUM> may protect the electronic control component <NUM> from damage from the aerosol precursor composition.

Although embodiments of the present disclosure are directed to avoiding leaking of the aerosol precursor composition from the reservoir compartment <NUM> and/or entry of the aerosol precursor composition into the electronics compartment <NUM>, the particular construction of the cartridge configured to provide these benefits may vary. In this regard, whereas the embodiment of the cartridge <NUM>' described above and illustrated in <FIG> includes deformable ribs <NUM>, <NUM> and the base <NUM> is directly coupled to the outer body <NUM>, in other embodiments the construction of the cartridge may vary.

For example, <FIG> illustrates a partial sectional view through a second embodiment of the cartridge <NUM>" along line <NUM> - <NUM> from <FIG>. In the embodiment of the cartridge <NUM>" illustrated in <FIG>, the base <NUM> is indirectly coupled to the outer body <NUM> and other sealing configurations are employed. In this regard, in the embodiment of the cartridge <NUM>" illustrated in <FIG>, the flow director <NUM> is coupled to the outer body <NUM>. Further, the base <NUM> is coupled to the flow director <NUM>. More particularly, the outer body <NUM> and the base <NUM> are directly coupled to the base portion <NUM> of the flow director <NUM>. Accordingly, the base <NUM> may be indirectly coupled to the outer body <NUM> via direct coupling with the flow director <NUM>.

As illustrated, in one embodiment the base portion <NUM> of the flow director <NUM> may extend to define a shape and size corresponding to a size and shape of an outer surface 314d of the outer body <NUM> and/or an outer surface 302d of the base <NUM>. For example, in the illustrated embodiment the base portion <NUM> of the flow director <NUM>, the outer body <NUM>, and the base <NUM> are each round and extend to substantially the same diameter. Thereby, the cartridge <NUM>" may define an exterior that appears to be integral, despite the exterior being formed from the base <NUM>, the flow director <NUM>, and the outer body <NUM>.

Further, in some embodiments a first recessed portion <NUM> of the base portion <NUM> of the flow director <NUM> may contact the inner surface 314c of the outer body <NUM>. Alternatively or additionally, a second recessed portion <NUM> of the base portion <NUM> of the flow director <NUM> may contact an inner surface 302c of the base <NUM>. Accordingly, by engaging the inner surface 314c of the outer body <NUM> and/or the inner surface 302c of the base <NUM> with the base portion <NUM> of the flow director <NUM>, engagement between the flow director and the outer body and/or between the flow director and the base may be improved. In this regard, in addition to the sealing mechanisms and methods described above, interference fit may improve the connection between the flow director <NUM> and the outer body <NUM> and/or improve the connection between the flow director and the base <NUM>.

The flow director <NUM> may be coupled to the base <NUM> via a variety of mechanisms and methods. In this regard, welding and various other methods for attaching the base <NUM> to the flow director <NUM> which may also be employed in the cartridge <NUM>" are described above. As further noted above, in some embodiments the coupling between the base <NUM> and the flow director <NUM> may produce a seal therebetween to prevent ingress of fluids such as the aerosol precursor composition into the electronics compartment <NUM>.

Similarly, the flow director <NUM> may be coupled to the outer body <NUM> via a variety of mechanisms and manners. In some embodiments the outer body <NUM> may be sealed to the flow director <NUM>. For example, the outer body <NUM> may be welded to the flow director <NUM> or the outer body may be adhered to the flow director via a glue, adhesive, epoxy, or sealant. With respect to welding, various embodiments of methods thereof may be employed depending on the particular materials from which the flow director <NUM> and the outer body <NUM> are formed. For example, arc welding, gas welding, resistance welding, energy beam welding, and solid-state welding may be employed. An example of a solid-state welding process is ultrasonic welding which uses ultrasonic vibrations to create a weld between two workpieces held together under pressure. Another example of a solid-state welding process is induction welding, which uses electromagnetic induction to heat workpieces. However, in embodiments in which the outer body <NUM> and the flow director <NUM> are formed from plastic or other non-ferromagnetic materials, the material may be implanting with metallic or ferromagnetic compounds, called susceptors in order to allow for induction welding thereof. As may be understood, use of these welding methods may provide a hermetic seal which may retain the aerosol precursor composition in the reservoir compartment <NUM>. However, various other embodiments of coupling mechanisms and methods may be employed.

As described above, the flow director <NUM> and the base may cooperatively define the electronics compartment <NUM>. Further, the flow director <NUM> and the outer body <NUM> may cooperatively define the reservoir compartment <NUM>. As part of the formation of the compartments <NUM>, <NUM>, certain sealing arrangements may be employed. For example, as described above, the flow director <NUM> may be sealed to the outer body <NUM> and the flow director may be sealed to the base <NUM>. Accordingly, by sealing the reservoir compartment <NUM>, the likelihood of egress of the aerosol precursor composition therefrom may be reduced. Further, by providing separate compartments for the reservoir substrate <NUM> and the electronic control component <NUM>, wherein at least one seal is positioned therebetween, the likelihood of the aerosol precursor composition damaging the electronic control component <NUM> may be reduced.

As noted above, embodiments of the present disclosure are directed to avoiding leakage of fluid from the reservoir compartment <NUM>. In particular, embodiments of the present disclosure are directed to avoiding leakage of an aerosol precursor composition from the reserve In this regard, following attachment of the outer body <NUM>, the reservoir compartment <NUM> may be filled with the aerosol precursor composition.

The aerosol precursor, or vapor precursor composition, can vary. Most preferably, the aerosol precursor is composed of a combination or mixture of various ingredients or components. The selection of the particular aerosol precursor components, and the relative amounts of those components used, may be altered in order to control the overall chemical composition of the mainstream aerosol produced by the aerosol generating piece. Of particular interest are aerosol precursors that can be characterized as being generally liquid in nature. For example, representative generally liquid aerosol precursors may have the form of liquid solutions, viscous gels, mixtures of miscible components, or liquids incorporating suspended or dispersed components. Typical aerosol precursors are capable of being vaporized upon exposure to heat under those conditions that are experienced during use of the aerosol generating pieces that are characteristic of the current disclosure; and hence are capable of yielding vapors and aerosols that are capable of being inhaled.

For aerosol delivery systems that are characterized as electronic cigarettes, the aerosol precursor most preferably incorporates tobacco or components derived from tobacco. In one regard, the tobacco may be provided as parts or pieces of tobacco, such as finely ground, milled or powdered tobacco lamina. In another regard, the tobacco may be provided in the form of an extract, such as a spray dried extract that incorporates many of the water soluble components of tobacco. Alternatively, tobacco extracts may have the form of relatively high nicotine content extracts, which extracts also incorporate minor amounts of other extracted components derived from tobacco. In another regard, components derived from tobacco may be provided in a relatively pure form, such as certain flavoring agents that are derived from tobacco. In one regard, a component that is derived from tobacco, and that may be employed in a highly purified or essentially pure form, is nicotine (e.g., pharmaceutical grade nicotine).

The aerosol precursor may incorporate a so-called "aerosol forming materials. " Such materials have the ability to yield visible aerosols when vaporized upon exposure to heat under those conditions experienced during normal use of aerosol generating pieces that are characteristic of the current disclosure. Such aerosol forming materials include various polyols or polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures thereof). Many embodiments of the present disclosure incorporate aerosol precursor components that can be characterized as water, moisture or aqueous liquid. During conditions of normal use of certain aerosol generating pieces, the water incorporated within those pieces can vaporize to yield a component of the generated aerosol. As such, for purposes of the current disclosure, water that is present within the aerosol precursor may be considered to be an aerosol forming material.

It is possible to employ a wide variety of optional flavoring agents or materials that alter the sensory character or nature of the drawn mainstream aerosol generated by the aerosol delivery system of the present disclosure. For example, such optional flavoring agents may be used within the aerosol precursor to alter the flavor, aroma and organoleptic properties of the aerosol. Certain flavoring agents may be provided from sources other than tobacco. Exemplary flavoring agents may be natural or artificial in nature, and may be employed as concentrates or flavor packages.

Exemplary flavoring agents include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach and citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavorings and flavor packages of the type and character traditionally used for the flavoring of cigarette, cigar and pipe tobaccos. Syrups, such as high fructose corn syrup, also can be employed. Certain flavoring agents may be incorporated within aerosol forming materials prior to formulation of a final aerosol precursor mixture (e.g., certain water soluble flavoring agents can be incorporated within water, menthol can be incorporated within propylene glycol, and certain complex flavor packages can be incorporated within propylene glycol).

Aerosol precursors also may include ingredients that exhibit acidic or basic characteristics (e.g., organic acids, ammonium salts or organic amines). For example, certain organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included in an aerosol precursor formulation incorporating nicotine, preferably in amounts up to being equimolar (based on total organic acid content) with the nicotine. For example, the aerosol precursor may include about <NUM> to about <NUM> moles of levulinic acid per one mole of nicotine, about <NUM> to about <NUM> moles of succinic acid per one mole of nicotine, about <NUM> to about <NUM> moles of lactic acid per one mole of nicotine, about <NUM> to about <NUM> moles of pyruvic acid per one mole of nicotine, or various permutations and combinations thereof, up to a concentration wherein the total amount of organic acid present is equimolar to the total amount of nicotine present in the aerosol precursor.

As one non-limiting example, a representative aerosol precursor can have the form of a mixture of about <NUM>% to about <NUM>% glycerin, often about <NUM>% to about <NUM>% glycerin; about <NUM>% to about <NUM>% water, often about <NUM>% to about <NUM>% water; about <NUM>% to about <NUM>% propylene glycol, often about <NUM>% to about <NUM>% propylene glycol; about <NUM>% to about <NUM>% nicotine, often about <NUM>% to about <NUM>% nicotine; and optional flavoring agent in an amount of up to about <NUM>%, often about <NUM>% to about <NUM>% flavoring agent; on a weight basis. For example, a representative aerosol precursor may have the form of a formulation incorporating greater than about <NUM>% glycerin, about <NUM>% water, about <NUM>% propylene glycol, about <NUM>% to about <NUM>% nicotine, and less than about <NUM>% optional flavoring agent, on a weight basis. For example, a representative aerosol precursor may have the form of a formulation incorporating greater than about <NUM>% glycerin, about <NUM>% water, about <NUM>% propylene glycol, about <NUM>% nicotine, and less than about <NUM>% optional flavoring agent. For example, a representative aerosol precursor may have the form of a formulation incorporating greater than about <NUM>% glycerin, about <NUM>% water, about <NUM>% propylene glycol, about <NUM>% nicotine, and less than about <NUM>% optional flavoring agent, on a weight basis.

As another non-limiting example, a representative aerosol precursor can have the form of a mixture of about <NUM>% to about <NUM>% glycerin, often about <NUM>% to about <NUM>% glycerin; about <NUM>% to about <NUM>% water, often about <NUM>% to about <NUM>% water; about <NUM>% to about <NUM>% propylene glycol, often about <NUM>% to about <NUM>% propylene glycol; about <NUM>% to about <NUM>% nicotine, often about <NUM>% to about <NUM>% nicotine; about <NUM>% to about <NUM>%, often about <NUM>% to about <NUM>% menthol; and optional additional flavoring agent in an amount of up to about <NUM>%, often about <NUM>% to about <NUM>% flavoring agent; on a weight basis. For example, a representative aerosol precursor may have the form of a formulation incorporating about <NUM>% glycerin, about <NUM>% water, about <NUM>% propylene glycol, about <NUM>% nicotine, about <NUM>% menthol, and about <NUM>% other flavoring agent, on a weight basis.

Representative types of aerosol precursor components and formulations also are set forth and characterized in <CIT> and <CIT>; <CIT> and <CIT> Other aerosol precursors that may be employed include the aerosol precursors that have been incorporated in the VUSE® product by R. Reynolds Vapor Company, the BLU™ product by Lorillard Technologies, the MISTIC MENTHOL product by Mistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirable are the so-called "smoke juices" for electronic cigarettes that have been available from Johnson Creek Enterprises LLC.

The amount of aerosol precursor that is incorporated within the aerosol delivery system is such that the aerosol generating piece provides acceptable sensory and desirable performance characteristics. For example, it is highly preferred that sufficient amounts of aerosol forming material (e.g., glycerin and/or propylene glycol), be employed in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. The amount of aerosol precursor within the aerosol generating system may be dependent upon factors such as the number of puffs desired per aerosol generating piece. Typically, the amount of aerosol precursor incorporated within the aerosol delivery system, and particularly within the aerosol generating piece, is less than about <NUM>, generally less than about <NUM>, often less than about <NUM> and frequently less than about <NUM>.

The reservoir substrate <NUM> may be configured to absorb or otherwise retain the aerosol precursor composition directed into the reservoir compartment <NUM>. However, in some instances the aerosol precursor composition may be directed into the reservoir compartment <NUM> at a fill rate that is greater than an absoptive rate of the reservoir substrate <NUM>. Further, in some instances the amount of aerosol precursor composition directed into the reservoir compartment <NUM> may exceed the absorptive capacity of the reservoir substrate <NUM>. Additionally, in some instances the aerosol precursor composition may absorb ambient moisture, causing the quantity of fluid in the reservoir compartment <NUM> to exceed the absorptive capacity of the reservoir substrate <NUM>, even if the initially-filled quantity of the aerosol precursor composition did not exceed the absorptive capacity of the reservoir substrate.

However, despite the absorptive rate or absorptive capacity of the reservoir substrate <NUM> being exceeded, the aerosol precursor composition may still be retained in the reservoir compartment <NUM>. In this regard, as discussed above, the seal between the outer body <NUM> and the flow director <NUM> may prevent leakage from the reservoir compartment <NUM>. Accordingly, by employing the sealed reservoir compartment <NUM>, issues with respect to exceeding the absorptive capacity of the cartridge <NUM> may be avoided, and the cartridge may be filled more quickly, which may expedite the cartridge assembly process.

<FIG> illustrates a lateral sectional view through the partially assembled cartridge <NUM> along line <NUM> - <NUM> from <FIG> with the outer body <NUM> (see, e.g., <FIG>) not shown for clarity purposes. In this regard, as may be understood, the outer body <NUM> may be attached prior to the filling process such that the aerosol precursor composition is retained in the reservoir compartment <NUM> (see, e.g., <FIG>) during the filling process. As illustrated, one embodiment of the flow director <NUM>' may define features configured to facilitate filling of the cartridge <NUM>. In particular, the flow director <NUM>' may define one or more recesses 392a-c.

In the illustrated embodiment the flow director <NUM>' defines three recesses 392a-c. However additional or fewer recesses may be employed in other embodiments. The recesses 392a-c may each define a channel 394a-c between the flow director <NUM>' and the reservoir substrate <NUM> configured to receive a filling device. For example, a filling needle or nozzle may be inserted into each channel 394a-c, or a nozzle may be directed into proximity to each channel, and an aerosol precursor composition may be directed into the channels. Accordingly, each channel 394a-c may facilitate rapid filling of the reservoir compartment <NUM> by allowing the channels 394a-c to initially fill up and then the reservoir substrate <NUM>, which partially surrounds each channel, to absorb the aerosol precursor composition therefrom. When a filling needle or nozzle is directed into one of the channels 394a-c, the remaining channels may facilitate venting of air from around and in the reservoir substrate <NUM> displaced by the aerosol precursor composition to further facilitate rapid filling.

In embodiments in which the reservoir substrate <NUM> defines the gap <NUM> between the first and second ends 312a, 312b thereof, the gap may provide the same or similar functionality as the channels 394a-c. In this regard, a filling needle or nozzle may be inserted into the gap <NUM> to facilitate filling of the reservoir <NUM> with the aerosol precursor composition. Alternatively or additionally, the gap <NUM> may allow for venting of air from in and around the reservoir substrate <NUM> when the aerosol precursor composition is directed into contact with the reservoir substrate (e.g., when the aerosol precursor composition is directed into one of the channels 394a-c).

As further illustrated in <FIG>, in some embodiments the flow director <NUM>' may define a non-circular cross-section. For example, the flow director <NUM>' may define, in cross-section, a core <NUM> and a plurality of lateral extensions or wings 393a, 393b protruding therefrom. The core <NUM> may be substantially tubular and the through hole <NUM> may extend therethrough. The above-described channels 394a-c may be defined in the core <NUM>. Further, the wings 393a, 393b may extend from the core <NUM> so as to receive the heating terminals 320a, 320b therethrough.

<FIG> illustrates a longitudinal cross-sectional view through the cartridge <NUM> in an assembled configuration along line <NUM> - <NUM> from <FIG>. As illustrated, the mouthpiece <NUM> may couple to the outer body <NUM> at a second end 314b thereof, opposite from the base <NUM>. Thereby, the mouthpiece <NUM> may at least partially enclose the reservoir compartment <NUM> at the second end 314b of the outer body <NUM>. As further illustrated in <FIG>, the label <NUM> may at least partially surround one or more of the outer body <NUM>, the base <NUM>, and the mouthpiece <NUM>, for example, to provide the exterior of the cartridge <NUM> with a continuous, integral appearance. The label <NUM> may include an adhesive at an inner surface thereof or adhesive may otherwise be positioned between the label and the outer body <NUM>, the base <NUM>, and/or the mouthpiece <NUM>.

In one embodiment the label <NUM> may comprise a single layer of a material (e.g., plastic, paper, or foil). Alternatively, the label <NUM> may comprise a multi-layer lamination (e.g., a lamination of plastic, paper, and/or foil). The label <NUM> may include indicia on an outer surface thereof. For example, the indicia may include information such as a product identifier, which may be formed by ink applied to one or more of the layers of the label <NUM>. The indicia on the label <NUM> likewise may include texturing, coloring, and/or other physical attributes that may provide a desired appearance to the device, such as resembling a conventional cigarette or a conventional electronic cigarette. Example embodiments of labels which may be employed in the aerosol delivery device of the present disclosure are provided in <CIT>.

The mouthpiece <NUM> may be retained in engagement with the outer body <NUM> via a variety of mechanisms and methods. For example, the mouthpiece <NUM> may be secured to the outer body <NUM> via an adhesive, glue, sealant, or epoxy. In another embodiment the mouthpiece <NUM> may be welded (e.g., ultrasonically welded) to the outer body <NUM>. Alternatively or additionally, the mouthpiece <NUM> may engage the outer body <NUM> via threaded engagement, interference fit, a crimp, or any other coupling mechanism.

As illustrated, the mouthpiece <NUM> may define an end portion <NUM> and an extension <NUM>. The end portion <NUM> of the mouthpiece <NUM> may extend outwardly from the second end 314b of the outer body <NUM>. Conversely, the extension <NUM> may extend into the outer body <NUM> such that the mouthpiece <NUM> is at least partially surrounded by the outer body.

The mouthpiece <NUM> may be configured to receive a draw from a user. In this regard, the mouthpiece <NUM> may define at least one aperture <NUM> through which air mixed with aerosol produced by the atomizer <NUM> may be directed when a user draws on the mouthpiece. In this regard, the aperture <NUM> may extend from an inlet <NUM> to an outlet <NUM>. The inlet <NUM> may be configured to receive the aerosol generated by the atomizer <NUM> in the reservoir compartment <NUM>. Conversely, the outlet <NUM> may be configured to deliver the aerosol to a user. In order to collect the aerosol generated by the atomizer <NUM>, the inlet <NUM> to the aperture <NUM> may be relatively large. The outlet <NUM> to the aperture <NUM> may be smaller than the inlet <NUM> in order to provide a desired resistance to a draw on the mouthpiece <NUM> and substantially prevent access to the atomizer <NUM>. For example, the inlet <NUM> may define a larger diameter than the outlet <NUM> in embodiments in which the inlet and outlet are round.

The extension <NUM> may be configured to reduce an empty volume within the outer body <NUM>. In this regard, by reducing the empty volume (e.g., open space) in the outer body <NUM>, the amount of air in the cartridge <NUM> may be reduced. Thereby, aerosol produced by the atomizer <NUM> may mix with less air prior to exiting through the mouthpiece <NUM>. By reducing the quantity of air in the outer body <NUM> positioned between the atomizer <NUM> and the outlet <NUM> to the mouthpiece <NUM>, the amount of aerosol precursor composition required to reach a given desired aerosol concentration exiting the mouthpiece <NUM> may be reduced. Thereby, for example, the cartridge <NUM> may produce a desired concentration of aerosol even in an instance in which a user makes a relatively small draw on the cartridge <NUM> and may reduce the quantity of any aerosol precursor composition wasted during such a small puff.

Further, as a result of the extension <NUM> decreasing the volume of open space in the cartridge <NUM>, and in particular between the atomizer <NUM> and the outlet <NUM> to the aperture <NUM> through the mouthpiece <NUM>, the quantity of aerosol remaining in the cartridge after a draw may be reduced. By reducing the amount of residual aerosol in the cartridge <NUM>, less condensation may occur as the aerosol cools. As may be understood, such condensation may undesirably result in corrosion of metal parts (although any such metal parts may be selected and configured to avoid corrosion) or fluid leakage from the cartridge <NUM>. Condensation remaining in the cartridge may also detrimentally affect the taste of the aerosol during future draws. Further, condensation may form deposits on the heating element <NUM> that may reduce the effectiveness thereof. Thereby, reducing the volume of empty space between the atomizer <NUM> and the outlet <NUM> to the aperture <NUM> through the mouthpiece <NUM> may provide additional benefits. The extension <NUM> may also improve a mechanical connection between the mouthpiece <NUM> and the outer body <NUM> by providing an elongated joint therebetween.

In some embodiments the mouthpiece <NUM> or a portion thereof may be deformable, consumable, and/or replaceable. For example, in some embodiments the extension <NUM> may be deformable, consumable, and/or replaceable. In this regard, some users may chew on the mouthpiece <NUM> during use of the aerosol delivery device <NUM>. Thereby, use of a deformable material (e.g., a rubber material and/or cellulose acetate) may provide a user with a desired feel that mimics the feel of a filter of a traditional cigarette, for example. In some embodiments a tube may surround and support the aperture <NUM> such that the aperture does not become blocked in instances in which the mouthpiece <NUM> is deformed. Thereby, flow through the mouthpiece <NUM> may not be blocked when the user chews thereon. The mouthpiece <NUM> may define an elongated configuration external to the outer body <NUM> in some embodiments so as to facilitate chewing thereon. For example, the extension <NUM> may define a length about to about one inch in some embodiments.

<FIG> illustrates a sectional view through the cartridge <NUM> along line <NUM> - <NUM> from <FIG> including an alternate embodiment of the mouthpiece <NUM>'. As illustrated, the mouthpiece <NUM>' includes the end portion <NUM> and the extension <NUM>. Further, the mouthpiece <NUM>' includes the aperture <NUM> extending therethrough between the inlet <NUM> and the outlet <NUM>.

However, the mouthpiece <NUM>' illustrated in <FIG> differs from the embodiment of the mouthpiece <NUM> illustrated in <FIG> in that the mouthpiece illustrated in <FIG> further comprises a lip <NUM> extending inwardly toward the atomizer <NUM> proximate the aperture <NUM>. For example, as illustrated, the lip <NUM> may extend around the aperture <NUM> between the inlet <NUM> and the outlet <NUM>. The lip <NUM> may define a bellmouth configured to reduce turbulence associated with flow of air and aerosol through the aperture <NUM> during a draw on the mouthpiece <NUM>'. Accordingly, the amount of suction required to produce a desired airflow through the cartridge <NUM> during a draw on the mouthpiece <NUM>' may be reduced by the lip <NUM>, which may improve a user experience. The lip <NUM> may additionally or alternatively define a channel <NUM> extending around the aperture <NUM> and configured to capture small amounts of liquid (e.g., condensation), which may tend to form in proximity to the mouthpiece <NUM>', as described above. In this regard, the lip <NUM> and the channel <NUM> may resist flow of any such liquid out of the aerosol delivery device through the aperture <NUM>, which may otherwise undesirably leak out of the aerosol delivery device.

Although an extension of the mouthpiece was generally described above as reducing the volume of empty space within the cartridge between the atomizer and the outlet to the aperture through the mouthpiece, this volume of empty space may be reduced in additional or alternative manners. For example, a separate spacer may be inserted between the atomizer and the mouthpiece prior to coupling the mouthpiece to the outer body. In this regard, as further illustrated in <FIG>, in one embodiment a spacer <NUM>, which may comprise a separate component relative to the mouthpiece <NUM> (e. g, separated at the dashed lined <NUM>), may be received in the outer body <NUM> between the mouthpiece and the atomizer <NUM>.

By way of further example, as illustrated in <FIG> and <FIG>, in one embodiment the outer body <NUM> may define an increased thickness proximate the mouthpiece <NUM> such that an internal diameter thereof is reduced. By way of further example, <FIG> schematically illustrates a modified sectional view through an alternate embodiment of a cartridge <NUM>‴. The cartridge <NUM>‴ may include some or all of the above described components. In this regard, as illustrated, the cartridge <NUM>‴ may include a base <NUM>"', a flow director <NUM>‴, an atomizer <NUM>"' including a liquid transport element <NUM>‴ and a heating element <NUM>‴, a reservoir substrate <NUM>‴, an outer body <NUM>"', and a mouthpiece <NUM>‴. Note that certain components such as the heating terminals and label are not shown for clarity purposes.

However, as illustrated, a portion of the flow director <NUM>‴ may extend between the mouthpiece <NUM>‴ and the atomizer <NUM>‴. For example, the atomizer <NUM>‴ may extend through a transverse aperture <NUM>‴ defined in the flow director <NUM>‴. This configuration allows the reservoir substrate <NUM>‴ to be positioned between the atomizer <NUM>‴ and the mouthpiece <NUM>‴ (in terms of the longitudinal position thereof), which may provide the cartridge <NUM>‴ with an increased storage capacity for the aerosol precursor composition. In this regard, the flow director <NUM>‴ may separate the reservoir substrate <NUM> from contact with the atomizer <NUM>"'. Further, by positioning the atomizer <NUM>'" such that the heating element <NUM>‴ is separated from the reservoir substrate <NUM>‴ by the flow director <NUM>‴, issues with respect to the reservoir substrate migrating into contact with the heating element and/or being initially placed in contact with the heating element may be avoided.

As may be understood, alternate or additional configurations may be employed to reduce or eliminate empty space between the atomizer and the mouthpiece. For example, as described above, the outer body may protrude between the mouthpiece and the atomizer. However, regardless of the particular configuration employed, by reducing the empty space in the cartridge, and in particular the empty space between the atomizer and the mouthpiece, the cartridge may provide improved aerosol delivery to a user, reduce condensation in the cartridge, and/or provide as described above.

With reference, for example, to <FIG> and <FIG>, the cartridges <NUM> of the present disclosure may be employed with the control body <NUM> to produce aerosol. In this regard, during use a user may draw on the mouthpiece <NUM> of the cartridge <NUM> of the aerosol delivery device <NUM>. This may pull air through an opening in the control body <NUM> or in the cartridge <NUM>. For example, in one embodiment an opening may be defined between the coupler <NUM> and the outer body <NUM> of the control body <NUM>, as described in <CIT>. However, the flow of air may be received through other parts of the aerosol delivery device <NUM> in other embodiments.

A sensor in the aerosol delivery device <NUM> such as the flow sensor <NUM> in the control body <NUM> may sense the puff. When the puff is sensed, the control body <NUM> may direct current to the heating element <NUM> from the electrical power source <NUM> through a circuit including the first heating terminal 320a and the second heating terminal 320b. Accordingly, the heating element <NUM> may vaporize the aerosol precursor composition directed to an aerosolization zone from the reservoir substrate <NUM> by the liquid transport element <NUM>. Thus, the mouthpiece <NUM> may allow passage of air and entrained vapor (i.e., the components of the aerosol precursor composition in an inhalable form) from the cartridge <NUM> to a consumer drawing thereon. In particular, air may enter the cartridge from the coupler <NUM> through the third aperture 350c (see, e.g., <FIG>) in the base <NUM> and travel through the through hole <NUM> in the flow director <NUM> past the atomizer <NUM> to the mouthpiece <NUM>. Accordingly, the user may be provided with aerosol.

As noted above, the cartridges of the present disclosure may include a greater or lesser number of components in some embodiments. In this regard, <FIG> illustrates the cartridge <NUM>' of <FIG> wherein the cartridge further comprises a one-way valve <NUM>. The one-way valve <NUM> may be configured to resist flow of air from the flow director <NUM> through the base <NUM>, which is opposite to the ordinary flow path therethrough. In other words, as described below, the one-way valve <NUM> is configured to resist a reverse puff received from the user and directed through the mouthpiece <NUM> to the flow director <NUM>. As illustrated, the one-way valve <NUM> may include a retention portion <NUM> and a valve portion <NUM>. The retention portion <NUM> may be configured to engage an adjacent portion of the cartridge <NUM>' (e.g., part of the base <NUM>) so as to retain the one-way valve <NUM> in place.

The valve portion <NUM> may be configured to allow flow through the cartridge <NUM>' in one direction. In this regard, in the illustrated embodiment the one-way valve <NUM> is positioned in electronics compartment <NUM>. Thereby, the valve portion <NUM> may extend into a flow path defined through the cartridge <NUM>'.

The one-way valve <NUM> may comprise a flap valve in one embodiment. In this regard, the valve portion <NUM> may comprise a flap that at least partially blocks the third aperture 350c extending through the base <NUM> during certain situation. For example, the valve portion <NUM> may be configured to allow flow of air through the third aperture 350c in the base <NUM> to the through hole <NUM> through the flow director <NUM> when a user draws on the mouthpiece <NUM>. However, in instances in which the user blows air into the mouthpiece <NUM>, which may inadvertently or intentionally occur during use, flow of air through the through hole <NUM> through the flow director <NUM> and the base <NUM> may be resisted by the one-way valve <NUM>. In this regard, the valve portion <NUM> may resist reverse flow through the third aperture 350c by coming into contact with the base <NUM>, the electronic control component <NUM>, the control component terminal <NUM> and/or any portion of a surrounding structure positioned proximate the third aperture 350c. In this regard, in some embodiments the valve portion <NUM> may press against such surrounding structure when there is no flow of air through the cartridge.

However, various other embodiments of one-way valves may be employed in accordance with the present disclosure. In this regard, <FIG> illustrates the cartridge <NUM>" of <FIG> further comprising a second embodiment of a one-way valve <NUM>'. As illustrated, the one-way valve <NUM>' may be positioned in the electronics compartment <NUM>. Further, the one-way valve <NUM>' may comprise a retention portion <NUM>' and a valve portion <NUM>'. The one-way valve <NUM>' illustrated in <FIG> differs from the one-way valve of <FIG> in that the one-way valve illustrated in <FIG> comprises a cross-valve. In this regard, the valve portion <NUM>' of the one-way valve <NUM>' may comprise a plurality of elastomeric members <NUM>' that separate to allow flow therethrough from the third aperture 350c in the base <NUM> through the through hole <NUM> in the flow director <NUM> when a user draws on the mouthpiece <NUM>. However, the elastomeric members <NUM>' may press against one another when a user blows air into the mouthpiece <NUM> to substantially prevent flow of air through the through hole <NUM> through the flow director <NUM> and through the base <NUM>. In this regard, in some embodiments the elastomeric members <NUM>' may press against one another when there is no flow of air through the cartridge.

Accordingly, as described above, in some embodiments the one-way valves may comprise passive valves that respond to a user interaction with the cartridge to either allow or substantially prevent flow through the cartridge depending on whether a user is drawing on, or blowing into, the mouthpiece. However in other embodiments active one-way valves (e.g., solenoid valves) may be employed. Such active valves may act in substantially the same manner as described above based on the detected flow through the cartridge as controlled by a controller in the aerosol delivery device such as the electronic control component <NUM> or the control component <NUM> in the control body <NUM> (see, e.g., <FIG>).

Further, although the one-way valves are generally described above as being positioned in the electronics compartment proximate the base, in other embodiments the one-way valve may be positioned in a different location. In this regard, the one-way valve may be positioned at any location along the flow path through the aerosol delivery device. Thus, by way of example, the one-way valve may be positioned at or near the mouthpiece, the flow director, the base, or even within the control body, such as at or near the coupler. Further, although use of one one-way valve is generally described herein, more than one one-way valve may be employed in other embodiments.

Various other details with respect to the components that may be included in the cartridge <NUM>, are provided, for example, in <CIT>. In this regard, <FIG> thereof illustrates an enlarged exploded view of a base and a control component terminal; <FIG> thereof illustrates an enlarged perspective view of the base and the control component terminal in an assembled configuration; <FIG> thereof illustrates an enlarged perspective view of the base, the control component terminal, an electronic control component, and heating terminals of an atomizer in an assembled configuration; <FIG> thereof illustrates an enlarged perspective view of the base, the atomizer, and the control component in an assembled configuration; <FIG> thereof illustrates an opposing perspective view of the assembly of <FIG> thereof; <FIG> thereof illustrates an enlarged perspective view of the base, the atomizer, the flow director, and the reservoir substrate in an assembled configuration; <FIG> thereof illustrates a perspective view of the base and an outer body in an assembled configuration; <FIG> thereof illustrates a perspective view of a cartridge in an assembled configuration; <FIG> thereof illustrates a first partial perspective view of the cartridge of <FIG> thereof and a coupler for a control body; <FIG> thereof illustrates an opposing second partial perspective view of the cartridge of <FIG> thereof and the coupler of <FIG> thereof; <FIG> thereof illustrates a perspective view of a cartridge including a base with an anti-rotation mechanism; <FIG> thereof illustrates a perspective view of a control body including a coupler with an anti-rotation mechanism; <FIG> thereof illustrates alignment of the cartridge of <FIG> with the control body of <FIG>; <FIG> thereof illustrates an aerosol delivery device comprising the cartridge of <FIG> thereof and the control body of <FIG> thereof with a modified view through the aerosol delivery device illustrating the engagement of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body; <FIG> thereof illustrates a perspective view of a base with an anti-rotation mechanism; <FIG> thereof illustrates a perspective view of a coupler with an anti-rotation mechanism; and <FIG> thereof illustrates a sectional view through the base of <FIG> thereof and the coupler of <FIG> thereof in an engaged configuration.

A method for assembling a cartridge for an aerosol delivery device is also provided. As illustrated in <FIG>, the method may include coupling a base to a flow director such that the flow director and the base define an electronics compartment at operation <NUM>. Further, the method may include positioning an atomizer within an outer body at operation <NUM>. The method may additionally include coupling the outer body to the flow director such that the outer body and the flow director define a reservoir compartment at operation <NUM>.

In some embodiments the method may further comprise wrapping a reservoir substrate configured to store an aerosol precursor composition at least partially about the flow director. The method may additionally include positioning the reservoir substrate within the reservoir compartment, which may occur during positioning the atomizer within the outer body at operation <NUM>.

In some embodiments wrapping the reservoir substrate at least partially about the flow director may include engaging the reservoir substrate with a plurality of protrusions defined by the flow director and extending therefrom. In another embodiment wrapping the reservoir substrate at least partially about the flow director may include wrapping the reservoir substrate partially about the flow director such that a gap is defined between first and second ends thereof. In an additional embodiment wrapping the reservoir substrate at least partially about the flow director may comprise forming a channel between the flow director and the reservoir substrate at a cutout defined in the flow director. The method may additionally include filling the reservoir substrate with the aerosol precursor composition by directing the aerosol precursor composition into at least one of a gap between first and second ends of the reservoir substrate and a channel between the flow director and the reservoir substrate at a cutout defined in the flow director.

The method may further include molding at least one heating terminal into the flow director. Additionally, the method may include positioning an electronic control component in the electronics compartment and connecting a control component terminal to the electronic control component. Further, coupling the outer body to the flow director at operation <NUM> may comprise deforming a deformable rib of the flow director against an inner surface of the outer body. In another embodiment coupling the outer body to the flow director at operation <NUM> may comprise welding the outer body to the flow director.

The method may additionally include coupling the outer body to the base. Coupling the outer body to the base may comprise deforming a deformable rib of the base against an inner surface of the outer body. Further, coupling the base to the flow director at operation <NUM> may comprise welding the base to the flow director. Additionally, the method may include coupling a one-way valve to the base. The one-way valve may be configured to resist flow of air from the flow director through the base.

In an additional embodiment a controller is provided. The controller may be configured to execute computer code for performing the operations described herein. In this regard, as illustrated in <FIG>, the controller <NUM> may comprise a processor <NUM> that may be a microprocessor or a controller for controlling the overall operation thereof. In one embodiment the processor <NUM> may be particularly configured to execute program code instructions related to the functions described herein, including the operations for assembling the cartridge <NUM> of the present disclosure. The controller <NUM> may also include a memory device <NUM>. The memory device <NUM> may include non-transitory and tangible memory that may be, for example, volatile and/or non-volatile memory. The memory device <NUM> may be configured to store information, data, files, applications, instructions or the like. For example, the memory device <NUM> could be configured to buffer input data for processing by the processor <NUM>. Additionally or alternatively, the memory device <NUM> may be configured to store instructions for execution by the processor <NUM>.

The controller <NUM> may also include a user interface <NUM> that allows a user to interact therewith. For example, the user interface <NUM> can take a variety of forms, such as a button, keypad, dial, touch screen, audio input interface, visual/image capture input interface, input in the form of sensor data, etc. Still further, the user interface <NUM> may be configured to output information to the user through a display, speaker, or other output device. A communication interface <NUM> may provide for transmitting and receiving data through, for example, a wired or wireless network <NUM> such as a local area network (LAN), a metropolitan area network (MAN), and/or a wide area network (WAN), for example, the Internet. The communication interface <NUM> may enable the controller <NUM> to communicate with one or more further computing devices, either directly, or via the network <NUM>. In this regard, the communication interface <NUM> may include one or more interface mechanisms for enabling communication with other devices and/or networks. The communication interface <NUM> may accordingly include one or more interface mechanisms, such as an antenna (or multiple antennas) and supporting hardware and/or software for enabling communications via wireless communication technology (e.g., a cellular technology, communication technology, Wi-Fi and/or other IEEE <NUM> technology, Bluetooth, Zigbee, wireless USB, NFC, RF-ID, WiMAX and/or other IEEE <NUM> technology, and/or other wireless communication technology) and/or a communication modem or other hardware/software for supporting communication via cable, digital subscriber line (DSL), USB, FireWire, Ethernet, one or more optical transmission technologies, and/or other wireline networking methods. Further, the controller <NUM> may include an assembly module <NUM>. The assembly module <NUM> may be configured to, in conjunction with the processor <NUM>, direct operations for assembling a cartridge as described herein.

The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling the above-described operations. In particular, computer readable code may be configured to perform each of the operations of the methods described herein and embodied as computer readable code on a computer readable medium for controlling the above-described operations. In this regard, a computer readable storage medium, as used herein, refers to a non-transitory, physical storage medium (e.g., a volatile or non-volatile memory device, which can be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion.

As noted above, the controller <NUM> may be configured to execute computer code for performing the above-described assembly operations. In this regard, a non-transitory computer readable medium for storing computer instructions executed by a processor in a controller (e.g. controller <NUM>) configured to assemble a cartridge for an aerosol delivery device is provided. The non-transitory computer readable medium may comprise program code instructions for coupling a base to a flow director such that the flow director and the base define an electronics compartment, program code instructions for positioning an atomizer within an outer body; and program code instructions for coupling the outer body to the flow director such that the outer body and the flow director define a reservoir compartment.

The computer readable medium may further comprise program code instructions for wrapping a reservoir substrate configured to store an aerosol precursor composition at least partially about the flow director such that the reservoir substrate engages a plurality of protrusions defined by the flow director and extending therefrom and program code instructions for positioning the reservoir substrate within the reservoir compartment. The program code instructions for wrapping the reservoir substrate at least partially about the flow director may comprise program code instructions for forming a channel between the flow director and the reservoir substrate at a cutout defined in the flow director.

The computer readable medium may further comprise program code instructions for molding at least one heating terminal into the flow director. The computer readable medium may further comprise program code instructions for positioning an electronic control component in the electronics compartment and program code instructions for connecting a control component terminal to the electronic control component. The program code instructions for coupling the outer body to the flow director may comprise program code instructions for deforming a deformable rib of the flow director against an inner surface of the outer body. The program code instructions for coupling the outer body to the flow director may comprise program code instructions for welding the outer body to the flow director.

The computer readable medium may further comprise program code instructions for coupling the outer body to the base, wherein the program code instructions for coupling the outer body to the base comprise program code instructions for deforming a deformable rib of the base against an inner surface of the outer body. Further, the program code instructions for coupling the base to the flow director may comprise program code instructions for welding the base to the flow director. The computer readable medium may further comprise program code instructions for coupling a one-way valve to the base, the one-way valve being configured to resist flow of air from the flow director through the base.

Claim 1:
A cartridge for an aerosol delivery device, comprising:
an outer body (<NUM>);
a flow director (<NUM>) coupled to the outer body (<NUM>),
a base (<NUM>) coupled to the outer body (<NUM>);
a mouthpiece (<NUM>); and
an atomizer (<NUM>);
wherein the flow director (<NUM>), the mouthpiece (<NUM>), and the outer body (<NUM>) define a reservoir compartment (<NUM>) and the flow director (<NUM>) and the base (<NUM>) define an electronics compartment (<NUM>) having an electronic control component (<NUM>) positioned within, the base (<NUM>) defining a recess (<NUM>) configured to receive the electronic control component (<NUM>) therein;
characterized in that the atomizer (<NUM>) is positioned in the reservoir compartment (<NUM>), in that the base (<NUM>) comprises a ledge (<NUM>) configured to support the electronic control component (<NUM>) thereon and in that the flow director (<NUM>) including one or more deformable ribs (<NUM>) configured to engage the electronic control component (<NUM>) when the outer body (<NUM>) is coupled to the base (<NUM>) such that the electronic control component (<NUM>) is tightly sandwiched between the deformable ribs (<NUM>) and the ledge (<NUM>) in the recess (<NUM>) of the base (<NUM>).