BR112019000976B1 - AEROSOL DELIVERY DEVICE WITH A RESERVOIR AND UNIT LIQUID TRANSPORT ELEMENT COMPRISING A POROUS MONOLITH AND RELATED METHOD - Google Patents

Abstract

AEROSOL DELIVERY DEVICE WITH A LIQUID TRANSPORT ELEMENT COMPRISING A POROUS MONOLITH AND RELATED METHOD The present disclosure relates to aerosol delivery devices, methods of producing such devices, and elements of such devices. In some embodiments, the present disclosure provides devices configured for vaporizing an aerosol precursor composition that is contained in a reservoir and transported to a heating element by a liquid transport element. The liquid transport element may include a porous monolith.

Description

FUNDAMENTALS Field of Disclosure

[001] The present disclosure relates to aerosol delivery devices and, more particularly, to aerosol delivery devices that can utilize electrically generated heat for aerosol production (e.g., commonly referred to as electronic cigarettes). The aerosol delivery devices may be configured to heat an aerosol precursor, which may incorporate materials that may be produced or derived from tobacco or otherwise incorporate tobacco, the precursor being capable of forming an inhalable substance for human consumption.

Description of related art

[002] Many devices have been proposed over the years as improvements, or alternatives, to tobacco products that require the combustion of tobacco for use. Many of these devices are purportedly designed to provide the sensations associated with smoking cigarettes, cigars, or pipes, but without delivering considerable quantities of incomplete combustion and pyrolysis products that result from burning tobacco. To this end, numerous products, flavor generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a volatile material, or attempt to provide cigarette, cigar, or pipe sensations without burning tobacco to a significant degree. See, for example, the various alternative articles, aerosol delivery devices, and heat generating sources set forth in the prior art described in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 /0255702 by Griffith Jr. et al. and U.S. Patent Publication No. 2014/0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of articles, aerosol delivery devices, and electrically driven heat generating sources, referenced by trademark and commercial source in U.S. Patent Publication No. 2015/0216236 by Bless et al., which is incorporated herein by reference.

[003] It would be desirable to provide a reservoir and a liquid transport element for an aerosol precursor composition for use in an aerosol delivery device, the reservoir and liquid transport element being provided so as to improve the formation of the device. of aerosol delivery. It would also be desirable to provide aerosol delivery devices that are prepared to utilize such reservoirs and liquid transport elements.

BRIEF SUMMARY OF THE DISCLOSURE

[004] The present disclosure relates to aerosol delivery devices configured to produce aerosol and which aerosol delivery devices, in some embodiments, may be referred to as electronic cigarettes. In one aspect, an aerosol delivery device is provided. The aerosol delivery device may include an outer body, a heating element, and a unitary liquid reservoir and transport element. The unitary liquid reservoir and transport element may include an integral porous monolith positioned proximate to the heating element and may contain an aerosol precursor composition.

[005] In some embodiments, a longitudinal axis of the heating element may be substantially parallel to a longitudinal axis of the external body. The integral porous monolith may include at least one of a porous ceramic and a porous glass. The reservoir and integral liquid transport element may define one or more channels extending partially therethrough.

[006] In some embodiments, the aerosol delivery device may further include a first heating terminal and a second heating terminal coupled to the heating element. The first heating terminal and the second heating terminal may be at least partially received on the one or more channels. The heating element may be at least partially received in one or more channels. The aerosol delivery device may further include an electronic component at least partially received in one or more channels. The electronic component can be positioned between the first heating terminal and the second heating terminal. A longitudinal axis of the electronic component may extend substantially parallel to a longitudinal axis of the external body.

[007] In some embodiments, the heating element may extend at least partially around the reservoir and unitary liquid transport element. The unitary reservoir and liquid transport member may define a protrusion and the heating element may extend at least partially around the protrusion. The aerosol delivery device may further include a base engaged with the outer body and an electronic component positioned between the base and the reservoir and unitary liquid transport member. A longitudinal axis of the electronic component may extend substantially perpendicular to a longitudinal axis of the external body. Additionally, the aerosol delivery device may include a first heating terminal and a second heating terminal coupled to the heating element. The first heating terminal and the second heating terminal may extend substantially perpendicular to the longitudinal axis of the electronic component. The unitary reservoir and liquid transport element can define a variable porosity.

[008] In a further aspect, a method for producing a vapor is provided. The method may include containing an aerosol precursor composition in a reservoir and unitary liquid transport element. Additionally, the method may include vaporizing at least a portion of the aerosol precursor composition into the reservoir and unitary liquid transport element.

[009] In some embodiments, vaporizing at least a portion of the aerosol precursor composition in the unitary reservoir and liquid transport element may include directing an electrical current to a heating element substantially surrounded by the reservoir and liquid transport element. unit liquid. In a further embodiment, vaporizing at least a portion of the aerosol precursor composition in the reservoir and unitary liquid transport element may include directing an electrical current to a heating element extending around at least a portion of the reservoir and transport element. unit liquid transport. The method may further include directing an air flow through one or more channels extending at least partially through the reservoir and unitary liquid transport member. Containing the aerosol precursor composition in the reservoir and unitary liquid transport element may include containing the aerosol precursor composition in an integral porous monolith.

[0010] The present disclosure therefore includes, without limitation, the following modalities:

[0011] Modality 1: An aerosol delivery device, comprising: an external body; a heating element; and a unitary liquid reservoir and transport element comprising an integral porous monolith positioned in the vicinity of the heating element and containing an aerosol precursor composition.

[0012] Embodiment 2: The device of any anterior or posterior embodiment, or any combination thereof, in which a longitudinal axis of the heating element is substantially parallel to a longitudinal axis of the external body.

[0013] Modality 3: The device of any prior or subsequent embodiment, or any combination thereof, wherein the integral porous monolith comprises at least one of a porous ceramic and a porous glass.

[0014] Embodiment 4: The device of any prior or subsequent embodiment, or any combination thereof, wherein the unitary reservoir and liquid transport element defines one or more channels extending at least partially therethrough.

[0015] Modality 5: The device of any prior or subsequent embodiment, or any combination thereof, further comprising a first heating terminal and a second heating terminal coupled to the heating element, the first heating terminal and the second heating terminal heating being partially received on one or more channels.

[0016] Modality 6: The device of any previous or subsequent modality, or any combination thereof, in which the heating element is at least partially received in the one or more channels.

[0017] Modality 7: The device of any previous or subsequent modality, or any combination thereof, further comprising an electronic component, at least partially received on the one or more channels.

[0018] Modality 8: The device of any previous or subsequent modality, or any combination thereof, in which the electronic component is positioned between the first heating terminal and the second heating terminal.

[0019] Embodiment 9: The device of any anterior or posterior embodiment, or any combination thereof, in which a longitudinal axis of the electronic component extends substantially parallel to a longitudinal axis of the external body.

[0020] Embodiment 10: The device of any prior or subsequent embodiment, or any combination thereof, wherein the heating element extends at least partially around the reservoir and unitary liquid transport element.

[0021] Embodiment 11: The device of any anterior or posterior embodiment, or any combination thereof, wherein the unitary reservoir and liquid transport element defines a protrusion and the heating element extends at least partially around the protrusion.

[0022] Modality 12: The device of any previous or subsequent modality, or any combination thereof, further comprising a base engaged with the external body and an electronic component positioned between the base and the reservoir and unitary liquid transport element.

[0023] Embodiment 13: The device of any anterior or posterior embodiment, or any combination thereof, in which a longitudinal axis of the electronic component extends substantially perpendicular to a longitudinal axis of the external body.

[0024] Embodiment 14: The device of any prior or subsequent embodiment, or any combination thereof, further comprising a first heating terminal and a second heating terminal coupled to the heating element, wherein the first heating terminal and the second heating terminal extend substantially perpendicular to the longitudinal axis of the electronic component.

[0025] Modality 15: The device of any previous or subsequent modality, or any combination thereof, in which the unitary reservoir and liquid transport element defines a variable porosity.

[0026] Embodiment 16: A method for producing a vapor, the method comprising: containing an aerosol precursor composition in a reservoir and unitary liquid transport element; and vaporizing at least a portion of the aerosol precursor composition into the reservoir and unitary liquid transport member.

[0027] Embodiment 17: The method of any previous or subsequent embodiment, or any combination thereof, wherein vaporizing at least the portion of the aerosol precursor composition in the reservoir and unitary liquid transport element comprises directing an electrical current to an element heating element substantially surrounded by the reservoir and unitary liquid transport element.

[0028] Embodiment 18: The method of any previous or subsequent embodiment, or any combination thereof, wherein vaporizing at least the portion of the aerosol precursor composition in the reservoir and unitary liquid transport element comprises directing an electrical current to an element heating element extending around at least a portion of the reservoir and unitary liquid transport element.

[0029] Embodiment 19: The method of any previous or subsequent embodiment, or any combination thereof, further comprising directing an air flow through one or more channels extending at least partially through the reservoir and unitary liquid transport element.

[0030] Embodiment 20: The method of any prior or subsequent embodiment, or any combination thereof, wherein containing the aerosol precursor composition in the reservoir and unitary liquid transport element comprises containing the aerosol precursor composition in an integral porous monolith .

[0031] These and other features, aspects and advantages of the present disclosure will be evident from reading the following detailed description in conjunction with the attached drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more features or elements set forth in this disclosure or recited in any one or more of the claims, regardless of whether such features or elements are expressly combined or otherwise recited in a description of the embodiment or claim here. This disclosure is intended to be read holistically, so that any separable features or elements of the disclosure, in any of its aspects and embodiments, should be viewed as intended to be combinable, unless the context of the disclosure clearly dictates otherwise.

BRIEF DESCRIPTION OF FIGURES

[0032] Having thus described the disclosure in general terms above, reference will now be made to the attached drawings, which are not necessarily drawn to scale, and in which:

[0033] Figure 1 illustrates a longitudinal cross-sectional view through an aerosol delivery device comprising a control body and a cartridge including a reservoir and a liquid transport element in accordance with an exemplary embodiment of the present disclosure;

[0034] Figure 2 illustrates a longitudinal cross-section through perspective view of a cartridge for an aerosol delivery device comprising a reservoir and unitary liquid transport element surrounding a heating element in accordance with an exemplary embodiment of the present disclosure;

[0035] Figure 3 illustrates a side cross-section through a perspective view of the reservoir and unitary liquid transport element of Figure 2 in accordance with an exemplary embodiment of the present disclosure;

[0036] Figure 4 illustrates a modified perspective view of a cartridge for an aerosol delivery device comprising a reservoir and unitary liquid transport element including a protrusion proximate to a nozzle and over which a heating element extends accordingly. with an exemplary embodiment of the present disclosure;

[0037] Figure 5 illustrates a perspective view of the reservoir and unitary liquid transport element of Figure 4 in accordance with an exemplary embodiment of the present disclosure;

[0038] Figure 6 illustrates a modified perspective view of a cartridge for an aerosol delivery device comprising a reservoir and unitary liquid transport element including a protrusion proximate to a base and over which a heating element extends accordingly. with an exemplary embodiment of the present disclosure;

[0039] Figure 7 illustrates a modified side cross-section through a perspective view of the cartridge of Figure 6 in accordance with an exemplary embodiment of the present disclosure;

[0040] Figure 8 illustrates a partial end view of the reservoir and unitary liquid transport element of Figure 6 in accordance with an exemplary embodiment of the present disclosure;

[0041] Figure 9 illustrates a perspective view of terminals, an electronic component and a base of the cartridge of Figure 6 in accordance with an exemplary embodiment of the present disclosure;

[0042] Figure 10 illustrates a modified perspective view of a cartridge for an aerosol delivery device comprising a unitary reservoir and liquid transport element and a laterally extending electronic component in accordance with an exemplary embodiment of the present disclosure;

[0043] Figure 11 illustrates a perspective view of the reservoir and unitary liquid transport element of the cartridge of Figure 10 in accordance with an exemplary embodiment of the present disclosure;

[0044] Figure 12 illustrates a perspective view of terminals, an electronic component and a base of the cartridge of Figure 10 in accordance with an exemplary embodiment of the present disclosure;

[0045] Figure 13 schematically illustrates a method for producing a vapor in accordance with an exemplary embodiment of the present disclosure;

[0046] Figure 14 illustrates a longitudinal cross-section through a perspective view of a cartridge for an aerosol delivery device including a heating element and an electronic component received in a liquid transport element, the liquid transport element. liquid being received in a reservoir in accordance with an exemplary embodiment of the present disclosure;

[0047] Figure 15 illustrates a perspective view of the liquid transport element of Figure 14;

[0048] Figure 16 illustrates a modified perspective view of a cartridge for an aerosol delivery device including a liquid transport element defining a protrusion in which a heating element is positioned, the liquid transport element being received in a reservoir in accordance with an exemplary embodiment of the present disclosure;

[0049] Figure 17 illustrates a side cross-section through a perspective view of the cartridge of Figure 16;

[0050] Figure 18 illustrates a perspective view of the liquid transport element and an electronic component of the cartridge of Figure 16 in accordance with an exemplary embodiment of the present disclosure;

[0051] Figure 19 illustrates a modified longitudinal section through a perspective view of a cartridge for an aerosol delivery device including a liquid transport element defining a protrusion in which a heating element is positioned, the transport element of liquid being received in a reservoir, and an electronic component extending laterally in accordance with an exemplary embodiment of the present disclosure;

[0052] Figure 20 illustrates a side cross-section through a perspective view of the cartridge of Figure 19;

[0053] Figure 21 illustrates a modified perspective view of a cartridge for an aerosol delivery device including a liquid transport element defining a protrusion in which a heating element is positioned, the liquid transport element and a director. of flow being received in a reservoir, and an electronic component extending laterally in accordance with an exemplary embodiment of the present disclosure;

[0054] Figure 22 illustrates a side cross-section through a perspective view of the cartridge of Figure 21; It is

[0055] Figure 23 schematically illustrates a method for producing an aerosol delivery device in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0056] The present disclosure will now be described more fully below, with reference to its exemplary embodiments. These exemplary embodiments are described so that this disclosure is exhaustive and complete and fully conveys the scope of the disclosure to those skilled in the art. In fact, disclosure can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these modalities are provided so that this disclosure satisfies applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include variations in the plural, unless the context clearly dictates otherwise.

[0057] As described below, embodiments of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems in accordance with the present disclosure utilize electrical energy to heat a material (preferably without burning the material to a significant degree and/or without significant chemical alteration of the material) to form an inhalable substance; and the components of such systems are in the form of articles that, more preferably, are sufficiently compact to be considered portable devices. That is, the use of components of preferred aerosol delivery systems does not result in the production of smoke - that is, from by-products of tobacco combustion or pyrolysis, but rather, the use of these preferred systems results in the production of vapors/aerosols resulting from the volatilization or vaporization of certain components incorporated therein. In preferred embodiments, the components of aerosol delivery systems may be characterized as electronic cigarettes, and such electronic cigarettes more preferably incorporate tobacco and/or tobacco-derived components and thereby deliver tobacco-derived components in aerosol form.

[0058] Aerosol generating parts of certain preferred aerosol delivery systems can provide many of the sensations (e.g., inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical sensation, usage rituals, visual cues such as those provided by visible aerosol and the like) from smoking a cigarette, cigar or pipe that is employed by lighting and burning tobacco (and therefore inhaling tobacco smoke), without any substantial degree of combustion of any component thereof. For example, the user of an aerosol generating part of the present disclosure can hold and use that part in much the same way as a smoker using a traditional type of smoking article, sucking on one end of that part for inhalation of aerosol produced by that part. ask, take or suck puffs at selected and similar time intervals. The devices described herein, however, are not limited to devices that are substantially shaped and sized like a traditional cigarette. Rather, the present devices may take any shape and may be substantially larger than a traditional cigarette.

[0059] The aerosol delivery devices of the present disclosure can also be characterized as being vapor producing articles or medication delivery articles. Thus, such articles or devices may be adapted so as to deliver one or more substances (e.g., flavors and/or active pharmaceutical ingredients) in an inhalable form or state. For example, inhalable substances may be substantially in the form of a vapor (i.e., a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, inhalable substances may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term “aerosol” as used herein is intended to include vapors, gases and aerosols of a form or type suitable for human inhalation, whether visible or not, and in a form that may or may not be considered smoke-like.

[0060] The aerosol delivery systems of the present disclosure generally include several components provided within an outer body or casing, which may be referred to as a housing. The overall design of the outer body or housing may vary, and the shape or configuration of the outer body which may define the overall size and shape of the aerosol delivery device may vary. In exemplary embodiments, an elongated body similar to the shape of a cigarette or cigar may be formed from a single unitary housing, or the elongated housing may be formed from two or more separable bodies. For example, an aerosol delivery device may comprise an elongated housing or body which may be substantially tubular in shape and, as such, resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are contained within a housing. Alternatively, an aerosol delivery device may comprise two or more housings that are joined together and are separable. For example, an aerosol delivery device may have at one end a control body comprising a housing containing one or more components (e.g., a battery and/or capacitor and various electronics for controlling the operation of that article), and at the other end and removably attached thereto a body or outer casing containing aerosol-forming components (e.g., one or more aerosol precursor components such as flavorings and aerosol formers, one or more heating elements and/or one or more more wicks).

[0061] Aerosol delivery devices of the present disclosure may include a housing or outer shell that is not substantially tubular in shape, but may be formed to substantially larger dimensions - i.e., be substantially “palm-sized” to be held in the palm of a user. The housing or housing may be configured to include a nozzle and/or may be configured to receive a separate housing (e.g., a cartridge) that may include consumable elements, such as an aerosol precursor composition, and may include a vaporizer or atomizer.

[0062] Aerosol delivery devices of the present disclosure more preferably comprise some combination of a power source (i.e., a source of electrical energy), at least one control component (e.g., means for actuating, controlling, regulating and stopping the generation of heat, such as controlling the flow of electrical current from the power source to other components of the article - e.g., a microcontroller or microprocessor), a heating element or heat-generating member (e.g., a heating element) electrical resistance or other component, alone or in combination with one or more additional elements may be commonly referred to as an "atomizer"), an aerosol precursor composition (e.g., generally a liquid capable of producing an aerosol upon application of sufficient heat , such as ingredients commonly referred to as “smoke juice”, “e-liquid” and “e-juice”), and a mouthpiece or mouth region to enable sucking into the aerosol delivery device for aerosol inhalation (e.g. , an airflow path defined through the article in such a way that the generated aerosol can be removed from it after sucking).

[0063] More specific shapes, configurations, and arrangements of components within the aerosol delivery systems of the present disclosure will be apparent in light of the additional disclosure provided below. Additionally, the selection and arrangement of various components of the aerosol delivery system can be appreciated by considering commercially available electronic aerosol delivery devices, such as the representative products referenced in the prior art section of the present disclosure.

[0064] An example embodiment of an aerosol delivery device 100 illustrating components that can be used in an aerosol delivery device in accordance with the present disclosure is provided in Figure 1. As seen in the illustrated cross-sectional view, The aerosol delivery device 100 may include a control body 102 and a cartridge 104 that may be permanently or detachably aligned in an operating relationship. The control body 102 and the cartridge 104 may be engaged via press fit (as illustrated), threaded fit, interference fit, magnetic attraction, or the like. In particular, connecting components such as those described herein may be used. For example, the control body may include a coupler that is adapted to engage a connector on the cartridge.

[0065] In specific embodiments, one or both of the control body 102 and the cartridge 104 may be referred to as being disposable or as being reusable. For example, the control body may have a replaceable battery or a rechargeable battery and therefore may be unitary with any type of recharging technology, including connection to a typical electrical outlet, connection to a car charger (lighter receptacle), cigarettes), and connection to a computer, such as via a universal serial bus (USB) cable. For example, an adapter including a USB connector at one end and a control body connector at an opposite end is described in U.S. Patent Publication No. 2014/0261495 to Novak et al., which is incorporated herein by reference in its totality. Furthermore, in some embodiments, the cartridge may comprise a single-use cartridge, as disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0066] As illustrated in Figure 1, the control body 102 may comprise an external body 106. A control component 108 (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller or the like), a flow sensor 110, a pressure sensor), a battery 112, and a light emitting diode (LED) 114 may be positioned within the outer body 106 in any one of several alignments. Other indicators (e.g., a haptic feedback component, an audio feedback component, or the like) may be included in addition to or as an alternative to LED 114. Additional representative types of components that produce visual cues or indicators, such as emitting diode components (LED) and configurations and uses thereof are described in US Patent No. 5,154,192 to Sprinkel et al.; 8,499,766 for Newton and 8,539,959 for Scatterday; and U.S. Patent Application Publication No. 2015/0216233, to Sears et al.; which are incorporated herein by reference.

[0067] The cartridge 104 may include an outer body 116. The outer body 116 may enclose a reservoir 118 that is in fluid communication with a liquid transport member 120 adapted to absorb or otherwise transport an aerosol precursor composition stored in the reservoir housing for a heating element 122. Various embodiments of materials configured to produce heat when electrical current is applied therethrough can be employed to form the resistive heating element 122. Examples of materials from which the wire coil can be be formed include Kanthal (FeCrAl), Nickel-Chromium, molybdenum disilicide (MoSi2) molybdenum silicide (MoSi), aluminum doped molybdenum disilicide (Mo(Si,Al)2), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and threads) and ceramics (e.g., positive or negative temperature coefficient ceramics). As further described herein, a heating element may comprise a variety of materials configured to provide electromagnetic radiation, including laser diodes.

[0068] A mouth opening 124 may be present in the outer body 116 (e.g., at the mouth end) to allow the exit of the aerosol formed from the cartridge 104. Such components are representative of the components that may be present in a cartridge and are not intended to limit the scope of the cartridge components that are covered by the present disclosure.

[0069] Cartridge 104 may also include an electronic component 126, which may include an integrated circuit, a memory component, a sensor, or the like. The electronic component 126 of the cartridge 104 may be adapted to communicate with the control component 108 of the control body 102 and/or an external device via wired or wireless means. The electronic component 126 can be positioned anywhere within the cartridge 104.

[0070] Although the control component 108 and the flow sensor 110 are illustrated separately, it should be understood that the control component and the flow sensor may be unitary as an electronic circuit board with the air flow sensor directly attached the same. Furthermore, the electronic circuit board may be positioned horizontally with respect to the illustration in Figure 1 wherein the electronic circuit board may be longitudinally parallel to the central axis of the control body. In some embodiments, the airflow sensor may comprise its own circuit board or other base element to which it may be attached. In some embodiments, a flexible circuit board may be used. A flexible circuit board can be configured into a variety of shapes, including substantially tubular shapes.

[0071] The control body 102 and the cartridge 104 may include components adapted to facilitate fluid engagement between them. As illustrated in Figure 1, the control body 102 may include a coupler 128 having a cavity 130 defined therein. The cartridge 104 may include a base 132 adapted to engage the coupler 128 and may include a projection 134 adapted to fit within the cavity 130 defined by the coupler 128. Such engagement may facilitate a stable connection between the control body 102 and the cartridge 104 as well. such as how to establish an electrical connection between the battery 112 and the control component 108 in the control body and the heating element 122 and the electronic component 126 in the cartridge. Additionally, the outer body 106 may include an air inlet 136, which may be a notch in the housing where it connects to the coupler 128 that allows ambient air to pass around the coupler and into the housing, where it then passes through the cavity. 130 from the coupler and to the cartridge 104 through the projection 134.

[0072] A coupler and base useful in accordance with the present disclosure are described in U.S. Patent Publication No. 2014/0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. For example, the coupler 128, as seen in Figure 1, may define an outer periphery 138 configured to mate with an inner periphery 140 of the base 132. In one embodiment, the inner periphery of the base may define a radius that is substantially equal to, or slightly greater than, a radius from the outer periphery of the coupler. Furthermore, the coupler 128 may define one or more protrusions 142 on the outer periphery 138 configured to engage one or more recesses 144 defined on the inner periphery of the base. However, various other types of structures, shapes and components can be used to couple the base to the coupler. In some embodiments, the connection between the base 132 of the cartridge 104 and the coupler 128 of the control body 102 may be substantially permanent, while in other embodiments, the connection therebetween may be releasable such that, for example, the Control body can be reused with one or more additional cartridges that can be disposable and/or refillable.

[0073] The aerosol delivery device 100 may be substantially rod-shaped or substantially tubular-shaped or substantially cylindrical in some embodiments. In other embodiments, additional shapes and dimensions are encompassed - for example, a rectangular or triangular cross-section, multifaceted shapes, link shape, or the like.

[0074] The reservoir 118 illustrated in Figure 1 may assume any design configured to retain a liquid, such as a container or a mass configured to absorb and/or adsorb the liquid - for example, a fibrous reservoir is often used in existing embodiments of reservoirs. Or, as described below, reservoir 118 may comprise a porous monolith. As illustrated in Figure 1, the reservoir 118 may comprise one or more layers of non-woven fibers substantially formed in the form of a tube surrounding the interior of the outer body 116. An aerosol precursor composition may be retained in the reservoir 118.

[0075] The reservoir 118 may be in fluid connection with a liquid transport element 120. The liquid transport element 120 may transport the aerosol precursor composition stored in the reservoir 118 through capillary action to the heating element 122 which is in the form of a coil of metallic wire in this embodiment. As such, the heating element 122 is in a heating arrangement with the liquid transport element 120. In some embodiments of existing aerosol delivery devices, the liquid transport element comprises fiberglass or other fibrous material. However, as described below, in other embodiments, the liquid transport element may comprise a porous monolith.

[0076] In use, when a user sucks the article 100, airflow is detected by the sensor 110, the heating element 122 is activated, and the components for the aerosol precursor composition are vaporized by the heating element 122. Sugar in the nozzle of article 100 causes ambient air to enter air inlet 136 and pass through cavity 130 in coupler 128 and central opening in projection 134 of base 132 of cartridge 104. In cartridge 104, the sucked air combines with vapor formed to form an aerosol. The aerosol is lightly conveyed, aspirated, or otherwise sucked from the heating element 122 and out of the mouth opening 124 in the nozzle of the article 100.

[0077] An input device (e.g., a user interface) may be included with the aerosol delivery device. Input may be included to allow a user to control device functions and/or to output information to a user. Any component or combination of components can be used as an input to control the function of the device. For example, one or more buttons may be used as described in U.S. Patent Application Publication No. 2015/0245658, to Worm et al., which is incorporated herein by reference. Likewise, a touch screen may be used as described in U.S. Patent Application No. Ser. 14/643,626, filed March 10, 2015, to Sears et al., which is incorporated herein by reference. As another example, components adapted for gesture recognition based on specified movements of the aerosol delivery device can be used as an input. See, for example, U.S. Patent Application Publication No. 2016/0158782, by Henry et al., which is incorporated herein by reference.

[0078] In some embodiments, an input may comprise a computer or computing device, such as a smart phone or tablet. In particular, the aerosol delivery device may be connected to the computer or other device, such as through the use of a USB connector or similar protocol. The aerosol delivery device may also communicate with a computer or other device acting as an input via wireless communication. See, for example, systems and methods for controlling a device via a read request, as described in U.S. Patent Application Publication No. 2016/0007651, by Ampolini et al., the disclosure of which is incorporated herein by reference . In such embodiments, an application or other computer program may be used in connection with a computer or other computing device to introduce control instructions to the aerosol delivery device, such control instructions including, for example, the ability to form a aerosol of specific composition by choosing the nicotine content and/or the content of other flavors to be included.

[0079] The various components of an aerosol delivery device in accordance with the present disclosure may be chosen from components described in the art and commercially available. Representative commercially available products include AVIGO, VUSE, VUSE CONNECT, VUSE FOB and VUSE HYBRID from RJ Reynolds Vapor Company. Examples of batteries that may be used in accordance with the disclosure are described in U.S. Patent Publication No. 2010/0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0080] As noted above, the aerosol delivery device may incorporate a sensor or detector (e.g., flow sensor 110) to control the delivery of electrical energy to the heating element 122 when aerosol generation is desired (e.g. example, by being sucked during use). As such, for example, a way or method is provided for turning off the power source for the heat generating element when the aerosol delivery device is not sucked in during use, and for turning on the power source for activating or firing the generation of heat by the heat generating element during sucking. Additional representative types of sensing or sensing mechanisms, structure and configuration thereof, components thereof, and general methods of operation thereof, are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr.; 5,372,148 to McCafferty et al.; and PCT WO 2010/003480 to Flick; which are incorporated herein by reference.

[0081] The aerosol delivery device, more preferably, incorporates a control mechanism for controlling the amount of electrical energy to the heat generating element during suction. Representative types of electronic components, structure and configuration thereof, characteristics thereof, and general methods of operation thereof, are described in U.S. Patent No. 4,735,217 to Gerth et al.; 4,947,874 to Brooks et al.; 5,372,148 to McCafferty et al.; 6,040,560 to Fleischhauer et al.; 7,040,314 to Nguyen et al. and 8,205,622 from Pan; US Patent Publications Nos. 2009/0230117 to Fernando et al., 2014/0060554 to Collett et al., and 2014/0270727 to Ampolini et al.; and US Patent Application Publication No. 2015/0257445, to Henry et al.; which are incorporated herein by reference.

[0082] Representative types of substrates, reservoirs or other components for supporting the aerosol precursor are described in US Patent No. 8,528,569 to Newton; US Patent Publications Nos. 2014/0261487 to Chapman et al., 2014/0059780 to Davis et al. and 2015/0216232 by Bless et al.; which are incorporated herein by reference. Furthermore, various wicking materials, and the configuration and operation of these wicking materials within certain types of electronic cigarettes, are set forth in U.S. Patent No. 8910640 to Sears et al.; which is incorporated herein by reference.

[0083] The aerosol precursor composition, also referred to as a vapor precursor composition, may comprise a variety of components including, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract and/or flavorings. More preferably, the aerosol precursor composition is composed of a combination or mixture of several ingredients or components. The selection of particular aerosol precursor components, and the relative amounts of these components used, can be altered so as to control the overall chemical composition of the conventional aerosol produced by the aerosol generating arrangement(s). Of particular interest are aerosol precursor compositions which can be characterized as being generally liquid in nature. For example, representative generally liquid aerosol precursor compositions may be in the form of liquid solutions, viscous gels, mixtures of miscible components, or liquids incorporating suspended or dispersed components. Typical aerosol precursor compositions are capable of being vaporized upon exposure to heat under the conditions that are experienced during the use of the aerosol generating arrangement(s) that are characteristic of the present disclosure; and are therefore capable of producing vapors and aerosols capable of being inhaled.

[0084] For aerosol delivery systems that are characterized as electronic cigarettes, the aerosol precursor composition more preferably incorporates tobacco or tobacco-derived components. In one aspect, the tobacco may be provided as parts or pieces of tobacco, such as finely ground, shredded or powdered tobacco blades. In another aspect, the tobacco may be provided in the form of an extract (e.g., an extract from which nicotine is derived), such as a spray-dried extract that incorporates many of the water-soluble components of tobacco. Alternatively, tobacco extracts may be in the form of extracts of relatively high nicotine content, which extracts also incorporate smaller amounts of other extracted components derived from tobacco. In another aspect, tobacco-derived components may be provided in a relatively pure form, such as certain flavoring agents that are derived from tobacco. In one aspect, a component that is derived from tobacco, and that can be employed in a highly purified or essentially pure form, is nicotine (e.g., pharmaceutical grade nicotine).

[0085] In some aspects, the aerosol delivery device may include or incorporate tobacco, a tobacco component, or a tobacco-derived material (i.e., a material that is found naturally in tobacco that can be isolated directly from tobacco or synthetically prepared). For example, the aerosol delivery device may include a quantity of flavoring and aromatic tobaccos in cut filler form. In some aspects, the aerosol precursor composition may include tobacco, a tobacco component, or a tobacco-derived material that is processed to provide a desired quality, such as those processed in accordance with methods described in U.S. Pat. Nos. 9,066,538 to Chen et al.; 9,155,334 to Moldoveanu et al.; US Patent Application Publication No. 2016/0015078 to Moldoveanu et al.; US Patent Application No. Ser. 15/043,177, filed February 12, 2016 to Marshall et al.; the disclosures of which are incorporated in their entirety by reference.

[0086] As noted above, highly purified tobacco-derived nicotine (e.g., pharmaceutical grade nicotine having a purity greater than 98% or greater than 99%) or a derivative thereof can be used in the devices of the present disclosure. Representative nicotine-containing extracts can be provided using the techniques set forth in U.S. Patent No. 5,159,942 to Brinkley et al., which is incorporated herein by reference. In certain embodiments, the products of the present disclosure may include nicotine in any form from any source, whether tobacco-derived or synthetically derived. Nicotinic compounds used in the products of the present disclosure may include nicotine in free base form, salt form, as a complex or as a solvate. See, for example, the discussion of nicotine in freebase form in the US Patent Publication. No. 2004/0191322 to Hansson, which is incorporated herein by reference. At least a portion of the nicotinic compound may be employed in the form of a nicotine resin complex in which nicotine is bound in an ion exchange resin such as nicotine polacrilex. See, for example, US Patent No. 3,901,248 to Lichtneckert et al.; which is incorporated herein by reference. At least a portion of the nicotine may be used in the form of a salt. Nicotine salts can be delivered using the types of ingredients and techniques set forth in U.S. Patent No. 2,033,909 to Cox et al. and Perfetti, Beitrage Tabakforschung Int., 12, 43-54 (1983). Additionally, nicotine salts are available from sources such as Pfaltz and Bauer, Inc. and K & K Laboratories, Division of ICN Biochemicals, Inc. Exemplary pharmaceutically acceptable nicotine salts include nicotine tartrate salts (e.g., nicotine tartrate). nicotine and nicotine bitartrate), chloride (e.g., nicotine hydrochloride and nicotine dihydrochloride), sulfate, perchlorate, ascorbate, fumarate, citrate, malate, lactate, aspartate, salicylate, tosylate, succinate, pyruvate and the like; nicotine salt hydrates (e.g., nicotine zinc chloride monohydrate) and the like. In certain embodiments, at least a portion of the nicotinic compound is in the form of a salt with an organic acid portion, including, but not limited to, levulinic acid as discussed in U.S. Patent Publication No. 2011/0268809 to Brinkley et al. al., which is incorporated herein by reference.

[0087] In another aspect, the aerosol precursor composition may include tobacco, a tobacco component, or a tobacco-derived material that may be treated, manufactured, produced and/or processed to incorporate an aerosol-forming material (e.g., humectants such as, for example, propylene glycol, glycerin and/or the like). Additionally or alternatively, the aerosol precursor composition may include at least one flavoring agent. Additional components that may be included in the aerosol precursor composition are described in US Patent No. 7,726,320 to Robinson et al., which is incorporated herein by reference. Various ways and methods for incorporating tobacco and other ingredients into aerosol generating devices are set forth in U.S. Patent No. 4,497,874 to Brooks et al.; 7,290,549 to Banerjee et al; 7,647,932 to Cantrell et al.; 8,079,371 to Robinson et al.; and U.S. Patent Application Publications Nos. 2007/0215167 by Crooks et al.; 2016/0073695 to Sears et al., the disclosures of which are incorporated herein by reference in their entirety.

[0088] The aerosol precursor composition may also incorporate so-called "aerosol-forming materials". Such materials may, in some cases, have the ability to produce visible (or non-visible) aerosols when vaporized after exposure to heat under those conditions experienced during normal use of the aerosol generating arrangement(s) that are characteristic of the present disclosure. Such aerosol-forming materials include various polyols or polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures thereof). Aspects of the present disclosure also incorporate aerosol precursor components that may be characterized as water, saline, moisture, or aqueous liquid. During conditions of normal use of a given aerosol generating arrangement(s), water incorporated in such aerosol generating arrangements may vaporize to produce a component of the generated aerosol. As such, for purposes of the present disclosure, water that is present in the aerosol precursor composition can be considered as an aerosol-forming material.

[0089] It is possible to employ a wide variety of optional flavoring agents or materials that alter the sensory character or nature of the sucked conventional aerosol generated by the aerosol delivery system of the present disclosure. For example, such optional flavoring agents may be used within the aerosol precursor composition or substance to alter the flavor, aroma and organoleptic properties of the aerosol. Certain flavoring agents may be supplied from sources other than tobacco. Exemplary flavoring agents may be natural or artificial in nature, and may be employed as flavoring concentrates or packages.

[0090] 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, spearmint, peppermint, mint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, croton eluteria, cocoa, licorice and flavors and flavoring packages of the type and character traditionally used to flavor tobaccos of cigarettes, cigars and pipes. Syrups, such as high fructose corn syrup, can also be used. Certain flavoring agents may be incorporated into aerosol-forming materials prior to formulating a final aerosol precursor mixture (e.g., certain water-soluble flavoring agents may be incorporated in water, menthol may be incorporated in propylene glycol, and certain complex flavoring packages can be incorporated into propylene glycol). However, in some aspects of the present disclosure, the aerosol precursor composition is free of any flavorings, aromatic characteristics or additives.

[0091] Aerosol precursor compositions may also include ingredients that exhibit acidic or basic characteristics (for example, 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 being up to equimolar (based on the total organic acid content). ) with nicotine. For example, the aerosol precursor may include about 0.1 to about 0.5 moles of levulinic acid per one mole of nicotine, about 0.1 to about 0.5 moles of succinic acid per one mole of nicotine. , about 0.1 to about 0.5 moles of lactic acid per one mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per one mole of nicotine, or various permutations and combinations thereof, to a concentration where the total amount of organic acid present is equimolar to the total amount of nicotine present in the aerosol precursor composition. However, in some aspects of the present disclosure, the aerosol precursor composition is free of any acidic (or basic) characteristics or additives.

[0092] As a non-limiting example, a representative aerosol precursor composition or substance may include glycerin, propylene glycol, water, saline and nicotine and combinations or mixtures of any or all of these components. For example, in one case, a representative aerosol precursor composition may include (on a weight basis) about 70% to about 100% glycerin and often about 80% to about 90% glycerin; about 5% to about 25% water, often about 10% to about 20% water; and about 0.1% to about 5% nicotine, often about 2% to about 3% nicotine. In a particular non-limiting example, a representative aerosol precursor composition may include about 84% glycerin, about 14% water and about 2% nicotine. The representative aerosol precursor composition may also include propylene glycol, optional flavoring agents, or other additives in varying amounts based on weight. In some cases, the aerosol precursor composition may comprise up to about 100% by weight of any of glycerin, water and saline as needed or desired.

[0093] Representative types of aerosol precursor components and formulations are also set forth and characterized in US Patent No. 7,217,320 to Robinson et al.; 8,881,737 to Collett et al. and 9,254,002 from Chong et al.; and US Patent Publications Nos. 2013/0008457 to Zheng et al.; 2015/0020823 by Lipowicz et al. and 2015/0020830 to Koller, as well as WO 2014/182736 to Bowen et al, the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be employed include the aerosol precursors that have been incorporated into the VUSE product by RJ Reynolds Vapor Company, the BLUTM product by Lorillard Technologies, the MISTIC MENTHOL product by Mistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirable These are so-called “smoke juices” for e-cigarettes that are available from Johnson Creek Enterprises LLC.

[0094] The amount of aerosol precursor that is incorporated into the aerosol delivery system is such that the aerosol generating part provides desirable performance and acceptable sensory characteristics. For example, it is highly preferred that sufficient amounts of aerosol-forming material (e.g., glycerin and/or propylene glycol) be used so as to provide for the generation of a visible conventional aerosol that in many respects resembles the appearance of smoke from tobacco. The amount of aerosol precursor within the aerosol generating system may depend on factors such as the number of puffs desired per aerosol generating piece. Typically, the amount of aerosol precursor incorporated into the aerosol delivery system, and particularly within the aerosol generating part, is less than about 2 g, generally less than about 1.5 g, often less than about 1 g. g and often less than about 0.5 g.

[0095] Still other features, controls or components that may be incorporated into the aerosol delivery systems of the present disclosure are described in US Patent No. 5,967,148 to Harris et al.; 5,934,289 to Watkins et al.; 5,954,979 to Counts et al.; 6,040,560 to Fleischhauer et al.; Hon 8,365,742; 8,402,976 to Fernando et al.; 8,689,804 from Fernando et al. and 9,220,302 from DePiano et al.; US Patent Publication No. 2013/0192623 to Tucker et al.; 2013/0298905 by Leven et al.; 2013/0180553 by Kim et al., 2014/0000638 by Sebastian et al. and 2014/0261495 by Novak et al., which are incorporated herein by reference.

[0096] The foregoing description of the use of the article may be applied to the various embodiments described herein through minor modifications, which may be apparent to one skilled in the art in light of the additional disclosure provided herein. The above usage description, however, is not intended to limit the use of the article, but is provided to meet all necessary disclosure requirements of this disclosure. Any of the elements shown in the article illustrated in Figure 1 or as described above may be included in an aerosol delivery device in accordance with the present disclosure.

[0097] In one or more embodiments, the present disclosure may relate to the use of a porous monolithic material in one or more components of an aerosol delivery device. As used herein, a “porous monolithic material” or “porous monolith” is intended to mean comprising a substantially single unit which, in some embodiments, may be a single piece formed, composed or created without joints or seams and comprising substantially, but not necessarily all of uniform and rigid. In some embodiments, a monolith in accordance with the present disclosure may be undifferentiated, that is, formed of a single material, or may be formed of a plurality of units that are permanently combined, such as a sintered conglomerate. Thus, in some embodiments, the porous monolith may comprise an integral porous monolith.

[0098] In some embodiments, the use of a porous monolith may, in particular, refer to the use of a porous glass in components of an aerosol delivery device. As used herein, "porous glass" is intended to refer to glass that has a three-dimensional interconnected porous microstructure. The term specifically may exclude materials made from bundles (i.e., woven or nonwoven) of glass fibers. Thus, porous glass can exclude fibrous glass. Porous glass may also be referred to as controlled pore glass (CPG) and may be known by the trade name VYCOR®. Porous glass suitable for use in accordance with the present invention may be prepared by known methods such as, for example, metastable phase separation in borosilicate glasses followed by liquid extraction (e.g., acid extraction or combined acid and alkaline extraction) of one of the phases formed, through a sol-gel process, or by sintering glass powder. The porous glass may particularly be a glass with a high silica content, such as comprising 90% or more, 95%, 96% or more, or 98% or more silica by weight. Porous glass materials and methods of preparing porous glass that may be suitable for use in accordance with the present disclosure are described in U.S. Patent No. 2,106,744 to Hood et al., U.S. Patent No. 2,215,039 to Hood et al., U.S. Patent No. 3,485,687 to Chapman et al., U.S. Patent No. 4,657,875 to Nakashima et al., U.S. Patent No. 9,003,833 to Kotani et al., U.S. Patent Publication US Patent Publication No. 2013/0045853 to Kotani et al., US Patent Publication No. 2013/0067957 to Zhang et al., US Patent Publication No. 2013/0068725 to Takashima et al. and U.S. Patent Publication No. 2014/0075993 to Himanshu, the disclosures of which are incorporated herein by reference. Although the term porous “glass” may be used herein, it should not be construed as limiting the scope of the disclosure in that a “glass” may encompass a variety of silica-based materials.

[0099] Porous glass can be defined in some embodiments in relation to its average pore size. For example, porous glass may have an average pore size of about 1 nm to about 1000 μm, about 2 nm to about 500 μm, about 5 nm to about 200 μm, or about 10 nm to about of 100 μm. In certain embodiments, the porous glass for use in accordance with the present disclosure may be differentiated based on average pore size. For example, a small pore pore glass may have an average pore size of 1 nm up to 500 nm, an intermediate pore porous glass may have an average pore size of 500 nm up to 10 μm, and a large pore porous glass may have an average pore size of 10 μm up to 1000 μm. In some embodiments, a large-pore porous glass may preferably be useful as a storage element, and a small-pore porous glass and/or an intermediate pore porous glass may preferably be useful as a transport element.

[00100] Porous glass can also be defined in some embodiments in relation to its surface area. For example, porous glass may have a surface area of at least 100 m2/g, at least 150 m2/g, at least 200 m2/g, or at least 250 m2/g, such as about 100 m2/g to about 600 m2/g, about 150 m2/g to about 500 m2/g, or about 200 m2/g to about 450 m2/g.

[00101] Porous glass can be defined in some embodiments in relation to its porosity (that is, the volumetric fraction of the material that defines the pores). For example, the porous glass may have a porosity of at least 20%, at least 25%, or at least 30%, such as about 20% to about 80%, about 25% to about 70%, or about from 30% to around 60% in volume. In certain embodiments, a lower porosity may be desirable, such as a porosity of about 5% to about 50%, about 10% to about 40%, or about 15% to about 30% by volume.

[00102] Porous glass can also be defined in some embodiments in relation to its density. For example, porous glass may have a density of 0.25 g/cm3 to about 3 g/cm3, about 0.5 g/cm3 to about 2.5 g/cm3, or about 0.75 g /cm3 to about 2 g/cm3.

[00103] In some embodiments, the use of a porous monolith may, in particular, refer to the use of a porous ceramic in components of an aerosol delivery device. As used herein, "porous ceramic" is intended to refer to a ceramic material that has a three-dimensional interconnected porous microstructure. Porous ceramic materials and methods of producing porous ceramics suitable for use in accordance with the present disclosure are described in U.S. Patent No. 3,090,094 to Schwartzwalder et al., U.S. Patent No. 3,833,386 to Frisch et al., US Patent No. 4,814,300 to Helferich, US Patent No. 5,171,720 to Kawakami, US Patent No. 5,185,110 to Kunikazu et al., US Patent No. 5,227,342 to Anderson et al., U.S. Patent No. 5,645,891 to Liu et al., U.S. Patent No. 5,750,449 to Niihara et al., U.S. Patent No. 6753282 to Fleischmann et al., U.S. Patent No. 7,208,108 to Otsuka et al., U.S. Patent No. 7,537,716 to Matsunaga et al., U.S. Patent No. 8,609,235 to Hotta et al., the disclosures of which are incorporated herein by reference. Although the term porous “ceramic” may be used herein, it should not be construed as limiting the scope of the disclosure in that a “ceramic” may encompass a variety of alumina-based materials.

[00104] Porous ceramics can also be defined in some embodiments in relation to their average pore size. For example, porous ceramics may have an average pore size of about 1 nm to about 1000 μm, about 2 nm to about 500 μm, about 5 nm to about 200 μm, or about 10 nm to about of 100 μm. In certain embodiments, the porous ceramic for use in accordance with the present disclosure may be differentiated based on average pore size. For example, a small pore porous ceramic may have an average pore size of 1 nm up to 500 nm, an intermediate pore porous ceramic may have an average pore size of 500 nm up to 10 μm, and a large pore porous ceramic may have an average pore size of 10 μm up to 1000 μm. In some embodiments, a large-pore porous ceramic may preferably be useful as a storage element, and a small-pore porous ceramic and/or an intermediate-pore porous ceramic may preferably be useful as a storage element. transport.

[00105] Porous ceramics can also be defined in some embodiments in relation to their surface area. For example, the porous ceramic may have a surface area of at least 100 m2/g, at least 150 m2/g, at least 200 m2/g, or at least 250 m2/g, such as about 100 m2/g to about 600 m2/g, about 150 m2/g to about 500 m2/g, or about 200 m2/g to about 450 m2/g.

[00106] Porous ceramics can be defined in some embodiments in relation to their porosity (that is, the volumetric fraction of the material that defines the pores). For example, the porous ceramic may have a porosity of at least 20%, at least 25%, or at least 30%, such as about 20% to about 80%, about 25% to about 70%, or about 30% to about 60% by volume. In certain embodiments, a lower porosity may be desirable, such as a porosity of about 5% to about 50%, about 10% to about 40%, or about 15% to about 30% by volume.

[00107] Porous ceramics can also be defined in some embodiments in relation to their density. For example, porous ceramic may have a density of 0.25 g/cm3 to about 3 g/cm3, about 0.5 g/cm3 to about 2.5 g/cm3, or about 0.75 g /cm3 to about 2 g/cm3.

[00108] Although silica-based materials (e.g., porous glass) and alumina-based materials (e.g., porous ceramics) may be discussed separately herein, it is understood that a porous monolith, in some embodiments, may comprise a variety of materials aluminosilicate. For example, various zeolites may be used in accordance with the present disclosure. Thus, by way of example, the porous monoliths discussed herein may comprise one or both of a porous glass and a porous ceramic, which may be supplied as a composite. In one embodiment, such a composite may comprise SiO2 and Al2O3.

[00109] A porous monolith used in accordance with the present disclosure can be provided in a variety of sizes and shapes. Preferably, the porous monolith may be substantially elongated, substantially flat or flat, substantially curved (e.g., “U-shaped”), substantially in the form of a walled cylinder, or in any other shape suitable for use in in accordance with this disclosure. Additional example shapes of the porous monolith are described below and illustrated in the Figures.

[00110] In one or more embodiments, a porous monolith according to the present disclosure can be characterized with respect to the absorption rate. As a non-limiting example, the absorption rate can be calculated by measuring the mass absorption of a known liquid, and the rate (in mg/s) can be measured using a microbalance tensiometer or similar instrument. Preferably, the absorption rate is substantially within the range of the desired mass of aerosol to be produced over the duration of a puff in an aerosol-forming article including the porous monolith. The absorption rate may be, for example, in the range of about 0.05 mg/s to about 15 mg/s, about 0.1 mg/s to about 12 mg/s, or about 0.5 mg/s s at about 10 mg/s. The absorption rate may vary based on the liquid being absorbed. In some embodiments, absorption rates as described herein may be referenced to substantially pure water, substantially pure glycerol, substantially pure propylene glycol, a mixture of water and glycerol, a mixture of water and propylene glycol, a mixture of glycerol and propylene glycol, or a mixture of of water, glycerol and propylene glycol. The absorption rate may also vary based on the use of the porous monolith. For example, a porous monolith used as a liquid transport element may have a higher absorption rate than a porous monolith used as a reservoir. Absorption rates can be varied by controlling one or more pore sizes, pore size distribution, and wetting capacity, as well as the composition of the material being absorbed.

[00111] As noted above, some existing embodiments of aerosol delivery devices comprise a liquid transport element and/or a reservoir comprising a fibrous material. However, fibrous materials can suffer from certain detriments. In this regard, given that the heating element is positioned in close proximity to the liquid transport element, abrasion may occur on the fibrous liquid transport element which may detrimentally affect the flavor of the aerosol produced and/or the structural integrity of the element. liquid transport. Depending on the relative position of the components, abrasion may also occur in the fibrous reservoir.

[00112] Furthermore, fibrous materials may in general be relatively weak and prone to tearing or other failure when subjected to stresses such as may occur during repeated falling events or other serious incidents. Additionally, the use of fibrous materials in the airflow path can present challenges during assembly in terms of ensuring there are no loose fibers. Due to the flexible nature of fibrous materials, it may also be difficult to form and retain the liquid transport member and reservoir in the desired shapes.

[00113] Accordingly, the aerosol delivery devices of the present disclosure may include a reservoir and/or liquid transport element comprising a porous monolith. As can be understood, the use of a porous monolith may not suffer from the aforementioned potential detriments. In this regard, a relatively more durable material, such as porous glass or porous ceramic, which may not tear, can be selected. Furthermore, such material may not be subject to abrasion. Additionally, the absence of fibers in porous monoliths eliminates problems with regard to the movement of fibers in the airflow path defined therethrough. Furthermore, porous monoliths can be formed into substantially any shape and can have a stable shape.

[00114] By way of example, Figure 2 illustrates a modified cross-sectional view through a cartridge 204 for an aerosol delivery device. Cartridge 204 may include some or all of the components of cartridge 104 (see, Figure 1) described above. Furthermore, the cartridge 204 may be usable with the control body 102 described above and/or other embodiments of control bodies.

[00115] As illustrated, the cartridge 204 may include an outer body 216 and a base 232 coupled to one end of the outer body. A mouth opening 224 may be positioned at an opposite end of the outer body 216. An electronic component 226 and a heating element 222 may be positioned within the outer body 216.

[00116] The mouth opening 224 may be defined in a mouthpiece 246, which may be engaged with an end of the outer body 216 opposite from the base 232. A first heating terminal 248 and a second heating terminal 250 may be coupled to the heating element 222. Additionally, an electronic component terminal 252 may engage the electronic component 226. The first and second heating terminals 248, 250 may also engage the electronic component 226. The terminals 248, 250, 252 may extend up to the base 232 to allow electrical connectivity with a control body as described above.

[00117] Additionally, the cartridge 204 may include a reservoir and unitary liquid transport element 254. The term “unitary”, as used herein in connection with the reservoir and unitary liquid transport element 254, refers to the element reservoir and liquid transport element being one continuous piece formed, with a continuous transition from the reservoir to the liquid transport element. In this regard, the unitary liquid reservoir and transport member 254 may comprise a porous monolith, such as a porous glass or porous ceramic, as described above, which may be integral.

[00118] The reservoir and unitary liquid transport element 254 may contain an aerosol precursor composition. The unitary reservoir and liquid transport member 254 may be positioned in proximity to the heating element 222. In this way, the heating element 222 may heat the aerosol precursor composition contained by the unitary reservoir and liquid transport member 254 to produce vapor. .

[00119] Figure 3 illustrates a cross-sectional view through the reservoir and unitary liquid transport element 254. As illustrated, in some embodiments, the reservoir and unitary liquid transport element 254 may define at least one channel 255 extending through the least partially through it. The heating element 222 may be positioned in a first section 256 of the channel 255. In this way, the heating element 222 may be substantially surrounded by and in contact with the reservoir and unitary liquid transport element 254 so as to heat the aerosol precursor composition contained therein to produce vapor. In some embodiments, the first heating terminal 248 and/or the second heating terminal 250 may extend into the first section 256 of the channel 255 to engage opposite ends of the heating element 222. As illustrated, the heating element 222 may comprise a coiled wire.

[00120] As illustrated in Figure 3, the channel 255 extending at least partially through the reservoir and unitary liquid transport element 254 may further define a second section 258. As illustrated in Figure 2, the electronic component 226 may be received in the second section 258 of channel 255. In this regard, the electronic component 226 may be positioned between the first heating terminal 248 and the second heating terminal 250. Thus, in this embodiment, the heating element 222, the heating terminals 248, 250, and the electronic component 226 are at least partially received in channel 255. As described below, the first section 256 and the second section of channel 255 may define an airflow channel through the cartridge.

[00121] The heating element 222 may define a central longitudinal axis, which may be substantially parallel to a longitudinal axis of the outer body 216. For example, the longitudinal axis of the heating element 222 may be coaxial with a longitudinal axis of the outer body 216. Additionally, a longitudinal axis of the electronic component 226 may extend substantially parallel to the longitudinal axis of the outer body 226. Additionally, the channel 255 may extend substantially parallel to the longitudinal axis of the outer body 226. For example, the channel 255 may be coaxial with the longitudinal axis of the outer body 226.

[00122] The unitary liquid reservoir and transport element 254 may extend between a base end 260 and a nozzle end 262. The second section 258 of the channel 255 may extend from the base end 260 of the reservoir and transport element of unitary liquid 254 to the first section 256 of the first channel 256. The first section 256 of the channel 255 may extend from the second section 258 of the channel 255 to the nozzle end 262 of the reservoir and unitary liquid transport member 254.

[00123] In this way, an air flow path through the cartridge 204 can extend through the reservoir and unitary liquid transport member 254 from the base end 260 to the nozzle end 262. More particularly, the flow path of air can extend through the base 232, passing the electronic component 226 in the second section 258 of the channel 255, passing the heating element 222 in the first section 256 of the channel 255, and exiting through the mouth opening 224 defined in the nozzle 246. Consequently , the vapor produced by heating aerosol precursor composition contained in the reservoir and unitary liquid transport element 254 with the heating element 222 can unite with air to form an aerosol directed to the user through the nozzle 246.

[00124] In this way, the heating element 222 can be positioned in proximity to the nozzle 246. This configuration can decrease the potential for fluid condensation from the vapor produced by the heating element 222 in the cartridge 204 due to the flow path from from the heating element to the mouth opening 224 being relatively short. In this regard, any condensation of this type would reduce the effectiveness of the aerosol delivered to the user and could result in problems with regard to fluid leakage from the cartridge 204.

[00125] Note that, in this embodiment, the reservoir and unitary liquid transport element 254 can direct the air flow through the cartridge 204. In this regard, the channel 255 can direct the air flow to the heating element 222, which may be substantially surrounded by the reservoir and unitary liquid transport member 254. Consequently, the use of a separate flow director may not be necessary, which may reduce parts count and cartridge material and/or assembly costs .

[00126] Furthermore, the unitary liquid reservoir and transport element 254 contains the aerosol precursor composition and directs the aerosol precursor composition to the heating element 222. Accordingly, the unitary liquid reservoir and transport element 254 can be used instead of the separate reservoir element 118 and liquid transport 120 (see, Figure 1). In this regard, the porosity of the reservoir and unitary liquid transport member 254 may permit movement of fluid therethrough. Thereby, as the heating element 222 heats the aerosol precursor composition in the reservoir and unitary liquid transport member 254 positioned proximate thereto, the aerosol precursor composition may redistribute within the reservoir and unitary liquid transport member ( for example, through capillary action). Thus, the reservoir and unitary liquid transport element 254 can be refilled with an aerosol precursor composition in the vicinity of the heating element 222 by aerosol precursor composition from other positions within the reservoir and unitary liquid transport element.

[00127] In some embodiments, the reservoir and unitary liquid transport element 254 may define a variable porosity. In other words, the porosity of the reservoir and unitary liquid transport member 254 may vary depending on its location. Therefore, the volumetric fraction of the material that defines the pores can vary. By way of further example, in some embodiments, the number of pores per unit volume and/or the size of the pores may vary. Note that a variable porosity, as used herein, is distinguished from the inherent variations in porosity at individual points in the volume of the porous monolith, and instead refers to a porosity gradient that occurs between zones or regions therein. As discussed below, by varying the porosity of the reservoir and unitary liquid transport element 254, the characteristics of the reservoir and unitary liquid transport element may vary depending on their location.

[00128] As can be understood, cartridges including a reservoir and unitary liquid transport element can define other shapes. In this regard, Figure 4 illustrates a cartridge 304 in accordance with a further exemplary embodiment of the present disclosure. As illustrated, the cartridge 304 may include an outer body 316 and a base 332 coupled to one end of the outer body. A mouth opening 324 may be positioned at an opposite end of the outer body 316. A heating element 322 may be positioned within the outer body 316.

[00129] The mouth opening 324 may be defined in a mouthpiece 346, which may be engaged with an end of the outer body 316 opposite from the base 332. A first heating terminal 348 and a second heating terminal 350 may be coupled to the heating element 322. An electronic component 326 (see, Figure 5) may be positioned between the first heating terminal 348 and the second heating terminal 350, and an electronic component terminal may engage the electronic component as described above and illustrated. , for example, in Figure 2. Additionally, the terminals may extend to the base 332 to allow electrical connectivity with a control body as described above.

[00130] Additionally, the cartridge 304 may include a reservoir and unitary liquid transport element 354 that contains an aerosol precursor composition. The unitary reservoir and liquid transport member 354 may extend between a base end 360 and a mouth end 362. The unitary reservoir and liquid transport member 354 may comprise a porous monolith such as a porous glass or porous ceramic, and In some embodiments the unitary reservoir and liquid transport element may define a variable porosity.

[00131] Thus, cartridge 304 may be substantially similar to cartridge 204 of Figure 2 in several aspects. Therefore, for the sake of brevity, particular details of cartridge 304 shared with cartridge 204 of Figure 2 will not be repeated. However, the 304 cartridge may differ in one or more aspects.

[00132] In this regard, as illustrated in Figure 4, the heating element 322 may extend at least partially around the reservoir and unitary liquid transport element 354 and in contact therewith. More particularly, the unitary reservoir and liquid transport member 354 may define a protrusion 364, which may be located at a distal end of the unitary reservoir and liquid transport member. In this embodiment, the protrusion 364 may be positioned at the mouth end 362 of the reservoir and unitary liquid transport member 354. As illustrated in Figure 4, the heating element 322 may extend at least partially around the protrusion 364.

[00133] As illustrated in Figure 5, the reservoir and unitary liquid transport element 354 may define one or more channels 355 extending at least partially therethrough. The channels 355 may define a slot 366. As illustrated schematically, the electronic component 326 may be received in the slot 366. Additionally, the channels 355 may define a first slot 368 and a second slot 370. The slots 368, 370 may extend in on each side of the reservoir and unitary liquid transport member 354 between the protrusion 364 and the slot 366.

[00134] As illustrated in Figure 4, the heating terminals 348, 350 can extend through the slot 366 and the grooves 368, 370. In this way, the heating terminals 348, 350 can engage the ends of the heating element 322. In addition Furthermore, the electronic component 326 (see Figure 5) can be received in the slot 366 between the first heating terminal 348 and the second heating terminal 350. Consequently, the heating terminals 348, 350 and the electronic component 326 can be, at least less partially, received in channels 355. Additionally, as can be understood, the air flow can define a flow path through the base 332, around the reservoir and unitary liquid transport member 354 through the slit 366 and the grooves 368 , 370, passing through the heating element 322 in which steam is added thereto, and exiting the nozzle 346 through the mouth opening 324. Thus, the air flow can be directed through the channels 355 extending at least partially through the reservoir and unitary liquid transport element 354.

[00135] Figure 6 illustrates a cartridge 404 according to a further exemplary embodiment of the present disclosure. As illustrated, the cartridge 404 may include an outer body 416 and a base 432 coupled to one end of the outer body. A mouthpiece 446 may be engaged with an end of the outer body 416 opposite from the base 432. The mouthpiece 446 may define a mouth opening as described above.

[00136] A heating element 422 may be positioned within the outer body 416. As illustrated in Figure 7, the cartridge 404 may further comprise a first heating terminal 448 and a second heating terminal 450, which may be coupled to the heating element. heating 422. An electronic component 426 may be positioned between the first heating terminal 448 and the second heating terminal 450 and an electronic component terminal may engage the electronic component as described above and illustrated, for example, in Figure 2. Additionally , the terminals may extend to the base 432 to allow electrical connectivity with a control body as described above.

[00137] Additionally, as illustrated in Figure 6, the cartridge 404 may include a reservoir and unitary liquid transport element 454 that contains an aerosol precursor composition. The unitary reservoir and liquid transport member 454 may extend between a base end 460 and a nozzle end 462. The unitary reservoir and liquid transport member 454 may define a protrusion 464 onto which the heating element 422 can at least least partially extend in contact with it. The unitary reservoir and liquid transport member 454 may comprise a porous monolith, such as a porous glass or a porous ceramic, and in some embodiments, the unitary reservoir and liquid transport member may define a variable porosity.

[00138] Thus, cartridge 404 may be substantially similar to cartridge 304 of Figure 4 in several aspects. Therefore, for the sake of brevity, particular details of cartridge 404 shared with cartridge 304 of Figure 4 will not be repeated. However, the 404 cartridge may differ in one or more aspects.

[00139] In this regard, as illustrated in Figure 6, the protrusion 464 defined by the reservoir and unitary liquid transport member 454 may be positioned at the base end 460 thereof, instead of the nozzle end 462. Furthermore, the Reservoir and unitary liquid transport member 454 may include one or more channels 455. For example, as illustrated in Figure 8, channels 455 may define a compartment 458.

[00140] Additionally, as illustrated in Figure 8, channels 455 may define a recess 472. The recess 472 may extend from the base end 460 of the reservoir and unitary liquid transport member 454 to an opening 474 for the compartment. 458. Thus, as illustrated in Figure 7, the heating terminals 448, 450 and the electronic component 426 can extend through the recess 472 into the housing 458. Accordingly, the heating terminals 448, 450 and the electronic component 426 can be , at least partially, received in the channels 455. Use of the recess 472 in the base end 460 of the reservoir and unitary liquid transport member 454, rather than extending the housing 458 to the base end, may allow the heating element 422 engage heating terminals 448, 450.

[00141] Furthermore, as illustrated in Figure 6, channels 455 may define a first groove 468 and a second groove 470. The grooves 468, 470 may extend on each side of the reservoir and unitary liquid transport member 454. In particular , the slots 468, 470 may begin at the heating element 422, which is engaged with the protrusion 464 adjacent the recess 472, and terminate at the nozzle end 462 of the reservoir and unitary liquid transport member 454. Consequently, the air flow may define a flow path through the base 432 to the recess 472 (see, for example, Figure 8), past the heating element 422 wherein vapor is added thereto, around the reservoir and unitary liquid transport element. 454 through slots 468, 470, and out of the mouthpiece 446 through the mouth opening. Therefore, airflow may be directed through channels 455 extending at least partially through the reservoir and unitary liquid transport member 454.

[00142] In the embodiments of cartridges 204, 304, 404 described above, the electronic component is received between the first and second heating terminals. This configuration is illustrated, by way of example, in the assembly shown in Figure 9 that is included in the cartridge 404 of Figure 6. As illustrated, the heating terminals 448, 450 can support the electronic component 426 between them.

[00143] In this regard, as illustrated, each of the heating terminals 448, 450 may define a side support section 476 positioned on opposite sides of the electronic component 426. The side support sections 476 may restrict lateral movement of the electronic component 426 in lateral directions extending between the first heating terminal 448 and the second heating terminal 450. Additionally, the heating terminals 448, 450 may each define a primary surface support section 478 that may engage a rear primary surface 426A of the electronic component 426.

[00144] The electronic component terminal 452 may engage a front primary surface 426B of the electronic component 426. Additionally, in some embodiments, the first heating terminal 448 may include a tab 480 that powers and engages the front primary surface 426B of the electronic component. 426. In this way, the forward movement of the electronic component 426 can be resisted by the electronic component terminal 452 and the tab 480 of the first heating terminal 448. Conversely, the backward movement of the electronic component 426 can be resisted by the support sections of primary surface 478 of heating terminals 448, 450.

[00145] However, as described below, in other embodiments, the electronic component can be positioned and supported in different ways. In this regard, Figure 10 illustrates a cartridge 504 in accordance with a further exemplary embodiment of the present disclosure. As illustrated, the cartridge 504 may include an outer body 516 and a base 532 coupled to one end of the outer body. A mouthpiece 546 may be engaged with an end of the outer body 516 opposite from the base 532. The mouthpiece 546 may define a mouth opening as described above.

[00146] A heating element 522 may be positioned within the outer body 516. A first heating terminal 548 and a second heating terminal 550 may be coupled to the heating element 522. An electronic component 526 may be received in the outer body 516 An electronic component terminal 552 (see, Figure 12) may engage the electronic component 526. Additionally, terminals 548, 550, 552 may extend to the base 532 to allow electrical connectivity with a control body as described above.

[00147] Additionally, the cartridge 504 may include a reservoir and unitary liquid transport element 554 that contains an aerosol precursor composition. The unitary reservoir and liquid transport member 554 may extend between a base end 560 and a nozzle end 562. The unitary reservoir and liquid transport member 554 may define a protrusion 564 onto which the heating element 522 can at least least partially extend in contact with it.

[00148] As illustrated in Figure 11, the unitary reservoir and liquid transport member 554 may include one or more channels 555 extending at least partially therethrough. The channels 555 may define a first slot 568 and a second slot 570. As illustrated in Figure 10, the first heating terminal 548 and the second heating terminal 550 may respectively extend into the first slot 568 and the second slot 570. Thus, the heating terminals 548, 550 may be at least partially received in channels 555. The unitary reservoir and liquid transport element 554 may comprise a porous monolith, such as a porous glass or porous ceramic, and in some embodiments, the reservoir and element unit liquid transport capacity can define a variable porosity.

[00149] Thus, cartridge 504 may be substantially similar to cartridge 304 of Figure 4 in several aspects. Therefore, for the sake of brevity, particular details of cartridge 504 shared with cartridge 304 of Figure 4 will not be repeated. However, the 504 cartridge may differ in one or more respects.

[00150] As illustrated in Figure 10, the electronic component 526 may be positioned between the base 532 and the reservoir and unitary liquid transport member 554. In this regard, a longitudinal axis of the electronic component 526 may extend substantially perpendicular to an axis 12, the first heating terminal 548 and the second heating terminal 550 may extend substantially perpendicular to the longitudinal axis of the electronic component 526. In this regard, as noted above in relation to FIG. 10, heating terminals 548, 550 may be received in slots 568, 570 defined in the reservoir and unitary liquid transport member 554. However, as illustrated in Figure 12, the first heating terminal 548 may define a flap 548A and the second heating terminal 550 may define a flap 550A extending laterally therefrom. The tabs 548A, 550A and the electronic component terminal 552 can engage a large surface of the electronic component 526. In this way, the tabs 548A, 550A defined by the heating terminals 548, 550 and the electronic component terminal 552 can press the electronic component 526 against the 532 base, such that the electronic component is held in place.

[00151] Additionally, the electronic component 526 may include a plurality of contacts. Tab 548A of first heating terminal 548 may engage a first contact 582A. Tab 550A of second heating terminal 550 may engage a second contact 582B. Additionally, the electronic component terminal 552 may engage a third contact 582C. In this regard, the heating terminals 548, 550 can supply electrical power to the electronic component 526 and the electronic component terminal can establish an electrical connection with the electronic component such that data can be transferred between the cartridge 504 (see, Figure 10) and a control body as described above.

[00152] Referring to Figure 10, the airflow may define a flow path through the base 532, past the electronic component 526, around the reservoir and unitary liquid transport element 554 through the grooves 568, 570, passing the heating element 522 wherein steam is added thereto, and out of the nozzle 546 through the mouth opening. Thus, air flow can be directed through channels 555 (see, Figure 11) extending at least partially through the reservoir and unitary liquid transport element 554. In this way, the flow path can generally extend alongside, rather than of along the electronic component 526. In this regard, the electronic component 526 may define a semicircular shape and its longitudinal axis thereof may extend substantially perpendicular to a longitudinal axis of the outer body 516, such that the air flow may extend alongside rather than through or along the electronic component. Thus, the electronic component 526 can be substantially removed from the airflow path through the cartridge 504.

[00153] In a further embodiment, a method for producing a vapor is provided. As illustrated in Figure 13, the method may include containing an aerosol precursor composition in a reservoir and unitary liquid transport member in operation 602. Additionally, the method may include vaporizing at least a portion of the aerosol precursor composition in the reservoir and unitary liquid transport element in operation 604.

[00154] In some embodiments, vaporizing at least that portion of the aerosol precursor composition in the reservoir and unitary liquid transport element in operation 604 may comprise directing an electrical current to a heating element substantially surrounded by the reservoir and transport element of unit liquid. In another embodiment, vaporizing at least a portion of the aerosol precursor composition in the reservoir and unitary liquid transport element in operation 604 may comprise directing an electrical current to a heating element extending around at least a portion of the reservoir and unitary liquid transport element. The method may further include directing an air flow through one or more channels extending at least partially through the reservoir and unitary liquid transport member. Additionally, containing the aerosol precursor composition in the reservoir and unitary liquid transport element in operation 602 may comprise containing the aerosol precursor composition in an integral porous monolith.

[00155] In a further embodiment, a method for producing an aerosol delivery device is provided. The method may include forming a unitary reservoir and liquid transport member from a porous monolithic material. Furthermore, the method may include positioning a heating element and the unitary reservoir and liquid transport member in an external body such that the heating element is proximate to the unitary reservoir and liquid transport member. The method may further include distributing an aerosol precursor composition into the reservoir and unitary liquid transport element.

[00156] In some embodiments, forming the reservoir and unitary liquid transport element may comprise injection molding the reservoir and unitary liquid transport element. The method may further include engaging a first heating terminal and a second heating terminal with the heating element. Forming the unitary reservoir and liquid transport element from the porous monolithic material may comprise insertion molding of at least one heating element, the first heating terminal and the second heating terminal into the reservoir and liquid transport element. unitary. Furthermore, in some embodiments, forming the reservoir and unitary liquid transport element from a porous monolithic material may comprise forming the reservoir and unitary liquid transport element from a porous ceramic.

[00157] As described above, embodiments of the present disclosure include a unitary reservoir and liquid transport element formed from an integral porous monolith. However, as described below, in other embodiments, the liquid transport element and the reservoir may be provided as separate elements.

[00158] In this regard, Figure 14 illustrates a cartridge 704 according to a further exemplary embodiment of the present disclosure. As illustrated, the cartridge 704 may include an outer body 716 and a base 732 coupled to one end of the outer body. A mouth opening 724 may be positioned at an opposite end of the outer body 716. A heating element 722 may be positioned within the outer body 716. As illustrated, in one embodiment, a longitudinal axis of the heating element 722 may be substantially parallel to a longitudinal axis of the outer body 716.

[00159] The mouth opening 724 may be defined in a mouthpiece 746, which may be engaged with an end of the outer body 716 opposite from the base 732. A first heating terminal 748 and a second heating terminal 750 may be coupled to the heating element 722. An electronic component 726 may be positioned between the first heating terminal 748 and the second heating terminal 750. A longitudinal axis of the electronic component 726 may extend substantially parallel to a longitudinal axis of the outer body 716. A terminal of electronic component 752 may engage electronic component 726, as described above and illustrated, for example, in Figure 9. Additionally, terminals 748, 750, 752 may extend to base 732 to allow electrical connectivity with a control body such as described above. In this regard, the terminals, electronic component and base may be substantially similar to, or the same as, the corresponding elements in Figure 9.

[00160] Additionally, the cartridge 704 may include a reservoir 718 received in the outer body 716. The reservoir 718 may contain an aerosol precursor composition. Reservoir 728 may define a tubular configuration. The reservoir 718 may extend between a base end 718a and a nozzle end 718b.

[00161] The cartridge 704 may further include a liquid transport element 720. The liquid transport element 720 may extend between a base end 720a and a nozzle end 720b. Furthermore, the liquid transport member 720 may extend between the reservoir 718 and the heating element 722. In this regard, the liquid transport member 720 may be at least partially received and surrounded by the reservoir 718.

[00162] One or both of the reservoir 718 and the liquid transport element 720 may comprise a porous monolith, such as a porous glass or porous ceramic. In an exemplary embodiment, the liquid transport member 720 may comprise a porous monolith and the reservoir 718 may comprise a fibrous mat (e.g., cellulose acetate), which may be wrapped around it. In some embodiments, the liquid transport element 720 may be relatively more porous than the reservoir 718. In this regard, the liquid transport element 720 may be configured to suck the aerosol precursor composition retained in the reservoir 718 into the liquid transport element 720. heating 722. Additionally, in some embodiments, one or both of the reservoir 718 and the liquid transport element 720 may define a variable porosity.

[00163] Figure 15 illustrates the liquid transport element 720. As illustrated, the liquid transport element 720 may define at least one channel 755 extending at least partially therethrough. The channel 755 may include a first section 756 and a second section 766. The first section 756 of the channel 755 may extend from the nozzle end 720b of the liquid transport member 720 to the second section 766 of the channel. The second section 766 of the channel 755 may extend from the first section 756 of the channel to the base end 720a of the liquid transport member 720.

[00164] The electronic component 726 can be at least partially positioned within the liquid transport element 720. In this regard, the electronic component 726 can be received in the second section 766 of the channel 755. Furthermore, the heating element 722 can be positioned at least partially within the liquid transport element 720. In this regard, the heating element 722 is positioned in the first section 756 of the channel 755 and in contact therewith in the illustrated embodiment.

[00165] Additionally, as illustrated in Figure 14, one or both of the first heating terminal 748 and the second heating terminal 750 may at least partially extend through the liquid transport member 720. In this regard, the first terminal heating element 748 and the second heating terminal 750 may extend from the base 732 through the second section 766 of the channel 755 to the heating element 722 in the first section 756 of the channel. A longitudinal axis of the liquid transport member 720 may be substantially parallel to a longitudinal axis of the first heating terminal 748 and a longitudinal axis of the second heating terminal 750.

[00166] The air flow may define a flow path through the base 732 to the second section 766 of the channel 755 through the liquid transport element 720, passing the electronic component 726, passing the heating element 722 in the first section 756 from the channel in which vapor is added thereto, and out of the nozzle 746 through the mouth opening 724. In this regard, the liquid transport element 720 may define a flow director that directs air to the heating element 722 in which steam is produced. Consequently, the use of a separate flow director may not be necessary.

[00167] In relation to vapor production, the reservoir 718 may contain the aerosol precursor composition. The liquid transport member 720 may be in contact with the reservoir 718 along substantially its entire length. Furthermore, the liquid transport member 720 may extend around all or part of the inner circumference of the reservoir 718. For example, in the illustrated embodiment the liquid transport member 720 is in contact with an entire inner circumference of the opening. 784 defined by reservoir 718 at nozzle end 720b. By providing a relatively large contact area between the reservoir 718 and the liquid transport element 720, the transmission of fluid from the reservoir to the liquid transport element 720 can be improved. Likewise, the liquid transport member 720 may substantially surround the heating element 722 to provide improved vapor production.

[00168] Figures 16 and 17 illustrate a cartridge 804 according to a further exemplary embodiment of the present disclosure. As illustrated, the cartridge 804 may include an outer body 816 and a base 832 coupled to one end of the outer body. A mouth opening may be defined in a mouthpiece 846, which may be engaged with an end of the outer body 816 opposite from the base 832. A heating element 822 may be positioned within the outer body 816. As illustrated, in one embodiment , a longitudinal axis member of the heating element 822 may be substantially parallel to a longitudinal axis of the outer body 816.

[00169] A first heating terminal 848 and a second heating terminal 850 may be coupled to the heating element 822. An electronic component 826 (see, Figures 17 and 18) may be positioned between the first heating terminal 848 and the second heating terminal 850. A longitudinal axis of the electronic component 826 may extend substantially parallel to a longitudinal axis of the outer body 816, as described and illustrated above, by way of example, with respect to Figure 14. An electronic component terminal 852 may engage the electronic component 826 as described above and illustrated, for example, in Figure 9. Additionally, terminals 848, 850, 852 may extend to the base 832 to allow electrical connectivity with a control body as described above. In this regard, the terminals, electronic component and base may be substantially similar to, or the same as, the corresponding elements in Figure 9.

[00170] Additionally, the cartridge 804 may include a reservoir 818 received in the outer body 816. The reservoir 818 may contain an aerosol precursor composition. The reservoir 818 may extend between a base end 818a and a nozzle end 818b. The reservoir 818 may define a tubular configuration and include an opening 884 extending therethrough, as illustrated in Figure 17.

[00171] The cartridge 804 may further include a liquid transport element 820. The liquid transport element 820 may extend between a base end 820a and a nozzle end 820b. Furthermore, the liquid transport member 820 may extend between the reservoir 818 and the heating element 822 so as to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid transport member 820 may be at least partially received in the opening 884 (see, Figure 17) defined through the reservoir 818.

[00172] One or both of the reservoir 818 and the liquid transport element 820 may comprise a porous monolith, such as a porous glass or a porous ceramic. In an exemplary embodiment, the liquid transport element 820 may comprise a porous monolith and the reservoir 818 may comprise a fibrous mat (e.g., cellulose acetate), which may be wrapped around it. In some embodiments, the liquid transport element 820 may be relatively more porous than the reservoir 818. In this regard, the liquid transport element 820 may be configured to suck the aerosol precursor composition retained in the reservoir 818 into the reservoir 818. heating 822. Additionally, in some embodiments, one or both of the reservoir 818 and the liquid transport element 820 may define a variable porosity.

[00173] As illustrated in Figure 16, the heating element 822 may extend at least partially around the liquid transport element 820. More particularly, the liquid transport element 820 may define a protrusion 864, which may be located at a distal end of the liquid transport member. In this embodiment, the protrusion 864 may be positioned at the nozzle end 820b of the liquid transport member 820. As illustrated in Figure 16, the heating element 822 may extend at least partially around and in contact with the protrusion 864.

[00174] As illustrated in Figure 18, the liquid transport element 820 may define one or more channels 855 extending at least partially therethrough. The one or more channels 855 may include a slot 866. As illustrated schematically, the electronic component 826 may be received in the one or more channels 855 in the slot 866. Additionally, the one or more channels 855 defined in the liquid transport member 820 may include a first end groove 868 (see, Figure 17) and a second end groove 870. The protrusion 864 may extend from the nozzle end 820b of the liquid transport member 820 to the end grooves 868, 870. The end grooves 868, 870 may extend on each side of the liquid transport member 820 between the protrusion 864 and the slot 866. The slot 866 may extend from the terminal grooves 868, 870 to the base end 820a of the liquid transport member 820 .

[00175] As illustrated in Figures 16 and 17, heating terminals 848, 850 may extend through one or more channels 855 (see, Figure 18) in slot 866 and terminal slots 868, 870. In this regard, the first heating terminal 848 and the second heating terminal 850 may be positioned between the liquid transport member 820 and the reservoir 818. A longitudinal axis of the liquid transport element 820 may be substantially parallel to a longitudinal axis of the first heating terminal 848 and a longitudinal axis of the second heating terminal 850.

[00176] As noted above, the electronic component 826 (see, for example, Figures 17 and 18) can be at least partially positioned within the liquid transport element 820. In this regard, the electronic component 826 can be received in one or more channels 855 in the slot 866 between the first heating terminal 848 and the second heating terminal 850.

[00177] Additionally, the channels 855 defined in the liquid transport member 820 may include one or more airflow slots. In the illustrated embodiment, the liquid transport member 820 defines a first airflow slot 886 and a second airflow slot 888. The airflow slots 886, 888 may be positioned between the terminal slots 868, 870 and extending along the longitudinal length of the liquid transport member 820 on its outer surface. In this regard, the airflow may define a flow path through the base 832, around the liquid transport element 820 through the airflow slots 886, 888, in addition to the heating element 822 into which steam is added. , and out of the nozzle 846 through the mouth opening. Consequently, the use of a separate flow director may not be necessary.

[00178] In relation to vapor production, the reservoir 818 may contain the aerosol precursor composition. The liquid transport member 820 may be in contact with the reservoir 818 substantially along its entire length other than the protrusion 864. Furthermore, the liquid transport member 820 may contact a relatively large portion of the inner circumference of the opening. 884 extending through the reservoir 818 (e.g., about half of it at the base end 820a in the illustrated embodiment, as illustrated in Figure 17). By providing a relatively large contact area between the reservoir 818 and the liquid transport element 820, the transmission of fluid from the reservoir to the liquid transport element can be improved. In a similar method, the heating element 822 may substantially surround the liquid transport element 820 in the protrusion 864 to provide improved vapor production.

[00179] Figures 19 and 20 illustrate a cartridge 904 according to an example of a further embodiment of the present disclosure. As illustrated, the cartridge 904 may include an outer body 916 and a base 932 coupled to one end of the outer body. A mouth opening 924 may be defined in a mouthpiece 946, which may be engaged with an end of the outer body 916 opposite from the base 932. A heating element 922 may be positioned within the outer body 916. As illustrated, in a embodiment, the longitudinal axis of the heating element 922 may be substantially parallel to a longitudinal axis of the outer body 916.

[00180] A first heating terminal 948 and a second heating terminal 950 may be coupled to the heating element 922. An electronic component 926 (see, Figure 19) may be received in the outer body 916. A longitudinal axis of the electronic component 926 may extend substantially perpendicular to a longitudinal axis of the outer body 916. Additionally, the first heating terminal 948 and the second heating terminal 950 may extend substantially perpendicular to the longitudinal axis of the electronic component 926. The heating terminals 948, 950 and a Electronic component terminal may engage electronic component 926 and extend to base 932 to enable electrical connectivity with a control body as described above. In this regard, the terminals, base and electronic component of Figure 19 may be substantially similar or the same as the terminals, base and electronic components illustrated in Figure 12. Accordingly, the details regarding these components and the functions performed by this means will not be repeated for brevity.

[00181] Additionally, the cartridge 904 may include a reservoir 918 received in the outer body 916. The reservoir 918 may contain an aerosol precursor composition. The reservoir 918 may extend between a base end 918a and a nozzle end 918b. The electronic component 926 may be positioned between the base end 918a of the reservoir 918 and the base 932. The reservoir 918 may define a substantially tubular configuration and include an opening 984 extending therethrough (see, Figure 20).

[00182] The cartridge 904 may further include a liquid transport element 920. The liquid transport element 920 may extend between a base end 920a and a nozzle end 920b. The electronic component 926 may be positioned between the base end 920a and the base 932. Additionally, the liquid transport member 920 may extend between the reservoir 918 and the heating element 922 to transport the aerosol precursor composition from the reservoir for the heating element. In this regard, the liquid transport member 920 may be at least partially received in the opening 984 defined through the reservoir 918. For example, the liquid transport member 920 may define a cylindrical configuration, with a protrusion 964 extending outwardly the from the same at the nozzle end 920b.

[00183] One or both of the reservoir 918 and the liquid transport element 920 may comprise a porous monolith, such as a porous glass or a porous ceramic. In an exemplary embodiment, the liquid transport member 920 may comprise a porous monolith and the reservoir 918 may comprise a fibrous mat (e.g., cellulose acetate), which may be wrapped around it. In some embodiments, the liquid transport element 920 may be relatively more porous than the reservoir 918. In this regard, the liquid transport element 920 may be configured to suck the aerosol precursor composition retained in the reservoir 918 into the liquid transport element 920. heating 922. Additionally, in some embodiments, one or both of the reservoir 918 and the liquid transport element 920 may define a variable porosity.

[00184] As illustrated in Figure 19, the heating element 922 may extend at least partially around the liquid transport element 920. More particularly, the heating element 922 may extend at least partially around the protrusion 964, in which the liquid transport member 920 extends outwardly from the opening 984 (see, Figure 20) defined through and in contact with the reservoir 918.

[00185] As illustrated in Figure 20, the heating terminals 948, 950 can extend through the opening 984 defined through the reservoir 918. In this regard, the first heating terminal 948 and the second heating terminal 950 can be positioned adjacent of the liquid transport member 920 within the opening 984. A longitudinal axis of the liquid transport element 920 may be substantially parallel to a longitudinal axis of the first heating terminal 948 and a longitudinal axis of the second heating terminal 950.

[00186] In some embodiments, the airflow may define a flow path through the base 932, through the opening 984 through the reservoir 918, past the heating element 922 where steam is added thereto, and out the nozzle 946 through the mouth opening 924. However, in other embodiments, airflow may additionally or alternatively define a flow path through the base 932, around the reservoir 918, past the heating element 922 where steam is added thereto. , and out of the mouthpiece 946 through the mouth opening 924.

[00187] In each of these embodiments, the use of a separate flow director through which the air flows may not be necessary. However, as illustrated in Figures 19 and 20, the cartridge 904 may further comprise a reservoir tube 990. The reservoir tube 990 may surround the reservoir 918 such that air flow is directed between the reservoir tube 990 and the outer body 916. In this regard, the reservoir tube 990 may be configured to retain the reservoir 918 in a tubular configuration and separate the reservoir from the outer body 916 to allow air flow therebetween.

[00188] In relation to vapor production, the reservoir 918 may contain the aerosol precursor composition. The liquid transport member 920 may be in contact with the reservoir 918 substantially along its entire length other than protrusion 964. Furthermore, the liquid transport member 920 may contact a relatively large portion of the inner circumference of the reservoir. 918 as illustrated in Figure 20. By providing a relatively large contact area between the reservoir 918 and the liquid transport element 920, the transmission of fluid from the reservoir to the liquid transport element can be improved. Likewise, the heating element 922 may substantially surround the liquid transport element 920 in the protrusion 964 to provide improved vapor production.

[00189] Figures 21 and 22 illustrate a cartridge 1004 according to a further exemplary embodiment of the present disclosure. As illustrated, the cartridge 1004 may include an outer body 1016 and a base 1032 coupled to one end of the outer body. A mouth opening 1024 may be defined in a nozzle 1046, which may be engaged with an end of the outer body 1016 opposite from the base 1032. A heating element 1022 may be positioned within the outer body 1016. As illustrated, in a embodiment, a longitudinal axis of the heating element 1022 may be substantially parallel to a longitudinal axis of the outer body 1016.

[00190] A first heating terminal 1048 and a second heating terminal 1050 may be coupled to the heating element 1022. An electronic component 1026 may be received in the outer body 1016. A longitudinal axis of the electronic component 1026 may extend substantially perpendicular to a longitudinal axis of the outer body 1016. Additionally, the first heating terminal 1048 and the second heating terminal 1050 may extend substantially perpendicular to the longitudinal axis of the electronic component 1026. The heating terminals 1048, 1050 and an electronic component terminal may engage the electronic component 1026 and extend to the base 1032 to allow electrical connectivity with a control body as described above. In this regard, the terminals, base and electronic component of Figure 21 may be substantially similar to, or the same as, the terminals, base and electronic components illustrated in Figure 12. Accordingly, details regarding these components and the functions performed thereby will not be repeated for the sake of brevity.

[00191] Additionally, the cartridge 1004 may include a reservoir 1018 received in the outer body 1016. The reservoir 1018 may contain an aerosol precursor composition. The reservoir 1018 may extend between a base end 1018a and a nozzle end 1018b. The electronic component 1026 may be positioned between the base end 1018a of the reservoir 1018 and the base 1032. The reservoir 1018 may define a modified tubular configuration including an opening 1084 extending therethrough (see, Figure 22).

[00192] The cartridge 1004 may further include a liquid transport member 1020. The liquid transport member 1020 may extend between a base end positioned in the vicinity of the base 1032 and a nozzle end positioned in the vicinity of the nozzle 1046. electronic component 1026 may be positioned between the base end of the liquid transport element 1020 and the base 1032. Additionally, the liquid transport element 1020 may extend between the reservoir 1018 and the heating element 1022 so as to transport the aerosol precursor composition from the reservoir to the heating element. In this regard, the liquid transport member 1020 may be at least partially received in the opening 1084 defined through the reservoir 1018. For example, the liquid transport member 1020 may define a cylindrical configuration, with a protrusion 1064 extending outwardly the from the nozzle end thereof.

[00193] One or both of the reservoir 1018 and the liquid transport element 1020 may comprise a porous monolith, such as a porous glass or porous ceramic. In an exemplary embodiment, the liquid transport element 1020 may comprise a porous monolith and the reservoir 1018 may comprise a fibrous mat (e.g., cellulose acetate), which may be wrapped around it. In some embodiments, the liquid transport element 1020 may be relatively more porous than the reservoir 1018. In this regard, the liquid transport element 1020 may be configured to suck the aerosol precursor composition retained in the reservoir 1018 into the element heating element 1022. Additionally, in some embodiments, one or both of the reservoir 1018 and the liquid transport element 1020 may define a variable porosity.

[00194] As illustrated in Figure 21, the heating element 1022 may extend at least partially around the liquid transport element 1020. More particularly, the heating element 1022 may extend at least partially around the protrusion 1064, in which the liquid transport member 1020 extends outwardly from the opening 1084 (see, Figure 22) defined through the reservoir 1018 and in contact therewith.

[00195] As illustrated in Figure 22, the heating terminals 1048, 1050 can extend through the opening 1084 defined through the reservoir 1018. In this regard, the first heating terminal 1048 and the second heating terminal 1050 can be positioned adjacent of the liquid transport member 1020 within the opening 1084. A longitudinal axis of the liquid transport element 1020 may be substantially parallel to a longitudinal axis of the first heating terminal 1048 and a longitudinal axis of the second heating terminal 1050.

[00196] Additionally, the cartridge 1004 may include a flow director 1092. The flow director 1092, which may be tubular, may extend through the reservoir 1018. The flow director 1092 may be received in the opening 1084 extending through the reservoir 1018 as illustrated in Figure 22, or the flow director may be received in a separate opening extending therethrough. The flow director 1092 may define a longitudinal axis extending substantially parallel to a longitudinal axis of the liquid transport member 1020 and substantially parallel to a longitudinal axis of the outer body 1016. However, as illustrated in Figure 22, the flow director 1092 can be moved from a central longitudinal axis of the outer body 1016 and positioned next to the liquid transport element 1020.

[00197] Thus, in some embodiments, the airflow may define a flow path through the base 1032, through the flow director 1092, past the heating element 1022 where steam is added thereto, and out of the nozzle 1046 through mouth opening 1024. Accordingly, in some embodiments, a separate flow director may be employed to direct the air flow as desired.

[00198] In relation to steam production, the reservoir 1018 may contain the aerosol precursor composition. The liquid transport member 1020 may be in contact with the reservoir 1018 substantially along its entire length other than at the protrusion 1064. Furthermore, the liquid transport member 1020 may contact a relatively large portion of the inner surface of the reservoir. 1018 as illustrated in Figure 22. By providing a relatively large contact area between the reservoir 1018 and the liquid transport element 1020, the transmission of fluid from the reservoir to the liquid transport element can be improved. Likewise, the heating element 1022 may substantially surround the liquid transport element 1020 in the protrusion 1064 to provide improved vapor production.

[00199] In a further embodiment, a method for producing an aerosol delivery device is provided. As illustrated in Figure 23, the method may include positioning a heating element, a reservoir and a liquid transport element in an external body such that the liquid transport element is in contact with the reservoir and the liquid transport element. of heating element in operation 1102. Positioning of the heating element, reservoir and liquid transport element in the outer body in operation 1102 may include aligning a respective longitudinal axis of the heating element, reservoir and liquid transport element in operation 1103.

[00200] In some embodiments, the method may further include positioning the liquid transport element at least partially within the reservoir. Positioning the liquid transport element at least partially within the reservoir may include enclosing the liquid transport element with the reservoir. The method may further include inserting the heating element into a channel extending at least partially through the liquid transport element. In another embodiment, the method may further include coupling the heating element to an external surface of the liquid transport element.

[00201] In a further embodiment, a method for producing an aerosol delivery device is provided. The method may include forming a liquid transport member from a porous monolithic material. Furthermore, the method may include positioning a heating element, a reservoir and the liquid transporting element in an external body such that the liquid transporting element is in contact with the reservoir and the heating element is close to the liquid transport element. The method may further include distributing an aerosol precursor composition into the reservoir.

[00202] In some embodiments, forming the liquid transport element may comprise injection molding the liquid transport element. The method may further include engaging a first heating terminal and a second heating terminal with the heating element. Forming the liquid transport member from the porous monolithic material may include insertion molding of at least one heating element, the first heating terminal and the second heating terminal on the liquid transport element. Additionally, forming the liquid transport element from the porous monolithic material may comprise forming the liquid transport element from a porous ceramic.

[00203] As noted herein, the cartridge elements of the present disclosure may comprise a porous monolith. In this regard, the unitary reservoirs and liquid transport elements, reservoirs, and/or liquid transport elements of the present disclosure may comprise a porous monolith. The porous monoliths can be form stable, which can thus facilitate the assembly of the cartridges. For example, porous monoliths can be substantially rigid. Furthermore, shape-stable porous monoliths may be suitable for directing airflow through the cartridge. By way of contrast, embodiments of liquid transport elements formed from fiberglass and reservoirs formed from cellulose acetate may be flexible and their shape may change when contacted, such that assembly of cartridges including such components may be relatively more difficult and such components may not be suitable for directing airflow due to pressure changes within the cartridge, potentially altering the shape thereof. Furthermore, components comprising a porous monolith can be molded or otherwise formed to define shapes that may be difficult to form from materials that are flexible.

[00204] As noted here, each of the porous monoliths described here can define a variable porosity. The use of variable porosity can be used to store and direct the aerosol precursor composition to desired locations within the porous monoliths. For example, relatively higher porosity may be used in locations where storage or transport of fluid through it is desired. On the other hand, relatively lower porosity can be employed in locations where leakage from the porous monolith is a greater concern. Thus, for example, in embodiments of the cartridge including the reservoir and unitary liquid transport element, a relatively more porous region may be configured to store and direct the aerosol precursor composition to the heating element. In embodiments of the cartridge including a reservoir and a liquid transport element as separate elements, a relatively more porous region in the reservoir can be configured to store and suck the aerosol precursor composition into the liquid transport element. Additionally or alternatively, a relatively more porous region on the liquid transport element may be configured to suck the aerosol precursor composition within the liquid transport element to the heating element. In this regard, the aerosol precursor composition can flow relatively more easily through portions of the porous monoliths by defining a relatively greater porosity.

[00205] Therefore, one or more regions of the porous monoliths may define relatively greater porosity to accommodate storage and encourage movement of the aerosol precursor composition therethrough. Such regions may extend along at least a portion of the longitudinal length of the porous monoliths to facilitate movement of the aerosol precursor composition to the heating element, which may be positioned near one end thereof. Furthermore, these regions of relatively higher porosity may be partially or fully surrounded by a region of relatively lower porosity in order to resist leakage of the aerosol precursor composition from the porous monolith. In some embodiments, the portion of the porous monolith most susceptible to leaks may be the region exposed to airflow through the cartridge, which may be close to the heating element. Thus, the porous monolith may include relatively smaller pores near the heating element, while the porous monolith may include relatively larger pores near the reservoir. This porosity gradient will naturally pull the liquid aerosol precursor composition from the larger pore areas to the smaller pore areas. Therefore, by varying the porosity of the porous monolith, the fluid storage and transport characteristics may vary depending on its location.

[00206] Furthermore, the use of cartridges configured as described herein can provide benefits in terms of increased aerosol precursor composition capacity for a given cartridge size. For example, the cartridge 104 illustrated in Figure 1 may have a total aerosol precursor composition capacity of approximately 0.6 cubic centimeters (cc) for the liquid transport element 120 and the reservoir 118. However, use of a liquid transport system, reservoir or reservoir and unitary liquid transport element comprising a porous monolith can provide a greater aerosol precursor composition capacity in a cartridge having substantially identical external dimensions. In this regard, embodiments of the cartridges 204, 304, 404, 504, 704, 804, 904, 1004 illustrated in Figures 2, 4, 6, 10, 14, 16, 19 and 21 may have full aerosol precursor composition capabilities. of 1.1 cc, 0.9 cc, 1.1 cc, 1.0 cc, 1.1 cc, 1.1 cc, 0.9 cc and 1.1 cc respectively. In this regard, in the cartridge embodiments disclosed herein, space utilization within the outer body in which the aerosol precursor composition is received is maximized.

[00207] Furthermore, the use of cartridges configured as described herein may provide benefits in terms of improved vapor production. In this regard, while the heating element 122 included in the cartridge 104 of Figure 1 includes relatively small coils in view of the liquid transport element 120 defining a relatively small diameter, the heating elements of the cartridges 204, 304, 404, 504 , 704, 804, 904, 1004 illustrated in Figures 2, 4, 6, 10, 14, 16, 19 and 21 can be approximately twice as long in terms of the length of the wire defining the heating elements. In this regard, the liquid transport element or reservoir and unitary liquid transport element may define an increased internal or external dimension configured to receive the relatively larger heating element. The use of a relatively larger heating element may allow for the production of a greater amount of heat, thus allowing for faster production of steam and/or a greater quantity thereof.

[00208] Many modifications and other embodiments of the disclosure will come to mind of one skilled in the art to which this disclosure belongs having the benefit of the teachings presented in the preceding descriptions and associated drawings. Accordingly, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (12)

1. Aerosol delivery device, configured to heat an aerosol precursor capable of forming an inhalable substance for human consumption, comprising: an external body (216, 316, 416); a heating element (222, 322, 422); a unitary liquid reservoir and transport element (254, 354, 454) comprising an integral porous monolith positioned in the vicinity of the heating element (222, 322, 422) and containing an aerosol precursor composition, wherein the reservoir and liquid transport element (254, 354, 454) unit liquid transport (254, 354, 454) define one or more channels (255, 355, 455) extending at least partially therethrough; CHARACTERIZED by the fact that it further comprises an electronic component (226, 326, 426) at least partially received on one or more channels (255, 355, 455). 2. Aerosol delivery device according to claim 1, CHARACTERIZED by the fact that a longitudinal axis of the heating element (222, 322, 422) is parallel to a longitudinal axis of the outer body (216, 316, 416) , and optionally wherein a longitudinal axis of the electronic component (226, 326, 426) extends parallel to the longitudinal axis of the outer body (216, 316, 416). 3. Aerosol delivery device according to claim 1 or 2, CHARACTERIZED by the fact that the integral porous monolith comprises at least one of a porous ceramic and a porous glass. 4. Aerosol delivery device according to any one of claims 1 to 3, CHARACTERIZED by the fact that it further comprises a first heating terminal (248, 348, 448) and a second heating terminal (250, 350, 450 ) coupled to the heating element (222, 322, 422), the first heating terminal (248, 348, 448) and the second heating terminal (250, 350, 450) being, at least partially, received in one or more channels (255, 355, 455). 5. Aerosol delivery device according to claim 4, CHARACTERIZED by the fact that the heating element (222, 322, 422) is at least partially received in the one or more channels (255, 355, 455). 6. Aerosol delivery device according to claim 4 or 5, CHARACTERIZED by the fact that the electronic component (226, 326, 426) is positioned between the first heating terminal (248, 348, 448) and the second heating terminal (250, 350, 450). 7. Aerosol delivery device according to any one of claims 1 to 3, CHARACTERIZED by the fact that the heating element (222, 322, 422) extends at least partially around the reservoir and unitary liquid transport element (254, 354, 454), and optionally wherein the unitary reservoir and liquid transport member (254, 354, 454) defines a protrusion (364, 464) and the heating element (222, 322, 422) extends through the less partially around the protrusion (364, 464). 8. Aerosol delivery device according to any one of claims 1 to 7, CHARACTERIZED by the fact that the reservoir and unitary liquid transport element (254, 354, 454) defines a variable porosity. 9. Method for producing a vapor of inhalable substance for human consumption, the method CHARACTERIZED by the fact that it comprises: providing a unitary liquid reservoir and transport element (254, 354, 454) comprising an integral porous monolith positioned in the vicinity of a heating element (222, 322, 422) and defining one or more channels (255, 355, 455) extending at least partially therethrough; contain an aerosol precursor composition in the reservoir and unitary liquid transport member (254, 354, 454); positioning an electronic component (226, 326, 426) at least partially in one or more channels (255, 355, 455); and vaporizing at least a portion of the aerosol precursor composition into the reservoir and unitary liquid transport member (254, 354, 454). 10. Method according to claim 9, CHARACTERIZED by the fact that vaporizing at least the portion of the aerosol precursor composition in the reservoir and unitary liquid transport element (254, 354, 454) comprises directing an electrical current to the element heating element (222, 322, 422) surrounded by the reservoir and unitary liquid transport element (254, 354, 454). 11. Method according to claim 9, CHARACTERIZED by the fact that vaporizing at least the portion of the aerosol precursor composition in the reservoir and unitary liquid transport element (254, 354, 454) comprises directing an electrical current to the element heating element (222, 322, 422) extending around at least a portion of the reservoir and unitary liquid transport element (254, 354, 454). 12. Method according to any one of claims 9 to 11, CHARACTERIZED by the fact that the aerosol precursor composition in the reservoir and unitary liquid transport element (254, 354, 454) comprises containing the aerosol precursor composition in the monolith integral porous.