Patent ID: 7771642

Claim:
A method of making an aerosol generator assembly, the method comprising: providing an aerosol generator, wherein the aerosol generator comprises: an annular vibratory element; an actuator in mechanical communication with the vibratory element, wherein the actuator has a first face and a second face and defines an opening therethrough, and wherein the actuator is cup-shaped, having a substantially cylindrical side wall extending from an outer edge of the first face, and wherein the annular vibratory element is positioned proximate the first face, within the substantially cylindrical side wall and around the opening; and an aerosolization element mounted on one of the faces of the actuator and disposed substantially over the opening, wherein the aerosolization element comprises a first face and a second face and defines at least one aperture therethrough; placing the aerosol generator within a mold assembly formed to receive the aerosol generator; placing a mold material into the mold assembly; allowing mold material to form a sealing element about at least an annular peripheral portion of the aerosol generator, the sealing element covering the annular vibratory element and the cylindrical side wall and at least a portion of the second face of the actuator, leaving the at least one aperture unobstructed, and leaving the aerosolization element substantially free to vibrate; and removing the aerosol generator from the mold assembly.