RU2824939C2 - Aerosol delivery device (variants) - Google Patents

Abstract

FIELD: aerosol delivery devices.

SUBSTANCE: group of inventions relates to aerosol delivery devices with the possibility of using power supply. The device comprises a control device which includes an outer casing forming an outer wall and having a proximal end and a distal end, and a cartridge. The proximal end forms a chamber for accommodating the cartridge, and the control device also contains a power supply and a control component. A cartridge includes a mouthpiece part and a container part. The mouthpiece part and the container part have respective proximal and distal ends. The container part is configured to contain a liquid composition, and the cartridge includes a spray element and a liquid transfer element. Part of the cartridge is made with the possibility of detachable connection with the camera to accommodate the cartridge of the control device. At least a portion of the liquid transfer member is positioned near a spray element configured to vaporize the liquid composition to generate an aerosol and located above the proximal end of the container portion. The spray element includes a heating element containing a flat heating element and having a curved shape when it is inserted into the cartridge.

EFFECT: aerosol delivery with improved features for ease of use.

16 cl, 48 dwg

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Patent Application No. 16/598,505, entitled "Heater and Liquid Transfer for an Aerosol Delivery System," filed October 10, 2019, and U.S. Provisional Patent Application No. 62/744,978, entitled "Aerosol Generating Device," filed October 12, 2018, each of which is incorporated herein by reference in its entirety.

AREA OF TECHNOLOGY

[0002] The present invention relates to aerosol delivery devices, such as smoking articles, and more particularly to aerosol delivery devices that can use electrical power to generate an aerosol (e.g., smoking articles commonly referred to as electronic cigarettes). Smoking articles can be configured to vaporize an aerosol precursor, which can include materials that can be made or obtained from tobacco, or otherwise include tobacco, wherein said precursor is capable of forming an inhalable substance for human consumption.

LEVEL OF TECHNOLOGY

[0003] Over the years, a variety of smoking devices have been proposed as an improvement or alternative to smoking products that require the combustion of tobacco. It is understood that many of these devices have been designed to provide the sensations associated with smoking cigarettes, cigars, or tobacco pipes, but without delivering significant amounts of incomplete combustion and pyrolysis products that result from the combustion of tobacco. To this end, a variety of smoking products, flavor generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a vaporizable material or attempt to provide the sensations of smoking cigarettes, cigars, or tobacco pipes without substantially burning tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generating sources disclosed in the art as described in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Application Publication No. 2013/0255702 to Griffith Jr. et al., and U.S. Patent Application Publication No. 2014/0096781 to Sears et al., which are incorporated herein by reference in their entireties. Also see, for example, the various types of electrically powered smoking articles, aerosol delivery devices, and heat generating sources referenced by trademark and trade information in U.S. Patent Application Ser. No. 14/170,838 to Bless et al., filed February 3, 2014, which is incorporated herein by reference in its entirety. It is preferable to provide an aerosol delivery device with improved features for ease of use.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

[0004] The present invention relates to aerosol delivery devices, methods for making such devices, and elements of such devices. In particular, the present invention relates to an aerosol delivery device. In this regard, various embodiments of the present invention provide an aerosol delivery device with improved elements for ease of use. The present invention includes, without limitation, the following example implementations:

[0005] Example of implementation 1: An aerosol delivery device comprising a control device that includes an outer casing that forms an outer wall and has a proximal end and a distal end, wherein the proximal end of the control device forms a chamber for accommodating a cartridge, and the control device also comprises a power source and a control component, and a cartridge that includes a mouthpiece portion and a container portion, wherein the mouthpiece portion and the container portion have corresponding proximal and distal ends, wherein the container portion is configured to contain a liquid composition, and the cartridge also includes a spray element and a liquid transfer element, wherein a portion of the cartridge is configured to be detachably connected to the cartridge accommodating chamber of the control device, wherein at least a portion of the liquid transfer element is located near the spray element, and the spray element is configured to evaporate the liquid composition to generate an aerosol, wherein at least a portion of the spray element is located above the proximal end of the container portion.

[0006] Embodiment example 2: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the spray element comprises a heating element configured to heat the liquid composition to generate the aerosol.

[0007] Embodiment example 3: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the cartridge also includes a second liquid transfer element configured to transfer liquid to the first liquid transfer element.

[0008] Embodiment example 4: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein at least a portion of the heating element is located between the distal end of the mouthpiece portion and the proximal end of the container portion.

[0009] Embodiment example 5: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the cartridge also includes a sleeve portion located between the mouthpiece portion and the container portion, wherein at least a portion of the heating element is located in the sleeve portion.

[00010] Embodiment example 6: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element mounted in a curved orientation, wherein the second liquid transfer element forms a longitudinal portion that intersects the curved transverse portion, wherein the length of the longitudinal portion of the second liquid transfer element is greater than the length of the transverse portion.

[00011] Embodiment example 7: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, further comprising a curved covering element, wherein the curvature of the covering element is opposite to the curvature of the heating element.

[00012] Embodiment example 8: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element mounted in a curved orientation, wherein the second liquid transfer element forms a longitudinal portion that intersects the curved transverse portion, and the length of the transverse portion of the second liquid transfer element is greater than the length of the longitudinal portion.

[00013] Embodiment example 9: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, further comprising a curved covering element, wherein the curvature of the covering element is opposite to the curvature of the heating element.

[00014] Embodiment example 10: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a U-shape defining a central portion and two opposite support portions, wherein a portion of the heating element is wrapped around at least the central portion of the first liquid transfer element, wherein the second liquid transfer element defines a longitudinal portion that intersects the transverse portion, wherein the length of the longitudinal portion of the second transfer element is greater than the length of the transverse portion.

[00015] Embodiment example 11: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a U-shape defining a central portion and two opposite support portions, wherein a portion of the heating element is wrapped around at least the central portion of the first liquid transfer element, wherein the second transfer element surrounds both supports of the first liquid transfer element, and the length of the supports of the first liquid transfer element is greater than the length of the central portion of the first liquid transfer element.

[00016] Embodiment example 12: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge, wherein a portion of the heating element is wrapped around at least a portion of the first liquid transfer element, and the second liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge.

[00017] Embodiment example 13: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is substantially solid, and the length of the second liquid transfer element is greater than the length of a portion of the first liquid transfer element.

[00018] Embodiment example 14: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is hollow, wherein the second liquid transfer element surrounds at least a portion of the first liquid transfer element, and the length of the first liquid transfer element is greater than the length of the second liquid transfer element.

[00019] Embodiment example 15: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the first liquid transfer element is hollow and comprises a ceramic material.

[00020] Embodiment example 16: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the first liquid carrier comprises a cotton material and/or a silicon dioxide material.

[00021] Embodiment example 17: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge, wherein a portion of the heating element is embedded in at least a portion of the first liquid transfer element, and the second liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge.

[00022] Embodiment example 18: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is substantially solid, and the length of the second liquid transfer element is greater than the length of a portion of the first liquid transfer element.

[00023] Embodiment example 19: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is hollow, wherein the second liquid transfer element surrounds at least a portion of the first liquid transfer element, and the length of the first liquid transfer element is greater than the length of the second liquid transfer element.

[00024] Embodiment example 20: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element, wherein the second liquid transfer element comprises a plurality of capillary tubes, wherein the heating element and the first liquid transfer element are substantially aligned with a transverse axis of the cartridge, and the plurality of capillary tubes are substantially aligned with a longitudinal axis of the cartridge.

[00025] Embodiment example 21: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of capillary tubes comprises a pair of spaced apart capillary tubes.

[00026] Embodiment example 22: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of capillary tubes comprises five spaced apart capillary tubes arranged in a cross-shaped pattern.

[00027] Embodiment example 23: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element, wherein the second liquid transfer element forms a longitudinal portion that intersects the transverse portion, wherein the length of the longitudinal portion of the second liquid transfer element is greater than the length of the transverse portion.

[00028] Embodiment example 24: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the cartridge also includes a sleeve portion located between the mouthpiece portion and the container portion.

[00029] Embodiment example 25: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the spray element is located at least partially within the sleeve portion.

[00030] Embodiment example 26: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the spray element comprises a heating element configured to heat the liquid composition to generate the aerosol, and the device also comprises a covering element located near the heating element and located at least partially within the mouthpiece portion.

[00031] An embodiment example 27: An aerosol delivery device comprising a control device that comprises an outer casing that defines an outer wall and has a proximal end and a distal end, wherein the proximal end of the control device defines a chamber for accommodating a cartridge, and the control device also comprises a power source and a control component, and a cartridge that includes a mouthpiece portion and a container portion, wherein the mouthpiece portion and the container portion have corresponding proximal and distal ends, wherein the container portion is configured to contain a liquid composition, and the cartridge also includes a first liquid transfer element, a second liquid transfer element, and a spray element, wherein a portion of the cartridge is configured to be releasably connected to the cartridge accommodating chamber of the control device, wherein the spray element is configured to evaporate the liquid composition to generate an aerosol, wherein at least a portion of the spray element is located between the proximal end of the container portion and the distal end of the container portion, wherein at least a portion of the first liquid transfer element is located under the spray element, and the second liquid transfer element is located under the first liquid transfer element, wherein the second liquid transfer element is configured to transfer liquid to the first liquid transfer element.

[00032] Embodiment example 28: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the nebulization element comprises a heating element configured to heat the liquid composition to generate the aerosol.

[00033] Embodiment example 29: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element, and the heating element is located near the distal end of the container portion.

[00034] An embodiment example 30: An aerosol delivery device comprising a control device that comprises an outer casing that forms an outer wall and has a proximal end and a distal end, wherein the proximal end of the control device forms a chamber for accommodating a cartridge, and the control device also comprises a power source and a control component, and a cartridge that includes a mouthpiece portion and a container portion, wherein the mouthpiece portion and the container portion have corresponding proximal and distal ends, wherein the container portion is configured to contain a liquid composition, and the cartridge also includes a spray element and a liquid transfer element, wherein a portion of the cartridge is configured to be removably connected to the cartridge accommodating chamber of the control device, wherein at least a portion of the liquid transfer element is located near the spray element, and the spray element is configured to evaporate the liquid composition to generate an aerosol, wherein at least a portion of the spray element is located near the distal end of the mouthpiece portion.

[00035] Embodiment example 31: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the nebulization element comprises a heating element configured to heat the liquid composition to generate the aerosol.

[00036] Embodiment example 32: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the cartridge further includes a second liquid transfer element configured to transfer liquid to the first liquid transfer element.

[00037] Embodiment example 33: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element mounted in a curved orientation, wherein the second liquid transfer element forms a longitudinal portion that intersects the curved transverse portion, wherein the length of the longitudinal portion of the second liquid transfer element is greater than the length of the transverse portion.

[00038] Embodiment example 34: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, further comprising a curved cover element, wherein the curvature of the cover element is opposite to the curvature of the heater.

[00039] Embodiment example 35: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element mounted in a curved orientation, wherein the second liquid transfer element defines a longitudinal portion that intersects the curved transverse portion, wherein the length of the transverse portion of the second liquid transfer element is greater than the length of the longitudinal portion.

[00040] Embodiment example 36: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, further comprising a curved covering element, wherein the curvature of the covering element is opposite to the curvature of the heater.

[00041] Embodiment example 37: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a U-shape defining a central portion and two opposite support portions, wherein a portion of the heating element is wrapped around at least the central portion of the first liquid transfer element, wherein the second liquid transfer element defines a longitudinal portion that intersects the transverse portion, wherein the length of the longitudinal portion of the second transfer element is greater than the length of the transverse portion.

[00042] Embodiment example 38: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a U-shape defining a central portion and two opposing support portions, wherein a portion of the heating element is wrapped around at least the central portion of the first liquid transfer element, wherein the second transfer element surrounds both supports of the first liquid transfer element, and the length of the supports of the first liquid transfer element is greater than the length of the central portion of the first liquid transfer element.

[00043] Embodiment example 39: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge, wherein a portion of the heating element is wrapped around at least a portion of the first liquid transfer element, and the second liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge.

[00044] Embodiment example 40: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is substantially solid, and the length of the second liquid transfer element is greater than the length of a portion of the first liquid transfer element.

[00045] Embodiment example 41: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is hollow, wherein the second liquid transfer element surrounds at least a portion of the first liquid transfer element, and the length of the first liquid transfer element is greater than the length of the second liquid transfer element.

[00046] Embodiment example 42: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the first liquid transfer element is hollow and comprises a ceramic material.

[00047] Embodiment example 43: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the first liquid transfer element comprises a cotton material and/or a silicon dioxide material.

[00048] Embodiment example 44: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a heating element in the form of a coil, wherein the first liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge, wherein a portion of the heating element is embedded in at least a portion of the first liquid transfer element, and the second liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge.

[00049] Embodiment example 45: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is substantially solid, and the length of the second liquid transfer element is greater than the length of a portion of the first liquid transfer element.

[00050] Embodiment example 46: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the second liquid transfer element is hollow, wherein the second liquid transfer element surrounds at least a portion of the first liquid transfer element, and the length of the first liquid transfer element is greater than the length of the second liquid transfer element.

[00051] Embodiment example 47: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the heating element comprises a flat heating element, wherein the second liquid transfer element comprises a plurality of capillary tubes, wherein the heating element and the first liquid transfer element are substantially aligned with a transverse axis of the cartridge, and the plurality of capillary tubes are substantially aligned with a longitudinal axis of the cartridge.

[00052] Embodiment example 48: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of capillary tubes comprises a pair of spaced apart capillary tubes.

[00053] Embodiment example 49: An aerosol delivery device according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of capillary tubes comprises five spaced apart capillary tubes arranged in a cross-shaped pattern.

[00054] Embodiment example 50: An aerosol delivery device according to any preceding embodiment or any combination of any embodiments, wherein the heating element comprises a flat heating element, wherein the second liquid transfer element forms a longitudinal portion that intersects the transverse portion, wherein the length of the longitudinal portion of the second liquid transfer element is greater than the length of the transverse portion.

[00055] These and other features, aspects and advantages of the present disclosure will become apparent from a reading of the following detailed description with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more of the above embodiments, as well as combinations of two, three, four or more features or elements set forth in the present description, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole, so that any individual features or elements of the disclosed invention in any of its aspects and embodiments should be considered as combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF DRAWINGS

[00056] Having therefore described the present invention in the general terms set forth above, reference is now made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[00057] FIG. 1 is a perspective view of an aerosol delivery device according to an embodiment of the present invention;

[00058] FIG. 2 is a front view, partially cut away, of the aerosol delivery control device shown in FIG. 1, according to an embodiment of the present invention;

[00059] FIG. 3A is a perspective view of a cartridge according to an example embodiment of the present invention;

[00060] FIG. 3B is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00061] FIG. 4 shows an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00062] FIG. 5A is a partially sectioned side view of a cartridge according to an embodiment of the present invention;

[00063] FIG. 5B is a partially sectioned side view on an enlarged scale of a cartridge according to an embodiment of the present invention;

[00064] FIG. 6 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00065] FIG. 7A is a partially sectioned side view of a cartridge according to an exemplary embodiment of the present invention;

[00066] FIG. 7B is a partially sectioned side view on an enlarged scale of a cartridge according to an embodiment of the present invention;

[00067] FIG. 8 shows an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00068] FIG. 9 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00069] FIG. 10 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00070] FIG. 11 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00071] FIG. 12 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00072] FIG. 13 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00073] FIG. 14 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00074] FIG. 15 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00075] FIG. 16 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00076] FIG. 17 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00077] FIG. 18 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00078] FIG. 19 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00079] FIG. 20 is a perspective view with partial section of a cartridge according to an embodiment of the present invention;

[00080] FIG. 21 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00081] FIG. 22 is a front view, partially cut away, of a cartridge according to an embodiment of the present invention;

[00082] FIG. 23 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00083] FIG. 24 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00084] FIG. 25 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00085] FIG. 26 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00086] FIG. 27 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00087] FIG. 28 is a perspective view with partial section of a cartridge according to an embodiment of the present invention;

[00088] FIG. 29 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00089] FIG. 30 is a perspective view with a partial section of a cartridge according to an embodiment of the present invention;

[00090] FIG. 31 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00091] FIG. 32 is a perspective view with partial section of a cartridge according to an embodiment of the present invention;

[00092] FIG. 33 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00093] FIG. 34 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00094] FIG. 35 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00095] FIG. 36 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00096] FIG. 37 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00097] FIG. 38 is a front view in partial section of a cartridge according to an embodiment of the present invention;

[00098] FIG. 39 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[00099] FIG. 40 is a perspective view with partial section of a cartridge according to an embodiment of the present invention;

[000100] FIG. 41 is an exploded perspective view of a cartridge according to an embodiment of the present invention;

[000101] FIG. 42 is a front view with partial section of a cartridge according to an embodiment of the present invention;

[000102] FIG. 43 is a perspective view with a partial section of a portion of a cartridge according to an embodiment of the present invention;

[000103] FIG. 44 is a partial perspective view of a portion of a cartridge according to an embodiment of the present invention;

[000104] FIG. 45 is a front view with partial section of a cartridge according to an embodiment of the present invention;

IMPLEMENTATION OF THE INVENTION

[000105] The present invention is described in more detail below with reference to examples of its implementations. These examples of implementations are described in such a way that this disclosure thoroughly, completely and fully conveys the scope of the invention to a person skilled in the art. In fact, the present invention can be implemented in many different forms and should not be considered as limited to the embodiments given herein; on the contrary, these embodiments are given so that the present invention complies with applicable legal requirements. In this description and in the appended claims, a grammatical construction indicating that an element is given in the singular also includes the plural, unless the context of the invention clearly dictates otherwise.

[000106] As described below, embodiments of the disclosure of the present invention relate to aerosol delivery devices or vaporization devices, wherein these terms are used interchangeably herein. Aerosol delivery devices according to the disclosure of the present invention use electrical energy to vaporize (e.g., atomize, aerosolize, etc.) a material (preferably without burning the material to any significant extent and/or without significantly chemically changing the material) to form an inhalable substance; and the components of such devices are in the form of articles that are most preferably sufficiently compact to be considered portable devices. In other words, use of the components of the preferred aerosol delivery devices does not result in the formation of smoke, i.e., from by-products of combustion or pyrolysis of tobacco, but rather, use of these preferred systems results in the formation of vapors formed during the vaporization or vaporization of the aerosol precursor composition. In preferred embodiments, the components of the aerosol delivery devices may be characterized as electronic cigarettes, and said electronic cigarettes most preferably include tobacco and/or tobacco-derived components and thus deliver tobacco-derived components in the form of an aerosol.

[000107] Certain preferred aerosol delivery devices may provide a variety of sensations (e.g., inhalation and exhalation rituals, flavor and aroma types, organoleptic effects, physical sensation, rituals of use, visual cues such as those provided by a visible aerosol, and the like) of smoking a cigarette, cigar, or pipe that are caused by lighting and burning tobacco (and then inhaling the tobacco smoke) without significantly burning any of their components. For example, a user of an aerosol delivery device according to the disclosure of the present invention may hold and use the device in a manner similar to how a smoker uses a traditional type of smoking article, by drawing on one end of the device to inhale the aerosol generated by the device, by taking or performing puffs at selected intervals, and the like.

[000108] The disclosed aerosol delivery devices may also be characterized as vapor-generating articles or drug delivery articles. Thus, such articles or devices may be adapted to deliver one or more substances (e.g., flavoring agents and/or pharmaceutical active ingredients) in a form or state suitable for inhalation. For example, the inhalable substances may be substantially in the form of a vapor (e.g., a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, the inhalable substances may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is intended to refer to vapors, gases, and aerosols of a form or type that are suitable for inhalation by a person, whether or not they are visible and whether or not they have a shape that can be considered "smoke-like."

[000109] Aerosol delivery devices according to the disclosure of the present invention most preferably comprise some combination of a power source (e.g., an electrical power source), at least one control component (e.g., means for actuating, controlling, regulating, and stopping the supply of power to generate an aerosol, such as by controlling an electrical current from the power source to other components of the article - for example, a microcontroller or a microprocessor), an atomizing element (e.g., a piezoelectric vibrating element or a heating element such as, for example, an electrical resistive heating element or a material configured to generate heat as a result of eddy currents by induction, which alone or in combination with one or more additional elements may be generally referred to as an "atomizer"), a liquid composition (e.g., typically a liquid in the form of an aerosol precursor composition capable of forming an aerosol upon the application of sufficient heat or other energy, such ingredients are commonly referred to as "smoke juice", "e-liquid" and "e-juice"), and a mouthpiece or a mouthpiece area to allow a puff to be taken through an aerosol delivery device for inhaling the aerosol (e.g. a defined air flow path through the product so that the generated aerosol can be expelled from it after a puff has been taken).

[000110] More specific formats, configurations and arrangements of components in aerosol delivery devices in accordance with the present invention will be apparent in light of the further disclosure of the invention presented below. In addition, the selection and arrangement of various components of aerosol delivery devices may be understood by considering commercially available electronic aerosol delivery devices, such as those representative products referenced in the "Background of the Invention" section of the present disclosure.

[000111] In various embodiments, the present invention relates to aerosol delivery devices and cartridges for aerosol delivery devices that include one or more components configured to evaporate a liquid composition and one or more components configured to deliver a liquid to the one or more components configured to evaporate the liquid. In various embodiments, the one or more evaporation components and the one or more liquid transfer components may be located at different locations within the cartridge.

[000112] An example of an embodiment of an aerosol delivery device 100 of the disclosure of the present invention is shown in FIG. 1. As shown in the drawing, the aerosol delivery device 100 includes a control device 200 and a removable cartridge 300. Although only one cartridge is shown in the illustrated embodiment, it should be understood that in various embodiments, the aerosol delivery device 100 may include an interchangeable system. For example, in one or more embodiments, a single control device may be used with a plurality of different cartridges. Likewise, in one or more embodiments, a single cartridge may be used with a plurality of different control devices.

[000113] In various embodiments, the control device 200 comprises an outer housing 202 that forms an outer wall 204 that includes a distal end 206 and a proximal end 208. The aerosol delivery device 100 of the illustrated embodiment also includes an indicator window 240 formed in the outer housing 202. However, it should be noted that in some embodiments, the indicator window may be absent. FIG. 2 is a partially cutaway view of the control device 200 of the aerosol delivery device 100 of FIG. 1. As shown in the drawing, the control device 200 also includes an inner frame 215 that contains a chamber 212 for receiving a cartridge formed by a wall 214 of the inner frame. The control device 200 also includes a battery 216 located in the outer housing 202 and also includes an external connection element 218. In the illustrated embodiment, the external connection element 218 is located at the distal end 206 of the outer housing 202. The various components of the aerosol delivery device according to the present invention can be selected from components described in the art and commercially available. Examples of batteries that can be used according to the invention are described in U.S. Patent Application Publication No. 2010/0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference.

[000114] In various embodiments, the control device 200 may also include a light source 230 and at least one slit 232 (see FIG. 1) formed in the outer wall 204 of the control device 200 through which light from the light source 230 may be visible. In some embodiments, the light source 230 may comprise, for example, at least one light emitting diode (LED) configured to provide one or more colors of illumination. In some embodiments, the light source may be configured to provide illumination in only one color, while in other embodiments, the light source may be configured to provide illumination in various other colors. In still other embodiments, the light source may be configured to provide white light. As shown in FIG. 2, the second light source 230 can be located directly on the control component 234 (such as, for example, a printed circuit board (PCB)), in which additional control components (for example, a microcontroller and / or memory components) can be included. In various embodiments, the slit 232 can be provided in any desired shape and can be, in particular, located near the distal end 206 of the control device 200. In some embodiments, the slit 232 can be completely open or can be filled, for example, with a light guide material, or can be covered with a transparent or translucent element (for example, glass or plastic or other material, such as a fibrous polymer sheet material) on one or both of the inner surface and the outer surface of the outer wall 204 of the control device 200. The aerosol delivery device 100 can also contain a control mechanism for controlling the amount of electrical energy supplied to the spray element during a puff. Representative types of electronic components, their structure and configuration, their features, and their general methods of operation are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent No. 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., U.S. Patent No. 8,205,622 to Pan, U.S. Patent Application Publication No. 2009/0230117 to Fernando et al., U.S. Patent Application Publication No. 2014/0060554 to Collet et al. etc., in U.S. Patent Application Publication No. 2014/0270727 to Ampolini et al., and in U.S. Patent Application Publication No. 2015/0257445 to Henry et al., which are incorporated herein by reference in their entireties.

[000115] Electrical connectors 220 may be located in the chamber 212 for receiving a cartridge and, in the illustrated embodiment, are provided on the sides of the wall 214 of the inner frame. In various embodiments, electrical connectors 220 may be operatively connected to the battery (e.g., connected to the battery directly or via the control component 234). Electrical connectors may have various shapes and may be located in various other locations of the inner frame 215. As also shown in FIG. 2, the proximal end 208 of the outer housing 202 comprises an opening 210 that provides access to the chamber 212 for receiving a cartridge formed by the inner frame 215. It should be noted that for the purposes of the present invention, the terms "connected" and "operatively connected" should be interpreted in a broad sense to cover components that are directly connected and/or connected via one or more additional components.

[000116] In various embodiments, additional indicators (e.g., tactile feedback components, auditory feedback components, or the like) may be included in addition to or as an alternative to the light source. Additional representative types of components that provide visual signals or indicators, such as light emitting diode components, as well as the design and use thereof, are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al., 8,499,766 to Newton, and 8,539,959 to Scatterday, and in U.S. Patent Application Publication No. 2015/0020825 to Galloway et al. and in U.S. Patent Application Publication No. 2015/0216233 to Sears et al., which are incorporated herein by reference in their entireties. It should be understood that not all illustrated elements are necessary. For example, the LED may be missing or replaced with another indicator, such as a vibration indicator.

[000117] In various embodiments, an air flow sensor, a pressure sensor, or the like may be included in the device. For example, as shown in FIG. 2, the control device 200 may include a sensor 236 on the control component 234. Configurations of a printed circuit board and a pressure sensor, for example, are described in U.S. Patent Application Publication No. 2015/0245658 to Worm et al., the disclosure of which is incorporated herein by reference in its entirety. In various embodiments, the sensor 236 may be located anywhere within the control device 200 to be exposed to an air flow and/or a change in pressure that may signal a puff on the device and thereby cause the battery 216 to power the atomizing element in the cartridge 300. Alternatively, in the absence of an air flow sensor, the atomizing element may be manually activated, such as by means of a push button that may be located on the control housing 200 and/or the cartridge 300. Additional representative types of sensing and detecting mechanisms, their structure and configuration, their components, and general methods of operation are described in U.S. Patent No. 5,261,424 to Sprinkel, Jr., U.S. Patent No. 5,372,148 to McCafferty et al., and PCT No. WO 2010/003480 to Flick, which are incorporated herein by reference in their entireties.

[000118] In some embodiments, an input element may be included in the aerosol delivery device (and may replace or supplement the air flow or pressure sensor). An input device may be included to allow a user to control functions of the device and/or to output information to the user. Any component or combination of components may be used as an input to control a function of device 100. For example, one or more push buttons may be used as described in U.S. Publication No. 2015/0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touch screen may be used as described in U.S. Patent Application Ser. No. 14/643,626, filed March 10, 2015 to Sears et al., which is incorporated herein by reference in its entirety. As a further example, components configured to recognize gestures based on predetermined movements of the aerosol delivery device may be used as an input device. See US Publication No. 2016/0158782 by Henry et al., which is incorporated herein by reference in its entirety.

[000119] In some embodiments, the input device may comprise a computer or computing device, such as a smartphone or tablet. In particular, the aerosol delivery device may be connected to the computer or other device via wires, such as by using a USB cord or a similar protocol. The aerosol delivery device may also communicate with the computer or other device acting as the input device via wireless communication. See, for example, the systems and methods for controlling a device via a read request, as described in U.S. Publication No. 2016/0007561 to Ampolini et al., the disclosure of which is incorporated herein by reference in its entirety. In such embodiments, an application or other computer program may be used in conjunction with a computer or other computing device to input control commands to the aerosol delivery device, wherein such control commands include, for example, the ability to form an aerosol of a certain composition by selecting a nicotine content and/or a content of additional flavors to be included.

[000120] Although other embodiments may differ, in the illustrated embodiment, the inner frame 215 is separated from the outer casing 202. Thus, the inner frame 215, which forms a chamber 212 for receiving a cartridge, may exist independently and separately from the outer casing 202. The opening of the chamber may coincide with the opening at the near end 208 of the outer casing 202. Thus, in the illustrated embodiment, the wall 214 of the inner frame may be a completely different element that is attached to the outer casing 202; however, in other embodiments, the wall of the inner frame and the outer casing may be formed continuously. In any case, the side walls forming the wall of the inner frame are located inside the outer casing and are separated from it.

[000121] In various embodiments, the outer casing 202 may be formed from any suitable material, such as metal, plastic, ceramic, glass, or the like. In some embodiments, the inner frame 215 may be formed from a different material than that used to form the outer casing 202. For example, in some embodiments, the outer casing may comprise a metal material and the inner frame may comprise a plastic material. In other embodiments, the same materials may be used. The selection of materials, as noted above, may also extend to the outer casing for any additional control device(s) that is included in the device. For example, in the embodiment shown, the casing and the inner frame may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof). In other embodiments, one or more of these components may be made of other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000122] An example of an embodiment of a cartridge 300 for use in an aerosol delivery device of the present disclosure is shown in FIGS. 3A and 3B. In particular, FIG. 3A is a perspective view of a cartridge according to example embodiments of the present invention, and FIG. 3B is a partially cutaway view of the cartridge shown in FIG. 3. As shown in FIGS. 3A and 3B, the cartridge 300 comprises a container portion 302 that is formed by an outer wall 304 of the container that includes a near end 306 and a far end 308 that is closed. Thus, the container portion 302 can be characterized in that the container wall 304 is a side wall that is continuous around the container, and the far end 308 forms a bottom wall. The container portion 302 is also configured to contain a liquid composition 324 for vaporization (for example, an electronic liquid or an aerosol precursor composition), which can be configured as otherwise described herein. The cartridge 300 also comprises a mouthpiece portion 310, which is formed by an outer wall 312 of the mouthpiece, which includes a near end 314 with an outlet opening 315 passing through it, and a far end 316, which interacts with the near end 306 of the container portion 302.

[000123] For aerosol delivery systems that are characterized as electronic cigarettes, the aerosol precursor composition may include tobacco or tobacco-derived components. In one respect, the tobacco may be in the form of tobacco pieces or pieces, such as finely ground, shredded, or powdered tobacco strip. Tobacco balls, pellets, or other solid forms may be included, such as described in US Patent Application Publication No. 2015/0335070 to Sears et al., the disclosure of which is incorporated herein by reference. In another respect, the tobacco may be in the form of an extract, such as a spray-dried extract, that includes many of the water-soluble components of tobacco. Alternatively, the tobacco extracts may be in the form of relatively high nicotine extracts that also contain minor amounts of other extracted components derived from tobacco. In another respect, components derived from tobacco may be provided in a relatively pure form, such as certain flavoring substances that are derived from tobacco. On the one hand, a component that is derived from tobacco and that can be used in a highly purified or substantially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[000124] In the illustrated embodiment, the liquid composition, sometimes referred to as an aerosol precursor composition, a vapor precursor composition, or an “e-liquid,” may comprise various components including, by way of example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, and/or flavorings. Representative types of aerosol precursor components and compositions are also known and characterized in U.S. Patent No. 7,217,320 to Robinson and in U.S. Patent Application Publication Nos. 2013/0008457 to Zheng et al.; 2013/0213417 to Chong; and 2014/0060554 to Collett et al.; 2015/0020823 to Lipowicz et al.; and No. 2015/0020830 to Koller, and WO 2014/182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include aerosol precursors that are included in the VUSE® products of R.J. Reynolds Vapor Company, the BLUTM products of Fontem Ventures B.V., the MISTIC MENTHOL product of Mistic Ecigs, the MARK TEN products of Nu Mark LLC, the JUUL product of Juul Labs, Inc., and the VYPE products of CN Creative Ltd. Also desirable are the so-called "smoke juices" for electronic cigarettes that are available from Johnson Creek Enterprises LLC. Other additional examples of aerosol precursor compositions are sold under the trade names BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, MITTEN VAPORS, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THE JUICE MAN.

[000125] The amount of aerosol precursor included in the aerosol delivery system is such that the aerosol generating device has acceptable sensory and desired performance characteristics. For example, it is particularly preferred that a sufficient amount of aerosol forming material (e.g., glycerin and/or propylene glycol) is used to ensure the generation of a visible primary aerosol, which in many ways resembles the appearance of tobacco smoke. The amount of aerosol precursor within the aerosol generating system may depend on factors such as the number of puffs desired. In one or more embodiments, about 1 ml or more, about 2 ml or more, about 5 ml or more, or about 10 ml or more of the aerosol precursor composition may be included.

[000126] In some embodiments, the liquid composition 324 may contain one or more flavorings. As used herein, reference to "flavoring" refers to compounds or components that can be aerosolized or delivered to a user and that convey a sensory experience of taste and/or aroma. Examples of flavoring agents include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (such as apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hips, mate, gaius, honeybush, rooibos, californica, bacopa monnieri, ginkgo biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarola, cocoa, licorice, and flavoring agents and additives of the type and nature traditionally used to flavor cigarette, cigar, and pipe tobacco. Additionally, syrups such as high fructose corn syrup may be used. Examples of plant-derived compositions that may be suitable are described in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012/0152265 to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such additional components will vary depending on such factors as the sensory characteristics desired in the smoking article, and the present invention encompasses any such additional components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972), and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties. It should be noted that the reference to a flavoring agent need not be limited to any one flavoring agent as described above, and may in fact be a combination of one or more flavoring agents.

[000127] In various embodiments, the entire cartridge 300 or the mouthpiece portion 310 and/or the container portion 302 may be individually formed relative to a longitudinal axis (L), a first transverse axis (T1) that is perpendicular to the longitudinal axis, and a second transverse axis (T2) that is perpendicular to the longitudinal axis and perpendicular to the first transverse axis. As shown in FIG. 3B, the cartridge 300 also includes a spray element configured to evaporate the liquid composition. In the illustrated embodiment, the atomizing element comprises a heating element 320. Although the atomizing element of the illustrated embodiment comprises a heating element configured to heat a liquid composition to vaporize the composition to form an aerosol, in other embodiments, the atomizing element may comprise any device, element, or assembly configured to vaporize (e.g., atomize, aerosolize, etc.) a liquid composition to form an aerosol, including, for example, atomizing nozzle devices and piezoelectric devices, such as devices that are configured to subject the liquid composition to vibration (e.g., ultrasonic vibration), which vaporizes the composition to form an aerosol. In various embodiments, such devices may use electrical power from a power source to form an aerosol. Some examples of piezoelectric vibrating devices are described in U.S. Patent Application Publication No. 2013/0319404 to Amir et al., which is incorporated herein by reference in its entirety.

[000128] The cartridge also includes a liquid transfer element 321, at least a portion of which is located near (e.g., immediately adjacent to, adjacent to, in close proximity to, or in relatively close proximity to) the heating element 320. The liquid transfer element 321 of the illustrated embodiment extends between the heating element 320 and the liquid composition 324 contained within the container portion 302. In the illustrated embodiment, at least a portion of the heating element 320 is located above the proximal end 306 of the container portion 302. For the purposes of the disclosure of the present invention, it should be understood that the term "above" in this particular context should be interpreted as meaning toward the proximal end 314 of the mouthpiece portion 310 in a direction substantially along the longitudinal axis (L), as shown in FIG. 3B.

[000129] In various embodiments, the heating element 320 and the liquid transfer element 321 may be formed as separate elements that are fluidly connected, or may be formed as a combined element. Moreover, the heating element 320 and the liquid transfer element 321 may be formed from any structure as otherwise described herein. The cartridge 300 also includes one or more electrical contacts 325 that are configured to electrically connect the heating element 320 to the battery 216 and/or the control component 234 of the control device 200. It should be noted that in some embodiments, the heating element and the liquid transfer element may be combined into a single component. For example, in some embodiments, the heating element may be integrated into the liquid transfer element. Some examples of such components are described in U.S. Patent No. 8,833,364 to Buchberger and in U.S. Patent Application Publication No. 2017/0203057 to Buchberger et al., each of which is incorporated herein by reference in its entirety.

[000130] In various embodiments, the fluid transfer element 321 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, the fluid transfer element may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, the fluid transfer element 321 may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, the fluid transfer element 321 may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent Application Publication No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid (e.g., non-hollow) wick.

[000131] In various embodiments, the heating element 320 may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In some embodiments, the heating element 320 may be a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element 320 may be formed from a conductive ink, boron-doped silicon dioxide, and/or a ceramic (e.g., a positive or negative temperature coefficient ceramic). Other types of heaters, such as laser diodes or microheaters, may also be used. The laser diode may be configured to deliver electromagnetic radiation of a specific wavelength or range of wavelengths that may be tuned to vaporize the aerosol precursor composition and/or tuned to heat a liquid transport element by which the aerosol precursor composition may be provided for vaporization. The laser diode may in particular be arranged to deliver electromagnetic radiation within a chamber, and the chamber may be configured to capture the radiation (e.g., a black body or a white body). Suitable microheaters are described in U.S. Patent No. 8,881,737 to Collett et al., which is incorporated herein by reference in its entirety. For example, microheaters may comprise a substrate (e.g., quartz, silicon dioxide) with a heater track thereon (e.g., a resistive element such as Ag, Pd, Ti, Pt, Pt/Ti, boron-doped silicon, or other metals or metal alloys), which may be printed or otherwise applied to the substrate. A passivation layer (e.g., aluminum oxide or silicon dioxide) may be applied over the heater track. In particular, the heating element 320 may be substantially planar. Some examples of such heaters are described in U.S. Patent Application Publication No. 2016/0345633 to DePiano et al., which is incorporated herein by reference in its entirety.

[000132] In the embodiment shown, the outer wall 304 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 324 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 304 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 304 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 304 of the container or a portion thereof may be substantially opaque, and a strip (e.g., from about 1 mm wide to about 20 mm wide or from about 2 mm wide to about 18 mm wide or from about 5 mm wide to about 15 mm wide) extending from the near end 306 of the container portion 302 to the far end 308 of the container may be transparent or translucent. In additional embodiments, the outer wall 304 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 324 inside the container portion 302 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 304 of the container has a substantially opaque color.

[000133] In some embodiments, the control device 200 may be configured such that at least a portion of the container portion 302 is visible when the cartridge 300 interacts with the control device 200. As noted above, in some embodiments, at least a portion of the outer wall 304 of the container may be configured to be at least partially transparent and/or translucent such that the liquid composition 324 contained therein is visible from the outside, and the outer wall 204 of the control device 200 may be configured to include an indicator window 240 (see FIGS. 1 and 2) through which the outer wall 304 of the container and any liquid composition 324 present in the container portion 302 may be visible when the cartridge 300 interacts with the control device 200.

[000134] In one or more embodiments, the cartridge 300 may be configured such that the mouthpiece wall 312 includes a protruding portion located between its proximal end 314 and distal end 316. For example, with reference to FIG. 3A and 3B, the mouthpiece 310 comprises a projection 350 that extends along a circumferential surface from the wall 312 of the mouthpiece around substantially the entire mouthpiece 310. In some embodiments, the distance that the projection 350 extends from the wall 310 of the mouthpiece may be substantially uniform around the entire circumferential surface of the mouthpiece 310. In some embodiments, the distance that the projection 350 extends from the wall 312 of the mouthpiece may vary at one or more points around the circumferential surface of the mouthpiece 310. Still other embodiments may not include a projection.

[000135] In various embodiments, the electrical contacts 325, when located in the wall 312 of the mouthpiece, can be located longitudinally between the projecting portion 350 and the distal end 316 of the mouthpiece portion 310. Furthermore, in some embodiments, the projection 350 can be located substantially in line with the inner top wall 332. Thus, the projection 350 can be substantially parallel and/or can be located substantially in the same horizontal plane with the inner top wall 332. In some embodiments, the projection 350 can be located above the evaporation chamber 340 and above the heating element 320 along the longitudinal axis (L) of the mouthpiece portion 310.

[000136] In various embodiments, the projection 350 may cooperate with a corresponding bead on the control device 200 to ensure proper connection of the cartridge 300 to the control device 200. For example, with reference to FIG. 2, the control device 200 may be configured such that the opening 210 at its near end 208 includes a recess with a first inwardly projecting bead 221. Thus, the recess may comprise a rim wall 222 that is substantially parallel to the longitudinal axis of the device 100. The rim wall 222 may extend downwardly from the near end 208 a small distance that may substantially correspond to the thickness of the projection 350 of the cartridge 300 and/or the thickness of an additional element that may be located near the projecting part. For example, in some embodiments, the rim wall 222 that forms the downwardly extending recess may have a height (i.e., when measured from the upper surface of the inwardly projecting bead 221 to the proximal end 208 of the first device) of from about 1 mm to about 8 mm, from about 1 mm to about 6 mm, or from about 1 mm to about 5 mm. The inwardly projecting bead 221 may have a width (i.e., the distance the projection extends inward from the rim wall 222 to the terminal end) of from about 1 mm to about 8 mm, from about 1 mm to about 6 mm, or from about 1 mm to about 5 mm. In some embodiments, the inwardly projecting bead 221 may have a substantially constant width around the entire periphery of the opening 210. In other embodiments, the inwardly extending bead 221 may be continuous and thus may be formed from one or a plurality of inwardly extending beads located at a distance around the opening 210. In various embodiments, the projection 350 of the mouthpiece portion 310 is configured to be at least partially received in a recess formed by the rim wall 222 so as to contact the inwardly projecting bead 221. Thus, the lower surface of the projection 350 may be substantially in contact with the inwardly projecting bead 221, and the outer edge of the projection may be substantially adjacent to the rim wall 222.

[000137] In some embodiments, the projection 350 and/or the inwardly projecting flange 221 may be configured or may be configured to bias the cartridge 300 for coupling with the control device 200. For example, a magnetic coupling may be used. As shown in FIG. 3B, the cartridge 300 may include a magnet 352 located adjacent to the lower surface of the first projection 350. In various embodiments, the magnet 352 may extend substantially completely around the circumferential surface of the mouthpiece portion 310 or may be continuous such that it may be formed as one or a plurality of separate magnets. In various embodiments, the magnet 352 may be coupled to the wall 312 of the mouthpiece, may be coupled to the protruding portion 350, or may be coupled to both the wall 312 of the mouthpiece and the protruding portion 350. The inwardly projecting flange 221 may be made of metal or another material to which the magnet 352 will be attracted by a magnetic force. In additional embodiments, the magnet 352 may be located on the control device 200. More specifically, the magnet 352 may be coupled to the inwardly extending flange 221. In such embodiments, the projection 350 may be made of metal or another material to which the magnet 352 will be attracted by a magnetic force. In further embodiments, the magnet may be located on the cartridge 300 as well as on the control device 200. Thus, the magnet located adjacent to the lower surface of the projection 350 on the cartridge 300 may be attracted by a magnetic force to the magnet located adjacent to the upper surface of the inwardly projecting rib 221 on the control device 200. When the magnet is located on the mouthpiece 310, it is preferable that the combined thickness of the magnet and the projection 350 is substantially identical to the height of the rim wall 222 on the control device 200 so that the upper surface of the projection is substantially flush with the near end 208 of the device when the cartridge and the device are engaged.

[000138] In various embodiments, the aerosol delivery device 100 and/or the control device 200 of the aerosol delivery device 100 may also include an external connector configured to electrically contact each external connection element of the device (for example, the external connection element 218 of the device). The external connector may include a first end of the connector and a second end of the connector connected to each other by a connection, which may be, for example, a cord of variable length. In various embodiments, the first end of the connector may be configured to electrically and optionally mechanically connect to the control device. In particular, the first end of the connector may include an insert wall that can be received in a cavity present at the distal end 206 of the control device 200. The external connector may include a plurality of electrical pins within the insert wall configured to perform charging and/or a connection for transmitting information with the external connection element 218 of the device. In some embodiments, the control device 200 may include a mechanical connector (for example, a mechanical connector 242) near the external connection element 218 of the control device. In some embodiments, the mechanical connector 242 may be a magnet or a metal (or a similar element) that is configured to be magnetically attracted to a magnet. Thus, the first end of the external connection connector may similarly include a mechanical connection element that may be located between the insert wall and the electrical pins. In various embodiments, the mechanical connection element may be a magnet or a metal (or a similar element) that is configured to be magnetically attracted to a magnet. The second end of the connector may be configured to be connected to a computer or a similar electronic device or connected to a power source. For example, the second end of the connector has a universal serial bus (USB) connection; however, another connection may also be provided and/or an adapter (for example, a USB/AC adapter) may similarly be included. For example, an adapter including a USB connector on one end and a connector for a power supply on the opposite end is disclosed in U.S. Patent Application Publication No. 2014/0261495 to Novak et al., which is incorporated herein by reference.

[000139] Other features, controls, or components that may be included in aerosol delivery devices according to the present disclosure are described in U.S. Patent No. 5,967,148 to Harris et al., U.S. Patent No. 5,934,289 to Watkins et al., U.S. Patent No. 5,954,979 to Counts et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,402,976 to Fernando et al., U.S. Patent Application Publication No. 2010/0163063 to Fernando et al., U.S. Patent Application Publication No. No. 2013/0192623 to Tucker et al., U.S. Patent Application Publication No. 2013/0298905 to Leven et al., U.S. Patent Application Publication No. 2013/0180553 to Kim et al., U.S. Patent Application Publication No. 2014/0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014/0261495 to Novak et al., and U.S. Patent Application Publication No. 2014/0261408 to DePiano et al., which are incorporated herein by reference in their entireties.

[000140] In various embodiments, the mouthpiece portion 310 of the cartridge 300 may be configured to cooperate with the container portion 302. For example, as shown in FIG. 3B, the distal end 316 of the mouthpiece portion 310 may include a rim wall 330 that is at least partially inserted from the outer wall 312 of the mouthpiece. The rim wall 330 may be configured to cooperate with an interior region of the proximal end 306 of the outer wall 304 of the container. In some embodiments, the rim wall 330 may have a length of from about 1 mm to about 20 mm, from about 2 mm to about 18 mm, or from about 5 mm to about 15 mm, although other configurations are possible. In some embodiments, the rim wall 330 may interact with the outer wall 304 of the container only by friction fit, or the rim wall may be substantially permanently attached to the outer wall of the container, such as by welding or gluing with one or more adhesives.

[000141] In some embodiments, the mouthpiece portion 310 may form a substantially open interior space through which the generated vapor may combine with air to form an aerosol for discharge through the outlet opening 315 of the mouthpiece portion 310. In one or more embodiments, the mouthpiece 310 may include one or more additional interior walls that may be configured to form one or more mouthpiece compartments. The mouthpiece may include an interior upper wall between a proximal end and a distal end and also includes an interior lower wall between the upper wall and the distal end in the mouthpiece. More particularly, as seen in FIG. 3B, the mouthpiece portion 310 may include an inner upper wall 332 between the near end 314 and the far end 316 of the mouthpiece portion 310. In addition, the mouthpiece portion 310 may include an inner lower wall 334 between the inner upper wall 332 and the far end 316 of the mouthpiece portion 310.

[000142] In various embodiments, two or more walls in the mouthpiece may be configured to form a vapor chamber within which a heating element 320 may be located. As shown in FIG. 3B, the outer wall 312 of the mouthpiece, the inner upper wall 332 and the inner lower wall 334 form a first vapor chamber 340 in which the heating element 320 is located. In some embodiments, one or more electrical contacts 325 may be located within a portion of the outer wall 312 of the mouthpiece that forms the vapor chamber 340; however, it is understood that one or more electrical leads may extend from the heating element 320 to one or more electrical contacts located on another portion of the outer wall of the mouthpiece or located on the outer wall 304 of the container. One or more walls of the mouthpiece may also comprise one or more openings for passing through them one or more additional elements of the cartridge (300) or for passing the generated vapor/aerosol. For example, the inner upper wall 332 may include an opening 336 for vapor, through which the vapor generated in the evaporation chamber 340 may pass to the first outlet opening 315. In some embodiments, the opening 336 for vapor in the inner upper wall 332 may be substantially located therein in the center and may be substantially aligned with the heating element 320 along the longitudinal axis of the cartridge 300. As a further example, the inner lower wall 334 may include a passage 338 for a wick, through which the first element 321 for transferring liquid (for example, a wick) may pass between the heating element 320 and the liquid composition 324 in the container-like portion 302.

[000143] In various embodiments, two or more walls in the mouthpiece may be configured to form a cooling chamber within which the formed aerosol may be allowed to expand and/or allowed to cool before passing through the outlet. For example, as shown in FIG. 3B, the outer wall 312 of the mouthpiece and the inner top wall 332 form a cooling chamber 342 that receives the formed vapor/aerosol from the evaporation chamber 340. Thus, the vapor/aerosol formed by the heating element 320 passes from the second evaporation chamber 340 through the vapor opening 336 into the cooling chamber 342. In some embodiments, the evaporation chamber 340 and the cooling chamber 342 may be configured to have a predetermined relative volume ratio. For example, in some embodiments, the volume ratio of evaporation chamber 340 to cooling chamber 342 may be from about 2:1 to about 1:4, from about 1:1 to about 1:4, or from about 1:1.5 to about 1:3, although other configurations are possible.

[000144] If desired, the mouthpiece 310 may also include one or more elements configured to reduce or prevent leakage of condensed liquid therefrom. For example, in some embodiments, all or a portion of the inner region of the mouthpiece wall 312 and/or the inner top wall 332 forming the cooling chamber 342 may be formed from or include an absorbent or adsorbent material configured to retain liquid. Alternatively or additionally, all or a portion of the inner region of the mouthpiece wall 312 and/or the inner top wall 332 forming the cooling chamber 342 may be configured to direct liquid back to the evaporation chamber 340, such as by adding microchannels or the like.

[000145] In some embodiments, the entire cartridge 300 and/or the mouthpiece 310 may be formed with respect to the overall length along the longitudinal axis (L), the overall width along the first transverse axis (T1), and the overall depth along the second longitudinal axis (T2). The length may be greater than the width, which in turn may be greater than the depth. The distance by which the projection 350 extends away from the wall 312 of the mouthpiece may be greater along the second transverse axis (T2) than along the first transverse axis (T1). Thus, in some embodiments, the overall distance between the opposite outer edges of the projection 350 across the mouthpiece 310 along the first transverse axis (T1) may be greater than the overall distance between the opposite edges of the projection across the mouthpiece along the second transverse axis (T2); the total distance between the opposite outer edges of the projection 350 through the mouthpiece 310 along the first transverse axis (T1) can be substantially equal to the total distance between the opposite edges of the projection through the mouthpiece along the second transverse axis (T2); or the total distance between the opposite outer edges of the projection 350 through the mouthpiece 310 along the first transverse axis (T1) can be less than the total distance between the opposite edges of the projection through the mouthpiece along the second transverse axis (T2). In particular embodiments, the distance (d2) between the wall 312 of the mouthpiece and the outer edge of the projection 350 when measured along the second transverse axis (T2) can be greater than the distance between the wall of the mouthpiece and the outer edge of the projection when measured along the first transverse axis (T1). Said distances, in particular, can be measured approximately at the midpoint of each of the first transverse axis (T1) and the second transverse axis (T2).

[000146] In the illustrated embodiment, one or more of the mouthpiece portion 310 and the container portion 302 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. In the embodiment shown, the mouthpiece portion 310 is configured to be connected to the container portion 302 by means of a push-fit or lock-fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000147] FIGS. 4, 5A and 5B show a cartridge according to another embodiment of the present invention. In particular, FIG. 4 shows an exploded perspective view of a cartridge 500 according to an example embodiment of the present invention, FIG. 5A shows a partially cut-away view of a cartridge 500, and FIG. 5B shows a partially cut-away view on an enlarged scale of a cartridge 500. In various embodiments, a portion of the cartridge 500 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 500 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000148] Referring to FIG. 4, the cartridge 500 of the illustrated embodiment comprises a container portion 502 that is formed by an outer wall 504 of the container that includes a near end 506 and a far end 508. Thus, the container portion 502 can be characterized in that the container wall 504 is a side wall that is continuous around the container, and the far end 508 forms a bottom wall. The container portion 502 is also configured to contain a liquid composition 524 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 500 also comprises a mouthpiece portion 510, which is formed by an outer wall 512 of the mouthpiece, which includes a distal end 516 and a proximal end 514 with an outlet opening 515 passing through it. In the illustrated embodiment, the cartridge 500 also includes a sleeve portion 560, which is located between the mouthpiece portion 510 and the container portion 502. In the illustrated embodiment, the sleeve portion 560 is configured to connect to the mouthpiece portion 510 and the container portion 502 by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000149] In the illustrated embodiment, the outer wall 504 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 524 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 504 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 504 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 504 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 506 of the container 502 to the far end 508 of the container may be transparent or translucent. In additional embodiments, the outer wall 504 of the container may be colored. In some embodiments, the color can be configured so that the liquid composition 524 inside the container 502 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall can be designed so that the outer wall 504 of the container has a substantially opaque color.

[000150] In the illustrated embodiment, one or more of the mouthpiece portion 502 and the sleeve portion 560 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000151] As shown in FIG. 4, the cartridge 500 also includes a heating element 520 and a pair of electrical contacts 525A, 525B that are configured to electrically connect the heating element 520 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 525A, 525B are located on opposite sides of the cartridge 500 and are configured to be attached to the sleeve portion 560. Although in the shown embodiment, the contacts 525A, 525B are configured to be attached to the sleeve portion 560 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 525A, 525B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000152] In the illustrated embodiment, the heating element 520 may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 520 may be integrally formed with the first fluid transfer element 521. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000153] The cartridge 500 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 500 includes a first liquid transfer element 521 and a second liquid transfer element 522. In the illustrated embodiment, at least a portion of the first liquid transfer element 521 is configured to be located near the heating element 520. In addition, the second liquid transfer element 522 of the illustrated embodiment is configured to pass between the first liquid transfer element 521 and the liquid composition 524 contained in the container 502 such that the second liquid transfer element 522 is configured to transfer liquid to the first liquid transfer element 521. In the embodiment shown, the second liquid transfer element 522 has a T-shape with a transverse portion 527 that intersects the longitudinal portion 529. Although other configurations are possible, in the embodiment shown, the length of the longitudinal portion 529 is greater than the length of the transverse portion 527.

[000154] As shown in FIG. 5A and 5B, the first liquid transfer element 521 and the heating element 520 are arranged in the sleeve portion 560 of the cartridge 500. When installed in the cartridge, the heating element 520 of the shown embodiment has a curved or bent shape. In addition, when installed in the cartridge, the first liquid transfer element 521 of the shown embodiment also has a curved or bent shape. In particular, the heating element 520 of the shown embodiment comprises a flat heating element that, when installed in the cartridge 500, has a curved or bent shape corresponding to (e.g. similar to or approximately the same as) the curved shape of the upper surface of the first liquid transfer element 521 (or vice versa in some embodiments). Thus, the heating element 520 in the installed position is in contact with the upper surface of the first liquid transfer element 521. In the illustrated embodiment, the curved shape of the flat heating element 520 can provide a large ratio of the cross-sectional area of the flow to the length of the flow path through the first liquid transfer element 521. After installation, the curvature of the heating element 520 can also provide a compressive force against the first liquid transfer element 521. The installed curvature of the heating element 520 can also bias the deflection of the heating element 520 that may occur during thermal expansion in the direction of the first liquid transfer element 521, thus helping to maintain thermal contact between the heating element 520 and the first liquid transfer element 521. In addition, after installation in the cartridge 500, the transverse portion 527 of the second liquid transfer element 522 also has a curved or bent shape corresponding to (for example, similar or approximately the same) to the curved shape of the lower surface of the first liquid transfer element 521. Thus, the upper surface of the transverse part 527 of the second element 522 for transferring liquid is in contact with the lower surface of the first element 521 for transferring liquid. Thus, one or more of these elements can provide increased performance in relation to the delivery of the liquid composition to the first element 521 for transferring liquid.

[000155] In various embodiments, one or both of the first fluid transfer element 521 and the second fluid transfer element 522 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 521 comprises a fibrous material, and the second fluid transfer element 522 comprises a semi-rigid material. In the illustrated embodiment, the second fluid transfer element 522 is configured to fit tightly into the sleeve portion 560, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014/0261487 to Chapman et al., 2014/0059780 to Davis et al., and U.S. Patent Application Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent Application Publication No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid (e.g., non-hollow) wick.

[000156] In the illustrated embodiment, the cartridge 500 also includes a cover element 562 (which in the illustrated embodiment is a curved cover element), a portion of which is configured to be positioned above (e.g., downstream of) the heating element 520 and within the sleeve portion 560. In the illustrated embodiment, the cover element 562 is configured to direct aerosol, collect condensate, and/or protect against liquid and high temperatures directly exiting the cartridge 500. In the illustrated embodiment, the cover element 562 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the covering element may be made of other materials, including, for example, metallic materials (for example, aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. The covering element 562 of the illustrated embodiment has a bend that is opposite to the bend of the heating element 520. For example, in the illustrated embodiment, the heating element 520 has a convex bend (relative to the mouth end of the longitudinal axis shown in FIG. 3A), while the covering element 562 has a concave bend. In the embodiment shown, the heating element 520 and the covering element 562 form at least a part of the vaporization chamber 540. As indicated above, the aerosol is formed in the vaporization chamber 540 when the heating element 520 heats at least a part of the liquid composition contained in the first element 521 for transferring liquid. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 540 can be redirected by the covering element 562 and delivered to the user through the outlet opening 515 of the mouthpiece part 510.

[000157] FIGS. 6, 7A and 7B show a cartridge according to another embodiment of the present invention. In particular, FIG. 6 shows an exploded perspective view of a cartridge 700 according to an example embodiment of the present invention, FIG. 7A shows a partially cut-away view of a cartridge 700, and FIG. 7B shows a partially cut-away view on an enlarged scale of a cartridge 700. In various embodiments, a portion of the cartridge 700 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 700 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000158] With reference to the drawings, the cartridge 700 of the illustrated embodiment comprises a container portion 702 that is formed by an outer wall 704 of the container that includes a near end 706 and a far end 708. Thus, the container portion 702 can be characterized in that the container wall 704 is a side wall that is continuous around the container, and the far end 708 forms a bottom wall. The container portion 702 is also configured to contain a liquid composition 724 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 700 also comprises a mouthpiece portion 710, which is formed by an outer wall 712 of the mouthpiece, which includes a distal end 716 and a proximal end 714 with an outlet opening 715 passing through it. In the illustrated embodiment, the cartridge 700 also includes a portion 760 in the form of a sleeve, which is located between the mouthpiece portion 710 and the portion 702 in the form of a container. In the illustrated embodiment, the portion 760 in the form of a sleeve is configured to connect to the mouthpiece portion 710 and the portion 702 in the form of a container by means of a tight fit or a lock fit connection; however, in other embodiments, other methods of attachment are possible (for example, by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000159] In the illustrated embodiment, the outer wall 704 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 724 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 704 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 704 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 704 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 706 of the container 702 to the far end 708 of the container may be transparent or translucent. In additional embodiments, the outer wall 704 of the container may be colored. In some embodiments, the color can be configured so that the liquid composition 724 inside the container 702 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall can be designed so that the outer wall 704 of the container has a substantially opaque color.

[000160] In the illustrated embodiment, one or more of the mouthpiece portion 710 and the sleeve portion 760 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000161] As shown in FIG. 6, the cartridge 700 also includes a heating element 720 and a pair of electrical contacts 725A, 725B that are configured to electrically connect the heating element 720 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 725A, 725B are located on opposite sides of the cartridge 700 and are configured to be attached to the sleeve portion 760. Although in the shown embodiment, the contacts 725A, 725B are configured to be attached to the sleeve portion 760 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 725A, 725B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000162] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 720 may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 720 may be integrally formed with the first fluid transfer element 721. Other types of heating elements may also be used, as noted above.

[000163] The cartridge 700 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 700 includes a first liquid transfer element 721 and a second liquid transfer element 722. In the illustrated embodiment, at least a portion of the first liquid transfer element 721 is configured to be located near the heating element 720. In addition, the second liquid transfer element 722 of the illustrated embodiment is configured to pass between the first liquid transfer element 721 and the liquid composition 724 contained in the container 702 such that the second liquid transfer element 722 is configured to transfer liquid to the first liquid transfer element 721. In the illustrated embodiment, the second liquid transfer element 722 has a T-shape with a transverse portion 727 that intersects the longitudinal portion 729. Although other configurations are possible, in the illustrated embodiment, the length of the transverse portion 727 is greater than the length of the longitudinal portion 729.

[000164] As shown in FIG. 7A and 7B, the first liquid transfer element 721, the second liquid transfer element 722 and the heating element 720 are arranged in the sleeve portion 760 of the cartridge 700. When installed in the cartridge, the heating element 720 of the shown embodiment has a curved or bent shape. In addition, when installed in the cartridge, the first liquid transfer element 721 of the shown embodiment also has a curved or bent shape. In particular, the heating element 720 of the shown embodiment comprises a flat heating element that, when installed in the cartridge 700, has a curved or bent shape corresponding to (e.g. similar to or approximately the same as) the curved shape of the upper surface of the first liquid transfer element 721 (or vice versa in some embodiments). Thus, the heating element 720 in the installed position is in contact with the upper surface of the first liquid transfer element 721. In the illustrated embodiment, the curved shape of the flat heating element 720 can provide a large ratio of the cross-sectional area of the flow to the length of the flow path through the first liquid transfer element 721. After installation, the curvature of the heating element 720 can also provide a compressive force against the first liquid transfer element 721. The installed curvature of the heating element 720 can also bias the deflection of the heating element 720 that may occur during thermal expansion in the direction of the first liquid transfer element 721, thus helping to maintain thermal contact between the heating element 720 and the first liquid transfer element 721. In addition, after installation in the cartridge 700, the transverse portion 727 of the second liquid transfer element 722 also has a curved or bent shape corresponding to (for example, similar or approximately the same) to the curved shape of the lower surface of the first liquid transfer element 721. Thus, the upper surface of the transverse part 727 of the second element 722 for transferring liquid is in contact with the lower surface of the first element 721 for transferring liquid. Thus, one or more of these elements can provide increased performance in relation to the delivery of the liquid composition to the first element 721 for transferring liquid.

[000165] In various embodiments, one or both of the first fluid transfer element 721 and the second fluid transfer element 722 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 721 comprises a fibrous material, and the second fluid transfer element 722 comprises a semi-rigid material. In the illustrated embodiment, the second fluid transfer element 722 is configured to fit tightly into the sleeve portion 760, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000166] In the illustrated embodiment, the cartridge 700 also includes a cover element 762 (which in the illustrated embodiment is a curved cover element), a portion of which is configured to be positioned over the heating element 720 and within the sleeve portion 760. In the illustrated embodiment, the cover element 762 may be made of a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the covering element may be made of other materials, including, for example, metallic materials (for example, aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. The covering element 762 of the illustrated embodiment has a bend that is opposite to the bend of the heating element 720. For example, in the illustrated embodiment, the heating element 720 has a convex bend (relative to the mouth end of the longitudinal axis shown in FIG. 3A), while the covering element 762 has a concave bend. In the illustrated embodiment, the heating element 720 and the covering element 762 form at least a portion of the vaporization chamber 740. As indicated above, the aerosol is formed in the vaporization chamber 740 when the heating element 720 heats at least a portion of the liquid composition contained in the first liquid transfer element 721. In the illustrated embodiment, the covering element 762 is configured to direct the aerosol, collect condensate, and/or protect against liquid and high temperatures coming directly from the cartridge 700. Thus, when the user puffs on the aerosol delivery device, the aerosol from the vaporization chamber 740 can be redirected to the user through the outlet opening 715 of the mouthpiece portion 710.

[000167] FIGS. 8 and 9 show a cartridge according to another embodiment of the present invention. In particular, FIG. 8 shows an exploded perspective view of a cartridge 900 according to an example embodiment of the present invention, and FIG. 9 shows a partially cutaway view of a cartridge 900. In various embodiments, a portion of the cartridge 900 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 900 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000168] With reference to the drawings, the cartridge 900 of the illustrated embodiment comprises a container portion 902 that is formed by an outer wall 904 of the container that includes a near end 906 and a far end 908. Thus, the container portion 902 can be characterized in that the container wall 904 is a side wall that is continuous around the container, and the far end 908 forms a bottom wall. The container portion 902 is also configured to contain a liquid composition 924 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 900 also comprises a mouthpiece portion 910, which is formed by an outer wall 912 of the mouthpiece, which includes a distal end 916 and a proximal end 914 with an outlet opening 915 passing through it. In the illustrated embodiment, the cartridge 900 also includes a sleeve portion 960, which is located between the mouthpiece portion 910 and the container portion 902. In the illustrated embodiment, the sleeve portion 960 is configured to connect to the mouthpiece portion 910 and the container portion 902 by means of a tight fit or lock fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000169] In the illustrated embodiment, the outer wall 904 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 924 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 904 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 904 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 904 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 906 of the container 902 to the far end 908 of the container may be transparent or translucent. In additional embodiments, the outer wall 904 of the container may be colored. In some embodiments, the color can be configured so that the liquid composition 924 inside the container 902 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall can be designed so that the outer wall 904 of the container has a substantially opaque color.

[000170] In the illustrated embodiment, one or more of the mouthpiece portion 910 and the sleeve portion 960 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000171] As shown in the drawings, the cartridge 900 also includes a heating element 920 and a pair of electrical contacts 925A, 925B that are configured to electrically connect the heating element 920 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 925A, 925B are located on opposite sides of the cartridge 900 and are configured to be attached to the sleeve portion 960. Although in the shown embodiment, the contacts 925A, 925B are configured to be attached to the sleeve portion 960 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 925A, 925B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000172] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough, in the illustrated embodiment, the heating element 920 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heater 920 may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 920 may be integrally formed with the first fluid transfer element 921. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000173] The cartridge 900 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 900 includes a first liquid transfer element 921 and a second liquid transfer element 922. In the illustrated embodiment, a portion of the heating element 920 is configured to wrap around a portion of the first liquid transfer element 921. In the illustrated embodiment, the second liquid transfer element 922 is configured to pass between the first liquid transfer element 921 and the liquid composition 924 contained in the container 902 such that the second liquid transfer element 922 is configured to transfer the liquid to the first liquid transfer element 921. In the illustrated embodiment, the second liquid transfer element 922 has a T-shape with a transverse portion 927 that intersects the longitudinal portion 929. Although other configurations are possible, in the illustrated embodiment, the length of the longitudinal portion 929 is greater than the length of the transverse portion 927. The second liquid transfer element 922 of the illustrated embodiment also serves to seal the sleeve portion 960 from the liquid composition 924.

[000174] In the illustrated embodiment, the cartridge 900 also includes an upper frame portion 931 that may include various elements configured to hold the heating element 920 and at least a portion of the first fluid transfer element 921. In the illustrated embodiment, the upper body portion 931 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 931 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 920 to the corresponding electrical contacts 925A, 925B. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 931, the heating element 920, the first fluid transfer element 921, and the electrical contacts 925A, 925B are contained within the sleeve-like portion 960. When installed in the cartridge, the first liquid transfer element 921 has a U-shaped form comprising a transverse central portion 933 and two longitudinal support portions 935A, 935B which intersect with the central portion 933 and extend downwards from it. Although other configurations are possible, in the illustrated embodiment the length of the transverse longitudinal portion 933 is greater than the length of the longitudinal support portions 935A, 935B. In the illustrated embodiment, the corresponding ends of the support portions 935A, 935B are in contact with the upper surface of the transverse portion 927 of the second liquid transfer element 922. In this way, the second liquid transfer element 922 can facilitate the delivery of the liquid composition 924 to the first liquid transfer element 921.

[000175] In various embodiments, one or both of the first fluid transfer element 921 and the second fluid transfer element 922 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 921 comprises a fibrous material, and the second fluid transfer element 922 comprises a semi-rigid material. In the illustrated embodiment, the second fluid transfer element 922 is configured to fit tightly into the sleeve portion 960, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000176] As shown in the drawings, at least a portion of the heating element 920 is wrapped around the transverse central portion 933 of the first liquid transfer element 921. In the illustrated embodiment, the vaporization chamber 940 is located in the region around the first liquid transfer element 921, around which the heating element 920 is wrapped, and is formed, at least in part, by the upper frame portion 931 and the second liquid transfer element 922. As indicated above, the aerosol is formed in the vaporization chamber 940 when the heating element 920 heats at least a portion of the liquid composition contained in the first liquid transfer element 921. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 940 can be redirected to the user through the outlet opening 915 of the mouthpiece portion 910.

[000177] FIGS. 10 and 11 show a cartridge according to another embodiment of the present invention. In particular, FIG. 10 shows an exploded perspective view of a cartridge 1100 according to an example embodiment of the present invention, and FIG. 11 shows a partially cutaway view of a cartridge 1100. In various embodiments, a portion of the cartridge 1100 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 1100 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000178] With reference to the drawings, the cartridge 1100 of the illustrated embodiment comprises a container portion 1102 that is formed by an outer wall 1104 of the container and that includes a near end 1106 and a far end 1108. Thus, the container portion 1102 can be characterized in that the container wall 1104 is a side wall that is continuous around the container, and the far end 1108 forms a bottom wall. The container portion 1102 is also configured to contain a liquid composition 1124 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 1100 also includes a mouthpiece portion 1110, which is formed by an outer wall 1112 of the mouthpiece and which includes a distal end 1116 and a proximal end 1114 with an outlet opening 1115 passing through it. In the illustrated embodiment, the cartridge 1100 also includes a sleeve portion 1160, which is located between the mouthpiece portion 1110 and the container portion 1102. In the illustrated embodiment, the sleeve portion 1160 is configured to connect to the mouthpiece portion 1110 and the container portion 1102 by means of a tight fit or lock fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000179] In the illustrated embodiment, the outer wall 1104 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 1124 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 1104 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 1104 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 1104 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 1106 of the container 1102 to the far end 1108 of the container may be transparent or translucent. In additional embodiments, the outer wall 1104 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 1124 inside the container 1102 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 1104 of the container has a substantially opaque color.

[000180] In the illustrated embodiment, one or more of the mouthpiece portion 1110 and the sleeve portion 1160 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000181] As shown in the drawings, the cartridge 1100 also includes a heating element 1120 and a pair of electrical contacts 1125A, 1125B that are configured to electrically connect the heating element 1120 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 1125A, 1125B are located on opposite sides of the cartridge 1100 and are configured to be attached to the sleeve portion 1160. Although in the shown embodiment, the contacts 1125A, 1125B are configured to be attached to the sleeve portion 1160 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 1125A, 1125B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000182] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 1120 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heater 1120 may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 1120 may be integrally formed with the first fluid transfer element 1121. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000183] The cartridge 1100 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 1100 includes a first liquid transfer element 1121 and a second liquid transfer element 1122. In the illustrated embodiment, a portion of the heating element 1120 is configured to wrap around a portion of the first liquid transfer element 1121. In the illustrated embodiment, the second liquid transfer element 1122 is configured to be located below the first liquid transfer element 1121 and to wrap around at least a portion of the first liquid transfer element 1121. In the illustrated embodiment, the second liquid transfer element 1122 has a relatively flat shape.

[000184] In the illustrated embodiment, the cartridge 1100 also includes an upper frame portion 1131 that includes various elements configured to hold the heating element 1120 and at least a portion of the first fluid transfer element 1121. In the illustrated embodiment, the upper body portion 1131 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 1131, the heating element 1120, the first fluid transfer element 1121, the second fluid transfer element 1122, and the electrical contacts 1125A, 1125B are contained within the sleeve-like portion 1160. When installed in the cartridge, the first liquid transfer element 1121 has a U-shape comprising a transverse central portion 1133 and two longitudinal support portions 1135A, 1135B which extend downwards from the central portion 1133. Although other configurations are possible, in the embodiment shown the length of the longitudinal support portions is greater than the length of the transverse central portion. In the embodiment shown, the respective ends of the support portions 1135A, 1135B extend downwards into the container portion 1102 so that they extend into the liquid composition 1124. Although other configurations are possible, in the embodiment shown the ends of the longitudinal supports 1135A, 1135B extend toward (for example, near) the lower wall of the container portion 1102.

[000185] In various embodiments, one or both of the first fluid transfer element 1121 and the second fluid transfer element 1122 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 1121 comprises a fibrous material, and the second fluid transfer element 1122 comprises a semi-rigid material. In the illustrated embodiment, the second fluid transfer element 1122 is configured to fit snugly into the sleeve portion 1160, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely of a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000186] As shown in the drawings, at least a portion of the heating element 1120 is wrapped around the transverse central portion 1133 of the first liquid transfer element 1121. In the illustrated embodiment, the vaporization chamber 1140 is located in the region around the first liquid transfer element 1121, around which the heating element 1120 is wrapped, and is formed, at least in part, by the upper frame portion 931 and the second liquid transfer element 1122. As indicated above, the aerosol is formed in the vaporization chamber 1140 when the heating element 1120 heats at least a portion of the liquid composition contained in the first liquid transfer element 1121. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 1140 can be redirected to the user through the outlet opening 1115 of the mouthpiece portion 1110.

[000187] FIGS. 12 and 13 show a cartridge according to another embodiment of the present invention. In particular, FIG. 12 shows an exploded perspective view of a cartridge 1300 according to an example embodiment of the present invention, and FIG. 13 shows a partially cutaway view of a cartridge 1300. In various embodiments, a portion of the cartridge 1300 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 1300 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000188] With reference to the drawings, the cartridge 1300 of the illustrated embodiment comprises a container portion 1302 that is formed by an outer wall 1304 of the container that includes a near end 1306 and a far end 1308. Thus, the container portion 1302 can be characterized in that the container wall 1304 is a side wall that is continuous around the container, and the far end 1308 forms a bottom wall. The container portion 1302 is also configured to contain a liquid composition 1324 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 1300 also includes a mouthpiece portion 1310, which is formed by an outer wall 1312 of the mouthpiece, which includes a distal end 1316 and a proximal end 1314 with outlet openings 1315 formed therein. In the illustrated embodiment, the cartridge 1300 also includes a portion 1360 in the form of a coupling, which is located between the mouthpiece portion 1310 and the portion 1302 in the form of a container. In the illustrated embodiment, the portion 1360 in the form of a coupling is configured to be connected to the mouthpiece portion 1310 and the portion 1302 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000189] In the illustrated embodiment, the outer wall 1304 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 1324 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 1304 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 1304 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 1304 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 1306 of the container 1302 to the far end 1308 of the container may be transparent or translucent. In additional embodiments, the outer wall 1304 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 1324 inside the container 1302 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 1304 of the container has a substantially opaque color.

[000190] In the illustrated embodiment, one or more of the mouthpiece portion 1310 and the sleeve portion 1360 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000191] As shown in the drawings, the cartridge 1300 also includes a heating element 1320 and a pair of electrical contacts 1325A, 1325B that are configured to electrically connect the heating element 1320 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 1325A, 1325B are located on opposite sides of the cartridge 1300 and are configured to be attached to the sleeve portion 1360. Although in the shown embodiment, the contacts 1325A, 1325B are configured to be attached to the sleeve portion 1360 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 1325A, 1325B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000192] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 1320 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heater 1320 may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 1320 may be integrally formed with the first fluid transfer element 1321. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000193] The cartridge 1300 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 1300 includes a first liquid transfer element 1321 and a second liquid transfer element 1322. In the illustrated embodiment, a portion of the heating element 1320 is configured to wrap around a portion of the first liquid transfer element 1321. In the illustrated embodiment, the second liquid transfer element 1322 is configured to pass between the first liquid transfer element 1321 and the liquid composition 1324 contained in the container 1302 such that the second liquid transfer element 1322 is configured to transfer liquid to the first liquid transfer element 1321. In the embodiment shown, the first and second liquid transfer elements 1321, 1322 have substantially solid (e.g., non-hollow) cylindrical shapes and are substantially aligned with the longitudinal axis of the cartridge. Although other configurations are possible, in the embodiment shown, the outer diameter of the second liquid transfer element 1322 is greater than the outer diameter of the first liquid transfer element 1321, and the length of the second liquid transfer element is greater than the length of the first liquid transfer element 1321. The second liquid transfer element 1322 of the embodiment shown also serves to seal the sleeve portion 1360 from the liquid composition 1324.

[000194] In the illustrated embodiment, the cartridge 1300 also includes an upper frame portion 1331 that may include various elements configured to hold the heating element 1320 and at least a portion of the first fluid transfer element 1321. In the illustrated embodiment, the upper body portion 1331 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 1331 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 1320 with the corresponding electrical contacts 1325A, 1325B. In the embodiment shown, at least a portion of one or more of the upper frame portion 1331, the heating element 1320, the first element 1321 for transferring liquid and the electrical contacts 1325A, 1325B are contained within the portion 1360 in the form of a sleeve. In the embodiment shown, the distal end of the first element 1321 for transferring liquid is in contact with the proximal end of the second element 1322 for transferring liquid. Thus, as indicated above, the second element 1322 for transferring liquid can facilitate the delivery of the liquid composition 1324 to the first element 1321 for transferring liquid.

[000195] In various embodiments, one or both of the first fluid transfer element 1321 and the second fluid transfer element 1322 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 1321 comprises a ceramic material, and the second fluid transfer element 1322 comprises a semi-rigid material. In the illustrated embodiment, the first fluid transfer element 1321 is configured to be captured between the mouthpiece portion 1310 and the sleeve portion 1360. In the illustrated embodiment, the first fluid transfer element 1321 and the second fluid transfer element 1322 are configured to fit snugly into the sleeve portion 1360, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000196] As shown in the drawings, at least a portion of the heating element 1320 is wrapped around a portion of the first liquid transfer element 1321. In the embodiment shown, the vaporization chamber 1340 is located in the region around the first liquid transfer element 1321, around which the heating element 1320 is wrapped, and is formed, at least in part, by the upper frame element 1331. As indicated above, the aerosol is formed in the vaporization chamber 1340 when the heating element 1320 heats at least a portion of the liquid composition contained in the first liquid transfer element 1321. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 1340 can be delivered to the user through the outlet openings 1315 of the mouthpiece part 1310.

[000197] FIG. 14 shows a cartridge according to another embodiment of the present invention. In particular, FIG. 14 shows a partially cross-sectional view of a cartridge 1500 according to an example of an embodiment of the present invention. In various embodiments, a portion of the cartridge 1500 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 1500 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated here. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000198] With reference to the drawing, the cartridge 1500 of the illustrated embodiment comprises a container portion 1502 that is formed by an outer wall 1504 of the container that includes a near end 1506 and a far end 1508. Thus, the container portion 1502 can be characterized in that the container wall 1504 is a side wall that is continuous around the container, and the far end 1508 forms a bottom wall. The container portion 1502 is also configured to contain a liquid composition 1524 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 1500 also includes a mouthpiece portion 1510, which is formed by an outer wall 1512 of the mouthpiece, which includes a distant end 1516 and a near end 1514 with outlet openings 1515 formed therein. In the illustrated embodiment, the cartridge 1500 also includes a part 1560 in the form of a sleeve, which is located between the mouthpiece portion 1510 and the part 1502 in the form of a container. In the illustrated embodiment, the part 1560 in the form of a sleeve is configured to connect with the mouthpiece portion 1510 and the part 1502 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000199] In the illustrated embodiment, the outer wall 1504 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 1524 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 1504 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 1504 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 1504 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 1506 of the container 1502 to the far end 1508 of the container may be transparent or translucent. In additional embodiments, the outer wall 1504 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 1524 inside the container 1502 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 1504 of the container has a substantially opaque color.

[000200] In the illustrated embodiment, one or more of the mouthpiece portion 1510, the sleeve portion 1560, and the container portion 1502 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000201] As shown in the drawing, the cartridge 1500 also includes a heating element 1520 and a pair of electrical contacts 1525A, 1525B that are configured to electrically connect the heating element 1520 to the battery and/or the control component of the control device. In the shown embodiment, the contacts 1525A, 1525B are located on opposite sides of the cartridge 1500 and are configured to be attached to the sleeve portion 1560. Although in the shown embodiment, the contacts 1525A, 1525B are configured to be attached to the sleeve portion 1560 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 1525A, 1525B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000202] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 1520 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element 1520 may be formed from conductive ink, silicon dioxide doped with boron, and/or ceramics (e.g., ceramics with a positive or negative temperature coefficient). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 1520 may be integrally formed with the first fluid transfer element 1521. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000203] The cartridge 1500 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 1500 includes a first liquid transfer element 1521 and a second liquid transfer element 1522. In the illustrated embodiment, a portion of the heating element 1520 is configured to wrap around a portion of the first liquid transfer element 1521. In the illustrated embodiment, the second liquid transfer element 1522 has a substantially hollow cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge. In the illustrated embodiment, the first liquid transfer element 1521 has a substantially solid (e.g., non-hollow) cylindrical shape and is also substantially aligned with the longitudinal axis of the cartridge. In the illustrated embodiment, the first liquid transfer element 1521 passes through the second liquid transfer element 1522 in such a way that the first liquid transfer element 1521 and the second liquid transfer element 1522 extend to the lower part of the container-like portion 1502. In the illustrated embodiment, the second liquid transfer element 1522 is configured to surround at least a portion of the first liquid transfer element 1521 and extends between the sleeve-like portion 1560 and the liquid composition 1524 contained in the container 1502 in such a way that the second liquid transfer element 1522 is configured to transfer the liquid to the first liquid transfer element 1521. In the illustrated embodiment, the outer diameter of the second liquid transfer element 1522 is larger than the outer diameter of the first liquid transfer element 1521, and the length of the first liquid transfer element 1521 is larger than the length of the second liquid transfer element 1522. The second fluid transfer element 1522 of the illustrated embodiment also serves to seal the sleeve portion 1560 from the liquid composition 1524.

[000204] In the illustrated embodiment, the cartridge 1500 also includes an upper frame portion 1531 that may include various elements configured to hold the heating element 1520 and at least a portion of the first fluid transfer element 1521. In the illustrated embodiment, the upper body portion 1531 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 1531 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 1520 with the corresponding electrical contacts 1525A, 1525B. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 1531, the heating element 1520, the first fluid transfer element 1521, and the electrical contacts 1525A, 1525B are contained within the sleeve portion 1560.

[000205] In various embodiments, one or both of the first fluid transfer element 1521 and the second fluid transfer element 1522 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 1521 comprises a ceramic material, and the second fluid transfer element 1522 comprises a semi-rigid material. In the illustrated embodiment, the first fluid transfer element 1521 is configured to be captured between the mouthpiece portion 1510 and the sleeve portion 1560. In the illustrated embodiment, the first fluid transfer element 1521 and the second fluid transfer element 1522 are configured to fit snugly into the sleeve portion 1560, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected so that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000206] As shown in the drawings, at least a portion of the heating element 1520 is wrapped around a portion of the first liquid transfer element 1521. In the illustrated embodiment, the vaporization chamber 1540 is located in the region around the first liquid transfer element 1521, around which the heating element 1520 is wrapped, and is formed, at least in part, by the upper frame portion 1531. As indicated above, the aerosol is formed in the vaporization chamber 1540 when the heating element 1520 heats at least a portion of the liquid composition contained in the first liquid transfer element 1521. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 1540 can be delivered to the user through the outlet openings 1515 of the mouthpiece portion 1510.

[000207] FIGS. 15 and 16 show a cartridge according to another embodiment of the present invention. In particular, FIG. 15 shows an exploded perspective view of a cartridge 1700 according to an example embodiment of the present invention, and FIG. 16 shows a partially cutaway view of a cartridge 1700. In various embodiments, a portion of the cartridge 1700 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 1700 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000208] With reference to the drawings, the cartridge 1700 of the illustrated embodiment comprises a container portion 1702 that is formed by an outer wall 1704 of the container that includes a near end 1706 and a far end 1708. Thus, the container portion 1702 can be characterized in that the container wall 1704 is a side wall that is continuous around the container, and the far end 1708 forms a bottom wall. The container portion 1702 is also configured to contain a liquid composition 1724 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 1700 also comprises a mouthpiece portion 1710, which is formed by an outer wall 1712 of the mouthpiece, which includes a distal end 1716 and a proximal end 1714 with an outlet opening 1715 passing through it. In the illustrated embodiment, the cartridge 1700 also includes a portion 1760 in the form of a sleeve, which is located between the mouthpiece portion 1710 and the portion 1702 in the form of a container. In the illustrated embodiment, the portion 1760 in the form of a sleeve is configured to connect to the mouthpiece portion 1710 and the portion 1702 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (for example, by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000209] In the illustrated embodiment, the outer wall 1704 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 1724 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 1704 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 1704 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 1704 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 1706 of the container 1702 to the far end 1708 of the container may be transparent or translucent. In additional embodiments, the outer wall 1704 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 1724 inside the container 1702 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 1704 of the container has a substantially opaque color.

[000210] In the illustrated embodiment, one or more of the mouthpiece portion 1710, the sleeve portion 1760, and the container portion 1702 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000211] As shown in the drawings, the cartridge 1700 also includes a heating element 1720 and a pair of electrical contacts 1725A, 1725B that are configured to electrically connect the heating element 1720 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 1725A, 1725B are located on opposite sides of the cartridge 1700 and are configured to be attached to the sleeve portion 1760. Although in the shown embodiment, the contacts 1725A, 1725B are configured to be attached to the sleeve portion 1760 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 1725A, 1725B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000212] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 1720 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element 1720 may be formed from conductive ink, silicon dioxide doped with boron, and/or ceramics (e.g., ceramics with a positive or negative temperature coefficient). Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000213] The cartridge 1700 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 1700 includes a first liquid transfer element 1721 and a second liquid transfer element 1722. In the illustrated embodiment, a portion of the heating element 1720 is configured to be embedded in at least a portion of the first liquid transfer element 1721. In the illustrated embodiment, the second liquid transfer element 1722 is configured to extend between the first liquid transfer element 1721 and the liquid composition 1724 contained in the container 1702 such that the second liquid transfer element 1722 is configured to transfer the liquid to the first liquid transfer element 1721. In the illustrated embodiment, the first liquid transfer element has a cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge. In the illustrated embodiment, the second liquid transfer element 1722 has a substantially solid cylindrical shape and is also substantially aligned with the longitudinal axis of the cartridge. Although other configurations are possible, in the illustrated embodiment, the outer diameter of the second liquid transfer element 1722 is greater than the outer diameter of the first liquid transfer element 1721, and the length of the second liquid transfer element 1722 is greater than the length of the first liquid transfer element 1721. The second liquid transfer element 1722 of the illustrated embodiment also serves to seal the sleeve portion 1760 from the liquid composition 1724.

[000214] In the illustrated embodiment, the cartridge 1700 also includes an upper frame portion 1731 that may include various elements configured to hold the heating element 1720 and at least a portion of the first fluid transfer element 1721. In the illustrated embodiment, the upper body portion 1731 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 1731 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 1720 with the corresponding electrical contacts 1725A, 1725B. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 1731, the heating element 1720, the first element 1721 for transferring liquid and the electrical contacts 1725A, 1725B are contained within the portion 1760 in the form of a sleeve. In the illustrated embodiment, the distal end of the first element 1721 for transferring liquid is in contact with the proximal end of the second element 1722 for transferring liquid. Thus, the second element 1722 for transferring liquid can facilitate the delivery of the liquid composition 1724 to the first element 1721 for transferring liquid.

[000215] In various embodiments, one or both of the first fluid transfer element 1721 and the second fluid transfer element 1722 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 1721 comprises a ceramic material, and the second fluid transfer element 1722 comprises a semi-rigid material. In the illustrated embodiment, the first fluid transfer element 1721 is configured to be captured between the mouthpiece portion 1710 and the sleeve portion 1760. In the illustrated embodiment, the first fluid transfer element 1721 and the second fluid transfer element 1722 are configured to fit snugly into the sleeve portion 1760, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected so that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000216] As shown in the drawings, at least a portion of the heating element 1720 is integrated into at least a portion of the first liquid transfer element 1721. In the illustrated embodiment, the evaporation chamber 1740 is located in the region around the first liquid transfer element 1721, as well as in the region around the first liquid transfer element 1721 near the heating element 1720. The evaporation chamber 1740 may also be formed, at least in part, by the upper frame portion 1731. As indicated above, an aerosol is formed in the evaporation chamber 1740 when the heating element 1720 heats at least a portion of the liquid composition contained in the first liquid transfer element 1721. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 1740 can be redirected to the user through the outlet opening 1715 of the mouthpiece portion 1710.

[000217] FIG. 17 shows a cartridge according to another embodiment of the present invention. In particular, FIG. 17 shows a partially cross-sectional view of a cartridge 1900 according to an example embodiment of the present invention. In various embodiments, a portion of the cartridge 1900 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 1900 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000218] Referring to FIG. 17, the cartridge 1900 of the illustrated embodiment comprises a container portion 1902 that is formed by an outer wall 1904 of the container that includes a near end 1906 and a far end 1908. Thus, the container portion 1902 can be characterized in that the container wall 1904 is a side wall that is continuous around the container, and the far end 1908 forms a bottom wall. The container portion 1902 is also configured to contain a liquid composition 1924 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 1900 also comprises a mouthpiece portion 1910, which is formed by an outer wall 1912 of the mouthpiece, which includes a distal end 1916 and a proximal end 1914 with an outlet opening 1915 passing through it. In the illustrated embodiment, the cartridge 1900 also includes a sleeve portion 1960, which is located between the mouthpiece portion 1910 and the container portion 1902. In the illustrated embodiment, the sleeve portion 1960 is configured to connect to the mouthpiece portion 1910 and the container portion 1902 by means of a tight fit or lock fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000219] In the illustrated embodiment, the outer wall 1904 of the container may be formed at least partially transparent and/or translucent, so that the liquid composition 1924 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 1904 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 1904 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 1904 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 1906 of the container 1902 to the far end 1908 of the container may be transparent or translucent. In additional embodiments, the outer wall 1904 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 1924 inside the container 1902 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 1904 of the container has a substantially opaque color.

[000220] In the illustrated embodiment, one or more of the mouthpiece portion 1910, the sleeve portion 1960, and the container portion 2102 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000221] As shown in the drawing, the cartridge 1900 also includes a heating element 1920 and a pair of electrical contacts 1925A, 1925B that are configured to electrically connect the heating element 1920 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 1925A, 1925B are located on opposite sides of the cartridge 1900 and are configured to be attached to the sleeve portion 1960. Although in the shown embodiment, the contacts 1925A, 1925B are configured to be attached to the sleeve portion 1560 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 1925A, 1925B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000222] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 1920 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element 1920 may be formed from conductive ink, silicon dioxide doped with boron, and/or ceramics (e.g., ceramics with a positive or negative temperature coefficient). Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000223] The cartridge 1900 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 1900 includes a first liquid transfer element 1921 and a second liquid transfer element 1922. In the illustrated embodiment, a portion of the heating element 1920 is configured to be embedded in at least a portion of the first liquid transfer element 1921. In the illustrated embodiment, the second liquid transfer element 1922 has a substantially hollow cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge. In the illustrated embodiment, the first liquid transfer element 1921 passes through the second liquid transfer element 1922 such that the first liquid transfer element 1921 and the second liquid transfer element 1922 extend toward the bottom of the container-shaped portion 1902. In the illustrated embodiment, the second liquid transfer element 1922 is configured to surround at least a portion of the first liquid transfer element 1921 and extends between the sleeve portion 1960 and the liquid composition 1924 contained in the container 1902 such that the second liquid transfer element 1922 is configured to transfer liquid to the first liquid transfer element 1921. In the illustrated embodiment, the outer diameter of the second liquid transfer element 1922 is larger than the outer diameter of the first liquid transfer element 1921, and the length of the first liquid transfer element 1921 is larger than the length of the second liquid transfer element 1922. The second liquid transfer element 1922 of the illustrated embodiment also serves to seal the sleeve portion 1960 from the liquid composition 1924.

[000224] In the illustrated embodiment, the cartridge 1900 also includes an upper frame portion 1931 that may include various elements configured to hold the heating element 1920 and at least a portion of the first fluid transfer element 1921. In the illustrated embodiment, the upper body portion 1931 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 1931 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 1920 with the corresponding electrical contacts 1925A, 1925B. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 1931, the heating element 1920, the first fluid transfer element 1921, and the electrical contacts 1925A, 1925B are contained within the sleeve portion 1960.

[000225] In various embodiments, one or both of the first fluid transfer element 1921 and the second fluid transfer element 1922 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 1921 comprises a ceramic material, and the second fluid transfer element 1922 comprises a semi-rigid material. In the illustrated embodiment, the first fluid transfer element 1921 is configured to be captured between the mouthpiece portion 1910 and the sleeve portion 1960. In the illustrated embodiment, the first fluid transfer element 1921 and the second fluid transfer element 1922 are configured to fit snugly into the sleeve portion 1960, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000226] As shown in the drawings, at least a portion of the heating element 1920 is integrated into at least a portion of the first liquid transfer element 1921. In the illustrated embodiment, the evaporation chamber 1940 is located in the region around the first liquid transfer element 1921, as well as in the region around the first liquid transfer element 1921 near the heating element 1920. The evaporation chamber 1740 may also be formed, at least in part, by the upper frame portion 1931. As indicated above, an aerosol is formed in the evaporation chamber 1940 when the heating element 1920 heats at least a portion of the liquid composition contained in the first liquid transfer element 1921. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 1940 can be redirected to the user through the outlet opening 1915 of the mouthpiece portion 1910.

[000227] FIGS. 18 and 19 show a cartridge according to another embodiment of the present invention. In particular, FIG. 18 shows an exploded perspective view of a cartridge 2100 according to an example embodiment of the present invention, and FIG. 19 shows a partially cutaway view of a cartridge 2100. In various embodiments, a portion of the cartridge 2100 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 2100 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000228] With reference to the drawings, the cartridge 2100 of the illustrated embodiment comprises a container portion 2102 that is formed by an outer wall 2104 of the container that includes a near end 2106 and a far end 2108. Thus, the container portion 2102 can be characterized in that the container wall 2104 is a side wall that is continuous around the container, and the far end 2108 forms a bottom wall. The container portion 2102 is also configured to contain a liquid composition 2124 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 2100 also comprises a mouthpiece portion 2110, which is formed by an outer wall 2112 of the mouthpiece, which includes a distal end 2116 and a proximal end 2114 with an outlet opening 2115 passing through it. In the illustrated embodiment, the cartridge 2100 also includes a part 2160 in the form of a sleeve, at least a part of which is located between the mouthpiece portion 2110 and the part 2102 in the form of a container. In the illustrated embodiment, the part 2160 in the form of a sleeve is configured to be connected to the mouthpiece portion 2110 and the part 2102 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000229] In the illustrated embodiment, the outer wall 2104 of the container may be formed at least partially transparent and/or translucent, so that the liquid composition 2124 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 2104 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 2104 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 2104 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 2106 of the container 2102 to the far end 2108 of the container may be transparent or translucent. In additional embodiments, the outer wall 2104 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 2124 inside the container 2102 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 2104 of the container has a substantially opaque color.

[000230] In the illustrated embodiment, one or more of the mouthpiece portion 2110 and the sleeve portion 2160 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000231] As shown in the drawings, the cartridge 2100 also includes a heating element 2120 and a pair of electrical contacts 2125A, 2125B that are configured to electrically connect the heating element 2120 to a battery and/or a control component of the control device. In the illustrated embodiment, the contacts 2125A, 2125B are located on opposite sides of the cartridge 2100 and are configured to be attached to the sleeve portion 2160. Although in the illustrated embodiment the contacts 2125A, 2125B are configured to be attached to the sleeve portion 2160 by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 2120 is located near the distal end 2108 of the container portion 2102. Thus, the electrical contacts 2125A, 2125B extend downwardly such that their respective ends are in contact with the heating element 2120. In various embodiments, the heating element 2120 may be retained by the sleeve portion 2160 by means of a push-fit or lock-fit attachment, although other attachment methods are possible, including, for example, by means of an adhesive or by means of an insert molding process, or may be pressed by the sleeve portion 2160 against the lower portion of the container portion 2102 (for example, captured between the sleeve portion 2160, one or more liquid transfer elements and the lower portion of the container portion 2102). In the illustrated embodiment, the electrical contacts 2125A, 2125B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000232] In the illustrated embodiment, the heating element 2120 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 2120 may be integrally formed with the first fluid transfer element 2121. Other types of heating elements may also be used, as noted above.

[000233] The cartridge 2100 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 2100 includes a first liquid transfer element 2121 and a second liquid transfer element 2122. In the illustrated embodiment, at least a portion of the first liquid transfer element 2121 is configured to be located near the heating element 2120. In addition, the second liquid transfer element 2122 of the illustrated embodiment is configured to extend between the first liquid transfer element 2121 and the lower portion of the portion 2102 in the container such that the second liquid transfer element 2122 is configured to transfer liquid to the first liquid transfer element 2121. In the embodiment shown, the first and second liquid transfer elements 2121, 2122 have a flat shape, wherein the first liquid transfer element 2121 is located under the heating element 2120, and the second liquid transfer element 2122 is located under the first liquid transfer element 2121.

[000234] As shown in the drawings, the sleeve portion 2160 of the illustrated embodiment extends downwardly such that a portion of the sleeve portion 2160 is located near the distal end of the container portion 2102 and is configured to hold the heating element 2120, the first liquid transfer element 2121, and at least a portion of the second liquid transfer element 2122. In the illustrated embodiment, the heating element 2120 is in the installed position in contact with the upper surface of the first liquid transfer element 2121, and the upper surface of the transverse portion 3727 of the second liquid transfer element 2122 is in contact with the lower surface of the first liquid transfer element 2121. Thus, one or more of these elements can provide increased performance in relation to the delivery of the liquid composition to the first liquid transfer element 2121.

[000235] In various embodiments, one or both of the first fluid transfer element 2121 and the second fluid transfer element 2122 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transport elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various absorbent materials, as well as the design and operation of these absorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely of a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000236] In the illustrated embodiment, the cartridge 2100 also includes a cover element 2162 that is configured to be positioned near the distal end 2116 of the mouthpiece portion 2110. In the illustrated embodiment, the cover element 2162 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the covering element may be made of other materials, including, for example, metallic materials (for example, aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. The covering element 2162 of the illustrated embodiment has a block-like shape with a solid upper surface and openings formed in the lower and side surfaces. In the illustrated embodiment, the evaporation chamber 2140 is located above the heating element 2120 and is formed, at least in part, by the sleeve-like portion 2160. The sleeve portion 2160 of the illustrated embodiment also forms a vapor channel 2145 that begins near the vapor chamber 2140 and extends upward, leading to the cover element 2162. As indicated above, an aerosol is formed in the vapor chamber 2140 when the heating element 2120 heats at least a portion of the liquid composition contained in the first liquid transfer element 2121. In the illustrated embodiment, the cover element 2162 is configured to direct the aerosol, collect condensate and/or protect against liquid and high temperatures coming directly from the cartridge 2100. Thus, when the user puffs on the aerosol delivery device, the aerosol from the vapor chamber 2140 can move through the vapor channel 2145, can be redirected by the cover element 2162 and can be delivered to the user through the outlet opening 2115 of the mouthpiece portion 2110.

[000237] FIG. 20 shows a cartridge according to another embodiment of the present invention. In particular, FIG. 20 shows a partially cross-sectional view of a cartridge 2300. In various embodiments, a portion of the cartridge 2300 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 2300 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000238] With reference to the drawings, the cartridge 2300 of the illustrated embodiment comprises a container portion 2302 that is formed by an outer wall 2304 of the container that includes a near end 2306 and a far end 2308. Thus, the container portion 2302 can be characterized in that the container wall 2304 is a side wall that is continuous around the container, and the far end 2308 forms a bottom wall. The container portion 2302 is also configured to contain a liquid composition 2324 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 2300 also comprises a mouthpiece portion 2310, which is formed by an outer wall 2312 of the mouthpiece, which includes a distal end 2316 and a proximal end 2314 with an outlet opening 2315 passing through it. In the illustrated embodiment, the cartridge 2300 also includes a part 2360 in the form of a sleeve, at least a part of which is located between the mouthpiece portion 2310 and the part 2302 in the form of a container. In the illustrated embodiment, the part 2360 in the form of a sleeve is configured to be connected to the mouthpiece portion 2310 and the part 2302 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000239] In the illustrated embodiment, the outer wall 2304 of the container may be formed at least partially transparent and/or translucent, so that the liquid composition 2324 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 2304 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 2304 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 2304 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 2306 of the container 2302 to the far end 2308 of the container may be transparent or translucent. In additional embodiments, the outer wall 2304 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 2324 inside the container 2302 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 2304 of the container has a substantially opaque color.

[000240] In the illustrated embodiment, one or more of the mouthpiece portion 2310 and the sleeve portion 2360 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000241] As shown in the drawings, the cartridge 2300 also includes a heating element 2320 and a pair of electrical contacts 2325A, 2325B that are configured to electrically connect the heating element 2320 to a battery and/or a control component of the control device. In the illustrated embodiment, the contacts 2325A, 2325B are located on opposite sides of the cartridge 2300 and are configured to be attached to the sleeve portion 2360. Although in the illustrated embodiment the contacts 2325A, 2325B are configured to be attached to the sleeve portion 2360 by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 2320 is located near the distal end 2308 of the container portion 2302. Thus, the electrical contacts 2325A, 2325B extend downwardly such that their respective ends are in contact with the heating element 2320. In various embodiments, the heating element 2320 may be retained by the sleeve portion 2360 by means of a push-fit or lock-fit attachment, although other attachment methods are possible, including, for example, by means of an adhesive or by means of an insert molding process, or may be pressed by the sleeve portion 2360 against the lower portion of the container portion 2302 (for example, captured between the sleeve portion 2360, one or more liquid transfer elements and the lower portion of the container portion 2302). In the illustrated embodiment, the electrical contacts 2325A, 2325B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000242] In the illustrated embodiment, the heating element 2320 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 2320 may be integrally formed with the first fluid transfer element 2321. Other types of heating elements may also be used, as noted above.

[000243] The cartridge 2300 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 2300 includes a first liquid transfer element 2321 and a second liquid transfer element 2322. In the illustrated embodiment, at least a portion of the first liquid transfer element 2321 is configured to be located near the heating element 2320. In addition, the second liquid transfer element 2322 of the illustrated embodiment is configured to extend between the first liquid transfer element 2321 and the lower portion of the portion 2302 in the container such that the second liquid transfer element 2322 is configured to transfer liquid to the first liquid transfer element 2321. In the embodiment shown, the first liquid transfer element 2321 has a flat shape, wherein the first liquid transfer element 2321 is located below the heating element 2320, and the second liquid transfer element 2322 is located below the first liquid transfer element 2321.

[000244] As shown in the drawings, the sleeve portion 2360 of the illustrated embodiment extends downwardly such that a portion of the sleeve portion 2360 is located between the near end 2306 and the far end 2308 of the container portion 2302. In the illustrated embodiment, the sleeve portion 2360 is configured to hold the heating element 2320, the first liquid transfer element 2321, and at least a portion of the second liquid transfer element 2322. In the illustrated embodiment, the heating element 2320 is located between the near end 2306 and the far end 2308 of the container portion 2302, and in particular in the middle third portion along the length of the container portion 2302. In the embodiment shown, the heating element 2320 in the installed position is in contact with the upper surface of the first element 2321 for transferring liquid, and the upper surface of the second element 2322 for transferring liquid is in contact with the lower surface of the first element 2321 for transferring liquid. Thus, one or more of these elements can provide increased performance in relation to the delivery of the liquid composition to the first element 2321 for transferring liquid.

[000245] In various embodiments, one or both of the first fluid transfer element 2321 and the second fluid transfer element 2322 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transport elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various absorbent materials, as well as the design and operation of these absorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely of a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000246] In the illustrated embodiment, the cartridge 2300 also includes a cover element 2362 that is configured to be positioned within the lower portion of the mouthpiece portion 2310. In the illustrated embodiment, the cover element 2362 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the cover element may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. The cover element 2362 of the shown embodiment has a block-like shape with a solid upper surface and openings formed in the lower and side surfaces. In the shown embodiment, the evaporation chamber 2340 is located above the heating element 2320 and is formed, at least in part, by a part 2360 in the form of a sleeve. In the shown embodiment, the part 2360 in the form of a sleeve forms a channel 2345 for vapor, which begins near the evaporation chamber 2340 and passes upward, leading to the cover element 2362. As indicated above, an aerosol is formed in the evaporation chamber 2340, when the heating element 2320 heats at least a part of the liquid composition contained in the first element 2321 for transferring liquid. In the shown embodiment, the cover element 2362 is configured to direct the aerosol, collect condensate and/or protect from liquid and high temperatures coming directly from the cartridge 2300. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vapor chamber 2340 can move through the vapor channel 2345, can be redirected by the cover element 2362 and can be delivered to the user through the outlet opening 2315 of the mouthpiece portion 2310.

[000247] FIGS. 21 and 22 show a cartridge according to another embodiment of the present invention. In particular, FIG. 21 shows an exploded perspective view of a cartridge 2500 according to an example embodiment of the present invention, and FIG. 22 shows a partially cutaway view of a cartridge 2500. In various embodiments, a portion of the cartridge 2500 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 2500 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000248] With reference to the drawings, the cartridge 2500 of the illustrated embodiment comprises a container portion 2502 that is formed by an outer wall 2504 of the container that includes a near end 2506 and a far end 2508. Thus, the container portion 2502 can be characterized in that the container wall 2504 is a side wall that is continuous around the container, and the far end 2508 forms a bottom wall. The container portion 2502 is also configured to contain a liquid composition 2524 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 2500 also comprises a mouthpiece portion 2510, which is formed by an outer wall 2512 of the mouthpiece, which includes a distal end 2516 and a proximal end 2514 with an outlet opening 2515 passing through it. In the illustrated embodiment, the cartridge 2500 also includes a portion 2560 in the form of a coupling, at least a portion of which is located between the mouthpiece portion 2510 and the portion 2502 in the form of a container. In the illustrated embodiment, the portion 2560 in the form of a coupling is configured to be connected to the mouthpiece portion 2510 and the portion 2502 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000249] In the illustrated embodiment, the outer wall 2504 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 2524 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 2504 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 2504 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 2504 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 2506 of the container 2502 to the far end 2508 of the container may be transparent or translucent. In additional embodiments, the outer wall 2504 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 2524 inside the container 2502 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 2504 of the container has a substantially opaque color.

[000250] In the illustrated embodiment, one or more of the mouthpiece portion 2510 and the sleeve portion 2560 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000251] As shown in the drawings, the cartridge 2500 also includes a heating element 2520 and a pair of electrical contacts 2525A, 2525B that are configured to electrically connect the heating element 2520 to a battery and/or a control component of the control device. In the illustrated embodiment, the contacts 2525A, 2525B are located on opposite sides of the cartridge 2500 and are configured to be attached to the sleeve portion 2560. Although in the illustrated embodiment the contacts 2525A, 2525B are configured to be attached to the sleeve portion 2560 by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 2520 is located near the distal end 2508 of the container-like portion 2502. Thus, the electrical contacts 2525A, 2525B extend downwards such that their respective ends are in contact with the heating element 2520. In various embodiments, the heating element 2520 may be held by the sleeve-like portion 2560 by means of a press-fit or lock-fit attachment, although other attachment methods are possible, including, for example, by means of an adhesive or by means of an insert molding process, or may be pressed by the sleeve-like portion 2560 against the lower portion of the container-like portion 2502. In the illustrated embodiment, the electrical contacts 2525A, 2525B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000252] In the illustrated embodiment, the heating element 2520 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 2520 may be integrally formed with the liquid transfer element 2521. Other types of heating elements may also be used, as noted above.

[000253] The cartridge 2500 of the illustrated embodiment also includes a liquid transfer element 2521. In the illustrated embodiment, at least a portion of the liquid transfer element 2521 is configured to be located near the heating element 2520. In the illustrated embodiment, the liquid transfer element 2521 is located below the heating element 2520 and extends between the heating element 2520 and a lower portion of the container portion 2502. As shown in the drawings, the sleeve portion 2560 of the illustrated embodiment extends downwardly such that a portion of the sleeve portion 2560 is located near the distal end 2508 of the container portion 2502 and is configured to hold the heating element 2520 and at least a portion of the liquid transfer element 2521. In the embodiment shown, the heating element 2520 is in the installed position in contact with the upper surface of the liquid transfer element 2521.

[000254] In various embodiments, the fluid transfer element 2521 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, the fluid transfer element may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000255] In the illustrated embodiment, the cartridge 2500 also includes a cover element 2562 that is configured to be positioned within the lower portion of the mouthpiece portion 2510. In the illustrated embodiment, the cover element 2562 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the cover element may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. The cover element 2562 of the shown embodiment has a block-like shape with a solid upper surface and openings formed in the lower and side surfaces. In the shown embodiment, the evaporation chamber 2540 is located above the heating element 2520 and is formed, at least in part, by the sleeve-like portion 2560. In the shown embodiment, the sleeve-like portion 2560 also forms a steam channel 2545 that begins near the evaporation chamber 2540 and extends upward, leading to the cover element 2562. As noted above, an aerosol is formed in the evaporation chamber 2540 when the heating element 2520 heats at least a portion of the liquid composition contained in the liquid transfer element 2521. In the shown embodiment, the cover element 2562 is configured to direct the aerosol, collect condensate and/or protect against liquid and high temperatures coming directly from the cartridge 2500. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vapor chamber 2540 can move through the vapor channel 2545, can be redirected by the cover element 2562 and can be delivered to the user through the outlet opening 2515 of the mouthpiece portion 2510.

[000256] FIGS. 23 and 24 show a cartridge according to another embodiment of the present invention. In particular, FIG. 23 shows an exploded perspective view of a cartridge 2700 according to an example embodiment of the present invention, and FIG. 24 shows a partially cutaway view of a cartridge 2700. In various embodiments, a portion of the cartridge 2700 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 2700 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000257] With reference to the drawings, the cartridge 2700 of the illustrated embodiment comprises a container portion 2702 that is formed by an outer wall 2704 of the container that includes a near end 2706 and a far end 2708. Thus, the container portion 2702 can be characterized in that the container wall 2704 is a side wall that is continuous around the container, and the far end 2708 forms a bottom wall. The container portion 2702 is also configured to contain a liquid composition 2724 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 2700 also comprises a mouthpiece portion 2710, which is formed by an outer wall 2712 of the mouthpiece, which includes a distal end 2716 and a proximal end 2714 with an outlet opening 2715 passing through it. In the illustrated embodiment, the cartridge 2700 also includes a part 2760 in the form of a sleeve, at least a part of which is located between the mouthpiece portion 2710 and the part 2702 in the form of a container. In the illustrated embodiment, the part 2760 in the form of a sleeve is configured to be connected to the mouthpiece portion 2710 and the part 2702 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000258] In the illustrated embodiment, one or more of the mouthpiece portion 2710 and the sleeve portion 2760 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000259] As shown in the drawings, the cartridge 2700 also includes a heating element 2720 and a pair of electrical contacts 2725A, 2725B that are configured to electrically connect the heating element 2720 to a battery and/or a control component of the control device. In the illustrated embodiment, the contacts 2725A, 2725B are located on opposite sides of the cartridge 2700 and are configured to be attached to the sleeve portion 2760. Although in the illustrated embodiment the contacts 2725A, 2725B are configured to be attached to the sleeve portion 2760 by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 2720 is located near the distal end 2708 of the container-like portion 2702. Thus, the electrical contacts 2725A, 2725B extend downwardly such that their respective ends are in contact with the heating element 2720. In various embodiments, the heating element 2720 may be retained by the sleeve-like portion 2760 by means of a press-fit or lock-fit attachment, although other attachment methods are possible, including, for example, by means of an adhesive or by means of an insert molding process, or may be pressed by the sleeve-like portion 2760 (for example, captured between the sleeve-like portion 2760 and one or more fluid transfer elements). In the illustrated embodiment, the electrical contacts 2725A, 2725B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000260] In the illustrated embodiment, the heating element 2720 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 2720 may be integrally formed with the liquid transfer element 2721. Other types of heating elements may also be used, as noted above.

[000261] The cartridge 2700 of the illustrated embodiment also includes a fluid transfer element 2721. In the illustrated embodiment, at least a portion of the fluid transfer element 2721 is configured to be positioned near the heating element 2720. In the illustrated embodiment, the fluid transfer element 2721 is positioned above the heating element 2720 and extends between the heating element 2720 and the metering plate 2735. The metering plate 2735 of the illustrated embodiment comprises a flat member that includes a plurality of openings. In the illustrated embodiment, the metering plate 2735 may be made of a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the dosing plate may be made of other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000262] In the installed position, the heating element 2720 of the shown embodiment is in contact with the lower surface of the liquid transfer element 2721, and the upper surface of the liquid transfer element 2721 is in contact with the lower surface of the metering plate 2735. In the shown embodiment, the metering plate 2735 is located in the container 2702 and under the liquid composition 2724. Thus, the metering plate 2735 is configured to deliver the liquid composition from the container 2702 to the liquid transfer element 2721. As shown in the drawings, the sleeve portion 2760 of the illustrated embodiment extends downwardly in such a way that the sleeve portion 2760 is located near the distal end 2708 of the container portion 2702 and is configured to hold the heating element 2720, the liquid transfer element 2721 and the metering plate 2735. Additionally, after installation, a gap 2747 is formed between the sleeve portion 2760 and the inner surface of the container portion 2702, which is configured as a path for the aerosol.

[000263] In various embodiments, the fluid transfer element 2721 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, the fluid transfer element may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer element may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, the fluid transfer element may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000264] In the illustrated embodiment, the vapor chamber 2740 is formed below the heating element 2720 and near the distal end 2708 of the container portion 2702. In particular, the vapor chamber 2740 is formed, at least in part, by the sleeve portion 2760 and the distal end 2708 of the container portion 2702. As noted above, an aerosol is formed in the vapor chamber 2740 when the heating element 2720 heats at least a portion of the liquid composition contained in the liquid transfer element 2721. Based on the elements of the cartridge 2700, when the user puffs on the aerosol delivery device, the aerosol generated in the vaporization chamber 2740 is released and then passes along the aerosol path between the sleeve portion 2760 and the container portion 2702, where it is delivered to the user through the outlet opening 2715 of the mouthpiece portion 2710.

[000265] FIG. 25 shows a cartridge according to another embodiment of the present invention. In particular, FIG. 25 shows a partially cutaway view of a cartridge 2900. In various embodiments, a portion of the cartridge 2900 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 2900 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000266] With reference to the drawing, the cartridge 2900 of the illustrated embodiment comprises a container portion 2902 that is formed by an outer wall 2904 of the container that includes a near end 2906 and a far end 2908. Thus, the container portion 2902 can be characterized in that the container wall 2904 is a side wall that is continuous around the container, and the far end 2908 forms a bottom wall. The container portion 2902 is also configured to contain a liquid composition 2924 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 2900 also includes a mouthpiece portion 2910, which is formed by an outer wall 2912 of the mouthpiece, which includes a distant end 2916 and a near end 2914 with outlet openings 2915 formed therein. In the illustrated embodiment, the cartridge 2900 also includes a part 2960 in the form of a sleeve, which is located between the mouthpiece portion 2910 and the part 2902 in the form of a container. In the illustrated embodiment, the part 2960 in the form of a sleeve is configured to be connected to the mouthpiece portion 2910 and the part 2902 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000267] In the illustrated embodiment, the outer wall 2904 of the container may be made at least partially transparent and/or translucent, so that the liquid composition 2924 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 2904 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 2904 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 2904 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 2906 of the container 2902 to the far end 2908 of the container may be transparent or translucent. In additional embodiments, the outer wall 2904 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 2924 inside the container 2902 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 2904 of the container has a substantially opaque color.

[000268] In the illustrated embodiment, one or more of the mouthpiece portion 2910 and the sleeve portion 2960 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000269] As shown in the drawing, the cartridge 2900 also includes a heating element 2920 and a pair of electrical contacts 2925A, 2925B that are configured to electrically connect the heating element 2920 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 2925A, 2925B are located on opposite sides of the cartridge 2900 and are configured to be attached to the sleeve portion 2960. Although in the shown embodiment, the contacts 2925A, 2925B are configured to be attached to the sleeve portion 2960 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 2925A, 2925B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000270] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 2920 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element 2920 may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 2920 may be integrally formed with the first fluid transfer element 2921. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000271] The cartridge 2900 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 2900 includes a first liquid transfer element 2921 and a second liquid transfer element 2922. In the illustrated embodiment, a portion of the heating element 2920 is configured to wrap around a portion of the first liquid transfer element 2921 in the region of the sleeve portion 2960. In the illustrated embodiment, the second liquid transfer element 2922 has a relatively flat shape that includes an opening configured to surround a portion of the first liquid transfer element 2921 such that the second liquid transfer element 2922 forms a seal around the first liquid transfer element 2921. In the illustrated embodiment, the first liquid transfer element 2921 has a substantially cylindrical shape and is substantially aligned with the longitudinal axis of the cartridge. In the illustrated embodiment, the first liquid transfer element 2921 passes through the second liquid transfer element 2922 and the liquid composition 2924 to the lower part of the container-like portion 2902. In the illustrated embodiment, the outer diameter of the second liquid transfer element 2922 is larger than the outer diameter of the first liquid transfer element 2921, and the length of the first liquid transfer element 2921 is larger than the length of the second liquid transfer element 2922.

[000272] In the illustrated embodiment, the cartridge 2900 also includes an upper frame portion 2931 that may include various elements configured to hold the heating element 2920 and at least a portion of the first fluid transfer element 2921. In the illustrated embodiment, the upper body portion 2931 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 2931 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 2920 with the corresponding electrical contacts 2925A, 2925B. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 2931, the heating element 2920, the first fluid transfer element 2921, the second fluid transfer element 2922, and the electrical contacts 2925A, 2925B are contained within the sleeve portion 2960.

[000273] In various embodiments, one or both of the first fluid transfer element 2921 and the second fluid transfer element 2922 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 2921 comprises a ceramic material, and the second fluid transfer element 2922 comprises a semi-rigid material. In the illustrated embodiment, the first fluid transfer element 2921 and the second fluid transfer element 2922 are configured to fit snugly into the sleeve portion 2960, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000274] As shown in the drawings, at least a portion of the heating element 2920 is wrapped around a portion of the first liquid transfer element 2921. In the illustrated embodiment, the vaporization chamber 2940 is located in the region around the first liquid transfer element 2921, around which the heating element 2920 is wrapped, and is formed, at least in part, by the upper frame portion 2931. As indicated above, the aerosol is formed in the vaporization chamber 2940 when the heating element 2920 heats at least a portion of the liquid composition contained in the first liquid transfer element 2921. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 2940 can be redirected to the user through the outlet opening 2915 of the mouthpiece portion 2910.

[000275] FIG. 26 shows a cartridge according to another embodiment of the present invention. In particular, FIG. 26 shows a partially cross-sectional view of a cartridge 3100. In various embodiments, a portion of the cartridge 3100 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 3100 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000276] With reference to the drawing, the cartridge 3100 of the illustrated embodiment comprises a container portion 3102 that is formed by an outer wall 3104 of the container that includes a near end 3106 and a far end 3108. Thus, the container portion 3102 can be characterized in that the container wall 3104 is a side wall that is continuous around the container, and the far end 3108 forms a bottom wall. The container portion 3102 is also configured to contain a liquid composition 3124 that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 3100 also includes a mouthpiece portion 3110, which is formed by an outer wall 3112 of the mouthpiece, which includes a distal end 3116 and a proximal end 3114 with outlet openings 3115 formed therein. In the illustrated embodiment, the cartridge 3100 also includes a part 3160 in the form of a sleeve, which is located between the mouthpiece portion 3110 and the part 3102 in the form of a container. In the illustrated embodiment, the part 3160 in the form of a sleeve is configured to be connected to the mouthpiece portion 3110 and the part 3102 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000277] In the illustrated embodiment, the outer wall 3104 of the container may be formed at least partially transparent and/or translucent, so that the liquid composition 3124 contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 3104 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 3104 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 3104 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 3106 of the container 3102 to the far end 3108 of the container may be transparent or translucent. In additional embodiments, the outer wall 3104 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition 3124 inside the container 3102 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 3104 of the container has a substantially opaque color.

[000278] In the illustrated embodiment, one or more of the mouthpiece portion 3110 and the sleeve portion 3160 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000279] As shown in the drawing, the cartridge 3100 also includes a heating element 3120 and a pair of electrical contacts 3125A, 3125B that are configured to electrically connect the heating element 3120 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 3125A, 3125B are located on opposite sides of the cartridge 3100 and are configured to be attached to the sleeve portion 3160. Although in the shown embodiment, the contacts 3125A, 3125B are configured to be attached to the sleeve portion 3160 by means of a push-fit or lock-fit attachment, in other embodiments, other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the shown embodiment, the electrical contacts 3125A, 3125B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000280] In various embodiments, the heating element may comprise one or more different materials configured to generate heat when an electric current is passed therethrough. In the illustrated embodiment, the heating element 3120 comprises a wire coil. Examples of materials from which the wire coil may be made include, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element 3120 may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 3120 may be integrally formed with the first fluid transfer element 3121. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000281] The cartridge 3100 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 3100 includes a first liquid transfer element 3121 and a second liquid transfer element 3122. In the illustrated embodiment, a portion of the heating element 3120 is configured to wrap around a portion of the first liquid transfer element 3121 in the region of the sleeve portion 3160. In the illustrated embodiment, the second liquid transfer element 3122 has a relatively flat shape that includes an opening configured to surround a portion of the first liquid transfer element 3121 such that the second liquid transfer element 3122 forms a seal around the first liquid transfer element 3121. In the illustrated embodiment, the first liquid transfer element 3121 has a substantially cylindrical and solid (e.g., non-hollow) shape and is substantially aligned with the longitudinal axis of the cartridge. In the illustrated embodiment, the first liquid transfer element 3121 passes through the second liquid transfer element 3122 and the liquid composition 3124 to the lower part of the container part 3102. In particular, one end of the first liquid transfer element 3121 is attached to the mouthpiece part 3110 by means of the retaining ring 3137, and the other end of the first liquid transfer element 3121 passes to the lower part of the container part 3102. In the illustrated embodiment, the outer diameter of the second liquid transfer element 3122 is larger than the outer diameter of the first liquid transfer element 2921, and the length of the first liquid transfer element 3121 is larger than the length of the second liquid transfer element 3122.

[000282] In the illustrated embodiment, the cartridge 3100 also includes an upper frame portion 3131 that may include various elements configured to hold the heating element 3120 and at least a portion of the first fluid transfer element 3121. In the illustrated embodiment, the upper body portion 3131 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. The upper frame portion 3131 of the illustrated embodiment is also configured to facilitate the connection (such as, for example, by pressing together) of the ends of the heating element 3120 with the corresponding electrical contacts 3125A, 3125B. In the illustrated embodiment, at least a portion of one or more of the upper frame portion 3131, the heating element 3120, the first fluid transfer element 3121, the second fluid transfer element 3122, and the electrical contacts 3125A, 3125B are contained within the sleeve portion 3160.

[000283] In various embodiments, one or both of the first fluid transfer element 3121 and the second fluid transfer element 3122 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 3121 comprises a fibrous material, and the second fluid transfer element 3122 comprises a semi-rigid material. In the illustrated embodiment, the second fluid transfer element 3122 and the retaining ring 3137 are configured to fit snugly into the sleeve portion 3160, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000284] As shown in the drawings, at least a portion of the heating element 3120 is wrapped around a portion of the first liquid transfer element 3121. In the illustrated embodiment, the vaporization chamber 3140 is located in the region around the first liquid transfer element 3121, around which the heating element 3120 is wrapped, and is formed at least partially by the upper frame portion 3131. As indicated above, the aerosol is formed in the vaporization chamber 3140 when the heating element 3120 heats at least a portion of the liquid composition contained in the first liquid transfer element 3121. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 3140 can be redirected to the user through the outlet opening 3115 of the mouthpiece portion 3110.

[000285] FIGS. 27 and 28 show a cartridge according to another embodiment of the present invention. In particular, FIG. 27 shows an exploded perspective view of a cartridge 3300 according to an example embodiment of the present invention, and FIG. 28 shows a partially cutaway view of a cartridge 3300. In various embodiments, a portion of the cartridge 3300 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 3300 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000286] With reference to the drawings, the cartridge 3300 of the illustrated embodiment comprises a container portion 3302 that is formed by an outer wall 3304 of the container that includes a near end 3306 and a far end 3308. Thus, the container portion 3302 can be characterized in that the container wall 3304 is a side wall that is continuous around the container, and the far end 3308 forms a bottom wall. The container portion 3302 is also configured to contain a liquid composition that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 3300 also includes a mouthpiece portion 3310, which is formed by an outer wall 3312 of the mouthpiece, which includes a distal end 3316 and a proximal end 3314 with outlet openings 3315 formed therein. In the illustrated embodiment, the cartridge 3300 also includes a part 3360 in the form of a sleeve, which is located between the mouthpiece portion 3310 and the part 3302 in the form of a container. In the illustrated embodiment, the part 3360 in the form of a sleeve is configured to be connected to the mouthpiece portion 3310 and the part 3302 in the form of a container by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000287] In the illustrated embodiment, the outer wall 3304 of the container may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 3304 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 3304 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 3304 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 3306 of the container 3302 to the far end 3308 of the container may be transparent or translucent. In additional embodiments, the outer wall 3304 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition inside the container 3302 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 3304 of the container has a substantially opaque color.

[000288] In the illustrated embodiment, one or more of the mouthpiece portion 3302 and the sleeve portion 3360 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000289] As shown in the drawings, the cartridge 3300 also includes a heating element 3320 and a pair of electrical contacts (not shown) that are configured to electrically connect the heating element 3320 to a battery and/or a control component of the control device. In the illustrated embodiment, the contacts are located on opposite sides of the cartridge 3300 and are configured to be attached to the sleeve portion 3360. Although in the illustrated embodiment the contacts are configured to be attached to the sleeve portion 3360 by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the electrical contacts are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000290] In the illustrated embodiment, the heating element 3320 may be formed from a metallic material, such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 3320 may be integrally formed with the first fluid transfer element 3321. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000291] The cartridge 3300 of the shown embodiment also includes a plurality of liquid transfer elements. In particular, the cartridge 3300 includes a first liquid transfer element 3321 and a pair of second liquid transfer elements 3122 3322A, 3322B. In the shown embodiment, at least a portion of the first liquid transfer element 3321 is configured to be located near the heating element 3320. In addition, the second liquid transfer elements 3322A, 3322B of the shown embodiment are configured to extend between the first liquid transfer element 3321 and the lower portion of the portion 3302 in the container. In the shown embodiment, the second liquid transfer elements 3322A, 3322B comprise capillary tubes configured to deliver the liquid composition to the first liquid transfer element 3321 by capillary action. In the illustrated embodiment, the second fluid transfer elements 3322A, 3322B are substantially cylindrical and hollow in shape, although other configurations are possible.

[000292] As shown in the drawings, the first liquid transfer element 3321 and the heating element 3320 are located in the sleeve portion 3360 of the cartridge 3300. The heating element 3320 of the illustrated embodiment comprises a flat heating element, and the first liquid transfer element 3321 comprises a relatively flat element that has a substantially block-like shape. Although other configurations are possible, in the illustrated embodiment, the length and width of the first liquid transfer element 3321 are greater than its thickness. Thus, the heating element 3320 in the installed position is in contact with the upper surface of the first liquid transfer element 3321. In the embodiment shown, the second liquid transfer elements 3322A, 3322B are substantially aligned with the longitudinal axis of the cartridge and are spaced apart from each other such that the upper surfaces of the second liquid transfer elements 3322A, 3322B are in contact with the first liquid transfer element 3321, and the lower surfaces of the second liquid transfer elements 3322A, 3322B are located near (and in the embodiment shown are spaced slightly apart from) the lower portion of the container-like portion 3302.

[000293] In the illustrated embodiment, the first fluid transfer element 3321 may comprise a fibrous material, and the second fluid transfer elements 3322A, 3322B may be made of a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be made of other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. In still other embodiments, one or both of the first fluid transfer element 3321 and the second fluid transfer elements 3322A, 3322B may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the second fluid transfer elements 3322A, 3322B are configured to fit tightly into the sleeve portion 3360. Thus, in some embodiments, the fluid transport elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transport elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000294] As shown in the drawings, at least a portion of the heating element 3320 is located in the sleeve portion 3360. In the illustrated embodiment, the vaporization chamber 3340 is located in the region above the heating element 3320 and is formed, at least in part, by the mouthpiece portion 3310. As indicated above, the aerosol is formed in the vaporization chamber 3340 when the heating element 3320 heats at least a portion of the liquid composition contained in the first liquid transfer element 3321. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 3340 can be redirected to the user through the outlet opening 3315 of the mouthpiece portion 3310.

[000295] FIGS. 29 and 30 show a cartridge according to another embodiment of the present invention. In particular, FIG. 29 shows an exploded perspective view of a cartridge 3500 according to an example embodiment of the present invention, and FIG. 30 shows a partially cutaway view of the cartridge 3500. In various embodiments, a portion of the cartridge 3500 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 3500 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000296] With reference to the drawings, the cartridge 3500 of the illustrated embodiment comprises a container portion 3502 that is formed by an outer wall 3504 of the container that includes a near end 3506 and a far end 3508. Thus, the container portion 3502 can be characterized in that the container wall 3504 is a side wall that is continuous around the container, and the far end 3508 forms a bottom wall. The container portion 3502 is also configured to contain a liquid composition that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 3500 also comprises a mouthpiece portion 3510, which is formed by an outer wall 3512 of the mouthpiece, which includes a distal end 3516 and a proximal end 3514 with an outlet opening 3515 passing through it. In the illustrated embodiment, the cartridge 3500 also includes a portion 3560 in the form of a sleeve, which is located between the mouthpiece portion 3510 and the portion 3502 in the form of a container. In the illustrated embodiment, the portion 3560 in the form of a sleeve is configured to connect to the mouthpiece portion 3510 and the portion 3502 in the form of a container by means of a tight fit or a lock fit connection; however, in other embodiments, other methods of attachment are possible (for example, by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof.

[000297] In the illustrated embodiment, the outer wall 3504 of the container may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 3504 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 3504 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 3504 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 3506 of the container 3502 to the far end 3508 of the container may be transparent or translucent. In additional embodiments, the outer wall 3504 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition inside the container 3502 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 3504 of the container has a substantially opaque color.

[000298] In the illustrated embodiment, one or more of the mouthpiece portion 3510 and the sleeve portion 3560 and the container portion may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000299] The cartridge 3500 also includes a heating element 3520 and a pair of electrical contacts (not shown) that are configured to electrically connect the heating element 3520 to a battery and/or a control component of the control device. In the illustrated embodiment, the contacts are located on opposite sides of the cartridge 3500 and are configured to be attached to the sleeve portion 3560. Although in the illustrated embodiment the contacts are configured to be attached to the sleeve portion 3560 by means of a push-fit or lock-fit attachment, other attachment methods are possible in other embodiments, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the electrical contacts are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be formed from one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000300] In the illustrated embodiment, the heating element 3520 may be formed from a metallic material, such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 3520 may be integrally formed with the first fluid transfer element 3521. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000301] The cartridge 3500 of the illustrated embodiment also includes a plurality of liquid transfer elements. In particular, the cartridge 3500 includes a first liquid transfer element 3521 and a plurality of second transfer elements. Although other configurations are possible, the illustrated embodiment includes five second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E. In the illustrated embodiment, at least a portion of the first liquid transfer element 3521 is configured to be located near the heating element 3520. In addition, the second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E of the illustrated embodiment are configured to extend between the first liquid transfer element 3521 and the lower portion of the portion 3502 in the container. In the illustrated embodiment, the second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E comprise capillary tubes configured to deliver a liquid composition to the first liquid transfer element 3521 by capillary action. In the illustrated embodiment, the second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E have a substantially cylindrical and hollow shape, although other configurations are possible.

[000302] As shown in the drawings, the first liquid transfer element 3521 and the heating element 3520 are located in the sleeve portion 3560 of the cartridge 3500. The heating element 3520 of the illustrated embodiment comprises a flat heating element, and the first liquid transfer element 3521 comprises a relatively flat element that has a substantially block-like shape. Although other configurations are possible, in the illustrated embodiment, the length and width of the first liquid transfer element 3521 are greater than its thickness. Thus, the heating element 3520 in the installed position is in contact with the upper surface of the first liquid transfer element 3521. In the illustrated embodiment, the second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E are substantially aligned with the longitudinal axis of the cartridge and are spaced apart from each other such that the upper surfaces of the second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E are in contact with the first liquid transfer element 3521, and the lower surfaces of the second liquid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E are located near (and in the illustrated embodiment are spaced slightly to the side from) the lower portion 3502 in the form of a container.

[000303] In the illustrated embodiment, the first fluid transfer element 3521 may comprise a fibrous material, and the second fluid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components can be made of other materials, including, for example, metallic materials (for example, aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. In still other embodiments, one or both of the first fluid transfer element 3521 and the second fluid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E can be formed from one or more materials configured to transfer fluid, for example, by capillary action. In some embodiments, for example, one or both of the fluid transfer elements can be formed from fibrous materials (for example, organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes or the like. In the illustrated embodiment, the second fluid transfer elements 3522A, 3522B, 3522C, 3522D, 3522E are configured to fit tightly into the sleeve portion 3560. Thus, in some embodiments, the fluid transfer elements can be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may particularly relate to the use of non-fibrous transport elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various absorbent materials, as well as the design and operation of these absorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely of a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000304] As shown in the drawings, at least a portion of the heating element 3520 is located in the sleeve portion 3560. In the illustrated embodiment, the vaporization chamber 3540 is located in the region above the heating element 3520 and is formed, at least in part, by the mouthpiece portion 3510. As indicated above, the aerosol is formed in the vaporization chamber 3540 when the heating element 3520 heats at least a portion of the liquid composition contained in the first liquid transfer element 3521. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 3540 can be redirected to the user through the outlet opening 3515 of the mouthpiece portion 3510.

[000305] FIGS. 310 and 32 show a cartridge according to another embodiment of the present invention. In particular, FIG. 31 shows an exploded perspective view of a cartridge 3700 according to an example embodiment of the present invention, and FIG. 32 shows a partially cutaway view of a cartridge 3700. In various embodiments, a portion of the cartridge 3700 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 3700 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000306] With reference to the drawings, the cartridge 3700 of the illustrated embodiment comprises a container portion 3702 that is formed by an outer wall 3704 of the container that includes a near end 3706 and a far end 3708. Thus, the container portion 3702 can be characterized in that the container wall 3704 is a side wall that is continuous around the container, and the far end 3708 forms a bottom wall. The container portion 3702 is also configured to contain a liquid composition that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 3700 also comprises a mouthpiece portion 3710, which is formed by an outer wall 3712 of the mouthpiece, which includes a distal end 3716 and a proximal end 3714 with an outlet opening 3715 passing through it. In the illustrated embodiment, the cartridge 3700 also includes an internal frame element 3764, which is located under the distal end 3716 of the mouthpiece portion 3710 and between the proximal end 3706 and the distal end 3708 of the container-like portion 3702. In the illustrated embodiment, the inner frame member 3764 comprises a main portion 3765 and a sealing portion 3767. In the illustrated embodiment, the mouthpiece portion 3710 and the container portion 3702 are configured to be connected to each other by means of a push-fit or lock-fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof. In the illustrated embodiment, the inner frame 3764 is configured to be connected to the container portion 3702 by means of a push-fit or lock-fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000307] In the illustrated embodiment, one or more of the mouthpiece portion 3710 and the container portion 3702 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. In addition, in the illustrated embodiment, the main portion 3765 of the inner frame member 3764 may be made of a molded polymeric material, such as, for example, a molded plastic material (for example, acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate and combinations thereof), and the sealing portion 3767 of the inner frame member 3764 may be made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. Thus, in some embodiments, the sealing portion 3767 of the inner frame member 3764 may be formed by a pressing process or insert molding with the main portion 3765 of the inner frame member 3764.

[000308] As shown in the drawings, the cartridge 3700 also includes a heating element 3720 and a pair of electrical contacts 3725A, 3725B that are configured to electrically connect the heating element 3720 to the battery and/or the control component of the control device. In the shown embodiment, the contacts 3725A, 3725B are located on opposite sides of the cartridge 3700 and are configured to pass through a portion of the sealing portion 3767 of the inner frame, the heating element 3720 and into the mouthpiece portion 3710. Although in the shown embodiment the contacts 3725A, 3725B are configured to be attached to the container portion 3702 by means of an insert molding process, other methods are possible, including, for example, by means of attachment with a tight fit or a lock fit or by means of an adhesive. In the illustrated embodiment, the electrical contacts 3725A, 3725B are made of a conductive material. Examples of conductive materials may include, but are not limited to, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be made of one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold. The container portion 3702 of the illustrated embodiment also includes a metal plate 3766 (see FIG. 32) that is configured to interact with a magnetic element of the control device to facilitate a mechanical connection between the cartridge 3700 and the control device. In the illustrated embodiment, the metal plate 3766 may comprise any material capable of being attracted by a magnet, such as various ferromagnetic materials, including, but not limited to, iron, nickel, cobalt, alloys such as steel, and/or any combination thereof. Although other methods are possible, in the illustrated embodiment, the metal plate 3766 is integrated into the bottom wall of the container portion 3702 by means of an insert molding process.

[000309] In addition, in order to enable electrical connection between the heating element 3720 and the battery and/or the control component of the control device, the electrical contacts 3725A, 3725B of the illustrated embodiment may also perform other functions. For example, as shown in detail in FIG. 43, in some embodiments, the ends of the electrical contacts 3725A, 3725B may extend beyond the heating element 3720 and into corresponding channels formed in the mouthpiece portion 3710. Thus, the electrical contacts 3725A, 3725B may also facilitate assembly of the mouthpiece portion 3710. In addition, the electrical contacts 3725A, 3725B of some embodiments may facilitate attachment of the mouthpiece portion 3710 to the container portion 3702 and/or retention therein. Thus, at least a portion of the ends of the electrical contacts 3725A, 3725B near the mouthpiece portion 3710 can create an interference engagement with the corresponding channels of the mouthpiece portion. Additionally or alternatively, at least a portion of the ends of the electrical contacts 3725A, 3725B near the mouthpiece portion 3710 can be to facilitate the connection between the mouthpiece portion 3710 and the portion 3702 in the form of a container. In various embodiments, various types of knurling processing are possible, including, for example, direct knurling, screw knurling, diamond roller knurling, and the like. In some embodiments, the ends of the electrical contacts 3725A, 3725B with knurling can also facilitate a mechanical connection between the heating element 3720 and the electrical contacts 3725A, 3725B. In additional embodiments, the heating element 3720 itself may include features that may facilitate a connection between the heating element 3720 and the electrical contacts 3725A, 3725B. For example, FIG. 44 shows a perspective view of a portion of the cartridge of FIGS. 31 and 32. In the illustrated embodiment, the heating element 3720 includes apertures 3770A, 3770B for attachment that are configured to interact with the ends of the electrical contacts 3725A, 3725B. As shown in the detailed portion of the drawing, in some embodiments, the apertures 3770A, 3770B may have a star-shaped (or other) pattern that includes a plurality of protruding features configured to "engage" with the ends of the electrical contacts 3725A, 3725B when the heating element 3720 is assembled on the electrical contacts 3725A, 3725B.

[000310] In the illustrated embodiment, the heating element 3720 comprises a flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 3720 may be integrally formed with the first fluid transfer element 3721. Other types of heating elements (e.g., laser diodes, microheaters, etc.) may also be used, as noted above.

[000311] The cartridge 3700 of the illustrated embodiment also includes a pair of liquid transfer elements. In particular, the cartridge 3700 includes a first liquid transfer element 3721 and a second liquid transfer element 3722. In the illustrated embodiment, at least a portion of the first liquid transfer element 3721 is configured to be located near the heating element 3720. In addition, the second liquid transfer element 3722 of the illustrated embodiment is configured to pass between the first liquid transfer element 3721 and the liquid composition contained in the container 3702 such that the second liquid transfer element 3722 is configured to transfer the liquid to the first liquid transfer element 3721. In the illustrated embodiment, the second liquid transfer element 3722 has a T-shape with a transverse portion 3727 that intersects the longitudinal portion 3729. Although other configurations are possible, in the illustrated embodiment, the length of the longitudinal portion 3729 is greater than the length of the transverse portion 3727.

[000312] As shown in the drawings, the first liquid transfer element 3721, the heating element 3720 and a part of the second liquid transfer element 3722 are located in the inner frame part 3764 of the cartridge 3700. Thus, the heating element 3720 in the installed position is in contact with the upper surface of the first liquid transfer element 3721, and the upper surface of the second liquid transfer element 3722 is in contact with the lower surface of the first liquid transfer element 3721. Thus, the second liquid transfer element 3722 is configured to deliver a liquid composition to the first liquid transfer element 3721.

[000313] In various embodiments, one or both of the first fluid transfer element 3721 and the second fluid transfer element 3722 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. In the illustrated embodiment, the first fluid transfer element 3721 comprises a fibrous material, and the second fluid transfer element 3722 comprises a semi-rigid material. In the illustrated embodiment, the second fluid transfer element 3722 is configured to fit snugly into the inner frame portion 3764 in the form of a sleeve, although other attachment methods are possible. Thus, in various embodiments, the fluid transfer elements may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transfer elements may be expressly excluded. Alternatively, combinations of fibrous transfer elements and non-fibrous transfer elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Application Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, a porous monolith may form a substantially solid wick.

[000314] As shown in the drawings, at least a portion of the heating element 3720 is located in the inner frame element 3764. In the illustrated embodiment, the vaporization chamber 3740 is located in the region above the heating element 3720 and is formed, at least in part, by the mouthpiece portion 3710. As indicated above, the aerosol is formed in the vaporization chamber 3740 when the heating element 3720 heats at least a portion of the liquid composition contained in the first liquid transfer element 3721. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vaporization chamber 3740 can be redirected to the user through the outlet opening 3715 of the mouthpiece portion 3710.

[000315] In various embodiments, at least a portion of the heating element may be referred to as being near the distal end of the mouthpiece portion. To illustrate this point, reference is made to FIG. 45, which shows a partially cutaway view of the cartridge 3700 of FIGS. 31 and 32. In particular, in FIG. 45 shows a cartridge 3700 that includes a container portion 3702 formed by an outer wall 3704 of the container that includes a near end 3706 and a far end 3708, and a mouthpiece portion 3710 formed by an outer wall 3712 of the mouthpiece that includes a near end 3714 with an outlet opening 3715 passing through it, and a far end 3716 that cooperates with the near end 3706 of the container portion 3702. FIG. 45 also shows a heating element 3720 and electrical contacts 3725A, 3725B configured to electrically connect the heating element 3720 to a battery and/or a control component of a control device. It is apparent from the drawing that for this embodiment and many other embodiments shown, the heating element 3720 may be characterized as being located near the distal end 3716 (designated in the drawing by reference line M-D) of the mouthpiece portion 3710.

[000316] FIGS. 33 and 34 show a cartridge according to another embodiment of the present invention. In particular, FIG. 33 shows an exploded perspective view of a cartridge 3900 according to an example embodiment of the present invention, and FIG. 34 shows a partially cutaway view of a cartridge 3900. In various embodiments, a portion of the cartridge 3900 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 3900 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000317] With reference to the drawings, the cartridge 3900 of the illustrated embodiment comprises a container portion 3902 that is defined by an outer container wall 3904 that includes a proximal end 3906 and a distal end 3908. Thus, the container portion 3902 can be characterized in that the container wall 3904 is a side wall that is continuous around the sides of the container and includes an inner intermediate wall 3949 and an open distal end 3908 below the intermediate wall 3949. In the illustrated embodiment, the open distal end 3908 of the container portion 3902 is covered by a bottom cap 3972 and a lower frame 3968. The container portion 3902 is also configured to contain a liquid composition that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described The cartridge 3900 also comprises a mouthpiece portion 3910, which is formed by an outer wall 3912 of the mouthpiece, which includes a distal end 3916 and a proximal end 3914 with an outlet opening 3915 passing through it. In the illustrated embodiment, the cartridge 3900 also includes a sleeve portion 3960, at least a portion of which is located between the mouthpiece portion 3910 and the container portion 3902. In the illustrated embodiment, the sleeve portion 3960 is configured to connect to the mouthpiece portion 3910 and the container portion 3902 by means of a tight fit or lock fit connection; however, in other embodiments, other methods of attachment are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof.

[000318] In the illustrated embodiment, the outer wall 3904 of the container may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 3904 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 3904 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 3904 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 3906 of the container 3902 to the far end 3908 of the container may be transparent or translucent. In additional embodiments, the outer wall 3904 of the container may be colored. In some embodiments, the color can be configured so that the liquid composition inside the container 3902 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall can be designed so that the outer wall 3904 of the container has a substantially opaque color.

[000319] In the illustrated embodiment, one or more of the mouthpiece portion 3910, the sleeve portion 3960, the container portion 3902, the bottom frame 3968, and the bottom cap 3972 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be made of other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000320] As shown in the drawings, the cartridge 3900 also includes a heating element 3920 and a pair of electrical contacts 3925A, 3925B that are configured to electrically connect the heating element 3920 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 3925A, 3925B are located on opposite sides of the cartridge 3900 and are configured to be attached to at least one of the following: a bottom cover 3972, a lower frame 3968, and a container portion 3902. Although in the shown embodiment, the contacts 3925A, 3925B are configured to be attached to one or more of these components by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 3920 is located near the distal end 3908 of the container portion 3902. In various embodiments, the heating element 3920 may be located in the container portion 3902 and/or may be retained therein by means of a push-fit or lock-fit attachment, although other forms of attachment are possible, including, for example, by means of an adhesive or an insert molding process or capture by the lower frame 3968 in the container portion 3902. In the illustrated embodiment, the electrical contacts 3925A, 3925B are made of a conductive material. Examples of conductive materials may include, without limitation, copper, beryllium copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be formed from one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000321] The bottom cover 3972 of the illustrated embodiment also includes a member configured to be retained by a magnet 3970, which is configured to facilitate a mechanical connection between the cartridge 3900 and the control device. It should be noted that in other embodiments, the bottom cover may comprise a component, such as, for example, a metal disk configured to be attached by a magnet located in the control device. In various embodiments of the present invention, the magnet 3970 may comprise a plurality of different types of magnets, including rare earth magnets. For example, in some embodiments, one or more magnets may comprise neodymium magnets (also known as NdFeB, NIB, or Neo magnets). In various embodiments, different classes of neodymium magnets may be used, including, for example, N35, N38, N40, N42, N45, N48, N50 and/or N52 classes. In other embodiments, one or more magnets may comprise samarium cobalt magnets (also known as SmCo magnets). In yet other embodiments, one or more magnets may comprise ceramic/iron magnets. In other embodiments, one or more magnets may comprise aluminum nickel cobalt (AlNiCo) magnets. In any of the above embodiments, one or more magnets may comprise an electroplating and/or coating. For example, in some embodiments, one or more magnets may be nickel plated. In other embodiments, one or more magnets may be plated with one or more of zinc, tin, copper, epoxy, silver, and/or gold. In some embodiments, one or more magnets may be plated with a combination of these materials. For example, in one embodiment, one or more magnets may be nickel plated, copper plated, and nickel plated again. In another embodiment, one or more magnets may be nickel plated, copper plated, and a gold top coat.

[000322] In the illustrated embodiment, the heating element 3920 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 3920 may be integrally formed with the liquid transfer element 3921. Other types of heating elements may also be used, as noted above.

[000323] The cartridge 3900 of the illustrated embodiment also includes a liquid transfer element 3921, at least a portion of which is configured to be located near the heating element 3920. In particular, in the illustrated embodiment, the liquid transfer element 3921 is located above the heating element 3920 and is configured to be captured by the intermediate wall element 3949 of the container-like portion 3902. In the illustrated embodiment, the liquid transfer element 3921 has a relatively flat, block-like shape.

[000324] In various embodiments, the fluid transfer element 3921 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000325] In the illustrated embodiment, the container portion includes a vapor passage 3974 that is located on one side of the interior of the container portion 3902. As shown in the drawings, the vapor chamber 3940 is located in the region below the heating element 3920 and is formed, at least in part, by the lower frame 3968. As indicated above, the aerosol is formed in the vapor chamber 3940 when the heating element 3920 heats at least a portion of the liquid composition contained in the first liquid transfer element 3921. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vapor chamber 3940 can be delivered to the user via the vapor passage 3974 in the container portion 3902 and through the outlet opening 3915 of the mouthpiece portion 3910.

[000326] FIGS. 35 and 36 show a cartridge according to another embodiment of the present invention. In particular, FIG. 35 shows an exploded perspective view of a cartridge 4100 according to an example embodiment of the present invention, and FIG. 36 shows a partially cutaway view of a cartridge 4100. In various embodiments, a portion of the cartridge 4100 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 4100 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000327] With reference to the drawings, the cartridge 4100 of the illustrated embodiment comprises a container portion 4102 that is defined by an outer container wall 4104 that includes a proximal end 4106 and a distal end 4108. Thus, the container portion 4102 can be characterized in that the container wall 4104 is a side wall that is continuous around the sides of the container and includes an inner intermediate wall 4149 and an open distal end 4108 below the intermediate wall 4149. In the illustrated embodiment, the open distal end 4108 of the container portion 4102 is covered by a bottom cap 4172 and a lower frame 4168. The container portion 4102 is also configured to contain a liquid composition that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described The cartridge 4100 also includes a mouthpiece portion 4110, which is formed by an outer wall 4112 of the mouthpiece, which includes a distal end 4116 and a proximal end 4114 with outlet openings 4115 formed therein. In the illustrated embodiment, the distal end 4116 of the mouthpiece portion 4110 is configured to connect to the proximal end 4106 of the container portion by means of a tight fit or lock fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof. In the illustrated embodiment, the distal end of the cartridge portion 4110 includes a sealing element 4117 that is located around at least a portion of the distal end 4116 of the mouthpiece portion 4110. In the illustrated embodiment, the sealing element 4117 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. In some embodiment, the sealing element 4117 may be a separate part that is attached to the mouthpiece portion 4110 by means of an interference fit or by means of an adhesive; however, in other embodiments, the sealing element 4117 may be part of the mouthpiece portion 4110, for example, by overmolding.

[000328] In the illustrated embodiment, the outer wall 4104 of the container may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 4104 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 4104 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 4104 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 4106 of the container 4102 to the far end 4108 of the container may be transparent or translucent. In additional embodiments, the outer wall 4104 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition inside the container 4102 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 4104 of the container has a substantially opaque color.

[000329] In the illustrated embodiment, one or more of the mouthpiece portion 4110, the container portion 4102, the lower frame 4168, and the bottom cap 4172 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000330] As shown in the drawings, the cartridge 4100 also includes a heating element 4120 and a pair of electrical contacts 4125A, 4125B that are configured to electrically connect the heating element 4120 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 4125A, 4125B are located on opposite sides of the cartridge 4100 and are configured to be attached to at least one of the following: a bottom cover 4172, a lower frame 4168, and a container portion 4102. Although in the shown embodiment, the contacts 4125A, 4125B are configured to be attached to one or more of these components by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 4120 is located near the distal end 4108 of the container portion 4102. In various embodiments, the heating element 4120 may be located in the container portion 4102 and/or may be retained therein by means of a push-fit or lock-fit attachment, although other forms of attachment are possible, including, for example, by means of an adhesive or an insert molding process or capture by the lower frame 4168 in the container portion 4102. In the illustrated embodiment, the electrical contacts 4125A, 4125B are made of a conductive material. Examples of conductive materials may include, without limitation, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be formed from one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000331] In the illustrated embodiment, the heating element 4120 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 4120 may be integrally formed with the liquid transfer element 4121. Other types of heating elements may also be used, as noted above.

[000332] The cartridge 4100 of the illustrated embodiment also includes a liquid transfer element 4121, at least a portion of which is configured to be located near the heating element 4120. In particular, in the illustrated embodiment, the liquid transfer element 4121 is located below the heating element 4120 and is configured to be captured by the lower frame element 4168. In the illustrated embodiment, the liquid transfer element 4121 has a relatively flat shape.

[000333] In various embodiments, the fluid transfer element 4121 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are disclosed in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000334] As shown in the drawings, the vapor chamber 4140 is located in the region above the heating element 4120 and is formed, at least in part, by a portion of the intermediate wall 4149 of the container-like portion 4102. In the illustrated embodiment, the cartridge also includes a separate vapor tube 4174 that is configured to extend between the vapor chamber 4140 and the mouthpiece portion 4110. In the illustrated embodiment, the vapor tube 4110 can be made of a metal material (e.g., aluminum, stainless steel, metal alloys, etc.), although other materials are possible, including, for example, a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the vapor tube may be made of other materials, including, for example, glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. As noted above, the aerosol is formed in the vapor chamber 4140 when the heating element 4120 heats at least a portion of the liquid composition contained in the first liquid transfer element 4121. Thus, when the user puffs on the aerosol delivery device, the aerosol from the vapor chamber 4140 can be delivered to the user via the vapor tube 4174 and through the outlet openings 4115 of the mouthpiece 4110.

[000335] FIGS. 37 and 38 show a cartridge according to another embodiment of the present invention. In particular, FIG. 37 shows an exploded perspective view of a cartridge 4300 according to an example embodiment of the present invention, and FIG. 38 shows a partially cutaway view of a cartridge 4300. In various embodiments, a portion of the cartridge 4300 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 4300 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000336] With reference to the drawings, the cartridge 4300 of the illustrated embodiment comprises a container portion 4302 that is formed by an outer wall 4304 of the container that includes a near end 4306 and a far end 4308. Thus, the container portion 4302 can be characterized in that the container wall 4304 is a side wall that is continuous around the sides of the container, and the far end 4308 forms a bottom wall. In the illustrated embodiment, a lower frame 4368 is located near the far end 4308 of the container portion, and an intermediate frame 4374 is located above the lower frame 4368. The container portion 4302 is also configured to contain a liquid composition that is capable of vaporization (e.g., an e-liquid or an aerosol precursor composition, as described above). The cartridge 4300 also includes a mouthpiece portion 4310, which is formed by an outer wall 4312 of the mouthpiece, which includes a distal end 4316 and a proximal end 4314 with outlet openings 4315 formed therein. In the illustrated embodiment, the distal end 4316 of the mouthpiece portion 4310 is configured to be connected to the proximal end 4306 of the container portion by means of a tight fit or lock fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.) or any combination thereof. In the illustrated embodiment, the distal end of the cartridge portion 4310 includes a sealing element 4317 that is located around at least a portion of the distal end 4316 of the mouthpiece portion 4310. In the illustrated embodiment, the sealing element 4317 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. In some embodiment, the sealing element 4317 may be a separate part that is attached to the mouthpiece portion 4310 by means of an interference fit or by means of an adhesive; however, in other embodiments, the sealing element 4317 may be part of the mouthpiece portion 4310, for example, by overmolding.

[000337] In the illustrated embodiment, the outer wall 4304 of the container may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 4304 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 4304 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 4304 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 4306 of the container 4302 to the far end 4308 of the container may be transparent or translucent. In additional embodiments, the outer wall 4304 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition inside the container 4302 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall may be designed so that the outer wall 4304 of the container has a substantially opaque color.

[000338] In the illustrated embodiment, one or more of the mouthpiece portion 4310, the container portion 4302, the intermediate frame 4374, and the lower frame 4368 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000339] As shown in the drawings, the cartridge 4300 also includes a heating element 4320 and a pair of electrical contacts 4325A, 4325B that are configured to electrically connect the heating element 4320 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 4325A, 4325B are located on opposite sides of the cartridge 4300 and are configured to be attached to at least one of the following: an intermediate frame 4374, a lower frame 4168 and a container portion 4302. Although in the shown embodiment, the contacts 4325A, 4325B are configured to be attached to one or more of these components by means of a push-fit or lock-fit attachment, in other embodiments other attachment methods are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 4320 is located near the distal end 4308 of the portion 4302 in the form of a container. In various embodiments, the heating element 4320 can be located in the intermediate frame 4374 and/or can be retained therein by means of a press-fit or locking fit attachment, although other forms of attachment are possible, including, for example, by means of an adhesive or a process of molding with an insert or capture by the lower frame 4368 in the intermediate frame 4374. In the illustrated embodiment, the electrical contacts 4325A, 4325B are made of a conductive material. Examples of conductive materials can include, without limitation, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be formed from one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000340] In the illustrated embodiment, the heating element 4320 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 4320 may be integrally formed with the first fluid transfer element 4321. Other types of heating elements may also be used, as noted above.

[000341] The cartridge 4300 of the illustrated embodiment also includes a liquid transfer element 4321, at least a portion of which is configured to be located near the heating element 4320. In particular, in the illustrated embodiment, the liquid transfer element 4321 is located below the heating element 4320 and is configured to be captured by the lower frame element 4368. In the illustrated embodiment, the liquid transfer element 4321 has a relatively flat shape.

[000342] In various embodiments, the fluid transfer element 4321 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000343] As shown in the drawings, the vapor chamber 4340 is located in the region above the heating element 4320 and is formed, at least in part, by the intermediate frame 4374. In the illustrated embodiment, the cartridge also includes a separate vapor tube 4376 that is configured to pass between the vapor chamber 4340 and the mouthpiece portion 4310. In the illustrated embodiment, the vapor tube 4376 can be made of a metallic material (e.g., aluminum, stainless steel, metal alloys, etc.), although other materials are possible, including, for example, a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate and combinations thereof), although other materials are possible. In other embodiments, the vapor tube may be made of other materials, including, for example, glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. As noted above, the aerosol is formed in the vapor chamber 4340 when the heating element 4320 heats at least a portion of the liquid composition contained in the first liquid transfer element 4321. Thus, when the user puffs on the aerosol delivery device, the aerosol from the vapor chamber 4340 can be delivered to the user via the vapor tube 4376 and through the outlet openings 4315 of the mouthpiece 4310.

[000344] FIGS. 39 and 40 show a cartridge according to another embodiment of the present invention. In particular, FIG. 39 shows an exploded perspective view of a cartridge 4500 according to an example embodiment of the present invention, and FIG. 40 shows a partially cutaway perspective view of a cartridge 4500. In various embodiments, a portion of the cartridge 4500 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 4500 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000345] With reference to the drawings, the cartridge 4500 of the illustrated embodiment comprises a container portion 4502 that is defined by an outer container wall 4504 that includes a proximal end 4506 and a distal end 4508. Thus, the container portion 4502 can be characterized in that the container wall 4504 is a side wall that is continuous around the sides of the container, with an open distal end 4508. In the illustrated embodiment, the open distal end 4508 of the container portion 4502 is covered by a bottom cap 4572. Above the bottom cap 4572 is a lower frame 4568, and above the lower frame 4568 is an intermediate frame 4574. The container portion 4502 is also configured to contain a liquid composition configured to evaporate (e.g., an e-liquid or a precursor composition) aerosol, as described above). The cartridge 4500 also comprises a mouthpiece portion 4510, which is formed by an outer wall 4512 of the mouthpiece, which includes a distal end 4516 and a proximal end 4514 with an outlet opening 4515 passing therethrough. Although other configurations are possible, in the illustrated embodiment, the mouthpiece portion 4510 and the container portion 4502 comprise the same portion (referred to herein as the mouthpiece portion 4510/container portion 4502). In some embodiments, the outer wall 4512 of the mouthpiece of the mouthpiece portion 4510/container portion 4502 may be created through an overmolding process with the mouthpiece portion 4510 and the container portion 4502 (see, for example, FIG. 40).

[000346] In the illustrated embodiment, the outer wall 4512 of the mouthpiece and/or the outer wall 4504 of the container of the mouthpiece portion 4510/container portion 4502 may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 4512 of the mouthpiece and the outer wall 4504 of the container may be transparent or translucent. Alternatively, in some embodiments, only the outer wall 4504 of the container or only one side of the outer wall 4504 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 4504 of the container may be substantially opaque, and the strip extending from the near end 4506 of the container 4502 to the far end 4508 of the container may be transparent or translucent. In additional embodiments, the outer wall 4504 of the container may be colored. In some embodiments, the color may be configured so that the liquid composition inside the container 4502 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the wall of the container may be designed so that the outer wall 4504 of the container has a substantially opaque color.

[000347] In the illustrated embodiment, one or more of the mouthpiece portion 4510/container portion 4502, intermediate frame 4574, bottom frame 4568, and bottom cap 4572 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be made of other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metallic alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000348] As shown in the drawings, the cartridge 4500 also includes a heating element 4520 and a pair of electrical contacts 4525A, 4525B that are configured to electrically connect the heating element 4520 to a battery and/or a control component of the control device. In the shown embodiment, the contacts 4525A, 4525B are located on opposite sides of the cartridge 4500 and are configured to be attached to at least one of the following: a bottom cover 4572, a lower frame 4568, and an intermediate frame 4574. Although in the shown embodiment the contacts 4525A, 4525B are configured to be attached to one or more of these components by means of a push-fit or lock-fit attachment, in other embodiments other methods of attachment are possible, including, for example, by means of an adhesive or an insert molding process. In the illustrated embodiment, the heating element 4520 is located near the distal end 4508 of the portion 4502 in the form of a container. In various embodiments, the heating element 4520 can be located in the intermediate frame 4574 and/or can be retained therein by means of a press-fit or locking fit attachment, although other forms of attachment are possible, including, for example, by means of an adhesive or a process of molding with insertion or capture by the lower frame 4568 in the intermediate frame 4574. In the illustrated embodiment, the electrical contacts 4525A, 4525B are made of a conductive material. Examples of conductive materials can include, without limitation, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, conductive ceramic materials, or any combination thereof. In some embodiments, one or more of the electrical contacts may be formed from one conductive material and may be electroplated with another conductive material, such as, for example, nickel and/or gold.

[000349] The bottom cover 4572 of the illustrated embodiment also includes a member configured to be retained by a magnet 4570, which is configured to facilitate a mechanical connection between the cartridge 4500 and the control device. It should be noted that in other embodiments, the bottom cover may comprise a component, such as, for example, a metal disk configured to be attached by a magnet located in the control device. In various embodiments of the present invention, the magnet 4570 may comprise a plurality of different types of magnets, including rare earth magnets. For example, in some embodiments, one or more magnets may comprise neodymium magnets (also known as NdFeB, NIB or Neo magnets). In various embodiments, different classes of neodymium magnets may be used, including, for example, N35, N38, N40, N42, N45, N48, N50 and/or N52 classes. In other embodiments, one or more magnets may comprise samarium cobalt magnets (also known as SmCo magnets). In yet other embodiments, one or more magnets may comprise ceramic/iron magnets. In other embodiments, one or more magnets may comprise aluminum nickel cobalt (AlNiCo) magnets. In any of the above embodiments, one or more magnets may comprise an electroplating and/or coating. For example, in some embodiments, one or more magnets may be nickel plated. In other embodiments, one or more magnets may be plated with one or more of zinc, tin, copper, epoxy, silver, and/or gold. In some embodiments, one or more magnets may be plated with a combination of these materials. For example, in one embodiment, one or more magnets may be nickel plated, copper plated, and nickel plated again. In another embodiment, one or more magnets may be nickel plated, copper plated, and a gold top coat.

[000350] In the illustrated embodiment, the heating element 4520 comprises a substantially flat heating element and may be formed from a metallic material such as stainless steel, including, but not limited to, 304, 304L, 316, or 316L stainless steel. In other embodiments, the heating element may be formed from a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite, and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide, and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 4520 may be integrally formed with the liquid transfer element 4521. Other types of heating elements may also be used, as noted above.

[000351] The cartridge 4500 of the illustrated embodiment also includes a liquid transfer element 4521, at least a portion of which is configured to be located near the heating element 4520. In particular, in the illustrated embodiment, the liquid transfer element 4521 is located below the heating element 4520 and is configured to be captured by the lower frame element 4568. In the illustrated embodiment, the liquid transfer element 4521 has a relatively flat shape.

[000352] In various embodiments, the fluid transfer element 4521 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000353] As shown in the drawings, the vapor chamber 4540 is located in the region above the heating element 4520 and is formed at least in part by a portion of the intermediate frame 4574. In the illustrated embodiment, the cartridge also includes a vapor channel 4576 formed in the mouthpiece portion 4510/container portion 4502 that extends downwardly from the distal end 4516 of the mouthpiece portion 4510 toward the intermediate frame 4574. The illustrated embodiment also includes a vapor tube cap 4578 that is configured to connect an end of the vapor channel 4576 to the intermediate frame 4574. As noted above, an aerosol is formed in the vapor chamber 4540 when the heating element 4520 heats at least a portion of the liquid composition contained in the first transfer element 4521 liquid. Thus, when the user takes a puff on the aerosol delivery device, the aerosol from the vapor chamber 4540 can be delivered to the user via the vapor channel 4574 and through the outlet opening 4515 of the mouthpiece portion 4510.

[000354] FIGS. 41 and 42 show a cartridge according to another embodiment of the present invention. In particular, FIG. 41 shows an exploded perspective view of a cartridge 4700 according to an example embodiment of the present invention, and FIG. 42 shows a partially cutaway view of a cartridge 4700. In various embodiments, a portion of the cartridge 4700 is configured to be connected to a chamber for receiving a cartridge of a corresponding controller. In many aspects, the cartridge 4700 and the corresponding controller may have some similar configuration and may include some similar components (and some similar configuration and variations of components) as the cartridges 300 and the controller 200 described above, which will not be repeated herein. Thus, reference is made to the corresponding discussions of these configurations and components (as well as configurations and variations of components).

[000355] With reference to the drawings, the cartridge 4700 of the illustrated embodiment comprises a container portion 4702 that is defined by an outer container wall 4704 that includes a proximal end 4706 and a distal end 4708. Thus, the container portion 4702 can be characterized in that the container wall 4704 is a side wall that is continuous around the sides of the container and includes an inner intermediate wall 4749 and an open distal end 4708 below the intermediate wall 4749. In the illustrated embodiment, the open distal end 4708 of the container portion 4702 is covered by a bottom cap 4772. A lower frame 4768 is located above the bottom cap 4772. The container portion 4702 is also configured to contain a liquid composition configured to vaporize (e.g., an e-liquid or a composition aerosol precursor, as described above). The cartridge 4700 also comprises a mouthpiece portion 4710, which is formed by an outer wall 4712 of the mouthpiece, which includes a distal end 4716 and a proximal end 4714 with an outlet opening 4715 passing through it. In the illustrated embodiment, the distal end 4716 of the mouthpiece portion 4710 is configured to connect to the proximal end 4106 of the container portion by means of a tight fit or lock fit connection; however, in other embodiments, other attachment methods are possible (e.g., by means of adhesives, heat staking/thermal welding, ultrasonic welding, etc.), or any combination thereof. In the illustrated embodiment, the distal end of the cartridge portion 4710 includes a sealing element 4717 that is located around at least a portion of the distal end 4716 of the mouthpiece portion 4710. In the illustrated embodiment, the sealing element 4717 is made of a thermoplastic elastomer (TPE) or a silicon material, although other materials are possible. In some embodiment, the sealing element 4717 may be a separate part that is attached to the mouthpiece portion 4710 by means of an interference fit or by means of an adhesive; however, in other embodiments, the sealing element 4717 may be part of the mouthpiece portion 4710, for example, by overmolding.

[000356] In the illustrated embodiment, the outer wall 4704 of the container may be made at least partially transparent and/or translucent, so that the liquid composition contained therein is visible from the outside. Thus, in some embodiments, the entire outer wall 4704 of the container may be transparent or translucent. Alternatively, in some embodiments, only one side, or a portion (or portions) of one or more sides, of the outer wall 4704 of the container may be transparent or translucent, while the remaining portions of the outer wall of the container may be substantially opaque. In some embodiments, the outer wall 4704 of the container or a portion thereof may be substantially opaque, and a strip extending from the near end 4706 of the container 4702 to the far end 4708 of the container may be transparent or translucent. In additional embodiments, the outer wall 4704 of the container may be colored. In some embodiments, the color can be configured so that the liquid composition inside the container 4702 is still visible, for example, by using a transparent or translucent outer wall of the container. In other embodiments, the container wall can be designed so that the outer wall 4704 of the container has a substantially opaque color.

[000357] In the illustrated embodiment, one or more of the mouthpiece portion 4710, the container portion 4702, the lower frame 4768, and the bottom cap 4772 may be formed from a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, one or more of these components may be formed from other materials, including, for example, metallic materials (e.g., aluminum, stainless steel, metal alloys, and the like), glass materials, ceramic materials (e.g., aluminum oxide, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof.

[000358] As shown in the drawings, the cartridge 4700 also includes a heating element 4720. In the illustrated embodiment, the cartridge 4700 does not include separate electrical contacts. Instead, when connected to the control device, electrical connectors (e.g., spring contacts) in the control device are configured to pass through the bottom cover 4772 of the cartridge 4700 and make contact directly with the open ends of the heating element 4720 such that the heating element 4720 is electrically connected to the battery and/or the control component of the control device. In the illustrated embodiment, the heating element 4720 is located near the distal end 4708 of the container-like portion 4702. In other embodiments, the cartridge may include a pair of electrical contacts that are configured to electrically connect the heating element to the battery and/or the control component of the control device. In such embodiments, the contacts may be located on opposite sides of the cartridge and may be configured to be attached to at least one of the following: a bottom cap and a bottom frame. In various such embodiments, the contacts may be attached to the bottom cap by means of a push-fit or lock-fit attachment or another form of attachment, including, for example, by means of an adhesive or an insert molding process. In various embodiments, the heating element 4720 may be retained by the bottom frame 4768 by means of a push-fit or lock-fit attachment around the bottom frame 4768, although other forms of attachment are possible, including, for example, by means of an adhesive or an insert molding process.

[000359] In the illustrated embodiment, the heating element 4720 has a substantially flat heating surface and is wrapped around the lower frame 4768 in such a way that it can be attached to its opposite surface, for example, by a pair of fastening plates. In the illustrated embodiment, the heating element 4720 can be made of a metallic material, such as stainless steel, including, but not limited to, stainless steel grade 304, 304L, 316 or 316L. In other embodiments, the heating element may be made of a different material, such as, for example, stainless steel, pure nickel, nickel-iron alloys, fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), titanium, platinum, silver, palladium, silver-palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and filaments). In additional embodiments, the heating element may be formed from conductive ink, boron-doped silicon dioxide and/or ceramics (e.g., positive or negative temperature coefficient ceramics). In other embodiments, the heating element may be printed on, embedded in, or otherwise integrally formed with the porous element. For example, in some embodiments, the heating element 4720 may be formed integrally with the liquid transfer element 4721. Other types of heating elements may also be used, as noted above.

[000360] The cartridge 4700 of the illustrated embodiment also includes a liquid transfer element 4721, at least a portion of which is configured to be located near the heating element 4720. In particular, in the illustrated embodiment, the liquid transfer element 4721 is located below the heating element 4720 and is configured to be captured by the lower frame element 4768. In the illustrated embodiment, the liquid transfer element 4721 has a relatively flat shape, although any other shape is possible.

[000361] In various embodiments, the fluid transfer element 4721 may be formed from one or more materials configured to transfer fluid, such as by capillary action. In some embodiments, for example, one or both of the fluid transfer elements may be formed from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillary tubes, or the like. Thus, in various embodiments, the fluid transfer elements may be any material that comprises a network of open pores (i.e., a plurality of pores that are interconnected such that a fluid can flow from one pore to another in a plurality of directions through the element). As further described herein, some embodiments of the disclosure of the present invention may, in particular, relate to the use of non-fibrous transfer elements. Thus, fibrous transport elements may be expressly excluded. Alternatively, combinations of fibrous transport elements and non-fibrous transport elements may be used. Representative types of substrates, reservoirs, or other components for supporting an aerosol precursor are described in U.S. Patent No. 8,528,569 to Newton, U.S. Patent Application Publication No. 2014/0261487 to Chapman et al., U.S. Patent Publication No. 2014/0059780 to Davis et al., and U.S. Patent Publication No. 2015/0216232 to Bless et al., which are incorporated herein by reference in their entireties. Also, various adsorbent materials, as well as the design and operation of these adsorbent materials in certain types of electronic cigarettes, are described in U.S. Patent No. 8,910,640 to Sears et al., which is incorporated herein by reference in its entirety. In some embodiments, one or both of the fluid transfer elements may be formed partially or completely from a porous monolith, such as a porous ceramic, porous glass, or the like. Examples of monolithic materials that may be suitable for use in accordance with embodiments of the present disclosure are described, for example, in U.S. Patent Application Ser. No. 14/988,109, filed January 5, 2016, and U.S. Patent No. 2014/0123989 to LaMothe, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the porous monolith may form a substantially solid wick.

[000362] As shown in the drawings, the vapor chamber 4740 is located in the region above the heating element 4720 and is formed, at least in part, by a portion of the intermediate wall 4749 of the container-like portion 4702. In the illustrated embodiment, the cartridge also includes a separate vapor tube 4774 that is configured to extend between the vapor chamber 4740 and the mouthpiece portion 4710. In the illustrated embodiment, the vapor tube 4774 can be made of a metal material (e.g., aluminum, stainless steel, metal alloys, etc.), although other materials are possible, including, for example, a molded polymeric material, such as, for example, a molded plastic material (e.g., acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, copolyester, polybutylene terephthalate, and combinations thereof), although other materials are possible. In other embodiments, the vapor tube may be made of other materials, including, for example, glass materials, ceramic materials (for example, aluminum oxide, silicon dioxide, mullite, silicon carbide, silicon nitride, aluminum nitride, and the like), composite materials, and/or any combinations thereof. As noted above, the aerosol is formed in the vapor chamber 4740 when the heating element 4720 heats at least a portion of the liquid composition contained in the first liquid transfer element 4721. Thus, when the user puffs on the aerosol delivery device, the aerosol from the vapor chamber 4740 can be delivered to the user via the vapor tube 4774 and through the outlet opening 4715 of the mouthpiece 4710.

[000363] In some embodiments, it should be understood that at least a portion of the spray element may be located within a space formed by a sleeve portion located between the container portion and the mouthpiece portion of the cartridge. Such configurations are shown, for example, in FIGS. 5A, 5B, 7A, 7B, 9, 11, 13, 14, 16, 17, 25, 26, 28 and 30. In some embodiments, at least a portion of the spray element may be located near the distal end of the sleeve portion, wherein at least a portion of the sleeve is located between the container portion and the mouthpiece portion of the cartridge. Such configurations are shown, for example, in FIGS. 19, 20, 22 and 24. In some embodiments, the spray element may be located entirely at a distance from the distal end of the container portion of the cartridge. Such configurations are shown, for example, in FIG. 34 and 36, 38, 40, 42. In some such embodiments, the spray element may be located near the distal end of the cartridge. Some embodiments may include a cover element (which may or may not include a curved cover element), at least a portion of which may be located within the space formed by the mouthpiece portion of the cartridge. Such configurations are shown, for example, in FIGS. 5A, 5B, 7A, 7B, 19, 20 and 22. In some embodiments that include a sleeve portion, the sleeve portion interacts with the mouthpiece portion at the end and the container portion at the second end such that they form a wall of the cartridge. Such configurations are shown, for example, in FIG. 5A, 5B, 7A, 7B, 9, 11, 13, 14, 16, 17, 19, 20, 22, 24, 25, 26, 28, 30 and 34. In some embodiments that include a sleeve portion, the sleeve portion provides support and/or retains a portion of the electrical contacts of the cartridge. Such configurations are shown, for example, in FIGS. 4, 6, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25 and 26.

[000364] Although some of the drawings described herein illustrate a cartridge and a control device in an operative state, it is understood that the cartridge and the control device may exist as individual components. Accordingly, any discussion herein with respect to components in combination should also be understood as referring to the control device and the cartridge as individual and separate components.

[000365] According to another aspect, the present invention can be directed to kits that provide a variety of components as described herein. For example, a kit can comprise a control device with one or more cartridges. The kit can also comprise a control device with one or more charging components. The kit can also comprise a control device with one or more batteries. The kit can also comprise a control device with one or more cartridges and one or more charging components and/or one or more batteries. In additional embodiments, the kit can comprise a plurality of cartridges. The kit can also comprise a plurality of cartridges and one or more batteries and/or one or more charging components. In the above embodiments, the cartridges or control devices can be equipped with a heating element included therein. Kits according to the invention can also include a case (or other packaging, carrying or storage component) in which one or more additional components of the kit are placed. The case can be a reusable hard or soft container. In addition, the case can simply be a box or other packaging structure.

[000366] Many modifications and other embodiments of the present invention will be apparent to those skilled in the art to which this invention pertains, using the disclosures provided in the above description and the accompanying drawings. It is therefore to be understood that the present invention is not limited to the specific embodiments disclosed herein, and it is intended that modifications and other embodiments be included 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 (28)

1. An aerosol delivery device comprising: a control device that includes an outer casing that forms an outer wall and has a proximal end and a distal end, wherein the proximal end of the control device forms a chamber for accommodating a cartridge, and the control device also contains a power source and a control component, and a cartridge that includes a mouthpiece portion and a container portion, wherein the mouthpiece portion and the container portion have corresponding near and far ends, wherein the container portion is configured to contain a liquid composition, and the cartridge also includes a spray element and a liquid transfer element, wherein a portion of the cartridge is designed to be detachably connected to a chamber for accommodating a cartridge of the control device, wherein at least a portion of the element for transferring liquid is located near the spray element, and the spray element is designed to evaporate the liquid composition to generate an aerosol, wherein at least a portion of the spray element is located above the near end of the portion in the form of a container, wherein the spray element comprises a heating element comprising a flat heating element, wherein the heating element has a curved shape when it is inserted into the cartridge. 2. An aerosol delivery device according to claim 1, wherein the cartridge also includes a sleeve portion located between the mouthpiece portion and the container portion. 3. An aerosol delivery device according to claim 2, wherein the spray element is located at least partially within the sleeve portion. 4. The aerosol delivery device of claim 3, wherein the spray element comprises a heating element configured to heat the liquid composition to generate the aerosol, and the device also comprises a covering element located near the heating element and located at least partially within the mouthpiece portion. 5. An aerosol delivery device comprising: a control device that includes an outer casing that forms an outer wall and has a proximal end and a distal end, wherein the proximal end of the control device forms a chamber for accommodating a cartridge, and the control device also contains a power source and a control component, and a cartridge that includes a mouthpiece portion and a container portion, wherein the mouthpiece portion and the container portion have corresponding near and far ends, wherein the container portion is configured to contain a liquid composition, and the cartridge also includes a first liquid transfer element, a second liquid transfer element and a spray element, wherein a portion of the cartridge is configured to be detachably connected to a chamber for accommodating a cartridge of the control device, wherein the spray element is configured to evaporate the liquid composition to generate an aerosol, wherein at least a portion of the spray element is located between the near end of the container portion and the far end of the container portion, wherein at least a portion of the first liquid transfer element is located under the spray element, and the second liquid transfer element is located under the first liquid transfer element, wherein the second liquid transfer element is configured to transfer the liquid to the first liquid transfer element, wherein the spray element comprises a heating element comprising a flat heating element, wherein the heating element has a curved shape when it is inserted into the cartridge. 6. An aerosol delivery device comprising: a control device that includes an outer casing that forms an outer wall and has a proximal end and a distal end, wherein the proximal end of the control device forms a chamber for accommodating a cartridge, and the control device also contains a power source and a control component, and a cartridge that includes a mouthpiece portion and a container portion, wherein the mouthpiece portion and the container portion have corresponding near and far ends, wherein the container portion is configured to contain a liquid composition, and the cartridge also includes a spray element and a liquid transfer element, wherein a portion of the cartridge is configured to be detachably connected to a chamber for accommodating a cartridge of the control device, wherein at least a portion of the liquid transfer element is located near the spray element, and the spray element is configured to evaporate the liquid composition to generate an aerosol, wherein at least a portion of the spray element is located near the distal end of the mouthpiece portion, wherein the spray element comprises a heating element comprising a flat heating element, wherein the heating element has a curved shape when it is inserted into the cartridge. 7. An aerosol delivery device according to any one of claims 1, 5, 6, wherein the spray element comprises a heating element configured to heat the liquid composition to generate the aerosol. 8. An aerosol delivery device according to claim 7, wherein at least a portion of the heating element is located between the distal end of the mouthpiece portion and the proximal end of the container portion. 9. The aerosol delivery device of claim 7, wherein the cartridge also includes a sleeve portion located between the mouthpiece portion and the container portion, and wherein at least a portion of the heating element is located in the sleeve portion. 10. An aerosol delivery device according to claim 7, wherein the heating element is located near the distal end of the container portion. 11. The aerosol delivery device of claim 7, wherein the cartridge also includes a second liquid transfer element configured to transfer liquid to the first liquid transfer element. 12. An aerosol delivery device according to any one of claims 8, 11, wherein the second liquid transfer element forms a longitudinal portion that intersects the curved transverse portion, and the length of the longitudinal portion of the second liquid transfer element is greater than the length of the transverse portion. 13. The aerosol delivery device of claim 12, further comprising a curved covering element, wherein the curvature of the covering element is opposite to the curvature of the heater. 14. An aerosol delivery device according to any one of claims 8, 11, wherein the second liquid transfer element forms a longitudinal portion that intersects the curved transverse portion, and the length of the transverse portion of the second liquid transfer element is greater than the length of the longitudinal portion. 15. The aerosol delivery device of claim 14, further comprising a curved covering element, wherein the curvature of the covering element is opposite to the curvature of the heater. 16. An aerosol delivery device according to any one of claims 7, 8, wherein the second liquid transfer element forms a longitudinal portion that intersects the transverse portion, and the length of the longitudinal portion of the second liquid transfer element is greater than the length of the transverse portion.