RU2806171C2 - Aerosol delivery device containing bubble-jet head, and related method - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: present invention relates to aerosol delivery devices. Aerosol delivery devices contain mechanisms made with the possibility of delivery of an aerosol precursor composition from a reservoir to a sprayer containing a vapor-generating heating element for generation of vapor. For example, a bubble-jet head may be made with the possibility of delivery of the aerosol precursor composition to the sprayer. The bubble-jet head may be firmly connected to the sprayer. The bubble-jet head may contain an inlet for a precursor, an ejection heating element, and a nozzle for the precursor. The sprayer may contain a vapor-generating heating element.

EFFECT: obtaining an aerosol delivery device.

24 cl, 31 dwg

Description

TECHNICAL FIELD

[0001] The present invention relates to aerosol delivery devices such as smoking articles; and in particular to aerosol delivery devices that use electrically generated heat to generate an aerosol (eg, smoking products commonly referred to as electronic cigarettes). Aerosol delivery devices are provided that contain mechanisms for delivering an aerosol precursor composition to a nebulizer. Smoking articles may be configured to heat an aerosol precursor comprising materials that are derived from, derived from, or otherwise include tobacco and vaporizable to form a respirable aerosol for human consumption.

BACKGROUND OF THE ART

[0002] Over the years, many smoking products have been proposed as improvements to smoking products or alternatives to smoking products that require combustion of tobacco for use. Many of these devices are purportedly designed to provide the experience associated with smoking a cigarette, cigar or pipe without delivering significant amounts of incomplete combustion and pyrolysis products that result from burning tobacco. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat volatile material or create the sensation of smoking a cigarette, cigar, or pipe without substantially burning the tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generation sources of the prior art described in US Patent No. 7,726,320 (Robinson et al.), as well as US Patent Publications No. 2013/0255702 (Griffith, Jr. et al.) and 2014/0096781 (Sears et al.), which are incorporated by reference in their entirety herein. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered sources for generating heat to which the trademark and commercial reference is made in U.S. Patent Application No. 14/170,838, filed Feb. 3, 2014, (Bless et al. ), which is incorporated by reference in its entirety herein.

[0003] However, it may be desirable to provide aerosol delivery devices with improved functionality. In this regard, it may be desirable to improve the delivery of the aerosol precursor composition to the nebulizer.

DISCLOSURE OF THE INVENTION

[0004] The present invention relates to aerosol delivery systems. Such systems have the ability to generate an aerosol as a result of heat generated by electrical sources and deliver said aerosol which is designed to be drawn into the user's mouth. Particularly interesting are aerosol delivery systems that provide tobacco components in aerosol form such as those in which they are delivered to users by devices commonly known or characterized as electronic cigarettes. As used herein, the term "aerosol" is intended to refer to vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not visible and whether or not in a form that can be considered " like smoke."

[0005] Various embodiments of mechanisms for delivering an aerosol precursor composition to a nebulizer have been proposed. These mechanisms may include bubble jet heads, as described below. As described herein, a bubble jet head is a component configured to heat a fluid (eg, an aerosol precursor composition) to form a vapor bubble that applies pressure to the fluid and ejects one or more microdroplets of fluid from bubble jet head. Bubble jet heads may have an inlet (eg, a precursor inlet), an ejection heating element, and a nozzle (eg, a precursor nozzle), which may be housed in a plate, substrate, or housing, or may be formed by a plate, substrate, or casing.

[0006] In one aspect, an aerosol delivery device is provided. The aerosol delivery device may comprise a reservoir at least partially filled with the aerosol precursor composition. In addition, the aerosol delivery device may include a bubble-jet head in fluid communication with the reservoir. The bubble jet head may be configured to dispense the aerosol precursor composition from the reservoir. In addition, the aerosol delivery device may include a nebulizer configured to heat the aerosol precursor composition dispensed by the bubble jet head to form an aerosol. The bubble jet head and the spray gun can be firmly connected to each other.

[0007] In some embodiments, the aerosol delivery device may further comprise an outer housing and a housing housed within the outer housing. The bubble jet head and the spray gun can be firmly connected to each other by means of a housing. The bubble jet head may be connected to the sprayer by one or more spacers. In addition, the bubble jet head and the atomizer can be electrically connected through a flexible circuit.

[0008] In some embodiments, the atomizer may include a housing, vapor-generating heating elements coupled to the housing, and a reinforcement element coupled to the housing and configured to support the housing. The reinforcing element may form a cutout. The aerosol delivery device may further comprise an outer housing, wherein the heating surface of the atomizer is oriented at an angle other than zero relative to the longitudinal axis of the outer housing.

[0009] In some embodiments, the aerosol delivery device may comprise an outer housing. The heating surface of the atomizer may be oriented substantially parallel to the longitudinal axis of the outer housing. The bubble jet head may be configured to emit the aerosol precursor composition substantially perpendicular to the heating surface of the atomizer. The heating surface of the atomizer may not be flat. The heating surface of the atomizer may be substantially conical. The heating surface of the sprayer can be textured.

[0010] In some embodiments, the reservoir may comprise a reservoir substrate configured to direct the aerosol precursor composition to the bubble jet head. The bubble jet head may be connected to the distal end of the reservoir. The bubble jet head can be connected to the side of the tank. The bubble jet head and atomizer can be located between the reservoir and the mouthpiece. In yet another embodiment, the reservoir may be located between the mouthpiece and the atomizer and bubble jet head. The aerosol delivery device may further comprise a cartridge comprising a base and a control body containing a connector. The base may be configured to cooperate with the connector to provide a mechanical and electrical connection between the cartridge and the control housing.

[0011] In an additional aspect, a combined dispenser and sprayer assembly is provided. The combined dispenser and atomizer assembly may comprise a casing, a bubble-jet head containing an ejection heating element configured to dispense the aerosol precursor composition from the reservoir, and the atomizer contains a vapor-generating heating element configured to heat the aerosol precursor composition dispensed bubble-jet head for aerosol formation. The bubble jet head and the sprayer can be connected to each other through a housing. The housing may be configured to be placed in the outer housing of the aerosol delivery device.

[0012] In some embodiments, the bubble jet head may further comprise a precursor inlet and a precursor nozzle. The atomizer may further comprise an aerosol outlet. The aerosol outlet area may be larger than the nozzle area for the aerosol precursor composition. The thermal mass of the ejection heating element may be less than the thermal mass of the vapor-generating heating elements. The ejection heating element, the aerosol precursor composition nozzle, and the vapor-generating heating elements may be axially aligned. The housing may define at least one of a precursor inlet, a precursor nozzle, and an aerosol outlet.

[0013] In a further aspect, an aerosol delivery device is provided. The aerosol delivery device may comprise a reservoir at least partially filled with the aerosol precursor composition. In addition, the aerosol delivery device may include a housing containing an inlet for the aerosol precursor composition in fluid communication with the reservoir, the ejection heating element, and the precursor nozzle. The ejection heating element may be configured to emit an aerosol precursor composition received through the precursor inlet through a precursor nozzle. Additionally, the aerosol delivery device may include a nebulizer configured to heat the aerosol precursor composition dispensed from the housing to form an aerosol. The ejection heating element and the atomizer can be firmly connected to each other.

[0014] In some embodiments, the atomizer may be housed in a housing, and the housing and reservoir may be housed in an outer housing. In another embodiment, the housing may be connected to the atomizer by one or more spacers. The housing and the atomizer can be electrically connected via a flexible circuit.

[0015] In some embodiments, the atomizer may include a housing, a vapor-generating heating element coupled to the housing, and a reinforcement element coupled to the housing and configured to support the housing. The reinforcing element may form a cutout. The aerosol delivery device may further comprise an outer housing, and the heating surface of the atomizer may be oriented at an angle other than zero relative to the longitudinal axis of the outer housing. In another embodiment, the heating surface of the atomizer may be oriented substantially parallel to the longitudinal axis of the outer housing.

[0016] In some embodiments, the aerosol precursor composition nozzle may be configured to emit the aerosol precursor composition substantially perpendicular to the heating surface of the atomizer. The heating surface of the atomizer may not be flat. The heating surface of the atomizer may be substantially conical. The heating surface of the sprayer can be textured.

[0017] In some embodiments, the reservoir may comprise a reservoir substrate configured to direct the aerosol precursor composition to the precursor inlet. The casing may be connected to the distal end of the tank. In another embodiment, the housing may be connected to the side of the reservoir. The body and atomizer can be located between the reservoir and the mouthpiece. In another embodiment, the reservoir may be located between the mouthpiece and the atomizer and housing. The aerosol delivery device may further comprise a cartridge containing a base and a control body containing a connector. The base may be configured to cooperate with the connector to provide a mechanical and electrical connection between the cartridge and the control housing.

[0018] According to an additional aspect, a combined dispenser and atomizer assembly is provided. The combined dispenser and nebulizer assembly may include a housing, an ejection heating element configured to dispense an aerosol precursor composition from the reservoir, and a vapor-generating heating element configured to heat the aerosol precursor composition dispensed by the ejection heating element to form an aerosol. The ejection heating element and the steam generating heating element may be housed in the housing, and the housing may be configured to be housed in an outer housing of the aerosol delivery device.

[0019] In some embodiments, the combined dispenser and atomizer assembly may further comprise a precursor inlet, a precursor nozzle, a vapor-generating heating element, and an aerosol outlet. The area of the aerosol outlet can be larger than the area of the nozzle for its predecessor. The thermal mass of the ejection heating element may be less than the thermal mass of the vapor-generating heating element. The ejection heating element, the precursor nozzle and the steam generating heating element can be aligned in the axial direction. The housing may define at least one of a precursor inlet, a precursor nozzle, and an aerosol outlet.

[0020] In a further aspect, a method of generating an aerosol in an aerosol delivery device is provided. The method may include directing air flow from a control housing containing a power source through a cartridge containing a reservoir. The method may further include dispensing the aerosol precursor composition from the reservoir through a precursor inlet, an ejection heating element, and a precursor nozzle. The method may further include heating (eg, vaporizing) the aerosol precursor composition dispensed from the reservoir by the nebulizer.

[0021] In some embodiments, dispensing the aerosol precursor composition and heating the aerosol precursor composition may include independently supplying energy from a power source to the ejection heating element and the atomizer. Dispensing the aerosol precursor composition and heating the aerosol precursor composition may include directing energy to the nebulizer after applying energy to the ejection heating element. The method may further include preheating the aerosol precursor composition with an ejection heating element before dispensing the aerosol precursor composition. Additionally, the method may include measuring the temperature of the aerosol precursor composition, wherein preheating the aerosol precursor composition includes preheating the aerosol precursor composition to a desired temperature. Preheating the aerosol precursor composition may involve delivering energy of a relatively shorter pulse duration or pulse amplitude to the ejection heating element compared to the duration and amplitude of the output of the aerosol precursor composition. In some embodiments, heating the aerosol precursor composition with a nebulizer may include heating the aerosol precursor composition with a vapor-generating heating element.

[0022] According to a further aspect, a method of generating an aerosol by means of an aerosol delivery device is provided. The method may include directing air flow from a control housing containing a power source through a cartridge containing a reservoir. Additionally, the method may include dispensing the aerosol precursor composition from the reservoir via a bubble jet head. Additionally, the method may include heating the aerosol precursor composition dispensed from the reservoir by the bubble jet spray head.

[0023] In some embodiments, dispensing the aerosol precursor composition and heating the aerosol precursor composition may involve independently supplying energy from a power source to the bubble jet head and the atomizer. Dispensing the aerosol precursor composition and heating the aerosol precursor composition may include energizing the atomizer after energizing the bubble jet head. The method may further include preheating the aerosol precursor composition by the bubble jet head before dispensing the aerosol precursor composition. Additionally, the method may include measuring the temperature of the aerosol precursor composition. Preheating the aerosol precursor composition may include preheating the aerosol precursor composition to a desired temperature. Preheating the aerosol precursor composition may involve delivering energy of a relatively shorter pulse duration or pulse amplitude to the bubble jet head compared to the duration or amplitude of delivery of the aerosol precursor composition.

[0024] The invention includes, but is not limited to, the following embodiments.

[0025] Embodiment 1: an aerosol delivery device comprising:

a reservoir at least partially filled with the aerosol precursor composition;

a bubble-jet head in fluid communication with the reservoir, said bubble-jet head configured to dispense the aerosol precursor composition from the reservoir; And

a nebulizer configured to heat the aerosol precursor composition dispensed by the bubble jet head to form an aerosol, wherein the bubble jet head and the atomizer are firmly connected to each other.

[0026] Embodiment 2: an aerosol delivery device according to any one of the preceding or subsequent claims, further comprising an outer housing and a housing housed in the outer housing,

wherein the bubble-jet head and the sprayer are firmly connected to each other by means of a casing.

[0027] Embodiment 3: The aerosol delivery device of any one of the preceding or following claims, wherein the bubble-jet head is connected to the atomizer by one or more spacers.

[0028] Embodiment 4: The aerosol delivery device of any one of the preceding or following claims, wherein the bubble jet head and the atomizer are electrically connected through a flexible circuit.

[0029] Embodiment 5: The aerosol delivery device of any one of the preceding or following claims, wherein the atomizer comprises a casing, vapor-generating heating elements connected to the casing, and a reinforcing element connected to the casing and configured to support the casing.

[0030] Embodiment 6: an aerosol delivery device according to any one of the preceding or following claims, in which the reinforcing element forms a cutout.

[0031] Embodiment 7: an aerosol delivery device according to any of the preceding or subsequent claims, further comprising an outer housing, the heating surface of the atomizer being oriented at an angle other than zero relative to the longitudinal axis of the outer housing.

[0032] Embodiment 8: The aerosol delivery device of any one of the preceding or following claims, further comprising an outer housing, the heating surface of the atomizer being oriented substantially parallel to the longitudinal axis of the outer housing.

[0033] Embodiment 9: The aerosol delivery device of any one of the preceding or following claims, wherein the bubble-jet head is configured to emit the aerosol precursor composition substantially perpendicular to the heating surface of the atomizer.

[0034] Embodiment 10: The aerosol delivery device of any one of the preceding or following claims, wherein the heating surface of the atomizer is non-planar.

[0035] Embodiment 11: The aerosol delivery device of any one of the preceding or following claims, wherein the heating surface of the atomizer is substantially conical.

[0036] Embodiment 12: The aerosol delivery device of any one of the preceding or following claims, wherein the heating surface of the atomizer is textured.

[0037] Embodiment 13: The aerosol delivery device of any one of the preceding or following claims, wherein the reservoir comprises a reservoir substrate configured to direct the aerosol precursor composition to the bubble-jet head.

[0038] Embodiment 14: The aerosol delivery device of any one of the preceding or following claims, wherein the bubble jet head is coupled to a distal end of the reservoir.

[0039] Embodiment 15: The aerosol delivery device of any one of the preceding or following claims, wherein the bubble jet head is coupled to the side of the reservoir.

[0040] Embodiment 16: The aerosol delivery device of any one of the preceding or following claims, wherein the bubble jet head and the atomizer are located between the reservoir and the mouthpiece.

[0041] Embodiment 17: The aerosol delivery device of any one of the preceding or following claims, wherein the reservoir is located between the mouthpiece and the atomizer and the bubble-jet head.

[0042] Embodiment 18: The aerosol delivery device of any one of the preceding or following claims, further comprising a cartridge containing a base and a control body containing a connector, wherein the base is configured to interact with the connector to provide a mechanical and electrical connection between the cartridge and the control body.

[0043] Embodiment 19: a combined dispenser and sprayer assembly, comprising:

casing;

a bubble-jet head containing an ejection heating element configured to dispense the aerosol precursor composition from the reservoir; And

a nebulizer comprising vapor-generating heating elements configured to heat the aerosol precursor composition dispensed by the bubble-jet head to form an aerosol,

wherein the bubble jet head and the sprayer are connected to each other by means of a housing, and

wherein the casing is configured to be placed in the outer casing of the aerosol delivery device.

[0044] Embodiment 20: a combined dispenser and atomizer assembly according to any of the preceding or subsequent claims, wherein the thermal mass of the ejection heating element is less than the thermal mass of the vapor-generating heating elements.

[0045] Embodiment 21: the combined dispenser and atomizer assembly of any one of the preceding or following claims, wherein the bubble-jet head further comprises a precursor inlet and a precursor nozzle; And

wherein the sprayer further comprises an aerosol outlet.

[0046] Embodiment 22: the combined dispenser and atomizer assembly of any one of the preceding or subsequent claims, wherein the aerosol outlet area is larger than the nozzle area of the predecessor.

[0047] Embodiment 23: The combined dispenser and atomizer assembly of any one of the preceding or following claims, wherein the ejection heating element, the aerosol precursor composition nozzle, and the vapor-generating heating element are axially aligned.

[0048] Embodiment 24: The combined dispenser and atomizer assembly of any one of the preceding or following claims, wherein the housing defines at least one of a precursor inlet, a precursor nozzle, and an aerosol outlet.

[0049] Embodiment 25: A method for generating an aerosol in an aerosol delivery device, comprising:

direction of air flow from the control housing containing the power supply through the cartridge containing the reservoir,

dispensing the aerosol precursor composition from the reservoir via the bubble jet head and

heating the aerosol precursor composition dispensed from the reservoir by means of the bubble-jet head with the sprayer.

[0050] Embodiment 26: The aerosol generation method of any one of the preceding or following claims, wherein dispensing the aerosol precursor composition and heating the aerosol precursor composition includes independently supplying energy from a power source to the bubble jet head and the atomizer.

[0051] Embodiment 27: The aerosol generating method according to any one of the preceding or following claims, wherein dispensing the aerosol precursor composition and heating the aerosol precursor composition comprises directing energy to the atomizer after supplying energy to the bubble-jet head.

[0052] Embodiment 28: The aerosol generating method of any one of the preceding or following claims, further comprising preheating the aerosol precursor composition by the bubble jet head before dispensing the aerosol precursor composition.

[0053] Embodiment 29: The aerosol generation method of any one of the preceding or following claims, further comprising measuring the temperature of the aerosol precursor composition, wherein preheating the aerosol precursor composition includes preheating the aerosol precursor composition to a desired temperature.

[0054] Embodiment 30: The aerosol generation method of any one of the preceding or following claims, wherein preheating the aerosol precursor composition includes applying to the bubble jet head a pulse of energy having a relatively shorter duration or amplitude compared to the duration or amplitude of dispensing the precursor composition aerosol.

[0055] These and other features, aspects and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The invention includes any combination of two, three, four or more embodiments described above, as well as combinations of any two, three, four or more features or elements set forth herein, whether or not such features or elements are expressly combined. in the specific description of the embodiment in this application. The present invention is intended to be read in all elements such that any separable features or elements of the described invention in any of its various aspects and embodiments are to be considered as intended to be combined unless the context clearly indicates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Having thus described the present invention using the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily to scale, and in which:

[0057] FIG. 1 is an exploded perspective view of a control housing according to an exemplary embodiment of the present invention;

[0058] FIG. 2 is an exploded perspective view of an aerosol delivery device comprising a combined dispenser and nebulizer assembly containing a standard bubble-jet head, in accordance with an exemplary embodiment of the present invention;

[0059] FIG. 3 shows a modified perspective cross-sectional view of the aerosol delivery device shown in FIG. 2 showing the flow of air flowing therethrough according to an exemplary embodiment of the present invention;

[0060] FIG. 4 is a modified perspective cross-sectional view of a combined dispenser and nebulizer assembly for the aerosol delivery device shown in FIG. 2, according to an exemplary embodiment of the present invention;

[0061] FIG. 5 shows a modified perspective cross-sectional view of the aerosol delivery device shown in FIG. 2, adjacent to a combined dispenser/sprayer/reservoir assembly according to an exemplary embodiment of the present invention;

[0062] FIG. 6 shows a modified perspective cross-sectional view of the aerosol delivery device shown in FIG. 2 depicting steam generation according to an exemplary embodiment of the present invention;

[0063] FIG. 7 shows a perspective cross-sectional view of an additional embodiment of an aerosol delivery device comprising an integrated dispenser and nebulizer combination assembly according to an exemplary embodiment of the present invention;

[0064] FIG. 8 shows a perspective cross-sectional view of the aerosol delivery device shown in FIG. 7 showing a flow of air flowing therethrough according to an exemplary embodiment of the present invention;

[0065] FIG. 9 shows a perspective cross-sectional view of a combined dispenser and nebulizer assembly for the aerosol delivery device shown in FIG. 7, according to an exemplary embodiment of the present invention;

[0066] FIG. 10 shows an enlarged perspective cross-sectional view of a combined dispenser and nebulizer assembly for the aerosol delivery device shown in FIG. 7, according to an exemplary embodiment of the present invention;

[0067] FIG. 11 shows a partial perspective cross-sectional view of the aerosol delivery device shown in FIG. 7 depicting steam generation according to an exemplary embodiment of the present invention;

[0068] FIG. 12 shows a perspective cross-sectional view of an aerosol delivery device comprising a combined dispenser and nebulizer assembly comprising a flexible circuit, in accordance with a further exemplary embodiment of the present invention;

[0069] FIG. 13 shows an enlarged partial perspective cross-sectional view of the aerosol delivery device shown in FIG. 12, adjacent to a combined dispenser and sprayer assembly according to an exemplary embodiment of the present invention;

[0070] FIG. 14 shows a modified perspective cross-sectional view of the aerosol delivery device shown in FIG. 12 showing a flow of air flowing therethrough according to an exemplary embodiment of the present invention;

[0071] FIG. 15 shows a partial perspective cross-sectional view of an aerosol delivery device which is substantially similar to the aerosol delivery device shown in FIG. 12, except that the aerosol delivery device includes an integrated dispenser and nebulizer combination assembly, according to a further exemplary embodiment of the present invention;

[0072] FIG. 16 is a perspective cross-sectional view of an aerosol delivery device comprising a combined dispenser and nebulizer assembly located between a reservoir and a mouthpiece, in accordance with a further exemplary embodiment of the present invention;

[0073] FIG. 17 shows an enlarged partial perspective cross-sectional view of the aerosol delivery device shown in FIG. 16 showing a flow of air flowing therethrough according to an exemplary embodiment of the present invention;

[0074] FIG. 18 shows a perspective cross-sectional view of an aerosol delivery device comprising a combined dispenser and nebulizer assembly coupled to the side of a reservoir, in accordance with a further exemplary embodiment of the present invention;

[0075] FIG. 19 shows an enlarged partial modified perspective cross-sectional view of the aerosol delivery device shown in FIG. 18 showing a flow of air flowing therethrough according to an exemplary embodiment of the present invention;

[0076] FIG. 20 shows a partial schematic view of an aerosol delivery device in which the respective ejection and heating surfaces of the bubble jet head and atomizer are oriented at a non-zero angle relative to the longitudinal axis of the aerosol delivery device, according to a further exemplary embodiment of the present invention;

[0077] FIG. 21 is a perspective cross-sectional view of an aerosol delivery device comprising a combined dispenser and nebulizer assembly with air flowing centrally therethrough, in accordance with a further exemplary embodiment of the present invention;

[0078] FIG. 22 shows an enlarged perspective cross-sectional view of the aerosol delivery device shown in FIG. 21 showing a flow of air flowing therethrough according to an exemplary embodiment of the present invention;

[0079] FIG. 23 is a schematic, enlarged perspective exploded view of a combined dispenser and nebulizer assembly for the aerosol delivery device shown in FIG. 21, according to an exemplary embodiment of the present invention;

[0080] FIG. 24 is a perspective view of a substantially conical atomizer defining an internal heating surface, in accordance with a further exemplary embodiment of the present invention;

[0081] FIG. 25 is a perspective view of a substantially conical atomizer defining an outer heating surface, in accordance with a further exemplary embodiment of the present invention;

[0082] FIG. 26 is an exploded view of a combined dispenser and sprayer assembly including a reinforcing element, in accordance with a further exemplary embodiment of the present invention;

[0083] FIG. 27 shows a rear view of the combined dispenser and sprayer assembly shown in FIG. 26, the reinforcing element being shown in an assembled configuration according to an exemplary embodiment of the present invention;

[0084] FIG. 28A shows an enlarged perspective cross-sectional view of a sprayer for the combined dispenser and sprayer assembly shown in FIG. 26, wherein the atomizer forms a serrated heating surface, according to a further exemplary embodiment of the present invention;

[0085] FIG. 28B shows an enlarged perspective cross-sectional view of a sprayer for the combined dispenser and sprayer assembly shown in FIG. 26, wherein the atomizer forms a partially porous heating surface, according to a further exemplary embodiment of the present invention;

[0086] FIG. 28C shows an enlarged perspective cross-sectional view of a sprayer for the combined dispenser and sprayer assembly shown in FIG. 26, wherein the atomizer forms a completely porous heating surface, according to a further exemplary embodiment of the present invention;

[0087] FIG. 29 shows a perspective cross-sectional view of an aerosol delivery device with a combined dispenser and nebulizer assembly located in a control housing, according to a further exemplary embodiment of the present invention;

[0088] FIG. 30 is a perspective cross-sectional view of an aerosol delivery device including a control body, a dispenser and atomizer cartridge, and a reservoir cartridge, according to a further exemplary embodiment of the present invention; And

[0089] FIG. 31 shows a flow chart of a method for generating an aerosol by an aerosol delivery device according to a further exemplary embodiment of the present invention.

IMPLEMENTATION OF THE INVENTION

[0090] The present invention will now be described in detail with reference to illustrative embodiments thereof. These exemplary embodiments have been described in such a manner that the present invention will be presented in a comprehensive and complete manner with its scope fully disclosed to those skilled in the art. It should be noted that the present invention can be implemented in various forms and should not be construed as limited to the embodiments described in this application; rather, these embodiments are presented in such a way that the present invention satisfies the relevant legal requirements. As used in the description and in the appended claims, the English singular forms "a", "an", "the" include the plural unless the context clearly states otherwise.

[0091] As described below, embodiments of the present invention relate to aerosol delivery systems, delivery devices and components. The aerosol delivery systems of the present invention use electrical energy to heat the material (preferably without igniting the material to any significant extent) to form an inhalable substance; and the components of such systems are in the form of articles that are most preferably compact enough to be considered portable devices. Thus, the use of the components of the preferred aerosol delivery systems does not result in the generation of smoke in the sense that the aerosol is not the result primarily of by-products of combustion or pyrolysis of tobacco, but rather the use of the preferred systems results in the generation of vapors resulting from the volatilization or evaporation of certain built-in them components. In preferred embodiments, the components of aerosol delivery systems may be characterized as electronic cigarettes, and the electronic cigarettes most preferably include tobacco and/or tobacco-derived components and therefore deliver tobacco-derived components in aerosol form.

[0092] The aerosol generating portions of some preferred aerosol delivery systems may produce various sensations (e.g., inhalation and exhalation rituals, types of tastes or aromas, sensory effects, physical sensation, usage rituals, visual stimuli such as those created by a visible aerosol, etc. .) smoking a cigarette, cigar or pipe that is caused by glowing and burning tobacco (and therefore inhalation of tobacco smoke), without actually burning to any significant extent any component of that product. For example, a user of a smoking article according to the present invention may hold the article, which is very similar to a traditional type of smoking article, draw air from one end of the article to inhale the aerosol generated by the article, and take puffs at selected time intervals, and the like.

[0093] The aerosol delivery systems of the present invention can also be characterized as suitable vapor-generating articles or drug delivery articles. Thus, such articles or devices may be adapted to provide one or more substances (eg, flavoring agents and/or pharmaceutical active ingredients) in an inhalable form or state. For example, inhalable substances may be substantially in vapor form (ie, a substance that is in the gas phase at a temperature that is lower than its critical point). In another embodiment, the inhalable substances may be in the form of an aerosol (ie, a suspension of tiny solid particles or liquid droplets in a gas).

[0094] The aerosol delivery systems of the present invention in the most preferred embodiment comprise some combination of a power source (i.e., an electrical power source), at least one control component (e.g., means for activating power, controlling power, regulating, and stopping power for heat generation, such as by controlling electrical current flowing from a power source to other components of the aerosol generating device), a heater or heat generating component (for example, an electrical resistive heating element and related components, commonly referred to as a "nebulizer"), and an aerosol precursor ( for example, a composition which is typically a liquid capable of forming an aerosol when sufficient heat is applied to it, such as the ingredients commonly referred to as "smoking juice", "e-liquid" and "e-juice"), and a mouthpiece end region or a tip for holding a smoking article for inhaling an aerosol (eg, a predetermined path for air flow through the article such that the generated aerosol can be drawn out of the article when drawn by the user).

[0095] More specific dimensions, configurations and designs of components located in the aerosol delivery systems of the present invention will become apparent in light of the detailed description of the present invention provided below in this application. In addition, the selection and arrangement of the various components of the aerosol delivery system can be evaluated after consideration of commercially available electronic aerosol delivery devices, such as the exemplary products referenced in the BACKGROUND section of the present invention.

[0096] The alignment of components in the aerosol delivery device may vary. In specific embodiments, the aerosol precursor composition may be located near the end of the product (eg, in a cartridge that, in some circumstances, may be removable and disposable), which may be proximal to the user's mouth to maximize delivery of the aerosol to the user. However, other configurations are not excluded. In general, the components may be positioned relative to each other such that the heat emitted by the heating element can vaporize the aerosol precursor composition (as well as one or more flavorants, drugs, or the like that may be delivered to the user in a similar manner) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, released or generated in a physical form suitable for inhalation by the consumer. It should be noted that the above terms should be considered interchangeable, so that forms of the above term such as "release, release, releases or released" include forms such as "form or form, formation or education, forms or forms and formed or formed ". In particular, the respirable substance is released in the form of vapor or aerosol or a mixture thereof.

[0097] The aerosol delivery device includes a battery or other electrical power source to provide sufficient electrical current to operate various functions of the product, such as resistive heating, powering control systems, powering indicators, and the like. The energy source can be implemented according to various embodiments. Preferably, the energy source provides sufficient electrical power to rapidly heat the heating element sufficient to generate an aerosol and provide energy to the article for use for the required period of time. The energy source is preferably sized to fit comfortably within the aerosol delivery device such that the aerosol delivery device can be operated without effort; and further, the preferred energy source is light enough not to detract from the desired enjoyable experience of the smoking session.

[0098] The aerosol delivery device may include a cartridge and a control housing that may be permanently or releasably aligned with each other. Various engagement options may be used between the cartridge and the control body, such as threaded engagement, press fit, interference fit, magnetic engagement, or the like. The aerosol delivery device may have a substantially rod-shaped or substantially tubular shape, or a substantially cylindrical shape in some embodiments when the cartridge and control housing are in an assembled configuration.

[0099] In certain embodiments, one or both of the cartridge and the control body may be disposable or reusable. For example, the control housing may have a replaceable battery or accumulator and thus may be combined with any type of charging method, including connection to a typical electrical outlet, connection to a car charger (i.e., cigarette lighter receptacle), and connection to a computer. for example via a USB cable. Additionally, in some embodiments, the cartridge may comprise a disposable cartridge, as described in US Patent Publication No. 2014/0060555 (Chang et al.), which is incorporated herein by reference in its entirety.

[0100] In some embodiments, the cartridge may include a base that may include anti-rotation features that substantially prevent relative rotation between the cartridge and the control housing, as described in US Patent Publication No. 2014/0261495 (Novak et al.), which is in the form references are included in this application in their entirety.

[0101] The aerosol delivery device may include a component configured to hold the aerosol precursor composition. The aerosol precursor composition, also referred to as a vapor precursor composition, may contain various components including, for example, polyhydric alcohol (eg, glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, and/or flavorings. Various components that may be included in the aerosol precursor composition are described in US Patent No. 7,726,320 (Robinson et al.), which is incorporated herein by reference in its entirety. Additional exemplary aerosol precursor compositions are listed in US Pat. No. 4,793,365 (Sensabaugh, Jr. et al.); in US patent No. 5,101,839 (Jakob et al.); US Patent Publication No. 2013/0008457 (Zheng et al.); PCT WO 98/57556 (Biggs et al.); as well as in the monograph “ Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco ”, tobacco company RJ Reynolds (1988), the contents of which are in full by reference included in this application.

[0102] Various heater components may be used in the present aerosol delivery device. In various embodiments, one or more microheaters or similar solid-state heaters may be used. Embodiments of microheaters that may be used are further described herein. Additional microheaters and atomizers containing built-in microheaters suitable for use in the devices described herein are described in US Patent Publication No. 2014/0060554 (Collett et al.), which is incorporated by reference in its entirety herein. In some embodiments, the heating element may be formed by winding a wire around a liquid transport element, as described in US Patent Publication No. 2014/0157583 (Ward et al.), which is incorporated by reference in its entirety herein. Additionally, in some embodiments, the wire may have a variable turn spacing, as described in US Patent Publication No. 2014/0270730 (DePiano et al.), which is incorporated herein by reference in its entirety. To form a resistive heating element, various embodiments of materials designed to generate heat when an electric current passes through them can be used. Typical materials from which wire winding can be formed include kanthal (FeCrAl), nichrome, molybdenum disilicide ( _MoSi2 ), molybdenum silicide (MoSi), aluminum alloyed molybdenum disilicide (Mo(Si,Al) ₂ ), graphite and materials graphite based; and ceramics (eg, positive or negative temperature coefficient ceramics). In yet other embodiments, the atomizer may utilize a stamped heating element, as described in US Patent Publication No. 2014/0270729 (DePiano et al.), which is incorporated herein by reference in its entirety. In addition to the foregoing, additional exemplary heating elements and materials for use in these elements are described in US Pat. Nos. 5,060,671 (Counts et al.); 5,093,894 (Deevi et al.); 5,224,498 (Deevi et al.); 5,228,460 (Sprinkel Jr. et al.); 5,322,075 (Deevi et al.); 5,353,813 (Deevi et al.); 5,468,936 (Deevi et al.); 5,498,850 (Das); 5,659,656 (Das); 5,498,855 (Deevi et al.); 5,530,225 (Hajaligol); 5,665,262 (Hajaligol); 5,573,692 (Das et al.); and 5,591,368 (Fleischhauer et al.), the present inventions of which are incorporated by reference in their entirety herein. Additionally, in yet other embodiments, chemical heating may be used. Various additional examples of heaters and materials used to form the heaters are described in US Patent Publication No. 2014/0060554 (Collett et al.), which is incorporated by reference in its entirety herein as stated above.

[0103] In some embodiments, the aerosol delivery devices of the present invention may include a control housing and a cartridge. When the control housing is coupled to the cartridge, an electronic control component in the cartridge may form an electrical connection to the control housing. The control housing may thus use the electronic control component to determine whether the cartridge is genuine and/or perform other functions. In addition, various examples of electronic control components and the functions performed by these components are described in US Patent Publication No. 2014/0096781 (Sears et al.), which is incorporated by reference in its entirety herein.

[0104] During use, the user may draw air from the mouthpiece of the aerosol delivery device cartridge. This may draw air through an opening in the control housing or in the cartridge. For example, in one embodiment, an opening may be formed between the connector and the outer housing of the control housing, as described in US Patent Publication No. 2014/0261408 (DePiano et al.), which is incorporated by reference in its entirety herein. However, in yet other embodiments, air flow may be received through other portions of the aerosol delivery device.

[0105] A sensor in the aerosol delivery device (eg, a puff or flow sensor in the control housing) may sense the puff. When a puff is detected, the control housing can supply electric current to the heater via an electronic circuit. Accordingly, the heater may vaporize the aerosol precursor composition, and the mouthpiece may allow air and entrained vapor (ie, components of the aerosol precursor composition in respirable form) to pass from the cartridge to a consumer drawing air from the cartridge.

[00106] Various other details regarding components that may be contained in the cartridge are provided, for example, in US Patent Publication No. 2014/0261495 (Novak et al.), which is incorporated by reference in its entirety herein. In this regard, FIG. 7 of this publication shows an enlarged exploded view of the base and contact of the control component; in FIG. 8 of the said publication shows an enlarged perspective view of the base and contact of the control component in the assembled configuration; in FIG. Figure 9 of said publication shows an enlarged perspective view of the base, control component contact, electronic control component and atomizer heater contacts in an assembled configuration; in FIG. Figure 10 of said publication shows an enlarged perspective view of the base, atomizer and control component in an assembled configuration; in FIG. 11 of the said publication shows a perspective view from the opposite side of the assembly shown in FIG. 10 of the said publication; in FIG. 12 of the said publication shows an enlarged perspective view of the base, atomizer, air flow tube and reservoir substrate in an assembled configuration; in FIG. 13 of this publication shows a perspective view of the base and outer casing in an assembled configuration; in FIG. 14 of this publication shows a perspective view of the cartridge in its assembled configuration; in FIG. 15 of said publication shows a first partial perspective view of the cartridge shown in FIG. 14 of the specified publication, and a connector for the control housing; in FIG. 16 of the said publication shows a second partial perspective view from the opposite side of the cartridge shown in FIG. 14 of the said publication, and the connector shown in FIG. 11 of the said publication; in FIG. 17 of this publication shows a perspective view of a cartridge containing a base with an anti-rotation mechanism; in FIG. 18 of this publication shows a perspective view of the control housing containing a connector with an anti-rotation mechanism; in FIG. 19 of that publication shows the alignment of the cartridge shown in FIG. 17, with the control housing shown in FIG. 18; in FIG. 20 of this publication shows an aerosol delivery device containing the cartridge shown in FIG. 17 of the said publication, and the control housing shown in FIG. 18 of the said publication, with a modified view of the aerosol delivery device showing the interaction of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body; in FIG. 21 of the above publication shows a perspective view of the base with an anti-rotation mechanism; in FIG. 22 of this publication shows a perspective view of a connector with an anti-rotation mechanism; and in FIG. 23 of said publication shows a sectional view of the base shown in FIG. 21 of said publication, and the connector shown in FIG. 22 of the said publication, in an interoperable configuration.

[00107] The various components of the aerosol delivery device of the present invention may be selected from the known and commercially available components described. For example, reference is made to a reservoir and heater system for controlled delivery of various atomized materials in an electronic smoking article described in US Patent Publication No. 2014/0000638 (Sebastian et al.), which is incorporated by reference in its entirety herein.

[00108] In the present description of FIG. 1 shows an exploded view of a control housing 300 of an aerosol delivery device according to an exemplary embodiment. As shown in the drawing, the control housing 300 may include a connector 302, an outer housing 304, a sealing element 306, an adhesive element 308 (for example, KAPTON® tape), a flow sensor 310 (for example, a tightening sensor or a pressure sensor), a control component 312, a spacer 314, a power source 316 (eg, a battery, which may be rechargeable), a circuit board with an indicator 318 (eg, a light-emitting diode (LED)), a connecting circuit 320, and an end cap 322. Examples of power sources are described in US Patent Publication No. 2010/ 0028766 (Peckerar et al.), the present invention of which is incorporated by reference in its entirety herein. A typical mechanism that can provide puff activation includes a Model 163PC01D36 silicon sensor manufactured by the Microswitch Division of Honeywell, Inc., Freeport, Illinois. Additional examples of on-demand electrical switches that can be used in the heating circuit of the present invention are described in US Pat. No. 4,735,217 (Gerth et al.), which is incorporated by reference in its entirety herein. Additional description of electrical current control circuits and other control components containing microcontrollers that may be suitable for use in the present aerosol delivery device is presented in US Pat. Nos. 4,922,901; 4,947,874; and 4,947,875 (Brooks et al.); US Patent No. 5,372,148 (McCafferty et al.), US Patent No. 6,040,560 (Fleischhauer et al.), and US Patent No. 7,040,314 (Nguyen et al.), all of which are incorporated by reference in their entirety herein. Reference is also made to the control circuits described in US Patent Publication No. 2014/0270727 (Ampolini et al.), which is incorporated by reference in its entirety herein.

[00109] In one embodiment, indicator 318 may include one or more light-emitting diodes. Indicator 318 may be in communication with control component 312 via connecting circuit 320 and may illuminate, for example, when a user draws air from a cartridge connected to connector 302 that is detected by flow sensor 310. The end cap 322 may be configured to make visible the glow of the indicator 318. Accordingly, the indicator 318 may illuminate during use of the aerosol delivery device to simulate a glowing tip of a smoking article. However, in still other embodiments, the indicator 318 may be provided in various quantities and may have various shapes, and may even be an opening in the outer housing (such as to release sound when such indicators are present).

[00110] Other additional components may be used in the aerosol delivery devices of the present invention. For example, US Patent No. 5,154,192 (Sprinkel et al.) describes indicators for smoking articles; US Patent No. 5,261,424 (Sprinkel, Jr.) describes piezoelectric sensors that can be coupled to the oral end of the device to detect puff-related lip activity of a user, followed by heat activation; US Pat. No. 5,372,148 (McCafferty et al.) discloses a puff sensor for controlling the supply of energy to a heating load matrix in response to a drop in mouthpiece pressure; US Pat. No. 5,967,148 (Harris et al.) describes receptacles in a smoking device that include an identifier that detects infrared transmission unevenness of an inserted component and a controller that executes a detection routine when said component is inserted into the receptacle; US Pat. No. 6,040,560 (Fleischhauer et al.) describes a predetermined executable power supply cycle having multiple distinct phases; US Pat. No. 5,934,289 (Watkins et al.) describes photonic-optocoupler components; US Patent No. 5,954,979 (Counts et al.) describes a means for varying the resistance of draw through a smoking device; US Patent No. 6,803,545 (Blake et al.) describes specific battery configurations for use in smoking devices; US Pat. No. 7,293,565 (Griffen et al.) describes various charging systems for use with smoking devices; U.S. Patent No. 8,402,976 (Fernando et al.) describes a computer interface for smoking devices that facilitates charging and allows computer control of the device; US Pat. No. 8,689,804 (Fernando et al.) describes identification systems for smoking devices; and WO 2010/003480 (Flick) describes a sensor system indicating puffiness in an aerosol generation system; all of the above inventions are fully incorporated by reference into this application. Additional examples of components related to aerosol delivery electronic products and disclosed materials or components that may be used in an article of the present invention are contained in US Pat. No. 4,735,217 (Gerth et al.); US patent No. 5,249,586 (Morgan et al.); US patent No. 5,666,977 (Higgins et al.); US Pat. No. 6,053, 176 (Adams et al.); US Patent No. 6,164,287 (White); US Patent No. 6,196,218 (Voges); US Patent No. 6,810,883 (Felter et al.); US Patent No. 6,854,461 (Nichols); US Patent No. 7,832,410 (Hon); US Patent No. 7,513,253 (Kobayashi); US Patent No. 7,896,006 (Hamano); US Patent No. 6,772,756 (Shayan); US Patent Nos. 8,156,944 and 8,375,957 (Hon); US patents No. 8,794,231 (Thorens et al.) and No. 8,851,083 Oglesby et al.); US Patent Publications Nos. 2006/0196518 and 2009/0188490 (Hon); US patent publications No. 2009/0260641 and 2009/0260642 (Monsees et al.); US Patent Publication No. 2010/0024834 (Oglesby et al.); US Patent Publication No. 2010/0307518 (Wang); US Patent Publication No. 2014/0261408 (DePiano et al.); WO 2010/091593 (Hon); WO 2013/089551 (Foo), which are incorporated by reference in their entirety herein. Various materials described in accordance with the foregoing documents may be included in the present devices according to various embodiments, and all prior inventions are incorporated by reference in their entirety herein.

[00111] Accordingly, exemplary embodiments of aerosol delivery devices are described above. However, the present invention provides various other embodiments of aerosol delivery devices. As described below, such aerosol delivery devices may contain various configurations of components for storing, delivering and/or vaporizing the aerosol precursor composition. Some of the components of the aerosol delivery devices may in fact be similar to the components described above, and therefore, details regarding these components and their functions will not be described again or will be described only briefly. However, it should be understood that the description of the components listed above is equally applicable to the embodiments of aerosol delivery devices described hereinafter, unless otherwise indicated.

[00112] In this regard, FIG. 2 shows an exploded view of an aerosol delivery device 1200 according to a further exemplary embodiment of the present invention. As shown in the drawing, the aerosol delivery device 1200 may include a control housing 1202 and a cartridge 1204. The control housing 1202 may include an end cap 1206, a circuit board with an indicator 1208 (e.g., a light-emitting diode (LED)), a connecting circuit 1209, a power source 1210 (eg, a battery that may be rechargeable), a flow sensor 1212, a connector 1214, and an outer housing 1216 (which may include one or more inlets 1233). The cartridge 1204 may include a base 1218, a combined dispenser and atomizer assembly 1220, a reservoir 1222, a cap 1224, a mouthpiece 1226, and an outer housing 1228.

[00113] FIG. 3 shows a modified perspective cross-sectional view of the aerosol delivery device 1200 shown in FIG. 2. As shown in the drawing, the base 1218 of the cartridge 1204 may be configured to interact with the connector 1214 of the control housing 1202 to form a mechanical and electrical connection between them. The connection between the base 1218 of the cartridge 1204 and the connector 1214 of the control body 1202 may be releasable so that, for example, the cartridge may be replaced when the aerosol precursor composition 1246 (shown in FIG. 6) received therein is consumed. Even though FIG. 2 shows connection wires 1230 connected to base 1218, which connection wires may in fact be connected to connector 1214 to provide a releasable connection between cartridge 1204 and control housing 1202 according to some embodiments.

[00114] FIG. 3 further shows the path of air flow in the aerosol delivery device 1200 when the user draws air from the mouthpiece 1226. As shown in the drawing, the air flow or ambient air flow 1232 may enter the aerosol delivery device 1200 through one or more inlet openings 1233 and move near or past flow sensor 1212. Then, air 1232 may move through at least one opening 1261 in connector 1214 and at least one opening 1263 in base 1218, around the combined dispenser and nebulizer assembly 1220 and reservoir 1222 (e.g., through one or more aerosol delivery openings 1265, formed in the outer housing 1228, or in the space between the reservoir and the outer housing) and exit the mouthpiece 1226.

[00115] Inlet openings 1233 may be provided in the outer housing 1216 of the control housing 1202 such that a flow sensor 1212, which may also be located in the control housing, can detect the flow of air 1232. The control housing 1202 may be reusable, while cartridge 1204 may be disposable. In this regard, since some components in the cartridge 1204 may degrade or become exhausted, the flow sensor 1212 and other components in the control housing may maintain full functionality despite their reuse. Accordingly, positioning the flow sensor 1212 in the control housing 1202 and providing an appropriate flow path for air 1232 through the control housing or otherwise providing fluid communication of air moving through the aerosol delivery device 1200 with the flow sensor may reduce the cost of the cartridge 1204 by reducing the number and the type of components placed in it. In this regard, although in this embodiment and other embodiments described herein the air flow is generally described as flowing through the control housing, in still further embodiments a pressure signal may be used to enable detection by a flow sensor in the control housing, the flow of air flowing through the cartridge, in fact, in the absence of any air flow through the control housing, as described, for example, in US patent application No. 14/193,961, filed February 28, 2014, (Worm et al.), which by reference is included in its entirety in this application.

[00116] The cap 1224 and the combined dispenser and nebulizer assembly 1220 may be coupled to opposite ends of the reservoir 1222. Accordingly, the cap 1224 and the combined dispenser and nebulizer assembly 1220 may enclose the reservoir 1222 and hold the aerosol precursor composition 1246 therein (as shown in FIG. 6). However, if the flow sensor 1212 detects a puff, the combined dispenser and atomizer assembly 1220 may be activated such that the aerosol precursor composition 1246 (as shown in FIG. 6) is dispensed from the reservoir 1222 in a controlled manner.

[00117] In this regard, FIG. 4 shows a partial perspective cross-sectional view of a combined dispenser and sprayer assembly. As shown in the drawing, in one embodiment, the combined dispenser and sprayer assembly 1220 may include a bubble-jet head 1234 and a sprayer 1238 firmly coupled to said head. As described in detail below, bubble jet head 1234 may be configured to dispense aerosol precursor composition 1246 from reservoir 1222 (as shown, for example, in FIG. 6). In addition, the nebulizer 1238 may be configured to heat the aerosol precursor composition 1246 to generate an aerosol or vapor 1248 (as shown in FIG. 6).

[00118] Bubble jet head 1234 may include one or more aerosol precursor composition inlets 1245, one or more aerosol precursor composition channels 1235, one or more first or ejection heating elements 1240, one or more aerosol precursor composition nozzles 1242 and a plate, substrate or casing 1241 associated therewith in a suitable manner. In some embodiments, housing 1241 may comprise silicon, ceramic, graphite, or other low thermal conductivity and/or insulating materials. Aerosol precursor composition inlets 1245, aerosol precursor composition channels 1235, and/or aerosol precursor composition nozzles 1242, in some embodiments, may be formed by openings in the housing 1241. In yet another embodiment, aerosol precursor composition inlets, composition channels the aerosol precursor and/or the outlets for the aerosol precursor composition may comprise separate elements associated with the housing. In addition, the ejection heating elements 1240 may be located in one or more first or ejection chambers 1237, which may be defined by the housing 1241 of the bubble jet head 1234. In some embodiments, the bubble jet head 1234 may include a standard inkjet printer head ( for example, a standard bubble jet printhead commercially available from ImTech, Corvallis, Oregon, or a font 45 inkjet printhead commercially available from Hewlett Packard, Palo Alto, California).

[00119] Nebulizer 1238 may be positioned relative to bubble jet head 1234 to receive aerosol precursor composition 1246 dispensed from reservoir 1222 (as shown in FIG. 6). In some embodiments, the atomizer 1238 may be firmly coupled to the bubble-jet head 1234 such that the combined dispenser and atomizer assembly 1220 may be inserted into the outer housing 1228 of the cartridge 1204 (as shown, for example, in FIG. 3) as a unit, instead of being inserted separately into the outer housing. For example, a combined dispenser and spray assembly 1220 may interface with a reservoir 1222, and the combination assembly may be inserted into an outer housing 1228 (as shown, for example, in FIG. 3). In addition, the fixed connection of the bubble-jet head 1234 to the atomizer 1238 can ensure that the two components are precisely positioned relative to each other such that the dispensed aerosol precursor composition 1246 (as shown in FIG. 6) is received at the proper location in the atomizer for atomization.

[00120] As shown in FIG. 4, in one embodiment, the bubble jet head 1234 may be firmly coupled to the atomizer 1238 via one or more spacers 1236. Specifically, the atomizer 1238 may include a plate, substrate, or housing 1243 that is coupled to the housing 1241 of the bubble jet head 1234 by spacers 1236. In some embodiments, housing 1243 may comprise silicon, ceramic, graphite, or other non-conductive and/or insulating materials. Spacers 1236 may be configured to provide clearance between bubble jet head 1234 and atomizer 1238. In some embodiments, the clearance may be from about 1 mm to about 10 mm, and preferably from about 1 mm to about 3 mm, to reduce spattering of the aerosol precursor composition. . However, in still other embodiments, gaps of different sizes may be used. In this regard, the gap between the bubble-jet head 1234 and the atomizer 1238 can be selected or adjusted to ensure accurate delivery of the aerosol precursor composition to the heating surface of the atomizer based on the droplet scattering pattern associated with the emission of the aerosol precursor composition from the bubble-jet head (eg, to prevent the aerosol precursor composition from accumulating on one or more portions of the atomizer, to create a thin, uniform film of the aerosol precursor composition on the heating surface of the atomizer, and/or to target a specific area of the atomizer). The atomizer 1238 may further include one or more second or steam heating elements 1244. For example, a corresponding one of the steam heating elements 1244 may be associated with each ejection heating element 1240 and each nozzle 1242.

[00121] Bubble jet head 1234 may be coupled to reservoir 1222 or otherwise positioned in fluid communication with said reservoir. For example, as shown in FIG. 5, in some embodiments, a bubble jet head 1234 may be coupled to a distal end 1222A of the reservoir 1222 to block an opening 1222' in the reservoir and retain the aerosol precursor composition 1246 therein (as shown, for example, in FIG. 6), as described above. . Thus, the aerosol precursor composition inlets 1245 in the bubble-jet head 1234 may be in fluid communication with the reservoir 1222 and thus the aerosol precursor composition channels 1235 may direct the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) to the ejection chambers 1237, in which the ejection heating elements 1240 are located.

[00122] Attaching the bubble jet head 1234 to the distal end 1222A of the reservoir 1222 may be advantageous in that it provides a relatively simple mechanism for attachment and fluid communication. In this regard, the reservoir 1222 may define a cavity having a substantially cylindrical shape, and the distal end 1222A may define a substantially flat shape. Thus, the bubble jet head 1234 may be connected (eg, glued, attached, or welded) to the distal end 1222A of the reservoir 1222 to complete the reservoir and provide fluid communication between the reservoir and the bubble jet head.

[00123] Accordingly, bubble jet head 1234 may receive aerosol precursor composition 1246 (as shown, for example, in FIG. 6) from reservoir 1222. In some embodiments, as shown in FIG. 5, reservoir 1222 may include a reservoir substrate 1239 configured to direct an aerosol precursor composition 1246 (as shown, for example, in FIG. 6) to a bubble jet head 1234. In this regard, reservoir substrate 1239 may comprise any material configured with the ability to transfer by absorption or otherwise transport the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) to the bubble-jet head 1234, a material such as cellulose acetate, polyethylene terephthalate (PET) or any polymeric material, woven or non-woven, and/ either fibrous or non-fibrous. Additionally, in yet other embodiments, the reservoir substrate 1239 may comprise one or more non-polymeric materials, which may be in the form of an open-cell foam or the like (e.g., ceramic foam, carbon foam, sintered glass) such that the material (materials) forms porous media that create channels for absorption. Accordingly, by using reservoir substrate 1239, aerosol precursor composition 1246 (as shown, for example, in FIG. 6) can be directed to bubble-jet head 1234 regardless of the orientation of aerosol delivery device 1200 (as shown, for example, in FIG. 2). such that said aerosol delivery device does not necessarily have to be in a particular orientation during use. In some embodiments, the reservoir substrate may occupy only a portion of the longitudinal length of the reservoir. For example, the reservoir substrate may be located just adjacent to the distal end of the reservoir to which the bubble jet head is attached. Such a configuration can provide substantially the same benefits as those listed above in that movement of the aerosol delivery device can cause the aerosol precursor composition to contact the reservoir substrate while at the same time allowing the volume of the portion of the reservoir occupied by the reservoir substrate to be reduced to provide increased capacity fluid into it.

[00124] Initially, movement of the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) through the remainder of the combined dispenser and nebulizer assembly 1220 may be blocked by the aerosol precursor composition nozzles 1242. In this regard, the aerosol precursor composition nozzles 1242 may be suitably sized to block flow therethrough, for example, due to surface tension. In addition to this or another embodiment, negative pressure in the reservoir (e.g., created by a spring and piston in the reservoir or as a result of applying negative pressure to the reservoir before sealing it) may prevent the aerosol precursor composition from passively leaking from the reservoir through the bubble-jet head .

[00125] However, when flow sensor 1212 detects a puff, bubble jet head 1234 may direct aerosol precursor composition 1246 (as shown, for example, in FIG. 6) in reservoir 1222 to atomizer 1238. Specifically, electrical current from power source 1210 (as shown, for example, in FIG. 2) may be directed to ejection heating elements 1240 to heat the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) received through the aerosol precursor composition inlets 1245 and the aerosol precursor composition channels 1235. aerosol precursor composition such that vapor bubbles are formed that eject droplets of the aerosol precursor composition through nozzles 1242 to nebulizer 1238, as described below and shown in more detail with reference to alternative embodiments of the present invention.

[00126] Electrical current from power supply 1210 (as shown, for example, in FIG. 2) may be applied to steam heating elements 1244 before applying electric current to ejection heating elements 1240, simultaneously with said application, or after applying electric current to ejection heating elements. elements 1240. However, delaying the application of electric current to the vapor-generating heating elements 1244 until a point in time after the ejection heating elements 1240 receive the electric current can help prevent wasted energy. In this regard, a portion of the heat generated by the vaporizing heating elements 1244 before the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) comes into contact with said vaporizing heating elements 1244 may be undesirably dissipated among surrounding portions of the device 1200 for delivery of an aerosol or in the air in said aerosol delivery device, instead of properly applying an aerosol precursor to the composition.

[00127] In one embodiment, a plurality of walls formed by the housing 1241 of the bubble jet head 1234, the spacers 1236, and/or the housing 1243 of the atomizer 1238 may collectively form a second chamber or flash chamber 1247 (as shown, for example, in FIG. 4), in which vapor-generating heating elements 1244 are located and into which aerosol precursor composition 1246 is delivered (as shown, for example, in FIG. 6). In this way, problems associated with the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) being directed into the air 1232 and delivered to the user without evaporation can be eliminated. In this regard, the aerosol precursor composition 1246 may be contacted with vapor-generating heating elements 1244 in the flash chamber 1247 to cause it to vaporize before being directed into the air stream 1232 flowing through the aerosol delivery device 1200. As shown in FIG. 6, the air flow 1232 may flow generally around the combined dispenser and atomizer assembly 1220, instead of flowing between the bubble-jet head 1234 and the atomizer 1238, such that the air flow does not direct the aerosol precursor composition away from the atomizer prior to atomization. It should be noted that if the aerosol precursor composition is directed into the air without evaporation, the aerosol precursor composition may separate from the air and accumulate in the aerosol delivery device in areas outside the reservoir. This may result in unwanted leakage of fluid from the aerosol delivery device. In addition, or according to another embodiment, the liquid aerosol precursor composition may reach the user's mouth and cause an undesirable taste or sensation.

[00128] Thus, minute droplets of aerosol precursor composition 1246 ejected from nozzles 1242 can be vaporized by vapor-generating heating elements 1244 of atomizer 1238 to produce an aerosol or vapor 1248 (as shown, for example, in FIG. 6). As shown in FIG. 6, steam 1248 generated by vapor-generating heating elements 1244 can be released from the combined dispenser and atomizer assembly 1220 and mixed and transferred with air 1232 to the mouthpiece 1226. Accordingly, the bubble-jet head 1234 can be used to accurately dispense and deliver the aerosol precursor composition 1246 (as shown, for example, in FIG. 6) to the nebulizer 1238, which may provide advantages in ensuring that with each draw of air from the aerosol delivery device 1200, a precisely matched amount of aerosol is delivered, compared to delivery device embodiments. aerosols that rely on passive delivery mechanisms for the aerosol precursor composition, such as wicks.

[00129] The electrical power supplied to the bubble jet head 1234 and the atomizer 1238 from the power source 1210 can be controlled in one or more ways. For example, the energy supplied to the bubble jet head 1234 can be controlled independently of the atomizer 1238 in one or more ways. In addition, pulse width modulation and/or pulse amplitude modulation can be used to provide an appropriate amount of electrical current in the bubble jet head 1234 and atomizer 1238. Relatively long pulse duration and/or amplitude can be used to generate a relatively large amount of heat. . In this regard, ejection heating elements 1240 may have a relatively low thermal mass and may be configured to heat the aerosol precursor composition 1246 to a relatively lower degree than the vaporizing heating elements 1244 to emit and dispense the aerosol precursor composition, rather than completely vaporize the aerosol precursor composition. which occurs in the nebulizer 1238. In this regard, while emission of the aerosol precursor composition may involve evaporation, only a small portion of the aerosol precursor composition is evaporated, and the evaporation occurs substantially in the closed ejection chamber 1237 such that one or more microdroplets of the composition the aerosol precursor is ejected from it. In comparison, vapor-generating heating elements may be configured to completely vaporize an aerosol precursor composition delivered to them. Thus, to heat the ejection heating elements 1240 to a relatively lesser degree than the degree of heating of the steam generating heating elements 1244, energy pulses of relatively shorter duration and/or amplitude than the duration and/or amplitude of the energy pulses may be directed to the ejection heating elements. directed towards the steam-generating heating elements. In addition, the supply of energy to the vaporizing heating elements 1244 may be delayed relative to the supply of energy to the ejection heating elements 1240 such that energy is not wasted in the vaporizing heating elements before emitting the aerosol precursor composition.

[00130] As stated above, in one embodiment, the bubble jet head may comprise a virtually known bubble jet head, such as an ink jet head used in a printer. However, said jet head may be modified for use in aerosol delivery devices according to the present invention. For example, a different number of aerosol precursor composition nozzles and aerosol precursor composition inlets leading to the nozzles may be selected, the diameter and/or shape of the aerosol precursor composition inlets may be adjusted, and/or the aerosol precursor composition nozzles may be adjusted. , the size of the ejection heating elements in the bubble jet head can also be adjusted, the heat generated by the ejection heating elements can be adjusted, the pulse duration of the energy supplied to the ejection heating elements in the bubble jet head can be adjusted, and/or various other characteristics. These changes may include differences in the viscosity of the aerosol precursor composition compared to the ink, as well as differences in the targeting of the spray of the aerosol precursor composition in the atomizer to evaporate the aerosol precursor composition, as opposed to targeting the jet of ink sprayed onto a substrate such as paper.

[00131] The present invention provides various additional embodiments of aerosol delivery devices comprising bubble jet heads configured to dispense and deliver an aerosol precursor composition to a nebulizer. For the sake of brevity, the description of certain features and components of the aerosol delivery devices described above will not be repeated in detail below. However, it should be understood that the above description corresponds to the embodiments of the aerosol delivery devices described below, except in detail where otherwise indicated.

[00132] FIG. 7 shows a perspective cross-sectional view of an aerosol delivery device 1300 according to a further exemplary embodiment of the present invention. As shown in the drawing, the aerosol delivery device 1300 may include a control housing 1302 and a cartridge 1304. The control housing 1302 may include an end cap 1306, a flow sensor 1308, an electrical power source 1310 (e.g., a battery, which may be rechargeable), a connector 1312 forming at least one connection hole 1361, and an outer housing 1314. The control housing may further include a circuit board with an indicator (eg, a light-emitting diode (LED)) and a connecting circuit, as described elsewhere herein. The cartridge 1304 may include a base 1316 defining at least one opening 1363, a combined dispenser and atomizer assembly 1318, a reservoir 1320, a cap 1322 that encloses the reservoir, a mouthpiece 1324, and an outer housing 1326 defining one or more openings 1365 for delivering the aerosol. The base 1316 of the cartridge 1304 may be configured to interact with a connector 1312 of the control housing 1302 to form a mechanical and electrical connection therebetween, which may be removable to allow the cartridge to be replaced.

[00133] FIG. 8 is a perspective cross-sectional view of the aerosol delivery device 1300 showing the path of air flow in the aerosol delivery device when a user draws air from the mouthpiece 1324. As shown in the drawing, the air flow or ambient air flow 1328 may enter the aerosol delivery device 1300 through one or more inlet openings 1331 and move past or adjacent to the flow sensor 1308 and around the electrical power source 1310. Although ambient air 1328 is shown as flowing around the power source 1310, in still other embodiments the air may not flow past the power source and/or the flow sensor may be located in an alternative location. In addition, the inlet openings 1331 may be located in various alternative locations and provided in other components, such as the outer housing 1314 of the control housing 1302 between the power source 1310 and the connector 1312. Air 1328 may flow from the control housing 1302 through the opening 1361 in the connector 1312 and flow through the opening 1363 in the base 1316, around the combined dispenser and atomizer assembly 1318 and the reservoir 1320 (for example, through the aerosol delivery openings 1365 provided in the outer housing 1326, or between the reservoir and the outer housing), and exit through the mouthpiece 1324.

[00134] The combined dispenser and atomizer assembly 1318 may be activated when the flow sensor 1308 detects a puff. In this regard, as shown in the partial sectional view shown in FIG. 9, a combined dispenser and atomizer assembly 1318 may receive an aerosol precursor composition 1330 from a reservoir 1320 and produce an aerosol or vapor 1332. Specifically, as shown in the enlarged partial sectional view of FIG. 10, the combined dispenser and nebulizer assembly 1318 may include a plate, substrate, or housing 1333 defining at least one aerosol precursor composition inlet 1334 through which aerosol precursor composition 1330 is received. The aerosol precursor composition 1330 may then be moved through one or more channels. 1335 for the aerosol precursor composition to one or more nozzles 1336 for the aerosol precursor composition. In some embodiments, the aerosol precursor composition inlet 1334, the aerosol precursor composition channels 1335, and/or the aerosol precursor composition nozzle 1336 may be defined by the housing 1333. In another embodiment, the aerosol precursor composition inlets, the aerosol precursor composition channels, and /or outlets for the aerosol precursor composition may comprise separate components coupled to the housing. Initially, movement of the aerosol precursor composition 1330 through the remainder of the combined dispenser and nebulizer assembly 1318 may be blocked by the aerosol precursor composition nozzles 1336 leading into said assembly. In this regard, the aerosol precursor composition nozzles 1336 may be suitably sized to block flow therethrough, for example, due to surface tension. In addition, or according to another embodiment, the aerosol precursor composition may be subjected to negative pressure in the reservoir, as described above, to reduce the likelihood of fluid leakage through the combined dispenser and nebulizer assembly.

[00135] However, when flow sensor 1308 (as shown, for example, in FIG. 8) detects a puff in aerosol delivery device 1300, electrical current may be directed from power source 1310 (as shown, for example, in FIG. 8) to one or more first or ejection heating elements 1338 located in a first or ejection chamber 1339 defined by the housing 1333. Thus, the ejection heating elements 1338 can heat the aerosol precursor composition 1330 such that the aerosol precursor composition 1330 boils and vapor bubbles 1340 are formed. Each vapor bubble 1340 expands extremely rapidly, creating a pressure pulse that then causes a microdroplet 1342 of aerosol precursor composition 20 to be ejected through a respective of the aerosol precursor composition nozzles 1336. Upon application of energy to the ends of the ejection heating element 1338, the vapor bubble 1340 collapses as the composition of the aerosol precursor 1330 and the vapor bubble 1340 cools. The surface tension and surface energy generated in the aerosol precursor composition 1330 in the nozzle 1336 and the capillary force created by the interaction of the aerosol precursor composition with the microfluid channel formed by the inlet 1334, channels 1335 and nozzles can cause an increased amount of the aerosol precursor composition to move out of the reservoir. towards the ejection heating element 1338 such that the aerosol precursor composition refills the ejection chamber 1337 and thus the emission cycle can be repeated. Thus, the use of a separate valve may not be required to dispense and deliver the aerosol precursor composition 1330. Accordingly, the combined dispenser and nebulizer assembly 1318 may include a bubble-jet head 1350 containing ejection heating elements 1338, inlets 1334, channels 1335, and nozzles 1336.

[00136] As further shown in FIG. 10, droplets 1342 of the aerosol precursor composition 1330 may be ejected through nozzles 1336 to one or more second or vapor heating elements 1344. In this regard, each ejection heating element 1338, nozzle 1336, and vapor heating elements 1344 of a corresponding portion of the combined dispenser and atomizer assembly 1318 may be axially aligned such that the aerosol precursor composition 1330 is ejected onto the vapor-generating heating elements. Vapor-generating heating elements 1344 may be located in a second or vaporization chamber 1346 that is defined by housing 1333 and into which droplets 1342 of aerosol precursor composition 1330 are delivered. A respective of vapor-generating heating elements 1344 may be associated with each ejection heating element 1338 and each of nozzles 1336 for aerosol precursor compositions. Thus, droplets 1342 of aerosol precursor composition 1330 ejected from nozzles 1336 can be vaporized by vapor-generating heating elements 1344 to generate steam 1332 (as shown, for example, in FIG. 9).

[00137] In this regard, ejection heating elements 1338 may have a relatively low thermal mass and may be configured to heat the aerosol precursor composition 1330 to a relatively lesser extent compared to steam generating heating elements 1344. Then, steam 1332 (as shown, for example, in FIG. 9), formed by steam-generating heating elements 1344, may be released from the combined dispenser and atomizer assembly 1318 through one or more aerosol outlet openings 1348, which may be formed by a casing 1333 in the second chamber 1346. To force steam 1332 to exit through The aerosol outlets 1348, instead of moving backward through the nozzles 1336, the aerosol outlets may have an increased flow area compared to the flow area of the nozzles for the aerosol precursor composition. In addition, the use of aerosol outlets 1348 with a relatively larger flow area and/or the use of a second chamber 1346 with a relatively large volume can eliminate problems associated with the relatively rapid expansion of the aerosol precursor composition 1330 upon conversion to vapor 1332 (as shown, for example, in FIG. 9), which may cause damage to the dispenser and sprayer combination assembly 1318.

[00138] As shown in FIG. 11, steam 1332 may be mixed and moved with air 1328 to mouthpiece 1324 (as shown, for example, in FIG. 8). For example, steam 1332 and air 1328 may move through aerosol delivery openings 1365 in the outer housing 1326 of cartridge 1304. As described above, the aerosol precursor composition may be ejected into and vaporized into vaporization chambers 1346. In this way, problems regarding the aerosol precursor composition being directed into air 1328 (as shown, for example, in FIG. 8) without prior evaporation can be eliminated.

[00139] Accordingly, the combined dispenser and sprayer assembly 1318 shown in FIG. 7-11 may be a composite unit (e.g., in the form of a silicon chip) containing both a bubble jet head 1350 (e.g., containing ejection heating elements 1338, aerosol precursor composition inlets 1334, aerosol precursor composition channels 1335, and nozzles 1336 for an aerosol precursor composition) and a nebulizer 1352 (e.g., comprising aerosol outlets 1348 and vapor-generating heating elements 1344) firmly coupled to each other by means of a housing 1333 that is configured to be housed within an outer housing 1326 of the cartridge 1304 (as shown , for example, in FIG. 8). For comparison, the combined dispenser and sprayer assembly 1220 shown in FIG. 2-6 may include a standard bubble jet head 1234 (e.g., an inkjet printer bubble jet head) that can be firmly coupled to the atomizer 1238 (e.g., via spacers 1236) and modified for use as a dispenser and delivery dispenser aerosol precursor composition to the nebulizer.

[00140] FIG. 12 shows a perspective cross-sectional view of an aerosol delivery device 1400 according to a further exemplary embodiment of the present invention. As shown in the drawing, the aerosol delivery device 1400 may include a control housing 1402 and a cartridge 1404, which are shown in a disconnected configuration. The control housing 1402 may include an end cap 1406, a circuit board with an indicator 1408 (e.g., a light-emitting diode (LED)), a connecting circuit 1409, a power source 1410 (e.g., a battery, which may be rechargeable), a flow sensor 1411 (e.g., a puff sensor) or pressure sensor), connector 1412, connecting wires 1413, and an outer housing 1414. The cartridge 1404 may include a base 1416, a combined dispenser and atomizer assembly 1418, a reservoir 1420, a cap 1422 that encloses the reservoir, a mouthpiece 1424, and an outer housing 1426. The cartridge base 1416 1404 may be configured to interact with a connector 1412 of the control housing 1402 to form a mechanical and electrical connection therebetween, which may be removable to allow the cartridge to be replaced.

[00141] FIG. 13 shows an enlarged partial perspective cross-sectional view of an aerosol delivery device 1400 with the control housing 1402 and the cartridge 1404 connected to each other. As shown in the drawing, the combined dispenser and sprayer assembly 1418 may include a bubble jet head 1450 and a sprayer 1452. The bubble jet head 1450 and sprayer 1452 may include any of the components and features of the bubble jet heads and sprayers described elsewhere in this paragraph. application.

[00142] As further shown in FIG. 13, the bubble jet head 1450 and the atomizer may be coupled via a flex circuit 1453. Specifically, the flex circuit 1453 may be electrically coupled to the base 1416 such that the dispenser and atomizer assembly 1418 is electrically coupled to the cartridge 1402 via the base and connector 1412. Flexible circuit 1453 may further electrically couple bubble jet head 1450 to atomizer 1452 such that energy can be directed to the bubble jet head and atomizer in ways described elsewhere herein.

[00143] Additionally, in some embodiments, the flexible circuitry may mechanically attach the bubble jet head 1450 to the atomizer 1452 such that the bubble jet head and the atomizer are firmly coupled to each other. In this regard, flexible circuit 1453 may include a high temperature substrate of polyamide or other flexible non-conductive material with the circuit printed, etched, or otherwise formed thereon. Additionally, in some embodiments, a combined dispenser and atomizer assembly 1418 may be coupled to a reservoir 1420, and the assembly may then be inserted into the outer housing 1426 of the cartridge 1404. In this regard, the mechanical connection between the bubble-jet head 1450 and the atomizer 1452 is flexible circuit 1453 can provide insertion in the above manner. In addition, the flexible circuit 1453 may be flexible such that, for example, the combined dispenser and sprayer assembly 1418 may be press-bonded to the base 1416 to provide a desired gap or separation between the bubble-jet head 1450 and the sprayer 1452. In this, In relation, for example, the flexible circuit 1453 may initially allow the bubble jet head 1450 and the atomizer 1452 to be positioned at a relatively large separation distance from each other, and the flexible circuit may flex during assembly, for example, by contact with the base 1416 to create the desired separation .

[00144] As further shown in FIG. 13, in some embodiments, the outer housing 1414 of the control housing 1402 may define one or more inlet openings 1431, the connector 1412 may define at least one opening 1427, the base 1416 may define at least one opening 1429, and the outer housing 1426 of the cartridge 1404 may define at least one aerosol delivery opening 1465 that can allow air to pass through the aerosol delivery device 1400. In this regard, FIG. 14 shows a perspective cross-sectional view of an aerosol delivery device 1400 depicting the path of air flow through the aerosol delivery device as a user draws air from the mouthpiece 1424. As shown in the drawing, air flow or ambient air flow 1428 may enter the delivery device 1400 aerosol through inlets 1431, which may be provided in the outer housing 1414 of the control housing 1402, and move past or adjacent to the flow sensor 1411. Air 1428 may flow from control housing 1402 through connector 1412, i.e. through the connector opening 1427 (as shown, for example, in FIG. 13) and through the opening 1429 in the base 1416 of the cartridge 1404, through and/or around the combined dispenser and atomizer assembly 1418, around the reservoir 1420 (for example, through the aerosol delivery opening 1465 formed in the outer housing 1426, or between the reservoir and the outer housing, as shown in FIG. 15), and exit through the mouthpiece 1424. It should be noted that although the aerosol delivery opening 1465 is shown as forming a non-linear flow path, according to In yet another embodiment, the aerosol delivery opening may form a linear flow path (eg, running parallel to the longitudinal length of the cartridge) to simplify cartridge manufacture and provide a flow path with reduced pressure drop.

[00145] In particular, air 1428 may move through the base 1416 through at least one opening 1429 in the base (as shown, for example, in FIG. 13). As shown in FIG. 13, the base opening 1429 may be located adjacent the radially outer edge of the base 1412. Thus, as shown in FIG. 14, air 1428 may enter the cartridge adjacent the interior surface of the outer housing 1426. Air 1428 may flow around the combined dispenser and atomizer assembly 1418 and partially through the combination assembly 1418 between the bubble-jet head 1450 and the atomizer 1452 (as shown, for example, in FIG. . 13).

[00146] When the flow sensor 1411 detects a puff, the combined dispenser and atomizer assembly 1418 may be activated such that the bubble-jet head 1450 ejects the aerosol precursor composition from the reservoir 1420 to the atomizer 1452 (as shown, for example, in FIG. 13). Although the above-described configuration of the flow of at least a portion of the air 1428 flowing through the combined dispenser and atomizer assembly 1418 allows the aerosol precursor composition to be injected into the air flow 1428 prior to atomization, the use of an opening 1429 in the base can control the flow of air flowing through the combined dispenser and atomizer assembly such that substantially all of the aerosol precursor composition contacts the atomizer 1452 (as shown, for example, in FIG. 13) and is vaporized rather than captured in liquid form by the air and subsequently potentially separated from the air. In addition, a portion of the air 1428 may flow around, rather than through, the combined dispenser and atomizer assembly 1418, such that the air flow may be distributed over a relatively large area, and thus the air flow through the combined dispenser and atomizer assembly may have a relatively low speed that does not significantly affect the dispensing and delivery of the aerosol precursor composition to the nebulizer 1452 (as shown, for example, in FIG. 13). In addition, the flexible circuit 1453 and/or the casing of the bubble jet head 1450 and the atomizer 1452 may form a flash chamber that further prevents the aerosol precursor composition from being directed into the air stream 1428 without evaporating it. In some embodiments, the atomizer may be offset downstream of the bubble-jet head to account for movement of the aerosol precursor composition caused by air flow. Once atomized, the air and steam may move around the reservoir 1422 and exit through the mouthpiece 1424 to the user. It should be noted that embodiments of an aerosol delivery device comprising a flexible circuit may be configured to prevent problems associated with a liquid aerosol precursor composition becoming entrained in air without evaporating it. In this regard, for example, the bubble jet head and the atomizer may be positioned at a certain distance from each other, and the atomizer may be heated to a temperature at which the aerosol precursor composition can be vaporized even if it is not in contact with the atomizer.

[00147] As discussed above, flexible circuit 1453 can be used to establish a mechanical and electrical connection between the bubble-jet head 1450 and the atomizer 1452 of the combined dispenser and atomizer assembly 1418. However, the flexible circuit 1453 may also be configured to electrically connect the combined dispenser and atomizer assembly 1418 and the cartridge power source 1410 via connector 1412 and base 1416. In this regard, various other embodiments of the combined dispenser and atomizer assemblies may be electrically coupled to one or more other components of the device for delivering the aerosol via a flexible circuit.

[00148] For example, FIG. 15 shows a partial perspective cross-sectional view of one embodiment of an aerosol delivery device 1400' that is substantially similar to the aerosol delivery device 1400 shown in FIG. 12-14. However, as shown in the drawing, the aerosol delivery device 1400' shown in FIG. 15 may include a combined dispenser and atomizer assembly 1418' containing a combined plate, substrate, or housing 1433' that houses the bubble jet head and atomizer. In this regard, for example, the combined dispenser and sprayer assembly 1418' shown in FIG. 15 may be substantially similar to the combined dispenser and sprayer assembly 1318 shown in FIG. 9. In this embodiment, flex circuit 1453 can be used to provide electrical connection to a combined dispenser and atomizer assembly, whether or not the bubble jet head and atomizer are housed in separate housings or in a common housing. It should also be noted that the use of a combined dispenser and nebulizer assembly 1418', comprising a bubble-jet head and nebulizer housed in a common casing 1433' through which no air flows, can prevent any problems associated with the composition of the aerosol precursor in the form of a liquid transferred air flow without atomization.

[00149] FIG. 16 shows a perspective cross-sectional view of an aerosol delivery device 1500 according to a further exemplary embodiment of the present invention. As shown in the drawing, the aerosol delivery device 1500 may include a control housing 1502 and a cartridge 1504, which are shown in a disconnected configuration. In this regard, the base 1516 of the cartridge 1504 may be configured to interact with the connector 1512 of the control housing 1502 to form a mechanical and electrical connection therebetween, which may be removable to allow the cartridge to be replaced.

[00150] The control housing 1502 may include an end cap 1506, a circuit board with an indicator 1508 (e.g., a light-emitting diode (LED)), a connecting circuit 1509, a power source 1510 (e.g., a battery, which may be rechargeable), a flow sensor 1511 (e.g. , a tightening sensor or a pressure sensor), connector 1512, connecting wires 1513, and an outer housing 1514. The cartridge 1504 may include a base 1516, a combined dispenser and atomizer assembly 1518, a reservoir 1520, a mouthpiece 1524, an insulating material 1555, and an outer housing 1526. As shown in In the drawing, embodiment, connector 1516 forms a cap 1522 that closes reservoir 1520. In this regard, cartridge assembly 1504 may be simplified by sealing the end of reservoir 1520 via connector 1516. However, in still other embodiments, the cap may include a component that is separate from connector.

[00151] FIG. 17 shows an enlarged partial perspective cross-sectional view of an aerosol delivery device 1500 in which the control housing 1502 and the cartridge 1504 are coupled to each other. As shown in the drawing, the combined dispenser and sprayer assembly 1518 may include a bubble-jet head 1550 and a sprayer 1552, which may be firmly coupled to each other (eg, by one or more spacers). The bubble jet head 1550 and atomizer 1552 may comprise any of the components and features of the bubble jet heads and atomizers described elsewhere in this application.

[00152] FIG. 17 further shows the path of air flow flowing through the aerosol delivery device 1500 when the user draws air from the mouthpiece 1524. As shown in the drawing, the air flow or ambient air flow 1528 may enter the aerosol delivery device 1500 through one or more inlet openings 1531 , which may be provided in the outer housing 1514 of the control housing 1502, and moves past or adjacent to the flow sensor 1511. Air 1528 may flow from the control housing 1502 through at least one opening 1561 formed in the connector 1512, flow through one or more openings 1529 formed in the base 1516 of the cartridge 1504, around the reservoir 1520 (for example, through one or more delivery channels 1565 air formed in the outer housing 1526, or between the reservoir and the outer housing) around the combined dispenser and atomizer assembly 1518 and partially through the combined dispenser and atomizer assembly 1518 and exit through the mouthpiece 1524.

[00153] As a result of this configuration, some or all of the air 1528 can flow laterally through the cartridge 1504, through the dispenser and atomizer combination assembly 1518 between the bubble-jet head 1550 and the atomizer 1552. When the flow sensor 1511 detects a puff, the combination assembly The dispenser and atomizer 1518 may be activated such that the bubble-jet head 1550 ejects the aerosol precursor composition from the reservoir 1520 toward the atomizer 1552.

[00154] Although the above-described flow configuration of at least a portion of the air 1528 flowing through the combined dispenser and nebulizer assembly 1518 may result in the aerosol precursor composition being injected into the air flow 1528 prior to atomization, the use of one or more base openings 1529 may regulate the flow of air through the combined dispenser and nebulizer assembly such that substantially all of the aerosol precursor composition contacts the aerosol precursor 1552 (as shown, for example, in FIG. 13) and is vaporized rather than being entrained in liquid form by the air and then potentially separating From him. In addition, a portion of the air 1528 may flow around the combined dispenser and nebulizer assembly 1518 rather than through the combined dispenser and atomizer assembly 1518 such that the air flow may be distributed over a relatively large area and thus the air may flow through the combined dispenser and atomizer assembly 1518. a dispenser and nebulizer assembly at a relatively low speed that does not significantly affect the dispensing and delivery of the aerosol precursor composition to the atomizer 1552 (as shown, for example, in FIG. 13). In addition, as described above, one or more spacers and/or housings of the bubble jet head 1550 and atomizer 1552 may define a flash chamber that further prevents the aerosol precursor composition from being thrown into the air stream 1528 without evaporating it, and/or the atomizer may be located downstream of the bubble-jet head to account for the movement of the aerosol precursor composition by the air flow. Once atomized, the air and steam may move around the reservoir 1522 and be delivered through the mouthpiece 1524 to the user.

[00155] It should be noted that in the aerosol delivery devices 1200, 1300, 1400 shown in FIG. 2-15, the reservoir is located between the mouthpiece and the combined dispenser and atomizer assembly, which may include a bubble-jet head and a nebulizer. This configuration may be desirable in that the nebulizer is positioned further away from the mouthpiece so that the user's mouth does not contact the heated surface. By comparison, the combined dispenser and nebulizer assembly 1518 of the aerosol delivery device 1500 shown in FIG. 16 and 17, is located between the reservoir 1520 and the mouthpiece 1524. This configuration may be advantageous in that the aerosol generated by the atomizer can travel only a relatively short distance to the mouthpiece 1524 such that there is a reduced likelihood of the aerosol precursor composition condensing from the air 1528 after evaporation. However, to keep the mouthpiece 1524 and/or the outer housing 1526 cool to the touch in areas that the user may contact with their lips, the aerosol delivery device 1500 may further comprise an insulating material 1555, as shown in FIG. 16. Insulating material 1555 may comprise any embodiment of insulating materials, such as plastic, fiberglass, or phenolic materials. In addition, the insulating material 1555 may be located adjacent to one or both of the outer housing 1526 and the mouthpiece 1524 or portions thereof, or may form one or both of the outer housing 1526 and the mouthpiece 1524 or a portion thereof.

[00156] FIG. 18 shows a perspective cross-sectional view of an aerosol delivery device 1600 according to a further exemplary embodiment of the present invention. As shown in the drawing, the aerosol delivery device 1600 may include a control housing 1602 and a cartridge 1604, which are shown in a connected configuration. In this regard, the base 1616 of the cartridge 1604 may be configured to interact with the connector 1612 of the control housing 1602 to form a mechanical and electrical connection therebetween, which may be removable to allow the cartridge to be replaced.

[00157] The control housing 1602 may include an end cap 1606, a circuit board with an indicator 1608 (e.g., a light-emitting diode (LED)), a connecting circuit 1609, a power source 1610 (e.g., a battery, which may be rechargeable), a flow sensor 1611 (e.g. , tightening sensor or pressure sensor), connector 1612, connecting wires 1613, and an outer housing 1614. The cartridge 1604 may include a base 1616, a combined dispenser and atomizer assembly 1618, a reservoir 1620, a mouthpiece 1624, and an outer housing 1626. In the illustrated embodiment, the connector 1616 defines a cap 1622 that encloses the reservoir 1620. In this regard, by sealing the end of the reservoir 1620 via the connector 1616, the cartridge assembly 1604 can be simplified. However, in still other embodiments, the cap may include a component that is separate from the connector.

[00158] FIG. 19 shows an enlarged partial perspective cross-sectional view of an aerosol delivery device 1600 in which the control housing 1602 and the cartridge 1604 are coupled to each other. As shown in the drawing, the combined dispenser and sprayer assembly 1618 may include a bubble-jet head 1650 and a sprayer 1652, which may be firmly coupled to each other (eg, by one or more spacers 1636). The bubble jet head 1650 and atomizer 1652 may comprise any of the components and features of the bubble jet heads and atomizers described elsewhere in this application.

[00159] As further shown in FIG. 18, the outer housing 1614 of the control housing 1602 may define one or more inlet openings 1631, the connector 1612 may define at least one connector opening 1661, and the base 1616 may define at least one base opening 1629, which may allow air to flow through the device. 1600 for aerosol delivery. In this regard, FIG. 19 further shows the path of air flow through the aerosol delivery device 1600 when the user draws air from the mouthpiece 1624. As shown in the drawing, the air flow or ambient air flow 1628 may enter the aerosol delivery device 1600 through inlets 1631 that may be configured in the outer housing 1614 of the control housing 1602, and move past the flow sensor 1611 or adjacent to the flow sensor 1611. Air 1628 may flow from the control housing 1602 through an opening 1661 provided in the connector 1612 and through the base 1616 of the cartridge 1604 through an opening 1629 in the base, between the reservoir 1620 and the outer housing 1626, around and partially through the combined dispenser and atomizer assembly 1618, and exit through the mouthpiece 1624. When the flow sensor 1611 detects a puff, the combined dispenser and atomizer assembly 1618 may be activated such that the bubble-jet head 1650 ejects the aerosol precursor composition from the reservoir 1620 toward the atomizer 1652.

[00160] Although the above-described flow configuration of at least a portion of the air 1628 flowing through the combined dispenser and nebulizer assembly 1618 allows for the aerosol precursor composition to be injected into the air flow 1628 prior to atomization, the use of at least one hole 1629 in the base allows adjusting the flow of air through the combined dispenser and nebulizer assembly such that substantially all of the aerosol precursor composition contacts and vaporizes the aerosol precursor 1652 rather than being entrained in liquid form by the air and potentially separating therefrom. In addition, a portion of the air 1628 may flow around, rather than through, the combined dispenser and atomizer assembly 1618, such that the air flow can be distributed over a relatively large area, and thus the flow of air flowing through the combined dispenser and atomizer assembly , may have a relatively low velocity that does not significantly affect the dispensing and delivery of the aerosol precursor composition to the atomizer 1652. Additionally, as described above, the spacers 1636 and/or housings of the bubble jet head 1650 and the atomizer 1652 may define a flash chamber, which further prevents the aerosol precursor composition from being introduced into the air stream 1628 without evaporating it, and/or the atomizer may be located downstream of the bubble-jet head to account for the movement of the aerosol precursor composition caused by the air flow. Once atomized, air and vapor may move around the reservoir 1620 and flow through the mouthpiece 1624 to the user.

[00161] As shown in FIG. 18 and 19, a combined dispenser and nebulizer assembly may be located adjacent to the mouthpiece 1624, which may provide benefits in preventing vaporized aerosol precursor composition from condensing in the aerosol delivery device as described above. An insulating material may be used adjacent to the mouthpiece to reduce the amount of heat transferred to the user's lips, as further described above. As shown in FIG. 19, in some embodiments, a combined dispenser and atomizer assembly 1618 may be coupled to the side 1655 of a reservoir 1620. This configuration may allow a substantially longitudinal flow of air through the combined dispenser and atomizer assembly 1618 to a mouthpiece 1624. In this regard, the heating surface atomizer 1652 (e.g., having the outer surfaces of vapor-generating heating elements as described above) and the ejection surface of the bubble-jet head 1650 (e.g., containing nozzles for the aerosol precursor composition) may be oriented substantially parallel to the longitudinal axis of the outer housing 1626 of the cartridge 1604 and the longitudinal axis aerosol delivery devices 1600 in general. Thus, the air flow 1628 can flow between the parallel surfaces formed by the bubble jet head 1650 and the atomizer 1652 such that the air and aerosol flow can follow a substantially linear path to the mouthpiece 1624.

[00162] By comparison, embodiments of the aerosol delivery devices 1200, 1300, 1400, 1500 described above include embodiments of a combined dispenser and nebulizer assembly attached to the distal end of the reservoir in a manner that causes the heating surface of the atomizer and the ejection surface of the bubble The jet heads are generally oriented substantially perpendicular to the outer body of the cartridge and the longitudinal axis of the aerosol delivery device. Although attaching a combined dispenser and nebulizer assembly to the distal end of the reservoir allows for a simplified design of the aerosol delivery device, such a design may result in a non-linear path of air flow through the aerosol delivery device. For example, as shown in FIG. 14, the air may make one or more sharp turns as it enters and/or exits the dispenser and nebulizer combination assembly when the bubble-jet head and atomizer are oriented perpendicular to the longitudinal axis of the aerosol delivery device. These sharp turns may undesirably increase the pressure drop associated with use of the aerosol delivery device such that drawing in air flowing along such a path may require relatively increased force. In addition, sharp turns in the air flow path at or downstream of the combined dispenser and atomizer assembly may be disadvantageous in that such transitions may cause the aerosol to condense back into the liquid phase through collision with surrounding structural components of the aerosol delivery device (eg , outer body of the cartridge). Thus, it may be desirable to use an air flow path that is generally parallel to the longitudinal axis of the cartridge and does not include sharp turns. In this regard, the aerosol delivery device 1600, which is shown in FIG. 18 and 19 is configured to prevent the problems described above. However, it should also be noted that the use of bubble jet heads and atomizers oriented such that their respective ejection and heating surfaces are substantially perpendicular to the longitudinal axis of the cartridge, as described in the aerosol delivery device embodiments shown in FIG. 2-17 may be desirable in that such a configuration may cause a slower flow of air flowing through it, such that atomization of the aerosol precursor composition may be improved.

[00163] Although the bubble jet head and nebulizer of the aerosol delivery device shown in FIG. 18 and 19 are depicted as being configured such that the respective ejection and heating surfaces of said devices are oriented substantially parallel to the longitudinal axis of the cartridge and the aerosol delivery device as a whole, some embodiments of the aerosol delivery devices include bubble jet heads and nozzles in which the respective ejection and heating surfaces are oriented at non-zero angles relative to the longitudinal axis of the outer housing, yet may provide many of the benefits described above with respect to the aerosol delivery device 1600 shown in FIG. 18 and 19. In this regard, FIG. 20 shows a partial schematic view of an aerosol delivery device 1700 comprising a combined dispenser and atomizer assembly 1718, in which the respective ejection and heating surfaces of the bubble-jet head 1750 and the atomizer 1752 of said assembly are oriented at an angle other than zero relative to the longitudinal axis 1770 of the aerosol delivery device. aerosol delivery. However, the angle between these surfaces and the longitudinal axis 1770 is relatively small (for example, less than about 45°), such that the pressure drop caused by turns in the path of the air flow 1728 before exiting the mouthpiece 1724 is reduced compared to embodiments of delivery devices. aerosols that are otherwise similar but form sharper turns in the flow path. In addition, the relatively small angles between the ejection and heating surfaces of the bubble-jet head 1750 and atomizer 1752 and the longitudinal axis 1770 can also help eliminate the disadvantages associated with condensation of the aerosol after it has evaporated and entered the air stream 1728, since the air and aerosol released from combined dispenser and sprayer assembly, can come out of it without turbulence, without making a sharp turn.

[00164] FIG. 21 shows a perspective cross-sectional view of an aerosol delivery device 1800 according to a further exemplary embodiment of the present invention. As shown in the drawing, the aerosol delivery device 1800 may include a control housing 1802 and a cartridge 1804, which are shown in a connected configuration. In this regard, the base 1816 of the cartridge 1804 may be configured to interact with the connector 1812 of the control housing 1802 to form a mechanical and electrical connection therebetween, which may be removable to allow the cartridge to be replaced.

[00165] The control housing 1802 may include an end cap 1806, a circuit board with an indicator 1808 (e.g., a light-emitting diode (LED)), a connecting circuit 1809, a power source 1810 (e.g., a battery, which may be rechargeable), a flow sensor 1811 (e.g. , a tightening sensor or a pressure sensor), connector 1812, connection wires 1813, and an outer housing 1814. The cartridge 1804 may include a base 1816, a dispenser and atomizer combination assembly 1818, a reservoir 1820, a mouthpiece 1824, and an outer housing 1826. In the illustrated embodiment, the connector 1816 defines a lid 1822 that encloses the reservoir 1820. In this regard, by sealing the end of the reservoir 1820 via connector 1816, the cartridge assembly 1804 can be simplified. However, in yet other embodiments, the cap may include a component that is separate from the connector.

[00166] FIG. 22 shows an enlarged partial perspective cross-sectional view of an aerosol delivery device 1800 in which the control housing 1802 and the cartridge 1804 are coupled to each other. As shown in the drawing, the combined dispenser and sprayer assembly 1818 may include a bubble-jet head 1850 and a sprayer 1852, which may be firmly coupled to each other (eg, by one or more spacers 1836). The bubble jet head 1850 and atomizer 1852 may include any of the components and features of the bubble jet heads and atomizers described elsewhere in this application.

[00167] In FIG. 21 and 22 further illustrate the path of air flowing through the aerosol delivery device 1800 when the user draws air from the mouthpiece 1824. As shown in FIG. 21, the air flow or ambient air flow 1828 enters the aerosol delivery device 1800 through one or more inlets 1831 that may be formed in the outer housing 1814 of the control housing 1802 and moves past or adjacent to the flow sensor 1811. As shown in FIG. 22, air 1828 may exit the control housing 1802 through an inlet 1861 formed in the connector 1812 and pass into the base 1816 of the cartridge 1804, through the reservoir 1820, through the combined dispenser and atomizer assembly 1818, and out through the mouthpiece 1824.

[00168] In particular, air 1828 may be moved in the base 1816 through at least one hole 1829 in the base. In addition, the reservoir 1820 may define a channel 1854 extending along it. In this regard, the reservoir 1820 may form an elongated annular structure such that the aerosol precursor enclosed therein is separated from the channel 1854 (eg, by the inner wall of the reservoir defining the channel). The passage 1854 may direct air flow 1828 to the combined dispenser and atomizer assembly 1818. In this regard, bubble jet head 1850 may include an air flow opening 1856, and nebulizer 1852 may include an aerosol delivery opening 1858 configured to direct air flow 1828 therethrough. In the illustrated embodiment, an opening 1829 in the base, a channel 1854 extending through the reservoir 1820, an opening 1856 for air flow through the bubble-jet head 1850, and an opening 1858 for delivering the aerosol through the atomizer 1852 are linearly arranged along a longitudinal axis passing through the cartridge 1804. such that the air flow 1828 moves along a substantially linear path, and thus problems associated with a relative increase in pressure drop across the aerosol delivery device 1800 and condensation can be prevented. The aerosol delivery device 1800 may further be configured to prevent condensation due to the location of the combined dispenser and nebulizer assembly 1818 between the reservoir 1820 and the mouthpiece 1824. As described above, an insulating material may be used to reduce heat transfer to the mouthpiece and the outer housing.

[00169] FIG. 23 schematically shows an enlarged exploded perspective view of a cartridge 1804 located adjacent to a combined dispenser and atomizer assembly 1818. As shown in the drawing, reservoir 1820, bubble-jet head 1850, and nebulizer 1852 may be configured to dispense and vaporize the aerosol precursor composition in a radial or annular manner. In this regard, as schematically shown in the drawing, the aerosol precursor composition inlets, aerosol precursor composition channels, ejection heating elements, and/or aerosol precursor composition nozzles of the bubble jet head 1850 may be located at a variety of different radial positions 1860 in an annular manner around holes 1856 for air flowing through the bubble jet head. Similarly, the vapor-generating heating elements 1862 of the atomizer 1852 may extend substantially radially and annularly around the opening 1858 extending through the atomizer. Such a design may allow the aerosol precursor composition to be dispensed and vaporized around the direct air stream 1828 rather than in the direct air stream 1828 flowing through the aerosol delivery device 1800 to prevent the liquid aerosol precursor composition from being directed into the air stream. Such a design may also facilitate the flow of a substantially linear flow of air 1828, combining the advantages of the aerosol delivery devices described above.

[00170] According to the embodiments of aerosol delivery devices described above, the atomizer is generally described as forming a substantially flat heating surface on which vapor-generating heating element(s) are located. In this regard, the bubble jet heads form an ejection surface on which the aerosol precursor composition nozzles are located, which are also generally flat and parallel to the heating surface of the atomizer. Thus, the bubble jet head emits the aerosol precursor composition substantially perpendicular to the heating surface of the atomizer. However, various other embodiments of nozzles may be used.

[00171] For example, FIG. 24 shows a nebulizer 1900 according to an alternative embodiment of the present invention. The nebulizer 1900 may be used in connection with any of the combination dispenser and nebulizer assemblies described elsewhere in this application. For example, nebulizer 1900 may be used in place of nebulizer 1852 of the combined dispenser and nebulizer assembly 1818 in the aerosol delivery device shown in FIG. 21-23.

[00172] As shown in the drawing, the atomizer 1900 may include an internal heating surface 1902 that is not flat. In particular, the atomizer 1900 and the inner heating surface 1902 of the atomizer may be substantially conical (eg, form a hollow truncated conical structure as shown in the drawing). In this regard, the nebulizer 1900 may be configured to receive a stream of air and the aerosol precursor composition 1904 flowing through it such that the internal heating surface 1902 of the atomizer receives the flow of air and the aerosol precursor composition 1904.

[00173] Thus, heating surface 1902 can vaporize the aerosol precursor composition. For example, a plurality of vapor-generating heating elements 1906 may be located on the inner heating surface 1902. As a further example, in some embodiments, the heating elements may be arranged in a spiral manner on the inner heating surface 1902. Such a design may preferably contact the majority of the aerosol precursor composition flowing through the atomizer 1900. Thus, a stream of air and aerosol 1908 can be released from the atomizer 1900.

[00174] FIG. 25 shows an alternative embodiment of a nebulizer 2000 that may be used in place of the nebulizer 1852 of the combined dispenser and nebulizer assembly 1818 in the aerosol delivery device shown in FIG. 21-23. The atomizer 2000 may include an outer heating surface 2002. As shown in the drawing, the atomizer 2000 as a whole may form a substantially conical structure in addition to the outer heating surface 2002. In this embodiment, a flow of air and aerosol precursor composition 2004 may be directed toward the tapered end of the atomizer 2000. Thus, the aerosol precursor composition may be vaporized by one or more vaporizing heating elements 2006 located on the outer heating surface 2002 to generate a flow of air and aerosol. 2008. Vapor generating heating elements 2006 may be helically arranged on the outer heating surface 2002 to preferentially heat and vaporize the aerosol precursor composition.

[00175] It should also be noted that while the use of multiple steam heating elements 1906, 2006 is generally described above, in still other embodiments single steam heating elements may be used. For example, vapor-generating heating elements may comprise single continuous embedded or printed filaments in the heating surface. As a further example, a single continuous filament may have a helical configuration (eg, on the inner heating surface in the atomizer shown in FIG. 24, or on the outer heating surface in the atomizer shown in FIG. 25), as described above. The use of a single continuous filament for vapor-generating heating elements may be advantageous in that this approach may simplify the design of the atomizer.

[00176] Thus, in some embodiments, the heating surface of the atomizer may form a non-planar structure. The use of a nebulizer comprising a non-planar heating surface can provide various alternative flow configurations through the aerosol delivery devices. In particular, the substantially conical nozzles shown in FIG. 24 and 25 may be respectively configured to concentrate or distribute air and aerosol while providing a substantially straight air flow path while minimizing the increase in puff-related pressure drop across the aerosol delivery device. In these and other embodiments of combination dispenser and atomizers, the bubble-jet head may direct the aerosol precursor composition at an angle relative to the heating surface of the atomizer other than a right angle. By eliminating the delivery of the aerosol precursor composition directly perpendicular to the heating surface of the atomizer, problems associated with splashing of the aerosol precursor composition can be prevented. In this regard, the sprayed aerosol precursor composition may be deflected back toward the bubble jet head, which may cause clogging of the bubble jet head. In addition, according to the embodiment of the atomizer 1900 shown in FIG. 24, any atomized aerosol precursor composition may be retained in the atomizer and may contact another portion of the internal heating surface 1902 such that the atomized aerosol precursor composition does not nevertheless escape vaporization by the internal heating surface of the atomizer forming a chamber. Various other embodiments of truncated conical nozzles are described in US Patent Application No. 14/329,334, filed July 11, 2014, (Taluskie et al.), which is incorporated by reference in its entirety herein.

[00177] FIG. 26 shows an exploded view of an alternative embodiment of a combined dispenser and nebulizer assembly 2100 that may be included in embodiments of aerosol delivery devices described herein. As shown in the drawing, the combined dispenser and sprayer assembly 2100 may include a bubble jet head 2102 and a sprayer 2104. Details regarding embodiments of the bubble jet heads are described above and will not be repeated in full. Briefly, however, bubble jet head 2102 may include a plate, substrate, or housing 2106 that may have at least one aerosol precursor composition inlet 2108 (as shown, for example, in FIG. 27) configured to receive the precursor composition. aerosol from the reservoir, and at least one aerosol precursor composition nozzle 2110 configured to dispense and deliver the aerosol precursor composition to the atomizer 2104.

[00178] In addition, the atomizer 2104 may include a plate, substrate, or housing 2112. Additionally, as shown in the drawing, in some embodiments, the atomizer 2104 may further include a reinforcing element 2114. The reinforcing element 2114 may be configured to support the atomizer housing 2112 2104 to ensure its structural stability. For example, as shown in FIG. 27, the reinforcing member 2114 may be coupled to the housing 2112 of the atomizer 2104 such that the housing is supported. In particular, a reinforcing element 2114 may be coupled to a rear side of the casing 2112, with at least one vapor-generating heating element 2116 connected to a front side of the casing opposite said rear side.

[00179] In this regard, the reinforcing element may be configured to provide rigidity, support and structure to the atomizer 2014 without substantially increasing its thermal mass. It may be desirable to provide the nebulizer 2104 with a relatively low thermal mass such that the nebulizer can quickly heat up to a temperature sufficient to vaporize the aerosol precursor composition when electrical current is passed through it. Thus, the nebulizer 2104 can quickly heat up when the user draws air from the associated aerosol delivery device.

[00180] By positioning the amplification element 2114 opposite the vapor-generating heating elements 2116, it can be prevented from making direct contact with the heating element to reduce heat transfer to the amplification element. In addition, as shown in FIG. 26, the reinforcement element 2114 may have a cutout 2118. The cutout 2118 further reduces the thermal mass of the atomizer 2104 while at the same time allowing the reinforcement element 2114 to provide increased strength to the atomizer. In this regard, the cutout may be centrally located such that the reinforcing element forms a frame extending around the outer edge of the casing 2112. Such a design results in only a relatively small loss of moment of inertia of the reinforcing element 2114, and at the same time also the location of its mass is removed from the steam generating heating elements 2116 to further reduce heat transfer to the reinforcing element. In addition, the reinforcing element 2114 may comprise plastic, ceramic, glass, or other insulating and non-conductive material embodiments that are configured to prevent the transfer of heat and electricity thereto.

[00181] As shown in FIG. 27, atomizer 2104 may further include one or more conductive pads 2120. Conductive pads 2120 may be configured to contact vapor-generating heating elements 2116 to direct electrical current thereto. However, to prevent unwanted heat generation, conductive pads 2120 may comprise a material and/or design (e.g., increased thickness) that provide lower resistance than the material of vapor-generating heating elements 2116. For example, conductive pads 2120 may comprise a silver-palladium alloy, and vapor-generating heating elements 2116 may contain platinum. As a further example, in some embodiments, the conductive pads 2120 may comprise a silver-palladium alloy, and the vapor-generating heating elements 2116 may contain a silver-palladium alloy, which produces a relatively increased resistance. However, it should be understood that in still other embodiments, various other materials may be used, including, for example, gold, silver, platinum, palladium, tungsten, and combinations thereof. The materials forming the conductive pads and vapor-generating heating elements may be selected to achieve the required resistance and appropriate bonding characteristics to the housing and/or other parts of the atomizer.

[00182] In some embodiments, the nebulizer 2104 may be configured to firmly engage the bubble jet head 2102 via a support 2103 (as shown, for example, in FIG. 27). In this regard, as shown in FIG. 26, the housing 2112 and/or the reinforcing member 2114 may have recesses 2122a, 2122b configured to engage with the supports 2103. In some embodiments, the supports 2103 may electrically connect the bubble jet head 2102 to the atomizer 2104. Thus, for example, conductive pads 2120 may be located adjacent to recesses 2122a, 2122b formed in the atomizer 2104 such that an electrical connection can be established between them.

[00183] As stated above, it may be desirable to prevent the aerosol precursor composition from splashing toward the atomizer. Thus, embodiments of the aerosol delivery devices of the present invention may include additional or alternative features configured to reduce splashing of the aerosol precursor composition and provide other functions. In this regard, FIG. 28A-28C show enlarged partial views of embodiments of the atomizer 2104 shown in FIG. 26 and 27, in which its heating surface is not smooth, but textured. However, it should be noted that such texturing can be used in any of the atomizers described herein.

[00184] In particular, FIG. 28A shows an embodiment of atomizer 2104A in which the heating surface 2124A is serrated. In other words, the heating surface 2124A forms a substantially regular pattern of projections and recesses. FIG. 28B shows an embodiment of atomizer 2104B in which heating surface 2124B is partially porous. In this regard, the topography of heating surface 2124B may be substantially similar to that of closed cell foam. FIG. 28C shows an embodiment of atomizer 2104C in which the heating surface 2124C is completely porous. In this regard, the topography of the heating surface 2102C may be substantially similar to the surface of an open cell foam or sintered material.

[00185] In some embodiments, heating surface 2124A-2124AC may be passivated or coated with a passivation layer located on its outer surface (eg, on top of casing 2112 and vapor heating elements 2116). In this regard, the passivation layer is configured to prevent oxidation, catalytic reactions and various other chemical reactions from occurring adjacent to the atomizer when aerosol precursor composition 2128 is sprayed thereon. For example, the passivation layer may comprise an alumina, glass, or ceramic material that may be sprayed or otherwise deposited over vapor heating elements 2116 and mantle 2112.

[00186] When using a textured heating surface, the aerosol precursor composition may be less prone to spatter due to the textured heating surface, which captures the deflected aerosol precursor composition such that the aerosol precursor composition is less likely to be deflected back toward the bubble-jet head. In addition, the use of a textured heating surface can increase the effective heating surface area to which the aerosol precursor composition is directed. Accordingly, heat can be transferred with increased efficiency to the aerosol precursor composition to improve evaporation of the aerosol precursor composition.

[00187] In some embodiments, the heating surface may include an absorbent or absorbent layer, which may further provide a textured surface and which may be configured to reduce spatter and heat loss, and perform other functions as described below. The absorption layer, which in some embodiments may comprise alumina paper, may be located outside the passivation layer and may be configured to receive the aerosol precursor composition. Thus, the aerosol precursor composition can saturate the absorption layer such that heat applied to the aerosol precursor composition is absorbed by that layer. In this embodiment, the bubble jet head can replenish the aerosol precursor composition in the absorption layer as it evaporates. In this regard, the acquisition layer may be at least partially saturated with the aerosol precursor composition before receiving a puff from the aerosol delivery device such that the aerosol can be produced more quickly.

[00188] It should be noted that while specific nebulizer embodiments are described above, various other nebulizer embodiments may be used to vaporize the aerosol precursor composition according to various embodiments of the aerosol delivery devices provided herein. Such atomizers may include planar heaters, wire-wound surfaces, micro-heaters (eg, on-chip) glass plate heaters, laser heaters, resistive heaters, or any other heater shape or embodiment. For example, in one embodiment, vapor generating heating elements may be respectively associated with each aerosol precursor composition nozzle and each ejection heating element of the bubble jet head. However, in still other embodiments, a plurality of aerosol precursor composition nozzles and a plurality of ejection heating elements (e.g., all aerosol precursor composition nozzles and bubble jet head ejection heating elements) may eject the aerosol precursor composition onto single vaporizing heating elements to vaporize the aerosol precursor composition . Additionally, the materials used in ejection heating elements and vapor heating elements may be different. For example, the materials described above with respect to wire wound heating elements may be used. Various other materials that may be used in ejection heating elements and vapor heating elements, as well as various other heating elements described herein, may contain platinum or platinum-coated materials and resistive paste (for example, printed on a ceramic material ).

[00189] In another embodiment, the housing for the bubble jet head and/or atomizer may contain a silicon chip. In this embodiment, one or both of the vapor heating elements and the ejection heating elements may comprise doped silicon in the silicon chip. In other words, a portion of the silicon chip may form a resistive circuit configured to generate heat to emit or vaporize the aerosol precursor composition.

[00190] According to various embodiments of aerosol delivery devices containing a bubble-jet head, it may be desirable to reduce the viscosity of the aerosol precursor composition to facilitate the dispensing of droplets of the aerosol precursor composition, as described above. Accordingly, in one embodiment, the aerosol precursor composition may be preheated. For example, ejection heating elements may be used to preheat the aerosol precursor composition before main heating of the aerosol precursor composition to the point of forming vapor bubbles, and a droplet of the aerosol precursor composition is ejected through the aerosol precursor composition nozzle. Such preheating may involve applying a pulsating electrical current to the ejection heating elements. In this regard, during preheating of the aerosol precursor composition, a relatively reduced energy pulse duration may be applied to the bubble jet head ejection heating elements compared to the energy pulse duration applied to the bubble jet head ejection heating elements during dispensing of the aerosol precursor composition. In another embodiment, the aerosol precursor composition may be dissolved (eg, in water) to reduce its viscosity. Accordingly, the use of a bubble jet head with an aerosol precursor composition can be facilitated by any one or both of these methods. In one embodiment, the viscosity of the aerosol precursor composition may initially range from about 5 cP to about 400 cP at 20°C. However, the viscosity of the aerosol precursor composition can be reduced by any one or both methods, such as dissolution (eg, in water) or preheating, to achieve a viscosity of less than about 100 cP at 20°C. By comparison, ink used in inkjet printers may generally have a relatively low viscosity (eg, from about 10 cP to about 40 cP at 20° C.).

[00191] In embodiments provided herein, the combined dispenser and atomizer assembly is generally described as being located in a cartridge. However, according to another embodiment, the bubble jet head and/or atomizer may be located in the control housing. For example, in one embodiment, the bubble jet head may be located in the control housing and configured to emit an aerosol precursor composition to a nebulizer located in the cartridge. In this embodiment, the aerosol precursor composition may be directed from a reservoir located in the cartridge to a bubble jet head located in the control housing and back to the atomizer in the cartridge. In another embodiment, the bubble jet head may be located in the cartridge and configured to emit the aerosol precursor composition from a reservoir located in the cartridge to a sprayer located in the control housing.

[00192] Additionally, FIG. 29 shows an alternative embodiment of an aerosol delivery device 2200 in which a combined dispenser and nebulizer assembly is located in a control housing. As shown in the drawing, the aerosol delivery device 2200 may include a control housing 2202 and a cartridge 2204, which are shown in a disconnected configuration. In this regard, the base 2216 of the cartridge 2204 may be configured to interact with the connector 2212 of the control body 2202 to form a mechanical and electrical connection therebetween, which may be removable to allow the cartridge to be replaced.

[00193] The control housing 2202 may include an end cap 2206, a circuit board with an indicator 2208 (e.g., a light-emitting diode (LED)), a connecting circuit 2209, a power source 2210 (e.g., a battery, which may be rechargeable), a flow sensor 2211 (e.g. , tightening sensor or pressure sensor), connector 2212, connecting wires 2213, dispenser and sprayer combination assembly 2218, and outer housing 2214. In some embodiments, the control housing 2202 may further include a mounting plate 2219, and the dispenser and sprayer combination assembly 2218 may be installed between the mounting plate and connector 2212. In the illustrated embodiment, the bubble-jet head 2250 of the combined dispenser and spray assembly 2218 may be coupled to connector 2212, the atomizer 2252 of the combined dispenser and spray assembly may be coupled to the mounting plate 2219, and the bubble-jet the head can be connected to the atomizer via a flexible circuit 2253.

[00194] The cartridge 2204 may include a base 2216, a reservoir 2220, a cap 2222 that encloses the reservoir, a mouthpiece 2224, and an outer housing 2226. When the cartridge 2204 is coupled to the control housing 2202, the reservoir 2220 may be in fluid communication with the bubble jet head 2250. In this regard, reservoir 2220 may have an outlet 2256. In some embodiments, base 2216 may also have an outlet 2258 that may be aligned with outlet 2256 leading to reservoir 2220. One or both of outlets 2256, 2258 may be initially sealed to retain the aerosol precursor composition in reservoir 2220. In this regard, for example, a foil or plastic seal may cover the outlet openings 2256, 2258. However, the seal may be destroyed (eg, by being pierced) when the base 2216 of the cartridge 2204 interacts with the connector 2212 control housing 2202. Thus, by positioning the bubble jet head 2250 adjacent to the connector 2212, the bubble jet head can receive the aerosol precursor composition transferred from the reservoir 2220 through the outlet ports 2256, 2258 and through the inlet port 2260 in the connector. Thus, the bubble jet head 2250 can dispense and deliver the aerosol precursor composition to the atomizer 2252 to form an aerosol. Air flow may enter through one or more inlet openings 2262 in the outer housing 2214 of the control housing 2202 and move through and/or around an opening 2261 in the mounting plate 2219 and through and/or around the combined dispenser and atomizer assembly 2218. Thus, the combined air and aerosol may be directed through opening 2267 in connector 2212, opening 2263 in base 2216, and through aerosol delivery opening 2265 in outer housing 2226 (or between reservoir and outer housing) to mouthpiece 2224.

[00195] Additionally, FIG. 30 shows an alternative embodiment of an aerosol delivery device 2300, wherein the combined dispenser and nebulizer assembly is located in a separate dispenser and nebulizer housing. As shown in the drawing, the aerosol delivery device 2200 may include a control housing 2302, a dispenser and nebulizer cartridge 2303, and a reservoir cartridge 2304, which are shown in a disconnected configuration. In this regard, the base 2316 of the reservoir cartridge 2304 may be configured to interact with the connector 2364 of the dispenser and atomizer cartridge 2303, and the base 2366 of the dispenser and atomizer cartridge may be configured to interact with the connector 2312 of the control housing 2302 to form mechanical and electrical connections between them, which can be detachable to allow replacement of the dispenser and atomizer cartridge and/or reservoir cartridge.

[00196] The control housing 2302 may include an end cap 2306, a circuit board with an indicator 2308 (e.g., a light-emitting diode (LED)), a connecting circuit 2309, a power source 2310 (e.g., a battery, which may be rechargeable), a flow sensor 2311 (e.g. , a tightening sensor or a pressure sensor), connector 2312, and connecting wires 2313. The dispenser and sprayer cartridge 2303 may include an outer housing 2371, a base 2366, a connector 2364, and a dispenser and sprayer combination assembly 2318. As shown in the drawing, in one embodiment, a combined dispenser and sprayer assembly 2318 may be located between and connected to the base 2366 and the connector 2364. In particular, the combined dispenser and sprayer assembly 2318 may include a bubble-jet head 2350 and a sprayer 2352, which may be connected via a flexible circuit 2353. In one embodiment, the bubble-jet head 2350 may be mounted on a connector 2364, and the sprayer 2352 may be installed on the basis of 2366 cartridge 2303 dispenser and sprayer.

[00197] The reservoir cartridge 2304 may include a base 2316, a reservoir 2320, a cap 2322 that encloses the reservoir, a mouthpiece 2324, and an outer housing 2326. When the reservoir cartridge 2304 is coupled to the dispenser and atomizer cartridge 2303, the reservoir 2320 may be in fluid communication with the bubble jet head 2350. In this regard, the reservoir 2320 may have an outlet 2356. In some embodiments, the base 2316 of the reservoir cartridge 2304 may also have an outlet 2358, which may be aligned with the outlet 2356 of the reservoir. One or both of the outlets 2356, 2358 may be initially sealed to retain the aerosol precursor composition in the reservoir 2320. In this regard, for example, a foil or plastic seal may cover the outlets 2356, 2358. However, the seal may be broken (e.g., by puncturing) when the base 2316 of the reservoir cartridge 2304 interacts with the connector 2364 of the dispenser and atomizer cartridge 2303. Thus, by positioning the bubble-jet head 2350 adjacent to the connector 2364 of the dispenser and atomizer cartridge 2303, the bubble-jet head can receive the aerosol precursor composition transferred from the reservoir 2320 through the outlets 2356, 2358 and through the inlet 2360 in the dispenser assembly connector and sprayer. Thus, the bubble jet head 2350 can dispense and deliver the aerosol precursor composition to the atomizer 2352 to form an aerosol.

[00198] Air flow may enter through one or more inlet openings 2362 in the outer housing 2314 of the control housing 2302 and thus be directed through at least one opening 2361 in the control housing connector 2312, at least one opening 2363 in the base 2366, and through and/or around the aerosol dispenser and atomizer assembly 2318. The combined air and aerosol may then move through an opening 2365 in the connector 2364 of the dispenser and atomizer cartridge 2303, through an opening 2367 in the base 2316 of the reservoir cartridge 2304, through a vapor delivery opening 2369 formed in the outer housing 2326 of the reservoir cartridge, (or between the reservoir and outer body) to mouthpiece 2324.

[00199] Accordingly, various alternative positional configurations may be used for the components of the aerosol delivery devices described herein. As noted above, in one embodiment, a combined dispenser and sprayer assembly may be located in a control housing (as shown, for example, in FIG. 29). Such a configuration may be desirable in that the combined dispenser and sprayer assembly may have a usable service life that exceeds the service life of the reservoir. However, in another embodiment, the combined dispenser and atomizer assembly may be housed in a separate dispenser and atomizer cartridge (as shown, for example, in FIG. 30). This configuration may be desirable in that although the combined dispenser and atomizer assembly may have a usable life that exceeds the life of the reservoir, the service life of the combined dispenser and atomizer assembly may be less than the life of the power supply and other components of the control housing, or vice versa. In addition, such a configuration may allow the combination dispensers and nebulizer device or control housings to be replaced according to alternative embodiments to allow the aerosol delivery device to be customized to suit user preferences (e.g., by using a bubble jet head configured to produce more or more less aerosol with each puff, or by using a control body with a larger battery).

[00200] In embodiments of aerosol delivery devices comprising a bubble-jet head, the bubble-jet head is generally described as being firmly coupled to a nebulizer that vaporizes the aerosol precursor composition. For example, according to one embodiment (as shown, for example, in FIGS. 2-6), the bubble-jet head is connected to the atomizer via spacers. According to another embodiment (as shown, for example, in FIGS. 7-11), the bubble-jet head is firmly connected to the atomizer through a common casing. In yet another embodiment, the bubble-jet head is coupled to the atomizer via a flexible circuit, and one or both of the atomizer and the bubble-jet head are coupled to a structure surrounding the dispenser-atomizer combination assembly (as shown, for example, in FIGS. 12-15 ). However, in yet another embodiment, the bubble jet head may be detached from and aligned with the atomizer. Thus, the space between the bubble jet head and the atomizer can be adjusted to achieve a particular bubble jet head design, the viscosity of the aerosol precursor composition, and various other factors.

[00201] Additionally, in some embodiments, the atomizer and/or bubble-jet head may be configured to perform a cleaning cycle (e.g., when generating heat to remove sediment of the aerosol precursor composition therefrom) automatically (e.g., after a specified number of users) or manually as directed by the user. This approach may be particularly useful in embodiments in which the bubble jet head and/or atomizer are located in a control housing or dispenser and atomizer cartridge and are therefore reusable with different reservoirs.

[00202] The aerosol delivery devices described herein may overcome some of the disadvantages of the prior art associated with prior art aerosol delivery devices that use a wick to deliver an aerosol precursor composition to a nebulizer. In this regard, the use of a wick may cause the ingredients of the aerosol precursor composition to separate. Additionally, using a wick to transfer the aerosol precursor composition from the substrate to the heating element may result in leakage. Accordingly, embodiments of the aerosol delivery devices described herein may provide these and/or other benefits, including the benefits described above of improved control of the amount of aerosol precursor composition dispensed. In addition, the bubble jet heads and nebulizers described herein may require a reduced amount of energy to deliver and vaporize the aerosol precursor composition compared to other embodiments of fluid delivery and vaporization mechanisms. In addition, the use of a bubble jet head can allow for customization (e.g., whether manufactured by a factory or by the end user). For example, the frequency and/or duration of dispensing by the bubble jet head may be adjusted to match user preferences. Thus, for example, the aerosol delivery device may be configured to vaporize relatively less or more of the aerosol precursor composition with each puff through the aerosol delivery device, and such changes can be made without requiring changes to the equipment of the aerosol delivery device. In this regard, such changes can be made by software or by changing electronic settings.

[00203] It should be noted that while the aerosol delivery devices described herein are generally described as comprising a cartridge (eg, a refillable cartridge) and a control housing (eg, a reusable control housing), various other embodiments are possible. For example, in yet other embodiments, the aerosol delivery devices may comprise more than two parts (eg, as described above with reference to FIG. 30). In yet another embodiment, the aerosol delivery device may be an integrated, single-piece configuration. Thus, any of the aerosol delivery devices described herein may be configured in any of various ways in one or more outer housings.

[00204] This application describes various embodiments of atomizers and vapor-generating heating elements. As can be understood, in still other embodiments, various other embodiments of atomizers and vapor-generating heating elements may be used. For example, in some embodiments, the nebulizer may include a heating coil that may receive an aerosol precursor composition dispensed by the bubble jet head.

[00205] In addition, the specific configuration of the bubble jet head in relation to the atomizer may vary. For example, in one embodiment, the combined dispenser and sprayer assembly may include a housing with a first channel extending therethrough. The bubble jet head and the nebulizer may be coupled to opposite sides of the first channel such that the bubble jet head can dispense the aerosol precursor composition and direct it to the nebulizer. For example, a second channel formed in the housing may direct the aerosol precursor composition to the bubble jet head. The resulting steam can exit the housing through the first channel, which houses the bubble-jet head and atomizer.

[00206] According to another embodiment, a method for generating an aerosol through an aerosol delivery device is provided. As shown in FIG. 31, the method at step 2402 may include directing a flow of air from a control housing containing a power source through a cartridge containing a reservoir. Additionally, the method at step 2404 may include dispensing the aerosol precursor composition from the reservoir via a bubble jet head. The method at step 2406 may further include heating the aerosol precursor composition dispensed from the reservoir by the bubble jet head with the sprayer.

[00207] In some embodiments, the method of dispensing the aerosol precursor composition at step 2404 and heating the aerosol precursor composition at step 2406 involves independently applying energy from a power source to the bubble jet head and atomizer. In addition, dispensing the aerosol precursor composition at step 2404 and heating the aerosol precursor composition at step 2406 may include directing energy to the atomizer after applying energy to the bubble-jet head. The method may further include preheating the aerosol precursor composition by the bubble jet head prior to dispensing the aerosol precursor composition at step 2406. Additionally, the method may include detecting the temperature of the aerosol precursor composition, wherein preheating the aerosol precursor composition comprises preheating the aerosol precursor composition to a desired temperature. . Preheating the aerosol precursor composition may involve applying to the bubble jet head a pulse of energy having a relatively short duration compared to the duration of dispensing of the aerosol precursor composition.

[00208] Various modifications and other embodiments of the present invention can be implemented by one skilled in the art after becoming familiar with the present invention, taking advantage of the principles presented in the preceding descriptions and accompanying drawings. Thus, it is to be understood that the present invention is not intended to be limited to the specific embodiments described herein and that modifications and other embodiments fall within the scope of the appended claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (36)

1. A device for delivering an aerosol, containing: a reservoir at least partially filled with the aerosol precursor composition; a bubble-jet head comprising an ejection heating element and a precursor nozzle and in fluid communication with the reservoir, said bubble-jet head configured to dispense the aerosol precursor composition from the reservoir; And a nebulizer comprising a vapor-generating heating element and configured to heat the aerosol precursor composition dispensed by the bubble jet head to form an aerosol, wherein the bubble-jet head is configured to direct the aerosol precursor composition from the reservoir to the atomizer in response to an input stimulus, wherein said precursor nozzle is sized to prevent movement of the aerosol precursor composition therethrough such that movement of the aerosol precursor composition to the atomizer is initially blocked. 2. The aerosol delivery device of claim 1, wherein the bubble jet head comprises a plurality of precursor nozzles, wherein said plurality of precursor nozzles are sized to prevent movement of the aerosol precursor composition therethrough such that movement of the aerosol precursor composition to the atomizer is initially blocked. . 3. The aerosol delivery device of claim 1 or 2, wherein the pressure in the reservoir is negative, wherein the negative pressure prevents the aerosol precursor composition from passively moving out of the reservoir. 4. The aerosol delivery device of claim 3, wherein the reservoir comprises a movable piston, said movable piston being configured to generate negative pressure. 5. The aerosol delivery device of claim 4, wherein the reservoir also includes a spring, said piston and spring being configured to generate negative pressure. 6. The aerosol delivery device of claim 3, wherein a negative pressure is applied to the reservoir before sealing the reservoir to provide negative pressure in the reservoir. 7. Device for aerosol delivery according to any one of paragraphs. 1-6, also comprising a flow sensor, wherein said input action is an input action indicating user tightening detected by the flow sensor. 8. Device for aerosol delivery according to any one of paragraphs. 1-7, wherein, in response to said input stimulus, the aerosol delivery device is configured to emit an aerosol precursor composition to the atomizer. 9. The aerosol delivery device of claim 8, wherein the bubble-jet head also comprises one or more ejection heating elements, and in response to said input stimulus, the aerosol delivery device is configured to supply current to said one or more ejection heating elements. elements. 10. The aerosol delivery device of claim 1, wherein the bubble-jet head is configured to emit the aerosol precursor composition substantially perpendicular to the heating surface of the atomizer. 11. A device for delivering an aerosol according to claim 1, in which the heating surface of the atomizer is non-flat. 12. A device for delivering an aerosol according to claim 1, in which the heating surface of the atomizer is textured. 13. The aerosol delivery device of claim 1, wherein the reservoir comprises a reservoir substrate configured to direct the aerosol precursor composition to the bubble-jet head. 14. The aerosol delivery device of claim 1, wherein the bubble-jet head is connected to a distal end of the reservoir. 15. The aerosol delivery device according to claim 1, wherein the bubble-jet head is connected to the side of the reservoir. 16. A device for delivering an aerosol according to claim 1, in which the bubble-jet head and the sprayer are located between the reservoir and the mouthpiece. 17. A device for delivering an aerosol according to claim 1, in which the reservoir is located between the mouthpiece and the atomizer and the bubble-jet head. 18. The aerosol delivery device according to claim 1, wherein the thermal mass of the ejection heating element is less than the thermal mass of the vapor-generating heating element. 19. The aerosol delivery device according to claim 1, in which the bubble-jet head also contains an inlet for the precursor and a nozzle for the precursor; wherein the atomizer also includes an aerosol outlet. 20. The aerosol delivery device according to claim 19, in which the area of the aerosol outlet is larger than the area of the nozzle for the predecessor. 21. The aerosol delivery device of claim 19, wherein the ejection heating element, the precursor nozzle, and the vapor-generating heating element are axially aligned. 22. The aerosol delivery device of claim 19, wherein the housing defines at least one of a precursor inlet, a precursor nozzle, and an aerosol outlet. 23. A method for generating an aerosol in a device for delivering an aerosol, including: receiving input influence on the aerosol delivery device, direction of air flow from the control housing containing the power supply through the cartridge containing the reservoir, dispensing the aerosol precursor composition from the reservoir via a bubble jet head comprising an ejection heating element and a precursor nozzle, and heating the aerosol precursor composition dispensed from the reservoir by means of a bubble-jet head with a sprayer containing a vapor-generating heating element, wherein the aerosol precursor composition is directed from the reservoir to the nebulizer in response to said input stimulus, wherein said precursor nozzle is sized to prevent movement of the aerosol precursor composition therethrough such that movement of the aerosol precursor composition to the atomizer is initially blocked. 24. The method of claim 23, wherein, in response to said input stimulus, the aerosol precursor composition is emitted from the bubble-jet head to the atomizer.