Aerosol delivery device and method for manufacturing and operating the same

1. A method of operating an aerosol delivery device including an active liquid container configured to contain an active liquid having an active substance dissolved therein, a carrier liquid container configured to receive a carrier liquid, a piezo disc mounted relative to the carrier liquid container by a flexible gasket, and a piezo disc housing disposed between a base of the carrier liquid container and an oscillator, wherein the piezo disc is mounted relative to the carrier liquid container by inserting at least one fastener through the piezo disc housing, wherein the piezo disc is configured to be oscillated by ultrasonic waves generated by the oscillator and transmit oscillations through the carrier liquid to the active liquid to cause at least a portion of the active liquid to become an aerosol, the method comprising:

introducing the carrier liquid into the carrier liquid container;

introducing the active liquid having the active substance dissolved therein into the active liquid container;

inserting the active liquid container into the carrier liquid container such that a portion of the active liquid container is submerged in the carrier liquid;

generating an ultrasonic wave with the oscillator that causes the piezo disc to oscillate and transmit the oscillations through the carrier liquid to the active liquid to cause at least the portion of the active liquid to become the aerosol; and

manipulating a compression of the flexible gasket via the piezo disc housing to alter a particle size of the aerosol by adjusting the at least one fastener inserted through the piezo disc housing to mount the piezo disc housing relative to the carrier liquid container.

2. The method of claim 1 , wherein manipulating the compression of the flexible gasket includes increasing the compression of the flexible gasket to reduce the particle size of the aerosol or decreasing the compression of the flexible gasket to increase the particle size of the aerosol.

3. The method of claim 1 , wherein mounting the piezo disc relative to the active liquid container further includes inserting the at least one fastener through the piezo disc housing and into a bushing fixed within the carrier liquid container, and

wherein a pull force of the bushing is greater than a counter force of the flexible gasket.

4. The method of claim 3 , wherein fixing the bushing relative to the carrier liquid container comprises providing a contoured surface that conforms to and mates with an entire perimeter of a fixing section of the bushing to fix the bushing relative to the carrier liquid container.

5. The method of claim 4 , wherein fixing the bushing relative to the carrier liquid container comprises insert molding the contoured surface such that the contoured surface conforms to and mates with the entire perimeter of the fixing section of the bushing.

6. The method of claim 4 , wherein fixing the bushing relative to the carrier liquid container comprises:

providing an insert hole in the base of the carrier liquid container, the insert hole having a diameter greater than a diameter of the bushing;

inserting the bushing into the insert hole; and

introducing adhesive material into the insert hole between an exterior surface of the bushing and the carrier liquid container, the adhesive material conforming to and mating with the entire perimeter of the fixing section of the bushing.

7. The method of claim 3 , wherein manipulating the compression of the flexible gasket comprises loosening or tightening the at least one fastener.