U.S. patent application number 15/355903 was filed with the patent office on 2017-03-09 for electrically-powered aerosol delivery system.
The applicant listed for this patent is RAI Strategic Holdings, Inc.. Invention is credited to Balager Ademe, Michael F. Davis, Donna Walker Duggins, Anthony Richard Gerardi, Stephen Benson Sears, Karen V. Taluskie.
Application Number | 20170065000 15/355903 |
Document ID | / |
Family ID | 53366270 |
Filed Date | 2017-03-09 |
United States Patent
Application |
20170065000 |
Kind Code |
A1 |
Sears; Stephen Benson ; et
al. |
March 9, 2017 |
ELECTRICALLY-POWERED AEROSOL DELIVERY SYSTEM
Abstract
An aerosol delivery system is provided, comprising a control
body portion including a first elongate tubular member having a
power source disposed therein. A cartridge body portion includes a
second tubular member having opposed first and second ends. One of
the first and second ends is removably engaged with one end of the
control body portion. The cartridge body portion further comprises
a first aerosol generation arrangement disposed within the second
tubular member and configured to operably engage the power source
upon engagement between the control body portion and the cartridge
body portion. A second aerosol generation arrangement is disposed
between the first aerosol generation arrangement and a
mouth-engaging end of the aerosol delivery system, the second
aerosol generation arrangement being either removably engaged with
the cartridge body portion or housed within the second tubular
member of the cartridge body portion. An associated method is also
provided.
Inventors: |
Sears; Stephen Benson;
(Siler City, NC) ; Taluskie; Karen V.;
(Winston-Salem, NC) ; Davis; Michael F.;
(Clemmons, NC) ; Ademe; Balager; (Winston-Salem,
NC) ; Duggins; Donna Walker; (Winston-Salem, NC)
; Gerardi; Anthony Richard; (Winston-Salem, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RAI Strategic Holdings, Inc. |
Winston-Salem |
NC |
US |
|
|
Family ID: |
53366270 |
Appl. No.: |
15/355903 |
Filed: |
November 18, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2015/031563 |
May 19, 2015 |
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15355903 |
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14282768 |
May 20, 2014 |
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PCT/US2015/031563 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 47/008 20130101;
H05B 1/0244 20130101; H05B 2203/021 20130101; H05B 1/0288 20130101;
H05B 2203/018 20130101; H05B 3/145 20130101 |
International
Class: |
A24F 47/00 20060101
A24F047/00; H05B 1/02 20060101 H05B001/02; H05B 3/14 20060101
H05B003/14 |
Claims
1. An aerosol delivery system, comprising: a control body portion
including a first elongate tubular member having opposed ends, and
a power source disposed therein; a cartridge body portion including
a second tubular member having opposed first and second ends, the
first end being engaged with one of the opposed ends of the control
body portion, the cartridge body portion further comprising a first
aerosol generation arrangement disposed within the second tubular
member and configured to operably engage the power source upon
engagement between the one of the opposed ends of the control body
portion and the first end of the cartridge body portion, the second
end of the cartridge body portion facing toward a mouth-engaging
end of the aerosol delivery system; and a second aerosol generation
arrangement disposed between the first aerosol generation
arrangement and the mouth-engaging end of the aerosol delivery
system, the second aerosol generation arrangement being either
removably engaged with the cartridge body portion or housed within
the second tubular member of the cartridge body portion.
2. The aerosol delivery system of claim 1, wherein the second
aerosol generation arrangement further includes at least one
aerosol-generating element.
3. The aerosol delivery system of claim 2, wherein the at least one
aerosol-generating element is selected from the group consisting of
granules, pellets, beads, discrete small units, carbon pieces,
extruded carbon pieces, ceramic beads, marumarized tobacco pieces,
extruded or compressed cylindrical or spherical elements, milled
tobacco lamina, fillers, flavors, visible aerosol forming
materials, binders, ovoid elements, irregularly shaped elements,
shredded pieces, flakes, elements including tobacco, elements
including a visible aerosol-forming material, adsorbent objects,
absorbent objects, capsules, microcapsules, a honeycomb monolith, a
single porous structure, and combinations thereof.
4. The aerosol-producing article of claim 1, further comprising a
first separating element disposed within the second tubular member
between the first aerosol generation arrangement and the second
aerosol generation arrangement, the first separating element being
one of heat-conductive and air permeable.
5. The aerosol delivery system of claim 4, wherein the first
separating element extends along a longitudinal axis between
opposed ends so as to define a thickness, the thickness of the
first separating element being configured to space the second
aerosol generation arrangement from a heating element of the first
aerosol generation arrangement.
6. The aerosol delivery system of claim 1, further comprising a
second separating element between the second aerosol generation
arrangement and the mouth-engaging end, the second separating
element being one of heat-conductive and air permeable.
7. The aerosol delivery system of claim 1, wherein the second
aerosol generation arrangement comprises a cartridge having an
elongate tubular body and opposed end members, each of the end
members being one of heat-conductive and air permeable, the
elongate tubular body being further configured to receive at least
one aerosol-generating element and to cooperate with the opposed
end members to contain the at least one aerosol-generating element
therein, the cartridge being configured to be received by the
second tubular member.
8. The aerosol delivery system of claim 1, wherein the first
aerosol generation arrangement comprises a liquid reservoir
disposed within the second tubular member and configured to receive
an aerosol precursor substance used by the first aerosol generation
arrangement to generate a first aerosol.
9. The aerosol delivery system of claim 8, wherein the aerosol
precursor substance is one of flavorant-free and acid-free.
10. The aerosol delivery system of claim 8, wherein the aerosol
precursor substance is one of glycerin, propylene glycol, water,
saline, nicotine, and combinations thereof.
11. The aerosol delivery system of claim 1, wherein the first
aerosol generation arrangement includes a heating element
configured to provide heat for producing a first aerosol, and the
second aerosol generation arrangement includes at least one
aerosol-generating element, the at least one aerosol-generating
element being arranged to interact with the heat and the first
aerosol, drawn therethrough toward the mouth-engaging end, in
response to a suction applied to the mouth-engaging end.
12. The aerosol delivery system of claim 11, wherein the at least
one aerosol-generating element of the second aerosol generation
arrangement is configured to interact with one of the heat from the
heating element of the first aerosol generation arrangement and the
first aerosol generated by the first aerosol generation arrangement
to produce a second aerosol.
13. The aerosol delivery system of claim 12, wherein the first
aerosol generated by the first aerosol generation arrangement is
configured to interact with the second aerosol generated by the
second aerosol generation arrangement to form a tertiary aerosol,
drawn toward the mouth-engaging end in response to the suction
applied thereto.
14. The aerosol delivery system of claim 11, wherein the at least
one aerosol-generating element of the second aerosol-generation
arrangement is configured to interact with and impart an
enhancement substance to the first aerosol generated by the first
aerosol generation arrangement to produce an enhanced aerosol,
drawn toward the mouth-engaging end in response to the suction
applied thereto.
15. The aerosol delivery system of claim 11, wherein the at least
one aerosol-generating element of the second aerosol generation
arrangement is configured to interact with and remove heat from the
first aerosol generated by the first aerosol generation arrangement
to produce a cooled aerosol, drawn toward the mouth-engaging end in
response to the suction applied thereto.
16. The aerosol delivery system of claim 1, wherein the second
aerosol generation arrangement further includes a plurality of
aerosol-generating elements in the form of beads or pellets
comprising at least one aerosol forming material.
17. The aerosol delivery system of claim 16, wherein the
aerosol-generating elements further comprise one or more of
particulate tobacco, a tobacco extract, and nicotine, wherein the
nicotine in free base form, salt form, as a complex, or as a
solvate.
18. The aerosol delivery system of claim 17, wherein the
aerosol-generating elements further comprise one or more fillers,
binders, flavorants, and combinations thereof.
19. The aerosol delivery system of claim 16, wherein the
aerosol-generating elements are smoke-treated.
20. The aerosol delivery system of claim 1, wherein the second
aerosol generation arrangement is housed within the second tubular
member of the cartridge body portion and includes a plurality of
aerosol-generating elements in the form of beads or pellets
retained in place by a first air permeable separating element
disposed within the second tubular member between the first aerosol
generation arrangement and the second aerosol generation
arrangement and a second separating element between the second
aerosol generation arrangement and the mouth-engaging end.
21. The aerosol delivery system of claim 1, wherein the second
aerosol generation arrangement is removably engaged with the
cartridge body portion and includes a plurality of
aerosol-generating elements in the form of beads or pellets
retained in place by a first air permeable separating element
between the first aerosol generation arrangement and the second
aerosol generation arrangement and a second separating element
between the second aerosol generation arrangement and the
mouth-engaging end.
22. A method of forming an aerosol delivery system, said method
comprising: engaging one end of a first elongate tubular member
with a first end of a second tubular member, the first elongate
tubular member being configured as a control body portion and
having a power source disposed therein, and the second tubular
member being configured as a cartridge body portion and having a
first aerosol generation arrangement disposed therein, the first
aerosol generation arrangement being configured to operably engage
the power source upon engagement between the one end of the control
body portion and the first end of the cartridge body portion, the
second end of the cartridge body portion facing toward a
mouth-engaging end of the aerosol delivery system; and engaging a
second aerosol generation arrangement with the cartridge body
portion such that the second aerosol generation arrangement is
disposed between the first aerosol generation arrangement and the
mouth-engaging end of the aerosol delivery system.
23. The method of claim 22, wherein said step of engaging a second
aerosol generation arrangement with the cartridge body portion
comprises inserting the second aerosol generation arrangement
within the second tubular member of the cartridge body portion,
between the first aerosol generation arrangement and a second end
of the second tubular member, the second end being opposed to the
first end and being configured as a mouth-engaging end.
24. The method of claim 23, wherein inserting the second aerosol
generation arrangement within the second tubular member further
comprises inserting at least one aerosol-generating element, at
least partially forming the second aerosol generation arrangement,
into the second tubular member, the at least one aerosol-generating
element being selected from the group consisting of granules,
pellets, beads, discrete small units, carbon pieces, extruded
carbon pieces, ceramic beads, marumarized tobacco pieces, extruded
or compressed cylindrical or spherical elements, milled tobacco
lamina, fillers, flavors, visible aerosol forming materials,
binders, ovoid elements, irregularly shaped elements, shredded
pieces, flakes, elements including tobacco, elements including a
visible aerosol-forming material, adsorbent objects, absorbent
objects, capsules, microcapsules, a honeycomb monolith, a single
porous structure, and combinations thereof.
25. The method of claim 23, further comprising inserting a first
separating element in the second tubular member between the first
aerosol generation arrangement and the second aerosol generation
arrangement, the first separating element being one of
heat-conductive and air permeable.
26. The method of claim 25, further comprising inserting a second
separating element in the second tubular member between the second
aerosol generation arrangement and the mouth-engaging end of the
cartridge body portion, the second separating element being one of
heat-conductive and air permeable.
27. The method of claim 23, wherein the second aerosol generation
arrangement comprises a cartridge having an elongate tubular body
and opposed end members, each of the end members being one of
heat-conductive and air permeable, the elongate tubular body being
further configured to receive at least one aerosol-generating
element and to cooperate with the opposed end members to contain
the at least one aerosol-generating element therein, and wherein
inserting the second aerosol generation arrangement further
comprises inserting the cartridge within the second tubular member
of the cartridge body portion.
28. The method of any claim 23, wherein the second aerosol
generation arrangement comprises a plurality of aerosol-generating
elements in the form of beads or pellets retained in place by a
first air permeable separating element disposed within the second
tubular member between the first aerosol generation arrangement and
the second aerosol generation arrangement and a second separating
element between the second aerosol generation arrangement and the
mouth-engaging end.
29. The method of claim 22, wherein said step of engaging a second
aerosol generation arrangement with the cartridge body portion
comprises removably engaging the second aerosol generation
arrangement with the cartridge body portion, the second aerosol
generation arrangement comprising a first end configured to
removably engage with the cartridge body portion and a second end
adapted to provide the mouth-engaging end of the aerosol delivery
system, and wherein the second aerosol generation arrangement
comprises a plurality of aerosol-generating elements in the form of
beads or pellets retained in place by a first air permeable
separating element between the first aerosol generation arrangement
and the second aerosol generation arrangement and a second
separating element between the second aerosol generation
arrangement and the mouth-engaging end.
30. The method of claim 22, wherein the second aerosol generation
arrangement comprises a plurality of aerosol-generating elements in
the form of beads or pellets comprising at least one aerosol
forming material.
31. The method of claim 30, wherein the aerosol-generating elements
further comprise one or more of particulate tobacco, a tobacco
extract, and nicotine, wherein the nicotine in free base form, salt
form, as a complex, or as a solvate.
32. The method of claim 31, wherein the aerosol-generating elements
further comprise one or more fillers, binders, flavorants, and
combinations thereof.
33. The method of claim 30, wherein the aerosol-generating elements
are smoke-treated.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT/US2015/031563,
filed May 19, 2015, and a continuation-in-part of U.S. application
Ser. No. 14/282,768, filed May 20, 2014, which applications are
hereby incorporated in their entirety by reference in this
application.
BACKGROUND
[0002] Field of the Disclosure
[0003] The present disclosure relates to aerosol delivery devices
and systems, such as smoking articles; and more particularly, to
aerosol delivery devices and systems that utilize
electrically-generated heat for the production of aerosol (e.g.,
smoking articles commonly referred to as electronic cigarettes).
The aerosol delivery devices and systems may be configured to heat
an aerosol precursor, which incorporates materials that may be,
though not necessarily, made or derived from tobacco or otherwise
incorporate tobacco, and which are capable of vaporizing to form an
inhalable aerosol for human consumption.
[0004] Description of Related Art
[0005] Many smoking devices have been proposed through the years as
improvements upon, or alternatives to, smoking products that
require combusting tobacco for use. Many of those devices
purportedly have been designed to provide the sensations associated
with cigarette, cigar, or pipe smoking, but without delivering
considerable quantities of incomplete combustion and pyrolysis
products that result from the burning of tobacco. To this end,
there have been proposed numerous smoking products, flavor
generators, and medicinal inhalers that utilize electrical energy
to vaporize or heat a volatile material, or attempt to provide the
sensations of cigarette, cigar, or pipe smoking without burning
tobacco to a significant degree. See, for example, the various
alternative smoking articles, aerosol delivery devices and heat
generating sources set forth in the background art described in
U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S. Pat. App. Pub.
Nos. 2013/0255702 to Griffith, Jr. et al.; and 2014/0096781 to
Sears et al., which are incorporated herein by reference. See also,
for example, the various types of smoking articles, aerosol
delivery devices and electrically powered heat generating sources
referenced by brand name and commercial source in U.S. patent
application Ser. No. 14/170,838, filed Feb. 3, 2014, to Bless et
al., which is incorporated herein by reference.
[0006] It would be desirable to provide an electrically-powered
aerosol delivery system that is capable of allowing the user
thereof to draw aerosol that is highly flavorful. It may also be
desirable for the aerosol to be provided under pleasing or
comfortable conditions upon being drawn into the mouth of the
user.
SUMMARY OF THE DISCLOSURE
[0007] The present disclosure relates to aerosol delivery systems.
Such systems have the ability to generate aerosol as a result of
heat generated by electrical power sources, and to deliver aerosol
that is intended to be drawn into the mouth of a user. Of
particular interest are aerosol delivery systems that provide
components of tobacco in an aerosol form, such as is provided to
smokers by devices commonly known or characterized as electronic
cigarettes. As used herein, the term "aerosol" is meant to include
vapors, gases, aerosols, and/or particulate matter of a form or
type suitable for human inhalation, whether visible or not, and
whether or not of a form that might be considered to be
"smoke-like."
[0008] The above and other needs are met by aspects of the present
disclosure which, in one aspect, provides an aerosol delivery
system. Such an aerosol delivery system may comprise a control body
portion, wherein the control body portion includes a first elongate
tubular member having opposed ends, and a power source disposed
therein. A cartridge body portion includes a second tubular member
having opposed first and second ends. One of the first and second
ends of the cartridge body portion is removably engaged with one of
the opposed ends of the control body portion. The cartridge body
portion further comprises a first aerosol generation arrangement
disposed within the second tubular member, and configured to
operably engage the power source upon engagement between the one of
the opposed ends of the control body portion and the one of the
first and second ends of the cartridge body portion. The other of
the first and second ends of the cartridge body portion is further
configured as a mouth-engaging end. The cartridge body portion
further includes a second aerosol generation arrangement within the
second tubular member disposed between the first aerosol generation
arrangement and the mouth-engaging end. In some aspects, the second
aerosol generation arrangement may further include one or more
aerosol generation elements, wherein the one or more (at least one)
aerosol generation elements may be selected from the group
consisting of granules, pellets, beads, discrete small units,
carbon pieces, extruded carbon pieces, ceramic beads, marumarized
tobacco pieces, extruded or compressed cylindrical or spherical
elements, milled tobacco lamina, fillers, flavors, visible aerosol
forming materials, binders, ovoid elements, irregularly shaped
elements, shredded pieces, flakes, elements including tobacco,
elements including a visible aerosol-forming material, adsorbent
objects, absorbent objects, capsules, microcapsules, a honeycomb
monolith, a single porous structure, and combinations thereof.
[0009] Another aspect of the present disclosure provides a method
of forming an aerosol delivery system. Such a method may comprise
removably engaging one end of a first elongate tubular member with
a first end of a second tubular member, wherein the first elongate
tubular member is configured as a control body portion and having a
power source disposed therein, and the second tubular member is
configured as a cartridge body portion and having a first aerosol
generation arrangement disposed therein. The first aerosol
generation arrangement is configured to operably engage the power
source upon engagement between the one end of the control body
portion and the first end of the cartridge body portion. The method
may also comprise inserting a second aerosol generation arrangement
within the second tubular member of the cartridge body portion,
between the first aerosol generation arrangement and a second end
of the second tubular member, wherein the second end is opposed to
the first end and is configured as a mouth-engaging end. In some
instances, inserting the second aerosol generation arrangement
within the second tubular member may further comprise inserting one
or more aerosol generation elements, at least partially forming the
second aerosol generation arrangement, into the second tubular
member, wherein the one or more (at least one) aerosol generation
elements is selected from the group consisting of granules,
pellets, beads, discrete small units, carbon pieces, extruded
carbon pieces, ceramic beads, marumarized tobacco pieces, extruded
or compressed cylindrical or spherical elements, milled tobacco
lamina, fillers, flavors, visible aerosol forming materials,
binders, ovoid elements, irregularly shaped elements, shredded
pieces, flakes, elements including tobacco, elements including a
visible aerosol-forming material, adsorbent objects, absorbent
objects, capsules, microcapsules, a honeycomb monolith, a single
porous structure, and combinations thereof.
[0010] The present disclosure thus includes, without limitation,
the following embodiments:
EMBODIMENT 1
[0011] An aerosol delivery system, comprising a control body
portion including a first elongate tubular member having opposed
ends, and a power source disposed therein; and a cartridge body
portion including a second tubular member having opposed first and
second ends, wherein one of the first and second ends is removably
engaged with one of the opposed ends of the control body portion,
wherein the cartridge body portion further comprises a first
aerosol generation arrangement disposed within the second tubular
member and configured to operably engage the power source upon
engagement between the one of the opposed ends of the control body
portion and the one of the first and second ends of the cartridge
body portion, wherein the other of the first and second ends of the
cartridge body portion is optionally further configured as a
mouth-engaging end, and wherein the cartridge body portion further
includes a second aerosol generation arrangement within the second
tubular member disposed between the first aerosol generation
arrangement and the mouth-engaging end.
EMBODIMENT 2
[0012] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the second aerosol
generation arrangement further includes at least one
aerosol-generating element.
EMBODIMENT 3
[0013] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the at least one
aerosol-generating element is selected from the group consisting of
granules, pellets, beads, discrete small units, carbon pieces,
extruded carbon pieces, ceramic beads, marumarized tobacco pieces,
extruded or compressed cylindrical or spherical elements, milled
tobacco lamina, fillers, flavors, visible aerosol forming
materials, binders, ovoid elements, irregularly shaped elements,
shredded pieces, flakes, elements including tobacco, elements
including a visible aerosol-forming material, adsorbent objects,
absorbent objects, capsules, microcapsules, a honeycomb monolith, a
single porous structure, and combinations thereof.
EMBODIMENT 4
[0014] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, further comprising a first
separating element disposed within the second tubular member
between the first aerosol generation arrangement and the second
aerosol generation arrangement, the first separating element being
one of heat-conductive and air permeable.
EMBODIMENT 5
[0015] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the first separating
element extends along a longitudinal axis between opposed ends so
as to define a thickness, the thickness of the first separating
element being configured to space the second aerosol generation
arrangement from a heating element of the first aerosol generation
arrangement.
EMBODIMENT 6
[0016] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, further comprising a second
separating element disposed within the second tubular member
between the second aerosol generation arrangement and the
mouth-engaging end, the second separating element being one of
heat-conductive and air permeable.
EMBODIMENT 7
[0017] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the second aerosol
generation arrangement comprises a cartridge having an elongate
tubular body and opposed end members, each of the end members being
one of heat-conductive and air permeable, the elongate tubular body
being further configured to receive at least one aerosol-generating
element and to cooperate with the opposed end members to contain
the at least one aerosol-generating element therein, the cartridge
being configured to be received by the second tubular member.
EMBODIMENT 8
[0018] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the first aerosol
generation arrangement comprises a liquid reservoir disposed within
the second tubular member and configured to receive an aerosol
precursor substance used by the first aerosol generation
arrangement to generate a first aerosol.
EMBODIMENT 9
[0019] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the aerosol precursor
substance is one of flavorant-free and acid-free.
EMBODIMENT 10
[0020] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the aerosol precursor
substance is one of glycerin, propylene glycol, water, saline,
nicotine, and combinations thereof.
EMBODIMENT 11
[0021] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the first aerosol
generation arrangement includes a heating element configured to
provide heat for producing a first aerosol, and the second aerosol
generation arrangement includes at least one aerosol-generating
element, the at least one aerosol-generating element being arranged
to interact with the heat and the first aerosol, drawn therethrough
toward the mouth-engaging end, in response to a suction applied to
the mouth-engaging end of the cartridge body portion.
EMBODIMENT 12
[0022] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the at least one
aerosol-generating element of the second aerosol generation
arrangement is configured to interact with one of the heat from the
heating element of the first aerosol generation arrangement and the
first aerosol generated by the first aerosol generation arrangement
to produce a second aerosol.
EMBODIMENT 13
[0023] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the first aerosol
generated by the first aerosol generation arrangement is configured
to interact with the second aerosol generated by the second aerosol
generation arrangement to form a tertiary aerosol, drawn toward the
mouth-engaging end in response to the suction applied thereto.
EMBODIMENT 14
[0024] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the at least one
aerosol-generating element of the second aerosol-generation
arrangement is configured to interact with and impart an
enhancement substance to the first aerosol generated by the first
aerosol generation arrangement to produce an enhanced aerosol,
drawn toward the mouth-engaging end in response to the suction
applied thereto.
EMBODIMENT 15
[0025] The aerosol delivery system of any preceding or subsequent
embodiment, or combinations thereof, wherein the at least one
aerosol-generating element of the second aerosol generation
arrangement is configured to interact with and remove heat from the
first aerosol generated by the first aerosol generation arrangement
to produce a cooled aerosol, drawn toward the mouth-engaging end in
response to the suction applied thereto.
EMBODIMENT 16
[0026] An aerosol delivery system, comprising: a control body
portion including a first elongate tubular member having opposed
ends, and a power source disposed therein; a cartridge body portion
including a second tubular member having opposed first and second
ends, the first end being engaged with one of the opposed ends of
the control body portion, the cartridge body portion further
comprising a first aerosol generation arrangement disposed within
the second tubular member and configured to operably engage the
power source upon engagement between the one of the opposed ends of
the control body portion and the first end of the cartridge body
portion, the second end of the cartridge body portion facing toward
a mouth-engaging end of the aerosol delivery system; and a second
aerosol generation arrangement disposed between the first aerosol
generation arrangement and the mouth-engaging end of the aerosol
delivery system, the second aerosol generation arrangement being
either removably engaged with the cartridge body portion or housed
within the second tubular member of the cartridge body portion.
EMBODIMENT 17
[0027] The aerosol delivery system of any preceding or subsequent
embodiment, wherein the second aerosol generation arrangement
further includes a plurality of aerosol-generating elements in the
form of beads or pellets comprising at least one aerosol forming
material.
EMBODIMENT 18
[0028] The aerosol delivery system of any preceding or subsequent
embodiment, wherein the aerosol-generating elements further
comprise one or more of particulate tobacco, a tobacco extract, and
nicotine, wherein the nicotine in free base form, salt form, as a
complex, or as a solvate.
EMBODIMENT 19
[0029] The aerosol delivery system of any preceding or subsequent
embodiment, wherein the aerosol-generating elements further
comprise one or more fillers, binders, flavorants, and combinations
thereof.
EMBODIMENT 20
[0030] The aerosol delivery system of any preceding or subsequent
embodiment, wherein the aerosol-generating elements are
smoke-treated.
EMBODIMENT 21
[0031] The aerosol delivery system of any preceding or subsequent
embodiment, wherein the second aerosol generation arrangement is
housed within the second tubular member of the cartridge body
portion and includes a plurality of aerosol-generating elements in
the form of beads or pellets retained in place by a first air
permeable separating element disposed within the second tubular
member between the first aerosol generation arrangement and the
second aerosol generation arrangement and a second separating
element between the second aerosol generation arrangement and the
mouth-engaging end.
EMBODIMENT 22
[0032] The aerosol delivery system of any preceding or subsequent
embodiment, wherein the second aerosol generation arrangement is
removably engaged with the cartridge body portion and includes a
plurality of aerosol-generating elements in the form of beads or
pellets retained in place by a first air permeable separating
element between the first aerosol generation arrangement and the
second aerosol generation arrangement and a second separating
element between the second aerosol generation arrangement and the
mouth-engaging end.
EMBODIMENT 23
[0033] A method of forming an aerosol delivery system, comprising
removably engaging one end of a first elongate tubular member with
a first end of a second tubular member, wherein the first elongate
tubular member is configured as a control body portion and has a
power source disposed therein, wherein the second tubular member is
configured as a cartridge body portion and has a first aerosol
generation arrangement disposed therein, and wherein the first
aerosol generation arrangement is configured to operably engage the
power source upon engagement between the one end of the control
body portion and the first end of the cartridge body portion; and
inserting a second aerosol generation arrangement within the second
tubular member of the cartridge body portion, between the first
aerosol generation arrangement and a second end of the second
tubular member, wherein the second end is opposed to the first end
and is configured as a mouth-engaging end.
EMBODIMENT 24
[0034] The method of any preceding or subsequent embodiment,
wherein said step of engaging a second aerosol generation
arrangement with the cartridge body portion comprises inserting the
second aerosol generation arrangement within the second tubular
member of the cartridge body portion, between the first aerosol
generation arrangement and a second end of the second tubular
member, the second end being opposed to the first end and being
configured as a mouth-engaging end.
EMBODIMENT 25
[0035] The method of any preceding or subsequent embodiment, or
combinations thereof, wherein inserting the second aerosol
generation arrangement within the second tubular member further
comprises inserting at least one aerosol-generating element, at
least partially forming the second aerosol generation arrangement,
into the second tubular member, the at least one aerosol-generating
element being selected from the group consisting of granules,
pellets, beads, discrete small units, carbon pieces, extruded
carbon pieces, ceramic beads, marumarized tobacco pieces, extruded
or compressed cylindrical or spherical elements, milled tobacco
lamina, fillers, flavors, visible aerosol forming materials,
binders, ovoid elements, irregularly shaped elements, shredded
pieces, flakes, elements including tobacco, elements including a
visible aerosol-forming material, adsorbent objects, absorbent
objects, capsules, microcapsules, a honeycomb monolith, a single
porous structure, and combinations thereof.
EMBODIMENT 26
[0036] The method of any preceding or subsequent embodiment, or
combinations thereof, further comprising inserting a first
separating element in the second tubular member between the first
aerosol generation arrangement and the second aerosol generation
arrangement, the first separating element being one of
heat-conductive and air permeable.
EMBODIMENT 27
[0037] The method of any preceding or subsequent embodiment, or
combinations thereof, further comprising inserting a second
separating element in the second tubular member between the second
aerosol generation arrangement and the mouth-engaging end of the
cartridge body portion, wherein the second separating element is
one of heat-conductive and air permeable.
EMBODIMENT 28
[0038] The method of any preceding or subsequent embodiment, or
combinations thereof, wherein the second aerosol generation
arrangement comprises a cartridge having an elongate tubular body
and opposed end members, wherein each of the end members is one of
heat-conductive and air permeable, wherein the elongate tubular
body is further configured to receive at least one
aerosol-generating element and to cooperate with the opposed end
members to contain the at least one aerosol-generating element
therein, and wherein inserting the second aerosol generation
arrangement further comprises inserting the cartridge within the
second tubular member of the cartridge body portion.
EMBODIMENT 29
[0039] A method of forming an aerosol delivery system, said method
comprising: engaging one end of a first elongate tubular member
with a first end of a second tubular member, the first elongate
tubular member being configured as a control body portion and
having a power source disposed therein, and the second tubular
member being configured as a cartridge body portion and having a
first aerosol generation arrangement disposed therein, the first
aerosol generation arrangement being configured to operably engage
the power source upon engagement between the one end of the control
body portion and the first end of the cartridge body portion, the
second end of the cartridge body portion facing toward a
mouth-engaging end of the aerosol delivery system; and engaging a
second aerosol generation arrangement with the cartridge body
portion such that the second aerosol generation arrangement is
disposed between the first aerosol generation arrangement and the
mouth-engaging end of the aerosol delivery system.
EMBODIMENT 30
[0040] The method of any preceding or subsequent embodiment,
wherein the second aerosol generation arrangement comprises a
plurality of aerosol-generating elements in the form of beads or
pellets retained in place by a first air permeable separating
element disposed within the second tubular member between the first
aerosol generation arrangement and the second aerosol generation
arrangement and a second separating element between the second
aerosol generation arrangement and the mouth-engaging end.
EMBODIMENT 31
[0041] The method of any preceding or subsequent embodiment,
wherein said step of engaging a second aerosol generation
arrangement with the cartridge body portion comprises removably
engaging the second aerosol generation arrangement with the
cartridge body portion, the second aerosol generation arrangement
comprising a first end configured to removably engage with the
cartridge body portion and a second end adapted to provide the
mouth-engaging end of the aerosol delivery system, and wherein the
second aerosol generation arrangement comprises a plurality of
aerosol-generating elements in the form of beads or pellets
retained in place by a first air permeable separating element
between the first aerosol generation arrangement and the second
aerosol generation arrangement and a second separating element
between the second aerosol generation arrangement and the
mouth-engaging end.
EMBODIMENT 32
[0042] The method of any preceding or subsequent embodiment,
wherein the second aerosol generation arrangement comprises a
plurality of aerosol-generating elements in the form of beads or
pellets comprising at least one aerosol forming material.
EMBODIMENT 33
[0043] The method of any preceding or subsequent embodiment,
wherein the aerosol-generating elements further comprise one or
more of particulate tobacco, a tobacco extract, and nicotine,
wherein the nicotine in free base form, salt form, as a complex, or
as a solvate.
EMBODIMENT 34
[0044] The method of any preceding or subsequent embodiment,
wherein the aerosol-generating elements further comprise one or
more fillers, binders, flavorants, and combinations thereof.
EMBODIMENT 35
[0045] The method of any preceding or subsequent embodiment,
wherein the aerosol-generating elements are smoke-treated.
[0046] These and other features, aspects, and advantages of the
present disclosure will be apparent from a reading of the following
detailed description together with the accompanying drawings, which
are briefly described below. The present disclosure includes any
combination of two, three, four, or more of the above-noted aspects
as well as combinations of any two, three, four, or more features
or elements set forth in this disclosure, regardless of whether
such features or elements are expressly combined in a specific
embodiment description herein. This disclosure is intended to be
read holistically such that any separable features or elements of
the present disclosure, in any of its various aspects and
embodiments, should be viewed as intended to be combinable unless
the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0048] FIG. 1 schematically illustrates an aerosol delivery device
comprising a cartridge body and a control body, the cartridge body
being illustrated in an exploded configuration and the control body
being illustrated in an assembled configuration according to an
example aspect of the present disclosure;
[0049] FIG. 2 schematically illustrates the control body of FIG. 1
in an exploded configuration according to an example aspect of the
present disclosure;
[0050] FIG. 3 schematically illustrates the cartridge body of FIG.
1 implementing an additional aerosol generation arrangement,
including one or more aerosol-generating elements, according to one
aspect of the present disclosure;
[0051] FIG. 4 schematically illustrates the additional aerosol
generation arrangement of FIG. 3, configured as a cartridge
including one or more aerosol-generating elements, according to
another aspect of the present disclosure;
[0052] FIG. 5 schematically illustrates an exploded view of an
alternate carbon-based cartridge body according to an example
aspect of the present disclosure;
[0053] FIG. 6A schematically illustrates an assembled view of the
carbon-based cartridge body of FIG. 5, according to an example
aspect of the present disclosure;
[0054] FIG. 6B schematically illustrates an assembled view of the
carbon-based cartridge body, implementing an additional aerosol
generation arrangement, including one or more aerosol-generating
elements, according to one aspect of the present disclosure;
[0055] FIG. 7 is a cross-sectional view of a second aerosol
generation arrangement housed within the same outer body as a first
aerosol generation arrangement according to an example aspect of
the present disclosure; and
[0056] FIG. 8 is a cross-sectional view of a second aerosol
generation arrangement removably attached to the outer body housing
a first aerosol generation arrangement according to an example
aspect of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] The present disclosure will now be described more fully
hereinafter with reference to exemplary embodiments thereof. These
exemplary embodiments are described so that this disclosure will be
thorough and complete, and will fully convey the scope of the
disclosure to those skilled in the art. Indeed, the disclosure may
be embodied in many different forms and should not be construed as
limited to the embodiments set forth herein; rather, these
embodiments are provided so that this disclosure will satisfy
applicable legal requirements. As used in the specification, and in
the appended claims, the singular forms "a", "an", "the", include
plural variations unless the context clearly dictates
otherwise.
[0058] As described hereinafter, aspects of the present disclosure
relate to aerosol delivery systems. Aerosol delivery systems
according to the present disclosure use electrical energy to heat a
material (preferably without combusting the material to any
significant degree) to form an inhalable substance; and components
of such systems have the form of articles most preferably
sufficiently compact for such systems to be considered hand-held
devices. That is, use of components of preferred aerosol delivery
systems does not result in the production of smoke in the sense
that aerosol results principally from by-products of combustion or
pyrolysis of tobacco, but rather, use of those preferred systems
results in the production of vapors (including vapors within
aerosols that can be considered to be visible/not visible aerosols
that might be considered to be described as smoke-like), resulting
from volatilization or vaporization of certain components
incorporated therein. In preferred aspects, components of aerosol
delivery systems may be characterized as electronic cigarettes, and
those electronic cigarettes most preferably incorporate tobacco
and/or components derived from tobacco, and hence deliver tobacco
derived components in aerosol form.
[0059] Aerosol generating pieces of certain preferred aerosol
delivery systems may provide many of the sensations (e.g.,
inhalation and exhalation rituals, types of tastes or flavors,
organoleptic effects, physical feel, use rituals, visual cues such
as those provided by visible aerosol, and the like) of smoking a
cigarette, cigar, or pipe that are provided by lighting and burning
tobacco (and hence inhaling tobacco smoke), without any substantial
degree of combustion of any component thereof. For example, the
user of an aerosol generating piece of the present disclosure can
hold and use that piece much like a smoker employs a traditional
type of smoking article, draw on one end of that piece for
inhalation of aerosol produced by that piece, take or draw puffs at
selected intervals of time, and the like.
[0060] Aerosol delivery systems of the present disclosure also can
be characterized as being suitable vapor-producing articles,
aerosol-producing articles, or medicament delivery articles. Thus,
such articles, systems, or devices can be adapted so as to provide
one or more substances (e.g., flavors, pharmaceutical active
ingredients, peptides, protein fragments, and/or protein coats) in
an inhalable form or state. For example, inhalable substances can
be substantially in the form of a vapor (i.e., a substance that is
in the gas phase at a temperature lower than its critical point).
Alternatively, inhalable substances can be in the form of an
aerosol (i.e., a suspension of fine solid particles or liquid
droplets in a gas). For purposes of simplicity, the term "aerosol"
as used herein is meant to include vapors, gases, aerosols, and/or
particulate matter of a form or type suitable for human inhalation,
whether or not visible, and whether or not of a form that might be
considered to be smoke-like.
[0061] Aerosol delivery systems of the present disclosure most
preferably comprise some combination of a power source (i.e., an
electrical power source), at least one control component (e.g.,
means for actuating, controlling, regulating and/or ceasing power
supplied for heat generation, such as by controlling electrical
current flow from an electrical power release unit to other
components of the aerosol generating arrangement), a heater or heat
generation component (e.g., an electrical resistance heating
element and related components commonly referred to as providing an
"atomizer"), and an aerosol precursor composition (e.g., a
composition that commonly is a liquid capable of yielding an
aerosol upon application of sufficient heat, such as ingredients
commonly referred to as "smoke juice," "e-liquid" and "e-juice"),
and a mouth end region, mouth-engaging end, or tip for allowing
draw upon the aerosol delivery system for aerosol inhalation (e.g.,
a defined air flow path through the aerosol generation arrangement
such that aerosol generated can be withdrawn therefrom upon
draw).
[0062] More specific formats, configurations and arrangements of
components within the aerosol delivery systems of the present
disclosure will be evident in light of the further disclosure
provided hereinafter. Additionally, the selection and arrangement
of various aerosol delivery system components can be appreciated
upon consideration of the commercially available electronic aerosol
delivery devices, such as those representative products referenced
in background art section of the present disclosure.
[0063] In some aspects, the use of aerosol delivery devices of the
present disclosure may be subjected to many of the physical actions
employed by an individual in using a traditional type of smoking
article (e.g., a cigarette, cigar or pipe that is employed by
lighting and inhaling tobacco). For example, the user of an aerosol
delivery device of the present disclosure can hold that article
much like a traditional type of smoking article, draw on one end of
that article for inhalation of aerosol produced by that article,
take puffs at selected intervals of time, or for selected durations
of time, etc.
[0064] One such example of an aerosol delivery system 100 is
illustrated in FIG. 1. In particular, FIG. 1 illustrates a
partially exploded view of an aerosol delivery system 100 including
a cartridge body 200 and a control body 300 (otherwise referred to
herein as "cartridge body portion" and "control body portion,"
respectively). The cartridge body 200 and the control body 300 can
be permanently or detachably aligned, or removably engaged, in a
functioning relationship. Various mechanisms may be used to connect
the cartridge body 200 to the control body 300 to result in a
threaded engagement, a press-fit engagement, an interference fit, a
magnetic engagement, or the like. The aerosol delivery system 100
may be substantially rod-like, substantially tubular shaped, or
substantially cylindrically shaped in some embodiments, when the
cartridge body 200 and the control body 300 are in an assembled
configuration. As used herein, "tubular" is intended to refer to a
hollow, elongated body, but is not limited to a specific
cross-sectional shape or to a specific outer contour of the body.
One skilled in the art will also appreciate that, in some instances
and though not described in detail herein, the cartridge body 200
and the control body 300 forming the aerosol delivery system 100
may be configured in a single-piece, non-detachable form and may
incorporate the components, aspects, and features associated with
and disclosed in the present disclosure.
[0065] In some instances, one or both of the cartridge body 200 and
the control body 300 may be referred to as being disposable (i.e.,
the single piece, non-detachable form previously disclosed) or as
being reusable. For example, a reusable control body 300 may have a
replaceable battery or a rechargeable battery and thus may be
combined with any type of recharging technology, including
connection to a typical alternating current electrical outlet,
connection to a car charger (i.e., cigarette lighter receptacle),
and connection to a computer, such as through a universal serial
bus (USB) cable. In general, an aerosol delivery system of the type
disclosed herein incorporates a battery or other electrical power
source to provide current flow sufficient to provide various
functionalities to the article, such as powering of a heater or
heating element, powering of control systems, powering of
indicators, and the like. The power source can take on various
embodiments. Preferably, the power source is able to deliver
sufficient power to rapidly heat the heating element to provide for
aerosol formation and power the article through use for the desired
duration of time. The power source preferably is sized to fit
conveniently within the aerosol delivery device/system so that the
aerosol delivery device/system can be easily handled; and
additionally, a preferred power source is of a sufficiently light
weight to not detract from a desirable smoking experience. Further,
in some instances, the cartridge body 200 may comprise a single-use
cartridge (i.e., disposable), as disclosed, for example, in U.S.
Pat. App. Pub. No. 2014/0060555 to Chang et al., which is
incorporated herein by reference in its entirety.
[0066] FIG. 2 illustrates an exploded view of the control body 300
of the aerosol delivery system 100 according to another example. As
illustrated, the control body 300 may comprise a coupler 302, an
outer body 304, a sealing member 306, an adhesive member 308 (e.g.,
KAPTON.RTM. tape), a flow sensor 310 (e.g., a puff sensor or
pressure switch), a control component 312, a spacer 314, an
electrical power source 316 (e.g., a battery, which may be
rechargeable), a circuit board with an indicator 318 (e.g., a light
emitting diode (LED)), a connector circuit 320, and an end cap 322.
Examples of electrical power sources are described in U.S. Pat.
App. Pub. No. 2010/0028766 by Peckerar et al., the disclosure of
which is incorporated herein by reference in its entirety.
[0067] With respect to the flow sensor 310, representative current
regulating components and other current controlling components
including various microcontrollers, sensors, and switches for
aerosol delivery devices/systems are described, for example, in
U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 4,947,874 to
Brooks et al.; U.S. Pat. No. 5,372,148 to McCafferty et al.; U.S.
Pat. No. 6,040,560 to Fleischhauer et al.; U.S. Pat. No. 7,040,314
to Nguyen et al. and U.S. Pat. No. 8,205,622 to Pan; U.S. Pat. Pub.
Nos. 2009/0230117 to Fernando et al.; 2014/0060554 to Collett et
al.; and 2014/0270727 to Ampolini et al., and U.S. patent
application Ser. No. 14/209,191, filed Mar. 13, 2014, to Henry et
al., which are incorporated herein by reference.
[0068] In some instances, the indicator 318 may comprise one or
more light emitting diodes. The indicator 318 can be in
communication with the control component 312 through the connector
circuit 320 and illuminate, for example, during a user drawing on a
cartridge body 200 coupled to the coupler 302, as detected by the
flow sensor 310. The end cap 322 may be adapted to make visible the
illumination provided thereunder by the indicator 318. Accordingly,
the indicator 318 may illuminate during use of the aerosol delivery
system 100 to simulate the lit end of a smoking article. However,
in other instances, the indicator 318 can be provided in varying
numbers and can take on different shapes and can even be an opening
in the outer body (such as for release of sound when such
indicators are present). Additional representative types of
components that yield visual cues or indicators, such as light
emitting diode (LED) components, and the configurations and uses
thereof, are described in U.S. Pat. No. 5,154,192 to Sprinkel et
al.; U.S. Pat. No. 8,499,766 to Newton and U.S. Pat. No. 8,539,959
to Scatterday; and U.S. patent application Ser. No. 14/173,266,
filed Feb. 5, 2014, to Sears et al.; which are incorporated herein
by reference.
[0069] Still further features, controls or components that can be
incorporated into aerosol delivery devices and systems of the
present disclosure are described in U.S. Pat. No. 5,967,148 to
Harris et al.; U.S. Pat. No. 5,934,289 to Watkins et al.; U.S. Pat.
No. 5,954,979 to Counts et al.; U.S. Pat. No. 6,040,560 to
Fleischhauer et al.; U.S. Pat. No. 7,726,320 to Robinson et al.;
U.S. Pat. No. 8,365,742 to Hon; U.S. Pat. Nos. 8,402,976 and
8,689,804 to Fernando et al.; U.S. Pat. App. Pub. Nos. 2013/0192623
to Tucker et al.; 2013/0298905 to Leven et al.; 2013/0180553 to Kim
et al. and 2014/0000638 to Sebastian et al.; and U.S. Pat. App.
Pub. Nos. 2014/0261495 to Novak, III et al. and 2014/0261408 to
DePiano et al.; which are incorporated herein by reference in their
entireties.
[0070] Returning to FIG. 1, the cartridge body 200 is illustrated
in an exploded configuration. As illustrated, the cartridge body
200 may comprise a base shipping plug 202, a base 204, a control
component terminal 206, an electronic control component 208, a flow
tube 210, an atomizer 212, a reservoir substrate 214, an outer body
216, a label 218, a mouthpiece 220, and a mouthpiece shipping plug
222 according to an example embodiment of the present disclosure.
The base 204 may be coupled to a first end of the outer body 216
and the mouthpiece 220 may be coupled to an opposing second end of
the outer body 216 to enclose the remaining components of the
cartridge body 200 therein. The base 204 may be configured to
removably engage the coupler 302 of the control body 300. In some
instances, the base 204 may comprise anti-rotation features that
substantially prevent relative rotation between the cartridge body
and the control body as disclosed in U.S. Pat. App. Pub. No.
2014/0261495 to Novak, III et al., which is incorporated herein by
reference in its entirety. Various representative coupling
mechanisms for upstream and downstream components of electronic
cigarettes have been set forth in the patent literature and have
been employed for the production of commercially available
electronic cigarettes. For example, representative types of
coupling mechanisms and components for electronic cigarettes are
described in U.S. Pat. App. Pub. No. 2014/0261495 to Novak, III et
al., and U.S. patent application Ser. No. 14/170,838, filed Feb. 3,
2014, to Bless et al.; which are incorporated herein by
reference.
[0071] The base shipping plug 202 may be configured to engage and
protect the base 204 prior to use of the cartridge body 200.
Similarly, the mouthpiece shipping plug 222 may be configured to
engage and protect the mouthpiece 220 prior to use of the cartridge
body 200. The control component terminal 206, the electronic
control component 208, the flow tube 210, the atomizer 212, and the
reservoir substrate 214 (engaging the aerosol precursor composition
or substance) may be retained within the outer body 216. The label
218 may at least partially surround the outer body 216 and include
information such as a product identifier thereon.
[0072] Alignment of the components within either or both of the
control body and the cartridge body of the aerosol delivery
device/system can vary. In particular aspects, the aerosol
precursor composition can be located near one end of the overall
article (e.g., within a cartridge body, which in certain
circumstances can be replaceable and disposable), which may be
configured to be positioned in relatively closer proximity to the
mouth of a user so as to maximize aerosol delivery to the user.
Other configurations, however, are not excluded. Generally, the
heating element can be positioned sufficiently near the aerosol
precursor composition so that heat from the heating element can
volatilize the aerosol precursor (and/or one or more flavorants,
medicaments, or the like that may likewise be provided for delivery
to a user) and form an aerosol for delivery to the user. When the
heating element heats the aerosol precursor composition, an aerosol
is formed, released, or generated in a physical form suitable for
inhalation by a consumer. It should be noted that the foregoing
terms are meant to be interchangeable such that reference to
release, releasing, releases, or released includes form or
generate, forming or generating, forms or generates, and formed or
generated. Specifically, an inhalable substance is released in the
form of a vapor or aerosol or mixture thereof. Additionally, the
selection of various aerosol delivery device components can be
appreciated upon consideration of the commercially available
electronic aerosol delivery devices, such as those representative
products listed above in the present disclosure.
[0073] The atomizer (i.e., an aerosol generation arrangement) 212
may comprise a first heating terminal 234a and a second heating
terminal 234b, a liquid transport element 238 and a heating element
240. In this regard, the reservoir and/or reservoir substrate 214
may be configured to hold an aerosol precursor composition. The
aerosol precursor composition, also referred to as a vapor
precursor composition, may comprise a variety of components in
different aspects. Such components may include, by way of example,
any of a polyhydric alcohol (e.g., glycerin, propylene glycol, or a
mixture thereof), nicotine, tobacco, tobacco extract, water,
flavorants, and combinations thereof.
[0074] The aerosol precursor, or vapor precursor composition, can
vary. Most preferably, the aerosol precursor composition is
comprised of a combination or mixture of various ingredients or
components. The selection of the particular aerosol precursor
components, and the relative amounts of those components used, may
be altered in order to control the overall chemical composition of
the mainstream aerosol produced by the aerosol generation
arrangement(s). Of particular interest are aerosol precursor
compositions that can be characterized as being generally liquid in
nature. For example, representative generally liquid aerosol
precursor compositions may have the form of liquid solutions,
viscous gels, mixtures of miscible components, or liquids
incorporating suspended or dispersed components. Typical aerosol
precursor compositions are capable of being vaporized upon exposure
to heat under those conditions that are experienced during use of
the aerosol generation arrangement(s) that are characteristic of
the present disclosure; and hence are capable of yielding vapors
and aerosols that are capable of being inhaled.
[0075] For aerosol delivery systems that are characterized as
electronic cigarettes, the aerosol precursor composition most
preferably incorporates tobacco or components derived from tobacco.
In one regard, the tobacco may be provided as parts or pieces of
tobacco, such as finely ground, milled or powdered tobacco lamina.
In another regard, the tobacco may be provided in the form of an
extract, such as a spray dried extract that incorporates many of
the water soluble components of tobacco. Alternatively, tobacco
extracts may have the form of relatively high nicotine content
extracts, which extracts also incorporate minor amounts of other
extracted components derived from tobacco. In another regard,
components derived from tobacco may be provided in a relatively
pure form, such as certain flavoring agents that are derived from
tobacco. In one regard, a component that is derived from tobacco,
and that may be employed in a highly purified or essentially pure
form, is nicotine (e.g., pharmaceutical grade nicotine).
[0076] As noted above, highly purified tobacco-derived nicotine
(e.g., pharmaceutical grade nicotine having a purity of greater
than 98% or greater than 99%) or a derivative thereof can be used
in the present invention. Representative nicotine-containing
extracts can be provided using the techniques set forth in U.S.
Pat. No. 5,159,942 to Brinkley et al., which is incorporated herein
by reference. In certain embodiments, the products of the invention
can include nicotine in any form from any source, whether
tobacco-derived or synthetically-derived. Nicotinic compounds used
in the products of the invention can include nicotine in free base
form, salt form, as a complex, or as a solvate. See, for example,
the discussion of nicotine in free base form in U.S. Pat. Pub. No.
2004/0191322 to Hansson, which is incorporated herein by reference.
At least a portion of the nicotinic compound can be employed in the
form of a resin complex of nicotine where nicotine is bound in an
ion exchange resin such as nicotine polacrilex. See, for example,
U.S. Pat. No. 3,901,248 to Lichtneckert et al.; which is
incorporated herein by reference. At least a portion of the
nicotine can be employed in the form of a salt. Salts of nicotine
can be provided using the types of ingredients and techniques set
forth in U.S. Pat. No. 2,033,909 to Cox et al. and Perfetti,
Beitrage Tabakforschung Int., 12, 43-54 (1983). Additionally, salts
of nicotine have been available from sources such as Pfaltz and
Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals,
Inc. Exemplary pharmaceutically acceptable nicotine salts include
nicotine salts of tartrate (e.g., nicotine tartrate and nicotine
bitartrate), chloride (e.g., nicotine hydrochloride and nicotine
dihydrochloride), sulfate, perchlorate, ascorbate, fumarate,
citrate, malate, lactate, aspartate, salicylate, tosylate,
succinate, pyruvate, and the like; nicotine salt hydrates (e.g.,
nicotine zinc chloride monohydrate), and the like. In certain
embodiments, at least a portion of the nicotinic compound is in the
form of a salt with an organic acid moiety, including, but not
limited to, levulinic acid as discussed in U.S. Pat. Pub. No.
2011/0268809 to Brinkley et al., which are incorporated herein by
reference.
[0077] The aerosol precursor composition may also incorporate
so-called "aerosol forming materials." Such materials may, in some
instances, have the ability to yield visible (or not visible)
aerosols when vaporized upon exposure to heat under those
conditions experienced during normal use of aerosol generation
arrangement(s) that are characteristic of the present disclosure.
Such aerosol forming materials include various polyols or
polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures
thereof). Aspects of the present disclosure also incorporate
aerosol precursor components that can be characterized as water,
saline, moisture or aqueous liquid. During conditions of normal use
of certain aerosol generation arrangement(s), the water
incorporated within those aerosol generation arrangement(s) can
vaporize to yield a component of the generated aerosol. As such,
for purposes of the current disclosure, water that is present
within the aerosol precursor composition may be considered to be an
aerosol forming material.
[0078] It is possible to employ a wide variety of optional
flavoring agents or materials that alter the sensory character or
nature of the drawn mainstream aerosol generated by the aerosol
delivery system of the present disclosure. For example, such
optional flavoring agents may be used within the aerosol precursor
composition or substance to alter the flavor, aroma and
organoleptic properties of the aerosol. Certain flavoring agents
may be provided from sources other than tobacco. Exemplary
flavoring agents may be natural or artificial in nature, and may be
employed as concentrates or flavor packages.
[0079] Exemplary flavoring agents include vanillin, ethyl vanillin,
cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach
and citrus flavors, including lime and lemon), maple, menthol,
mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender,
cardamom, ginger, honey, anise, sage, cinnamon, sandalwood,
jasmine, cascarilla, cocoa, licorice, and flavorings and flavor
packages of the type and character traditionally used for the
flavoring of cigarette, cigar and pipe tobaccos. Syrups, such as
high fructose corn syrup, also can be employed. Certain flavoring
agents may be incorporated within aerosol forming materials prior
to formulation of a final aerosol precursor mixture (e.g., certain
water soluble flavoring agents can be incorporated within water,
menthol can be incorporated within propylene glycol, and certain
complex flavor packages can be incorporated within propylene
glycol). However, in some aspects of the present disclosure, the
aerosol precursor composition is free of any flavorants, flavor
characteristics or additives.
[0080] Aerosol precursor compositions also may include ingredients
that exhibit acidic or basic characteristics (e.g., organic acids,
ammonium salts or organic amines). For example, certain organic
acids (e.g., levulinic acid, succinic acid, lactic acid, and
pyruvic acid) may be included in an aerosol precursor formulation
incorporating nicotine, preferably in amounts up to being equimolar
(based on total organic acid content) with the nicotine. For
example, the aerosol precursor may include about 0.1 to about 0.5
moles of levulinic acid per one mole of nicotine, about 0.1 to
about 0.5 moles of succinic acid per one mole of nicotine, about
0.1 to about 0.5 moles of lactic acid per one mole of nicotine,
about 0.1 to about 0.5 moles of pyruvic acid per one mole of
nicotine, or various permutations and combinations thereof, up to a
concentration wherein the total amount of organic acid present is
equimolar to the total amount of nicotine present in the aerosol
precursor composition. However, in some aspects of the present
disclosure, the aerosol precursor composition is free of any acidic
(or basic) characteristics or additives.
[0081] As one non-limiting example, a representative aerosol
precursor composition or substance can include glycerin, propylene
glycol, water, saline, and nicotine, and combinations or mixtures
of any or all of those components. For example, in one instance, a
representative aerosol precursor composition may include (on a
weight basis) about 70% to about 100% glycerin, and often about 80%
to about 90% glycerin; about 5% to about 25% water, often about 10%
to about 20% water; and about 0.1% to about 5% nicotine, often
about 2% to about 3% nicotine. In one particular non-limiting
example, a representative aerosol precursor composition may include
about 84% glycerin, about 14% water, and about 2% nicotine. The
representative aerosol precursor composition may also include
propylene glycol, optional flavoring agents or other additives in
varying amounts on a weight basis. In some instances, the aerosol
precursor composition may comprise up to about 100% by weight of
any of glycerin, water, and saline, as necessary or desired.
[0082] Representative types of aerosol precursor components and
formulations also are set forth and characterized in U.S. Pat. No.
7,217,320 to Robinson et al. and U.S. Pat. Pub. Nos. 2013/0008457
to Zheng et al.; 2013/0213417 to Chong et al. and 2014/0060554 to
Collett et al., the disclosures of which are incorporated herein by
reference. Other aerosol precursors that may be employed include
the aerosol precursors that have been incorporated in the VUSE.RTM.
product by R. J. Reynolds Vapor Company, the BLU.TM. product by
Lorillard Technologies, the MISTIC MENTHOL product by Mistic Ecigs,
and the VYPE product by CN Creative Ltd. Also desirable are the
so-called "smoke juices" for electronic cigarettes that have been
available from Johnson Creek Enterprises LLC.
[0083] The amount of aerosol precursor that is incorporated within
the aerosol delivery system is such that the aerosol generation
arrangement(s) provide acceptable sensory and desirable performance
characteristics. For example, it is highly preferred that
sufficient amounts of aerosol forming material (e.g., glycerin
and/or propylene glycol), be employed in order to provide for the
generation of a mainstream aerosol (visible or not visible) that in
many regards resembles the appearance of tobacco smoke. The amount
of the aerosol precursor composition within the aerosol generation
arrangement(s) may be dependent upon factors such as the number of
puffs desired per aerosol generation arrangement. Typically, the
amount of the aerosol precursor composition incorporated within the
aerosol delivery system, and particularly within the aerosol
generation arrangement(s), is less than about 2 g, generally less
than about 1.5 g, often less than about 1 g and frequently less
than about 0.5 g.
[0084] The reservoir substrate 214 may comprise a plurality of
layers of nonwoven fibers formed into the shape of a tube
encircling the interior of the outer body 216 of the cartridge body
200. Thus, liquid components, for example, can be sorptively
retained by the reservoir substrate 214. The reservoir substrate
214 is in fluid connection with the liquid transport element 238.
The liquid transport element 238 may be configured to transport
liquid (i.e., the aerosol precursor composition) from the reservoir
substrate 214 to the heating element 240 via capillary action.
Representative types of substrates, reservoirs or other components
for supporting the aerosol precursor composition are described in
U.S. Pat. No. 8,528,569 to Newton; and U.S. Pat. App. Pub. Nos.
2014/0261487 to Chapman et al and 2015/0059780 to Davis et al.; and
U.S. application Ser. No. 14/170,838; filed Feb. 3, 2014, to Bless
et al.; which are incorporated herein by reference. Additionally,
various wicking materials, and the configuration and operation of
those wicking materials within certain types of electronic
cigarettes, are set forth in U.S. Pat. App. Pub. No. 2014/0209105
to Sears et al.; which is incorporated herein by reference.
[0085] As illustrated, the liquid transport element 238 may be in
direct contact with the heating element 240. As further illustrated
in FIG. 1, the heating element 240 may comprise a wire defining a
plurality of coils wound about the liquid transport element 238. In
some instances, the heating element 240 may be formed by winding
the wire about the liquid transport element 238 as described in
U.S. Pat. App. Pub. No. 2014/0157583 to Ward et al., which is
incorporated herein by reference in its entirety. Further, in some
instances, the wire may define variable coil spacing, as described
in U.S. Pat. App. Pub. No. 2014/0270730 to DePiano et al., which is
incorporated herein by reference in its entirety. Various materials
configured to produce heat when an electrical current is applied
thereto may be employed to form the heating element 240. Example
materials from which the wire coil may be formed include Kanthal
(FeCrAl), Nichrome, molybdenum disilicide (MoSi.sub.2), molybdenum
silicide (MoSi), molybdenum disilicide doped with aluminum
(Mo(Si,Al).sub.2), graphite and graphite-based materials; and
ceramic (e.g., a positive or negative temperature coefficient
ceramic).
[0086] However, various other methods may be employed to form the
heating element 240, and various other aspects of heating elements
may be employed in the atomizer 212. For example, a stamped heating
element may be employed in the atomizer, as described in U.S. Pat.
App. Pub. No. 2014/0270729 to DePiano et al., which is incorporated
herein by reference in its entirety. Further to the above,
additional representative heating elements and materials for use
therein are described in U.S. Pat. No. 5,060,671 to Counts et al.;
U.S. Pat. No. 5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to
Deevi et al.; U.S. Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S.
Pat. No. 5,322,075 to Deevi et al.; U.S. Pat. No. 5,353,813 to
Deevi et al.; U.S. Pat. No. 5,468,936 to Deevi et al.; U.S. Pat.
No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 to Das; U.S. Pat. No.
5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to Hajaligol;
U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No. 5,573,692 to
Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the
disclosures of which are incorporated herein by reference in their
entireties. Further, chemical heating may be employed in other
aspects. A variety of heater components may also be used in
particular aspects of the present aerosol delivery device/system.
In various instances, one or more microheaters or similar solid
state heating elements may be used. Exemplary microheaters that may
be utilized are further described herein. Further microheaters and
atomizers incorporating microheaters suitable for use in the
presently disclosed devices/systems are described in U.S. Pat. App.
Pub. No. 2014/0060554 to Collett et al., which is incorporated
herein by reference in its entirety.
[0087] The first heating terminal 234a and the second heating
terminal 234b (e.g., positive and negative terminals) at the
opposing ends of the heating element 240 are configured to form an
electrical connection (which may be a removable or detachable
connection) with the control body 300 when the cartridge body 200
is connected thereto. Further, when the control body 300 is coupled
to the cartridge body 200, the electronic control component 208 may
form an electrical connection with the control body 300 through the
control component terminal 206. The control body 300 may thus
employ the electronic control component 208 to determine whether
the cartridge 200 is genuine and/or perform other functions.
Further, various examples of electronic control components and
functions performed thereby are described in U.S. Pat. App. Pub.
No. 2014/0096781 to Sears et al., which is incorporated herein by
reference in its entirety.
[0088] During use, a user may draw on the mouthpiece or
mouth-engaging end 220 of the cartridge body 200 of the aerosol
delivery system 100. This may pull air through an opening in the
control body 300 and/or in the cartridge body 200. For example, in
one instance, an opening may be defined between the coupler 302 and
the outer body 304 of the control body 300, as described in U.S.
Pat. App. Pub. No. 2014/0261408 to DePiano et al., which is
incorporated herein by reference in its entirety. However, the flow
of air may be received through other parts of the aerosol delivery
device/system 100 in other aspects. As noted above, in some aspects
the cartridge body 200 may include the flow tube 210. The flow tube
210 may be configured to direct the flow of air received from the
control body 300 to the heating element 240 of the atomizer
212.
[0089] A sensor in the aerosol delivery device/system 100 (e.g., a
puff or flow sensor in the control body 300) may sense the puff.
More generally, a sensor or detector may be implemented to control
of supply of electric power to the heating element 240 when aerosol
generation is desired (e.g., upon draw during use). As such, for
example, there is provided a manner or method for turning off the
power supply to the heating element 240 when the aerosol generation
is not desired during use, and for turning on the power supply to
actuate or trigger the generation of heat by the heating element
240 during draw. Additional representative types of sensing or
detection mechanisms, structure and configuration thereof,
components thereof, and general methods of operation thereof, are
described in U.S. Pat. No. 5,261,424 to Sprinkel, Jr.; U.S. Pat.
No. 5,372,148 to McCafferty et al.; and PCT WO 2010/003480 by
Flick; which are incorporated herein by reference. When the puff is
sensed, the control body 300 may direct current to the heating
element 240 through a circuit including the first heating terminal
234a and the second heating terminal 234b. Accordingly, the heating
element 240 may vaporize the aerosol precursor composition directed
to an aerosolization zone from the reservoir substrate 214 by the
liquid transport element 238. Thus, the mouthpiece 220 may allow
passage of air and entrained vapor (i.e., the components of the
aerosol precursor composition in an inhalable form, for example, as
an aerosol) from the cartridge body 200 to a consumer drawing
thereon. Various other details with respect to the components that
may be included in the cartridge body 200, are provided, for
example, in U.S. Pat. App. Pub. No. 2014/0261495 to Novak, III et
al., which is incorporated herein by reference in its entirety.
[0090] Various components of an aerosol delivery device/system can
be chosen from components described in the art and commercially
available. Reference is made for example to the reservoir and
heater system for controllable delivery of multiple aerosolizable
materials in an electronic smoking article disclosed in U.S. Pat.
App. Pub. No. 2014/0000638 to Sebastian et al., which is
incorporated herein by reference in its entirety. Note further that
portions of the cartridge body 200 illustrated in FIG. 1 are
optional. In this regard, by way of example, the cartridge body 200
may not necessarily include the flow tube 210, the control
component terminal 206, and/or the electronic control component
208, in some instances.
[0091] One particular aspect of the present disclosure is
illustrated, for example, in FIG. 3. In such instances, the
cartridge body 200 may further incorporate a second aerosol
generation arrangement 400 (the atomizer 212 being considered "a
first aerosol generation arrangement") disposed in the outer body
216, longitudinally between the atomizer 212 and the mouthpiece or
mouth-engaging end 220 of the cartridge body 200. In some aspects,
the second aerosol generation arrangement 400 is generally porous
or otherwise configured to allow the passage of air therethrough.
In some particular instances, the second aerosol generation
arrangement 400 may include one or more aerosol-generating elements
425 that may be comprised of at least one or a plurality of pellets
or beads or other appropriate elements or combinations thereof. In
some instances, the at least one or a plurality of pellets or beads
or other appropriate elements or combinations thereof forming the
aerosol-generating element(s) 425 may be coaxially circumscribed by
a generally tubular-shaped heat conductive member (not shown), if
necessary, and/or circumscribed or otherwise jacketed by insulation
(e.g., a non-woven mat or layer of glass filaments or fibers), or
other suitable material (not shown).
[0092] The overall configuration of the second aerosol generation
arrangement 400 within the cartridge body 200 of the aerosol
delivery device/system 100 can be considered to be generally
cylindrical in nature. Representative preferred beads or other
objects may be produced from a formulation that incorporates
tobacco (e.g., particulate tobacco), components of tobacco and/or
materials that are otherwise derived from tobacco (e.g., tobacco
extracts such as aqueous tobacco extracts or nicotine derived from
tobacco including pharmaceutical grade nicotine). The beads most
preferably incorporate flavors and a visible or non-visible aerosol
forming material (e.g., glycerin or other material that generates a
visible vapor that resembles smoke). That is, components of the
beads are preferably configured to act as substrate components for
volatile flavors, vapor forming materials, moisture or other
liquid(s), and/or aerosol forming materials that are carried
thereby. In some aspects, the aerosol-generating element(s) 425 may
include or otherwise comprise or be configured as, for example,
marumarized tobacco beads of varying shapes and sizes, a monolith
of bonded (e.g., sintered) beads; a porous monolith; a single
porous structure; a honeycomb monolith; a single piece of a porous
material; beads of extruded tobacco; beads of porous material
containing tobacco extract (e.g., calcium carbonate, ceramic, or
the like); reconstituted tobacco shreds; expanded tobacco shreds;
extruded rods of various materials (including hollow cylinders and
slotted rods) containing tobacco flavors; shavings, granules,
capsules, and/or microcapsules of various materials containing
tobacco flavors or other substances, whether in a liquid or other
form; and treatments or combinations thereof.
[0093] In general, as used herein, the terms "pellets" and "beads"
are meant to include beads, pellets, or other discrete small units
or pieces of that may include (in addition to those otherwise
disclosed herein), for example, carbon pieces, extruded carbon
pieces cut into pellets, ceramic beads, marumarized tobacco pieces,
and the like, or combinations thereof. For example, granules,
pellets or beads can be generally cylindrical or spherical extruded
or compressed granules, pellets or beads comprised of a moistened
mixture or slurry of milled tobacco lamina, fillers (e.g., granular
calcium carbonate), flavors, visible aerosol forming materials and
binders (e.g., carboxy methylcellulose) that are formed, cut or
spun to the desired size and shape, and then dried to retain the
desired configuration. However, such "pellets" or "beads" may
comprise any suitable elements, or combination of elements, meeting
the preferred aspects as disclosed herein. For example, some or all
of the beads or pellets can comprise spherical capsules that are
heat sensitive, so that when included in the aerosol-generating
element and exposed to heat, the rupture or decomposition thereof
causes the release of glycerin, propylene glycol, water, saline,
tobacco flavor and/or nicotine or other substances or additives.
Also, the beads can comprise ceramic or absorbent clay or silica or
absorbent carbon to hold and release an aerosol former. Further, in
some aspects, the beads/pellets may comprise a heat conductive
material such as, for example, heat conductive graphite, heat
conductive ceramic, a metal, tobacco cast on foil, a metal or other
suitable material impregnated with appropriate aerosol-generating
substances such as glycerin and flavor(s), or a suitable cast sheet
material appropriately formed into the desired beads/pellets.
[0094] In one particular example, the beads/pellets (particles) may
be comprised, by weight, of between about 15% and about 60% of
finely milled tobacco particles (e.g., a blend of Oriental, burley
and flue-cured tobaccos, essentially all Oriental tobacco,
essentially all burley tobacco, or essentially all flue-cured
tobacco), between about 15% and about 60% of finely milled
particles of calcium carbonate (or finely milled clay or ceramic
particles), between about 10% and about 50% of glycerol (and
optionally a minor amount of flavors), between about 0.25% and
about 15% of a binder (preferably carboxymethylcellulose, guar gum,
potassium, or ammonium alginate), and between about 15% and about
50% of water. In another example, the beads/pellets (particles) may
be comprised of about 30% of finely milled tobacco particles (e.g.,
a blend of Oriental, burley and flue-cured tobaccos, essentially
all Oriental tobacco, essentially all burley tobacco, or
essentially all flue-cured tobacco), about 30% of finely milled
particles of calcium carbonate (or finely milled clay or ceramic
particles), about 15% of glycerol (and optionally a minor amount of
flavors), about 1% of a binder (preferably carboxymethylcellulose,
guar gum, potassium, or ammonium alginate), and about 25% of water.
In such examples, the particles may be compressed to hold the
glycerol and, upon compression, may form a porous matrix that
facilitates migration of the aerosol generating components to
promote efficient aerosol formation. The manner by which the
aerosol forming material is contacted with the substrate material
can vary. The aerosol forming material can be applied to a formed
material, can be incorporated into processed materials during
manufacture of those materials, or can be endogenous to that
material. Aerosol-forming material, such as glycerin, can be
dissolved or dispersed in an aqueous liquid, or other suitable
solvent or liquid carrier, and sprayed onto that substrate
material. See, for example, U.S. Patent Appl. Pub. No. 2005/0066986
to Nestor et al. and 2012/0067360 to Conner et al.; which are
incorporated herein by reference. The calcium carbonate or other
inorganic filler assists in creating porosity within the particles,
and may also function to absorb heat which may, in some instances
limit or otherwise prevent scorching of the aerosol generating
components, as well as assisting in and promoting aerosol
formation. See also, for example, those types of materials set
forth in U.S. Pat. No. 5,105,831 to Banerjee, et al., and U.S. Pat.
App. Pub. Nos. 2004/0173229 to Crooks et al.; 2011/0271971 to
Conner et al.; and 2012/0042885 to Stone et al.; which are
incorporated herein by reference.
[0095] In one embodiment, the aerosol-generating elements 425, such
as those in the form of beads or pellets, can be smoke-treated to
impart smoky flavor or aroma. For example, the beads or pellets can
be prepared and then subjected to smoke from a combustible source,
such as a wood source (e.g., wood selected from hickory, maple,
oak, apply, cherry, or mesquite). The beads or pellets can be
treated with the smoke for a time sufficient to impart the desired
smoky flavor or aroma, with an exemplary time range being about 5
to about 45 minutes. The manner in which the beads or pellets are
contacted with smoke can vary, with one example involving heating
wood chips in a container until smoke is produced (e.g., heating
wood chips to a temperature of about 350-400.degree. F.) and
placing the beads or pellets to be treated within a closed
environment with the smoke produced by the wood chips.
[0096] The composition of the aerosol precursor composition of the
first aerosol generation arrangement and the composition of the
aerosol-generating elements of the second aerosol generation
arrangement are advantageously selected so as to complement one
another to produce a desirable sensory experience. In certain
embodiments, for example, the nicotine content of the aerosol
precursor composition and the aerosol-generating elements are
selected such that either or both of the aerosol precursor
composition and the aerosol-generating elements may contain
nicotine or a nicotinic compound or may be viewed as substantially
or completely free of nicotine or a nicotinic compound. In other
words, all nicotine content can be within the aerosol-generating
elements or all nicotine content can be in the aerosol precursor
composition or both compositions can include nicotine in some
form.
[0097] In some aspects, where the aerosol-generating elements 425
comprise, for example, beads or pellets cast or extruded from
materials of the various types set forth above (i.e., a graphite
bead including tobacco extract and glycerin), while "damp" or
otherwise before drying, may be rolled, for example, between
adjacent roller elements, to flatten the shape of the respective
beads/pellets. In some instances, the materials of the various
types set forth above may be extruded in the form of filamentary
strands, wherein the strands may be gathered to form a cylindrical
rod or other suitably shaped material (i.e., relative in size to
the beads/pellets used to otherwise form the aerosol generation
segment) for application in the second aerosol generation
arrangement 400. Upon drying, the flattened beads/pellets may then
be shredded or otherwise processed to form, for example, strands,
flakes, or other filler configuration that is flat or includes a
planar segment that inhibits or prevents roll. Any random
configurations resulting from the shredding process may be
sufficient. In such instances, the flattened and shredded
beads/pellets may then be included in the aerosol-generating
element(s) 425, and the irregular or random configurations thereof
may promote, for instance, a plurality of interstitial air spaces
throughout the aerosol-generating element(s) 425, wherein the
interstitial air spaces may, in turn, promote heat transfer with
the individual objects within the aerosol-generating element(s)
425. That is, heating of the air in the interstitial spaces within
the second aerosol generation arrangement 400 may expose more of
the aerosol-generating element(s) 425 to the heat from the heating
element 240, and thus result in enhanced or otherwise improved
heating of the aerosol-generating element(s) 425. In other
instances, the heat and the first aerosol (i.e., the combination
thereof) produced by the heating element 240/atomizer 212 are
directed through the porous matrix formed by the aerosol-generating
element(s) 425, wherein the heated vapors passing through and
heating the porous aerosol-generating element(s) 425 promotes, for
example, elution (i.e., liquid, fluid, or particulate extraction;
steam distillation; etc.) of an enhancement substance (i.e., a
flavorant or other additive) from the aerosol-generating element(s)
to the first aerosol, or otherwise promotes the enhancement
substance being entrained in, imparted to, reacted with, or
otherwise interacted with the first aerosol. The interaction
between the enhancement substance and the first aerosol may, for
example, change or alter the first aerosol, mix the enhancement
substance with the first aerosol to form an enhanced aerosol or
aerosol mixture, or facilitate a reaction that produces a different
aerosol. In such instances, increased interstitial spaces within
the aerosol-generating element(s) 425 may promote this interaction
process through the second aerosol generation arrangement 400.
[0098] In some aspects, the beads/pellets may originate from a
tobacco material cast on a foil/paper laminate. More particularly,
the tobacco material may comprise, for example, a slurry including
reconstituted tobacco, glycerin, and a binder material. Such a
tobacco material is disclosed, for example, in U.S. Pat. No.
5,101,839 to Jakob et al. and U.S. Patent Application No.
2010/0186757 to Crooks et al., which are incorporated herein by
reference. In addition, the slurry can incorporate granular
inorganic material (i.e., calcium carbonate). The slurry is cast
unto a paper element of a foil-paper laminate, such as disclosed,
for example, in U.S. Pat. No. 8,678,013 to Crooks et al. and U.S.
Pat. No. 7,647,932 to Cantrell et al., which is also incorporated
herein by reference, and the assembled cast sheet product is then
dried, for instance by the application of heat (i.e., by heated
air, microwave drying, etc.). The paper element may have, for
instance, a particular porosity or texture to promote an intimate
contact and interaction with the slurry, for instance, over direct
contact between the slurry and the foil. However, the exemplary
aspect presented herein does not preclude casting the tobacco
material (i.e., slurry) directly on a metal foil or other suitable
thin film heat conductor. Once such a laminate is cast, the dried
cast sheet (i.e., the foil/paper/tobacco material) may be shredded,
diced, or otherwise separated into a plurality of cast sheet
portion elements, wherein each such element preferably includes a
portion of the tobacco material (i.e., the substrate) intimately
interacted with a portion of the paper element which, in turn, is
in intimate contact with a portion of the foil element of the
foil-paper laminate. A plurality of the cast sheet portion elements
may then be included in the aerosol-generating element(s) 425
forming the second aerosol generation arrangement 400.
[0099] One skilled in the art will appreciate that, in some
circumstances, the cast sheet portion elements included in the
aerosol-generating element(s) 425 may cooperate to promote improved
heat transfer to the tobacco material forming a portion of those
cast sheet portion elements or otherwise to abutting elements. More
particularly, in some instances, heat transfer from the heating
element 240 to the tobacco material included in the
aerosol-generating element(s) 425 may be limited past any direct
interface therebetween, with the heat-conducting strip forming an
additional mechanism for conducting heat from the heating element
240 for heating the outer elements included in the
aerosol-generating element(s) 425 and any aerosol-generating
element(s) in contact therewith. In aspects including the cast
sheet portion elements included in the aerosol-generating
element(s) 425, the heat-conductive portions of the foil element
associated with the cast sheet portion elements may form, for
example, a plurality of additional heat conductive pathways. That
is, the cast sheet portion elements used as all or part of the
aerosol-generating element(s) 425 may provide additional
heat-conductive elements interspersed throughout the
aerosol-generating element(s) 425 within the second aerosol
generation arrangement 400 to thereby enhance or otherwise improve
heat transfer to and between the aerosol-generating elements. In
achieving such an aspect, it may be further advantageous to shred
or process a substrate material implemented in, for example, the
cast tobacco sheet substrate material forming the substrate
incorporated within the types of cigarettes commercially marketed
under the trade name "Eclipse" by R. J. Reynolds Tobacco Company,
as disclosed, e.g., by U.S. Pat. No. 5,469,871 to Barnes et al.
[0100] The pellets or other elements may have smooth, regular outer
shapes (e.g., spheres, cylinders, ovoids, or the like) and/or they
may have irregular outer shapes (e.g., shredded pieces, flakes, or
the like). The aerosol-generating element(s) 425, discretely or
cumulatively, may have a generally cylindrical form within the
second aerosol generation arrangement 400, and may in some
instances include a collection of about 800 to about 1200 generally
spherical beads, each having a mean or nominal diameter of about
0.05 mm to about 4 mm (e.g., about 1 mm.sup.3 in volume, in one
example), with the beads/pellets cumulatively weighing about 450 mg
to about 750 mg (e.g., 600 mg.+-.25%, in one example).
[0101] In one method of preparation, substantially spherical beads
or pellets of aerosol-generating elements can be formed by first
mixing together the desired composition followed by extrusion of
the composition to form an extrudate. The extrudate is then
processed in a spheronizer (e.g., such as spheronizers available
from Caleva Process Solutions Ltd. or LCI Corporation) to produce
variously-sized spheroids that can be processed through a series of
screens to provide the desired size range, such as the sizes noted
above.
[0102] The aerosol-generating elements can be selected so as to
have relatively uniform mean diameter or a range of sizes of
aerosol-generating elements can be included in the second aerosol
generation arrangement 400. Where different size ranges are used in
the same device, the differently sized elements can be arranged in
a gradient or layers within the second aerosol generation
arrangement 400 or the differently sized elements can be randomly
mixed within the aerosol generation arrangement 400. Although not
bound by any particular theory of operation, using
aerosol-generating elements of different sizes in the same aerosol
generation arrangement 400 can provide advantageous pressure drop
changes in the device and/or provide advantageous sensory
characteristics based on the different rates of evaporation
provided by the differently sized elements.
[0103] Preferably, sufficient beads are loaded into the second
aerosol generation arrangement 400 to provide at least about 95
percent of maximum fill, with beads and/or other suitable elements.
It is advantageous to avoid large open pockets within the aerosol
generation arrangement 400 that could allow air traveling through
the aerosol generation arrangement to substantially bypass
interaction with the aerosol-generating elements 425.
[0104] In some instances, a plurality of forms of the
aerosol-generating element(s) 425 may be selected (e.g.,
aerosol-generating element(s) having different compositions) and
each selected form of the aerosol-generating elements then
subsequently included in the second aerosol generation arrangement
400. In other instances, the selected forms of the
aerosol-generating elements may be combined, prior to inclusion in
the second aerosol generation arrangement 400, to produce an
aerosol-generating element mixture, and the mixture then
subsequently included in the second aerosol generation arrangement
400.
[0105] The atomizer or first aerosol generation arrangement 212 and
the second aerosol generation arrangement 400 may be physically
separate from one another and/or comprise discrete units or
segments within the cartridge body 200. In some instances, as
shown, those segments may be positioned/disposed so that the
downstream end (toward the mouthpiece or mouth-engaging end 220 of
the cartridge body 200) of the atomizer or first aerosol generation
arrangement 212 is adjacent to the upstream end of the second
aerosol generation segment 400 (i.e., the back face of the
aerosol-generating element(s) 425). That is, the atomizer or first
aerosol generation arrangement 212 and the second aerosol
generation segment 400 may be axially aligned in a serial
end-to-end relationship, in some instances adjacent to or abutting
one another. For example, in some instances, though physically
discrete and positioned downstream from the atomizer or first
aerosol generation arrangement 212, it may be desirable for the
aerosol-generating element(s) 425 of the second aerosol generation
arrangement 400 to physically contact the heating element 240 at
the downstream end of the atomizer or first aerosol generation
arrangement 212. Alternatively, those segments 212, 400 can be
slightly spaced apart from one another such that the respective
ends or components thereof 240, 425 are not necessarily in physical
contact with the other (i.e., to prevent scorching). One skilled in
the art will appreciate that, in some aspects, the second aerosol
generation arrangement 400 may comprise more than one section or
portion of aerosol-generating element(s) 425.
[0106] In some instances, an additional segment, spacer element, or
separating element (otherwise referred to herein as "a first
separating element"), acting as a spacer or screen (see, e.g.,
element 450 in FIG. 3) may be positioned generally perpendicular to
the longitudinal axis of the cartridge body 200, wherein the first
separating element 450 may provide for physical separation of those
two segments 212, 400 while, in some instances, maintaining a heat
conductive relationship therebetween. The first separating element
450 may, in some instances, not be conductive to heat and, in other
instances, the first separating element 450 may not be electrically
conductive. That is, the first separating element 450 may, but not
necessarily, be heat-conductive and/or arranged to conduct heat
from the heating element 240 of the atomizer/first aerosol
generation arrangement 212 to the second aerosol generation
arrangement 400, wherein the aerosol-generating element(s) 425 may
be responsive to the heat and/or accompanying first aerosol to form
a second aerosol. Further, in some instances, the first separating
element 450 may be air permeable or otherwise configured to permit
airflow therethrough, such that a first aerosol generated by the
atomizer/first aerosol generation arrangement 400 can pass
therethrough in the downstream direction. The first separating
element 450 may thus also be configured and/or arranged so as to
maintain the aerosol-generating element(s) 425 within the second
aerosol generation arrangement 400 and separate from the
atomizer/first aerosol generation arrangement 212. In still further
instances, the first separating element 450 may be configured as a
spacer (i.e., extending in a longitudinal direction along the
cartridge body 200 so as to define a thickness) for separating the
aerosol-generating element(s) 425 from the heating element 240 of
the atomizer/first aerosol generation arrangement 212, for example,
to minimize or prevent the aerosol-generating element(s) (i.e.,
beads) 425 from being scorched or burned by the heat from the
heating element 240. In some instances, the first separating
element 450 may also be configured as an insulator (i.e., not
electrically conductive) to prevent short-circuiting of the heating
element 240 in the event of contact therebetween.
[0107] Typically, the first separating element 450 is generally
cylindrical or discoid in shape and of one piece construction, and
is air permeable to allow the passage of drawn air through. The
first separating element 450 may be heat conductive in nature, so
that heat generated by the heating element 240 can be readily
transported to the second aerosol generation arrangement 400. The
length (thickness) of the first separating element 450 can vary,
and typically extends from about less than 1 mm up to about 10 mm.
In some instances, the relative longitudinal placement of the first
separating element 450 within the outer body 216, spaces the
interface of the first separating element 450 with the
aerosol-generating element(s) 425 at between about 1 mm and up to
about 20 mm (i.e., 7 mm in one example) away from the heating
element 240. Typically, the first separating element 450 is
comprised of a heat resistant material, such as a porous ceramic, a
porous graphite material, a metal (i.e., stainless steel, brass,
copper, etc.) mesh or screen, a high temperature-resistant plastic
or the like. In some instances, the first separating element 450
may include, for example, longitudinally-extending air passageways
formed during design/manufacture, drilled therethrough, or
otherwise molded, extruded, printed (i.e., a 3D printed element
using a 3D printer), or shaped into the spacer element during
manufacture thereof. If desired, the first separating element 450
can incorporate catalytic materials, such as materials
incorporating cerium or copper ions or oxides and/or salts of
cerium and copper ions. See, for example, U.S. Pat. Nos. 8,469,035
and 8,617,263 to Banerjee et al. and U. S. Pat. Appl. Pub. No.
2007/0215168 to Banerjee et al., which are incorporated herein by
reference.
[0108] In instances where the aerosol-generating element(s) 425 may
be circumscribed by an insulation layer, a layer of heat conductive
material (e.g., a layer or strip comprised of metal foil) may be
provided therebetween (not shown). That is, representative
aerosol-generating element(s) 425 include a plurality of pellets
and/or other appropriate elements that can be circumscribed along
its length by a layer of strip of metal foil. A representative
metal foil is, for example, aluminum foil having a thickness of
about 0.01 mm to about 0.05 mm. Preferably, the metal foil extends
along the entire length of the outer co-axial surface of the
aerosol-generating element(s) 425; and it may be preferred that the
metal foil extends over (i.e., at least partially overlaps) the
first separating element 450. The heat conductive material can be
provided by means other than the use of metal foil. For example,
the layer of metal foil can be replaced by a metal mesh or screen.
Alternatively, the metal foil can be replaced by a heat conductive
fabric, such as a layer or sheet of graphite fibers or heat
conductive ceramic fibers. Alternatively, the heat conductive
material can be provided by application of a heat conductive ink,
such as a coating of ink or paint that incorporates metal
particles, graphite fibers, particles of heat conductive ceramic
materials, or the like.
[0109] FIG. 7 provides an example of a further embodiment of a
second aerosol generation arrangement 400 positioned within the
outer body or tubular member 216 (downstream of the first aerosol
generation arrangement 212, which is not shown). As shown, the
aerosol-generating elements 425 are placed between separating
elements, 450 and 475, which serve to retain the aerosol-generating
elements 425 in place and to allow airflow therethrough. As noted
previously, the separating elements, 450 and 475, can be porous
elements (e.g., mesh screens or perforated metal plates) with pore
sizes selected to as to retain the aerosol-generating elements 425
within the second aerosol generation arrangement 400.
[0110] As shown, the second aerosol generation arrangement 400 can
further include a separate aerosol-generating element housing 460
in the form, for example, of a tubular housing with an open end
facing the mouthpiece 220, which as shown, can engage the open end
of the tubular housing and can be affixed thereto by a press fit or
other known means. The housing 460 can include an end 470 opposite
the mouthpiece 220, which as shown, can be perforated to allow
airflow therethrough. The housing 460 can be constructed of any
suitable material including metal (e.g., stainless steel) or
plastic. The separating elements, 450 and 475, can be press fit or
otherwise engaged with the housing 460, and the separating element
475 closest to the mouthpiece 220 can be affixed to the mouthpiece
if desired. In certain embodiments, the separating elements, 450
and 475, are incorporated into the housing 460 during the molding
process that forms the housing. The design of FIG. 7 is
particularly well-suited for embodiments of the invention wherein
the second aerosol generation arrangement 400 is intended to be
permanently affixed to the remainder of the cartridge body 200,
rather than separately removable or disposable.
[0111] Alternatively, in embodiments where the second aerosol
generation arrangement 400 is adapted for removal from the
cartridge body 200 as a separate unit, the design of FIG. 8 is
advantageous. As shown, in the embodiment of FIG. 8, the second
aerosol generation arrangement 400 is formed as a separate unit
with a separate housing body 520, which is attached (e.g., through
crimping or other means) to a first connector 540. Together, the
housing body 520 and first connector 540 form a cavity for the
aerosol-generating elements 425. As with the embodiment of FIG. 7,
the aerosol-generating elements 425 are placed between separating
elements, 450 and 475, which serve to retain the aerosol-generating
elements 425 in place and to allow airflow therethrough. Similar to
the embodiment of FIG. 7, the separating elements, 450 and 475, can
be press fit or otherwise engaged with the surrounding portions of
the first connector 540 or housing body 520, respectively, and can
be incorporated into these surrounding portions during a molding
process. The downstream separating element 475 is also optionally
affixed to the mouthpiece 220.
[0112] The first connector 540 of the second aerosol generation
arrangement 400 is adapted for engagement with a second connector
560 that is affixed (e.g., through press fit or other means) to the
outer body or tubular member 216 housing the first aerosol
generation arrangement 212 (not shown). The second connector 560
has an end facing the first connector 540 that enables the user to
removably affix the second aerosol generation arrangement 400 to
the cartridge body 200, such as through a threaded engagement or
other connection means. As shown, the second connector 560 is
porous to allow airflow from the first aerosol generation
arrangement 212 to enter the second aerosol generation arrangement
400. The second aerosol generation arrangement 400 of this
embodiment is cooperatively engaged with the mouthpiece 220 in a
manner similar to FIG. 7.
[0113] In some aspects, another spacer element, or another
separating element (otherwise referred to herein as "a second
separating element"), acting as a spacer or screen (see, e.g.,
element 475 in FIG. 3) may be positioned generally perpendicular to
the longitudinal axis of the cartridge body 200, wherein the second
separating element 475 may provide for physical separation of the
second aerosol generation arrangement 400 from the mouthpiece or
mouth-engaging end 220 of the cartridge body 200. That is, the
second separating element 475 may, but not necessarily, be
heat-conductive and/or arranged to conduct heat from the second
aerosol generation arrangement 400 and through the mouthpiece or
mouth-engaging end 220 of the cartridge body 200. However, the
second separating element 475 may be air permeable or otherwise
configured to permit airflow therethrough, such that a first
aerosol generated by the atomizer/first aerosol generation
arrangement 212 and/or a second aerosol generated by the second
aerosol generation arrangement 400, can pass therethrough in the
downstream direction and through the mouthpiece or mouth-engaging
end 220 of the cartridge body 200. The second separating element
475 may thus also be configured and/or arranged so as to maintain
the aerosol-generating element(s) 425 within the second aerosol
generation arrangement 400, without loss of any of the
aerosol-generating element(s) through the mouthpiece or
mouth-engaging end 220 of the cartridge body 200.
[0114] In some aspects, in the alternative to discrete first and
second separating elements 450, 475 being implemented in addition
to the aerosol-generating element(s) 425, the second aerosol
generation arrangement 400 may comprise a cartridge 500 (see, e.g.,
FIG. 4) having an elongate tubular body 525 and opposed end members
550, 575, wherein each of the end members 550, 575 may be
heat-conductive and/or air permeable in a similar manner to the
first and second separating elements 450, 475. The elongate tubular
body 525 may thus be further configured to receive the
aerosol-generating element(s) 425 and to cooperate with the opposed
end members 550, 575 to contain the aerosol-generating element(s)
425 therein. The assembled cartridge 500 may thus be configured to
be received as a unit (forming the second aerosol generation
arrangement 400) by the outer body or tubular member 216 of the
cartridge body 200.
[0115] In use, the mouthpiece or mouth-engaging end 220 of the
cartridge body 200 of the aerosol delivery system 100 is inserted
into the mouth of the user. The atomizer/first aerosol generation
arrangement 212 is then actuated, for example, by the user drawing
(e.g., a suction) on the mouthpiece or mouth-engaging end 220 of
the cartridge body 200. The heating element 240 and the liquid
transport element 238 are configured so as to be in a heat exchange
relationship. That is, the heat generated by the heating element
240 acts to heat the aerosol precursor composition carried by the
liquid transport element 238 to produce a first aerosol. The heat
generated by the heating element 240 and the first aerosol are then
drawn into engagement with and through the second aerosol
generation arrangement 400 (i.e., through the aerosol-generating
element(s) 425) toward the inhalation hole defined by the
mouthpiece or mouth-engaging end 220. In some instances, the heat
from the heating element 240 may interact with the
aerosol-generating element(s) 425 to generate a second aerosol. The
second aerosol may interact or mix with the first aerosol to form a
tertiary aerosol, the tertiary aerosol being the aerosol delivered
to the user by way of the mouthpiece 220 in response to the draw
imparted thereto by the user. In some instances, the interaction
between the heat and/or the first aerosol and the
aerosol-generating element(s) 425 may cause an enhancement
substance to be imparted to the first aerosol so as to produce an
enhanced aerosol. For example, a medicament adsorbed on the
aerosol-generating element(s) 425 may react with the first aerosol
and/or the heat, or otherwise be de-adsorbed from the
aerosol-generating element(s) 425 by the first aerosol and/or the
heat, and combine with the first aerosol to form the enhanced
aerosol. In still other instances, the aerosol-generating
element(s) 425 may be configured such that interaction of the first
aerosol therewith causes heat to be drawn away from the first
aerosol (i.e., cooling of the first aerosol). When appropriately
implemented by the user, at least the first aerosol generated by
the atomizer 212 and affected by the second aerosol generation
arrangement 400 aerosol are generated and drawn into the mouth of
the user.
[0116] The components of the second aerosol generation arrangement
400 and/or the aerosol-generating element(s) 425 therein can vary.
In general, the second aerosol generation arrangement 400 and/or
the aerosol-generating element(s) 425 therein may incorporate
components that can be vaporized, aerosolized or entrained in air
drawn through the aerosol delivery system 100 during use. Most
preferably, those components, by themselves or in cooperation with
the first aerosol produced by the first aerosol generation
arrangement 212, provide sensory and organoleptic effects, such as
aroma, flavor, mouthfeel, visible aerosol sensations, and the like.
Examples of components of the first and/or second aerosol
generation arrangement 212, 400 that are drawn into the mouth of
the user during draw include water (e.g., as water vapor), visible
or not visible aerosol forming materials (e.g., glycerin), various
volatile flavors (e.g., vanillin and menthol), volatile components
of tobacco (e.g., nicotine), and the like.
[0117] A preferred aerosol-forming material produces an aerosol
(whether visible or not) upon the application of sufficient heat
thereto, or otherwise through the action of aerosol forming
conditions using components of the aerosol delivery system. A
preferred aerosol-forming material produces a visible aerosol that
can be considered to be "smoke-like." A preferred aerosol-forming
material is chemically simple, relative to the chemical nature of
the smoke produced by burning tobacco. A preferred visible
aerosol-forming material is a polyol, and exemplary preferred
aerosol forming materials include glycerin, propylene glycol, and
mixtures thereof. If desired, aerosol forming materials can be
combined with other liquid materials, such as water. For example,
aerosol forming material formulations can incorporate mixtures of
glycerin and water, or mixtures of propylene glycol and water. See,
for example, the various aerosol forming materials referenced in
U.S. Pat. No. 8,678,013 to Crooks et al., which is incorporated
herein by reference.
[0118] The aerosol forming materials are carried or supported by
substrate materials so as to maintain those aerosol materials
within the desired region of the smoking article. Exemplary
substrate materials, and exemplary formulations incorporating
aerosol-forming materials, are set forth in U.S. Pat. No. 4,793,365
to Sensabaugh et al.; U.S. Pat. No. 4,893,639 to White; U.S. Pat.
No. 5,099,861 to Clearman et al.; U.S. Pat. No. 5,101,839 to Jakob
et al.; U.S. Pat. No. 5,105,836 to Gentry et al.; U.S. Pat. No.
5,159,942 to Brinkley et al.; U.S. Pat. No. 5,203,355 to Clearman
et al.; U.S. Pat. No. 5,271,419 to Arzonico et al.; U.S. Pat. No.
5,327,917 to Lekwauwa et al.; U.S. Pat. No. 5,396,911 to Casey, III
et al.; U.S. Pat. No. 5,533,530 to Young et al.; U.S. Pat. No.
5,588,446 to Clearman; U.S. Pat. No. 5,598,868 to Jakob et al.; and
U.S. Pat. No. 5,715,844 to Young et al.; and U.S. Patent
Application Pub. No. 2005/0066986 to Nestor et al.; which are
incorporated herein by reference. See, also, Chemical and
Biological Studies on New Cigarette Prototypes that Heat Instead of
Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988).
Exemplary substrate materials have been incorporated within the
types of cigarettes commercially marketed under the trade names
"Premier" and "Eclipse" by R. J. Reynolds Tobacco Company.
[0119] In some instances, the aerosol delivery system described
with reference to FIG. 1 may be used in much the same manner as
commercially marketed e-cigarettes. As a result, when smoked, a
preferred aerosol delivery system 100 of the types disclosed herein
may yield visible mainstream aerosol resulting principally from
volatilized components of the first and second aerosol generation
arrangements 212, 400, and that visible aerosol resembles in many
regards the mainstream tobacco smoke of a traditional type of
cigarette that burns tobacco cut filler.
[0120] In another example, substantially the entirety of the
cartridge body 200 may be formed from one or more carbon materials
(see, e.g., FIG. 5), which may provide advantages over other
cartridge body configurations disclosed herein in terms of
biodegradability and absence of wires. In this regard, the heating
element may comprise carbon foam, the reservoir may comprise
carbonized fabric, and graphite may be employed to form an
electrical connection with the battery and controller. Examples of
a carbon-based cartridge body are provided in U.S. Pat. App. Pub.
Nos. 2015/0059780 to Davis et al. or 2013/0255702 to Griffith et
al., which are incorporated herein by reference in its entirety. In
some instances, the incorporation of the second aerosol generation
arrangement disclosed herein may also be applicable to such a
carbon-based cartridge body. For example, as shown in FIGS. 6A and
6B, the portion 625 (see, e.g., FIG. 6A) of the cartridge element
600 disposed toward the mouthpiece of the cartridge body may be
configured or otherwise altered (see, e.g., FIG. 6B) so as to
receive one or more of the aerosol-generating element(s) 425 of the
types disclosed herein. In the alternative, a pre-assembled
cartridge including such aerosol-generating element(s) 425 may be
implemented, or the cartridge element 600 and/or the outer body
receiving the cartridge element 600 may be configured to receive
the first and second separating elements having the
aerosol-generating elements therebetween, as otherwise disclosed
herein.
[0121] Many modifications and other aspects of the disclosures set
forth herein will come to mind to one skilled in the art to which
these disclosures pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, those of skill in the art will appreciate
that embodiments not expressly illustrated herein may be practiced
within the scope of the present disclosure, and features described
herein for different embodiments may be combined with each other
and/or with currently-known or future-developed technologies while
remaining within the scope of the claims presented here. Therefore,
it is to be understood that the disclosures are not to be limited
to the specific aspects disclosed and that equivalents,
modifications, and other aspects are intended to be included within
the scope of the appended claims. Although specific terms are
employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.
* * * * *