Aerosol Delivery Device Comprising Multiple Outer Bodies and Related Assembly Method

Abstract

The present disclosure relates to an aerosol delivery device. The aerosol delivery device may include a first outer body, a second outer body, and a coupler received therebetween. A securing mechanism may couple the outer bodies together to retain the aerosol delivery device in an assembled configuration. Related assembly methods are also provided.

1 . An aerosol delivery device, comprising:
 a first outer body defining an inlet aperture;   a second outer body;   a power source positioned in the first outer body;   an atomizer positioned in the second outer body; and   a coupler positioned between, and engaged with, the first outer body and the second outer body, the coupler defining a coupler inlet and a longitudinal channel,   the coupler being configured to receive air from the inlet aperture defined in the first outer body through the coupler inlet and to direct the air through the longitudinal channel to the second outer body.   
     
     
         2 . The aerosol delivery device of  claim 1 , further comprising at least one securing mechanism configured to substantially irreversibly secure the first outer body to the second outer body. 
     
     
         3 . The aerosol delivery device of  claim 2 , wherein the at least one securing mechanism comprises a wrapper extending at least partially around the first outer body, the second outer body, and the coupler. 
     
     
         4 . The aerosol delivery device of  claim 1 , further comprising a reservoir substrate and a flow director positioned in the second outer body, the flow director extending at least partially through the reservoir substrate. 
     
     
         5 . The aerosol delivery device of  claim 4 , wherein the coupler defines a nipple and the flow director engages the nipple of the coupler. 
     
     
         6 . The aerosol delivery device of  claim 4 , further comprising a mouthpiece defining a nipple, wherein the flow director engages the nipple of the mouthpiece. 
     
     
         7 . The aerosol delivery device of  claim 4 , wherein the flow director defines a transverse aperture extending therethrough, the atomizer extending through the transverse aperture. 
     
     
         8 . The aerosol delivery device of  claim 1 , further comprising a plurality of electrical connectors extending from the atomizer through the coupler to the power source. 
     
     
         9 . The aerosol delivery device of  claim 1 , wherein the atomizer comprises a heating element and a liquid transport element defining a center portion and first and second opposing arms extending therefrom, the heating element being coupled to the center portion of the liquid transport element. 
     
     
         10 . The aerosol delivery device of  claim 1 , wherein the coupler defines a rib, the rib separating the first outer body from the second outer body. 
     
     
         11 . A method for assembling an aerosol delivery device, the method comprising:
 positioning a power source in a first outer body defining an inlet aperture;   positioning an atomizer in a second outer body; and   engaging a coupler defining a coupler inlet and a longitudinal channel with the first outer body and the second outer body such that the coupler is positioned to receive air from the inlet aperture defined in the first outer body through the coupler inlet and to direct the air through the longitudinal channel to the second outer body.   
     
     
         12 . The method of  claim 11 , further comprising substantially irreversibly securing the first outer body to the second outer body with a securing mechanism. 
     
     
         13 . The method of  claim 11 , wherein substantially irreversibly securing the first outer body to the second outer body with the securing mechanism comprises wrapping a wrapper at least partially around the first outer body, the second outer body, and the coupler. 
     
     
         14 . The method of  claim 11 , further comprising positioning a reservoir substrate and a flow director in the second outer body such that the flow director extends at least partially through the reservoir substrate. 
     
     
         15 . The method of  claim 14 , wherein positioning the atomizer in the second outer body comprises inserting the atomizer through a transverse aperture extending through the flow director. 
     
     
         16 . The method of  claim 14 , further comprising coupling the flow director to a nipple of the coupler. 
     
     
         17 . The method of  claim 14 , further comprising coupling the flow director to a nipple of a mouthpiece. 
     
     
         18 . The method of  claim 11 , further comprising inserting a plurality of electrical connectors through the coupler; and
 connecting the electrical connectors to the power source and the atomizer.   
     
     
         19 . The method of  claim 11 , further comprising coupling a heating element to a center portion of a liquid transport element to form the atomizer; and
 folding first and second opposing arms of the liquid transport element extending from the center section away from the coupler.   
     
     
         20 . The method of  claim 11 , wherein engaging the coupler with the first outer body and the second outer body comprises engaging a rib of the coupler with the first outer body and the second outer body. 
     
     
         21 . A coupler for an aerosol delivery device, the coupler comprising:
 a first engagement portion configured to engage a first outer body;   a second engagement portion configured to engage a second outer body;   a coupler inlet defined through a peripheral surface of the first engagement portion; and   a longitudinal channel in fluid communication with the coupler inlet and extending through the second engagement portion to a coupler outlet opening.   
     
     
         22 . The coupler of  claim 21 , further comprising a pressure port opening in fluid communication with at least one of the coupler inlet and the longitudinal channel and extending through the first engagement portion. 
     
     
         23 . The coupler of  claim 21 , wherein the coupler inlet is defined between first and second grooves configured to respectively receive a gasket. 
     
     
         24 . The coupler of  claim 21 , further comprising a recessed portion at the peripheral surface of the first engagement portion, the coupler inlet being defined through the recessed portion. 
     
     
         25 . The coupler of  claim 21 , further comprising a nipple configured to engage a flow director, the longitudinal channel extending through the nipple.