U.S. patent application number 16/564902 was filed with the patent office on 2019-12-26 for smoking articles and use thereof for yielding inhalation materials.
The applicant listed for this patent is RAI Strategic Holdings, Inc.. Invention is credited to Balager Ademe, Frederic Philippe Ampolini, David Glen Christopherson, Dennis Lee Potter, Stephen Benson Sears, Steven L. Worm.
Application Number | 20190387807 16/564902 |
Document ID | / |
Family ID | 46690724 |
Filed Date | 2019-12-26 |
United States Patent
Application |
20190387807 |
Kind Code |
A1 |
Worm; Steven L. ; et
al. |
December 26, 2019 |
SMOKING ARTICLES AND USE THEREOF FOR YIELDING INHALATION
MATERIALS
Abstract
The present invention describes articles, such as smoking
articles, that can provide an inhalable substance in a form
suitable for inhalation by a consumer. The article comprises a
cartridge with an inhalable substance medium therein, control
housing that includes an electrical energy source and an electrical
power source, and a heating member that may be located in either
the cartridge or the control housing. The control housing further
may include puff-actuated current actuation components and current
regulation components.
Inventors: |
Worm; Steven L.; (Raleigh,
NC) ; Christopherson; David Glen; (Raleigh, NC)
; Sears; Stephen Benson; (Siler City, NC) ;
Potter; Dennis Lee; (Kernersville, NC) ; Ampolini;
Frederic Philippe; (Winston-Salem, NC) ; Ademe;
Balager; (Winston-Salem, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RAI Strategic Holdings, Inc. |
Winston-Salem |
NC |
US |
|
|
Family ID: |
46690724 |
Appl. No.: |
16/564902 |
Filed: |
September 9, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15915679 |
Mar 8, 2018 |
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16564902 |
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14737706 |
Jun 12, 2015 |
9930915 |
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15915679 |
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13205841 |
Aug 9, 2011 |
9078473 |
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14737706 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 40/42 20200101;
A24F 40/40 20200101; A24F 47/008 20130101 |
International
Class: |
A24F 47/00 20060101
A24F047/00 |
Claims
1-94. (canceled)
95. A smoking article for receiving a disposable aerosol forming
substance, the smoking article comprising: a housing having a
proximal end for receiving the disposable aerosol forming substance
and an opposite distal end; a power source arranged within the
housing adjacent to the distal end; a receiving chamber formed at
the proximal end of the housing and having an opening for receiving
the disposable aerosol forming substance; a heating projection
extending at least partially in the receiving chamber towards the
proximal end of the housing and terminating at a free end which is
configured to be inserted into the disposable aerosol forming
substance for heating the disposable aerosol forming substance, the
heating projection comprising: a heating member comprising an
electrically resistive metal which is configured to heat the
disposable aerosol forming substance; an electrical connector for
providing a flow of electricity to the heating member for heating
the heating member; and a control circuit positioned within the
housing between the power source and the heating projection and
connecting the heating member of the heating projection to the
power source.
96. The smoking article of claim 95, further comprising a
pushbutton, wherein in response to the pushbutton being manually
actuated by a user, a flow of electrical current to the heating
member is initiated.
97. The smoking article of claim 95, further comprising an
indicator, wherein in response to activation of the smoking
article, the indicator is turned on.
98. The smoking article of claim 95, wherein the heating member is
a linear array of electrically resistive metal arranged on the
heating projection.
99. The smoking article of claim 95, wherein the heating projection
is formed of an electrically non-conductive material.
100. The smoking article of claim 95, wherein the heating
projection is formed of a thermal insulator.
101. The smoking article of claim 95, wherein at least a portion of
the heating member is provided in a substantially straight line
configuration.
102. The smoking article of claim 95, wherein a maximum heating
temperature of the heating member is about 150 degrees Celsius to
about 250 degrees Celsius.
103. The smoking article of claim 95, wherein the disposable
aerosol forming substance is a disposable cigarette.
104. The smoking article of claim 103, wherein the heating member
is present on the heating projection along a segment having a
length of about 75% to about 85% of a length of the disposable
aerosol forming substance.
105. The smoking article of claim 103, wherein the heating
projection projects through the disposable aerosol forming
substance of the disposable cigarette so that the heating member is
in direct contact with at least a portion of the disposable aerosol
forming substance.
106. The smoking article of claim 95, wherein the housing comprises
one or more apertures for allowing entrance of ambient air into an
interior of the receiving chamber.
107. The smoking article of claim 95, wherein the housing comprises
a first housing section at the proximal end and a second housing
section at the distal end, wherein the first housing section and
the second housing section are removably attached through
frictional engagement.
108. The smoking article of claim 107, wherein the first housing
section comprises a plurality of detents and the second housing
section comprises a plurality of projections, the detents and
projections configured to engage each other to facilitate
frictional engagement of the first housing section and the second
housing section.
109. The smoking article of claim 107, further comprising a mouth
end fluidly coupled with the disposable aerosol forming substance,
wherein, in use, a user draws on the mouth end and ambient air is
drawn into one or more openings in the first housing section,
through one or more apertures in a wall of the receiving chamber
and into an interior of the receiving chamber, and through the
disposable aerosol forming substance such that aerosol released
from heating the disposable aerosol forming substance mixes with
the drawn ambient air and is drawn into a user's mouth.
110. The smoking article of claim 107, further comprising a
disposable cigarette comprising the disposable aerosol forming
substance, wherein a first portion of the disposable cigarette is
tensioned within the first housing section and a second portion of
the disposable cigarette extends beyond the proximal end of the
housing.
111. The smoking article of claim 103, further comprising an air
passageway disposed between an external wall of the housing and an
external wrapping of the cigarette.
112. A system comprising the smoking article of claim 95 and a hard
case configured to store and charge the smoking article.
113. A smoking article for receiving a disposable aerosol forming
substance, the smoking article comprising: a housing having a
proximal end for receiving the disposable aerosol forming substance
and an opposite distal end; a power source arranged within the
housing adjacent to the distal end; a receiving chamber formed at
the proximal end of the housing and having an opening for receiving
the disposable aerosol forming substance; a heating projection
extending at least partially in the receiving chamber towards the
proximal end of the housing and terminating at a free end, the
heating projection comprising: a heating member comprising an
electrically resistive metal; and an electrical connector for
providing a flow of electricity to the heating member for heating
the heating member; and a disposable cigarette comprising a
disposable aerosol forming substance, wherein the heating
projection projects through the disposable aerosol forming
substance of the disposable cigarette so that the heating member is
in direct contact with at least a portion of the disposable aerosol
forming substance.
114. The smoking article of claim 113, further comprising a
pushbutton, wherein in response to the pushbutton being manually
actuated by a user, a flow of electrical current to the heating
member is initiated.
115. The smoking article of claim 113, further comprising an
indicator, wherein in response to activation of the smoking
article, the indicator is turned on.
116. The smoking article of claim 113, wherein the heating member
is a linear array of electrically resistive metal arranged on the
heating projection.
117. The smoking article of claim 113, wherein the heating
projection is formed of an electrically non-conductive
material.
118. The smoking article of claim 113, wherein the heating
projection is formed of a thermal insulator.
119. The smoking article of claim 113, wherein at least a portion
of the heating member is provided in a substantially straight line
configuration.
120. The smoking article of claim 113, wherein a maximum heating
temperature of the heating member is about 150 degrees Celsius to
about 250 degrees Celsius.
121. The smoking article of claim 113, wherein the heating member
is present on the heating projection along a segment having a
length of about 75% to about 85% of a length of the disposable
aerosol forming substance.
122. The smoking article of claim 113, wherein the housing
comprises one or more apertures for allowing entrance of ambient
air into an interior of the receiving chamber.
123. The smoking article of claim 113, further comprising a control
circuit positioned within the housing between the power source and
the heating projection and connecting the heating member of the
heating projection to the power source.
124. The smoking article of claim 113, wherein the disposable
aerosol forming substance comprises a tobacco-derived material.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to aerosol delivery articles
and uses thereof for yielding tobacco components or other materials
in an inhalable form. The articles may be made or derived from
tobacco or otherwise incorporate tobacco for human consumption.
More particularly, the invention provides articles wherein tobacco,
a tobacco derived material, or other material is heated, preferably
without significant combustion, to provide an inhalable substance,
the substance, in the various embodiments, being in a vapor or
aerosol form.
BACKGROUND
[0002] Many smoking articles have been proposed through the years
as improvements upon, or alternatives to, smoking products based
upon combusting tobacco. Exemplary alternatives have included
devices wherein a solid or liquid fuel is combusted to transfer
heat to tobacco or wherein a chemical reaction is used to provide
such heat source.
[0003] The point of the improvements or alternatives to smoking
articles typically has been to provide the sensations associated
with cigarette, cigar, or pipe smoking, without delivering
considerable quantities of incomplete combustion and pyrolysis
products. To this end, there have been proposed numerous smoking
products, flavor generators, and medicinal inhalers which 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.
[0004] Representative cigarettes or smoking articles that have been
described and, in some instances, been made commercially available
include those described in U.S. Pat. No. 4,735,217 to Gerth et al.;
U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et
al.; U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.
5,249,586 to Morgan et al.; U.S. Pat. No. 5,388,594 to Counts et
al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No.
6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S.
Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et
al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to
Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No. 7,726,320
to Robinson et al.; U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat.
No. 6,772,756 to Shayan; US Pat. Pub. No. 2009/0095311 to Hon; US
Pat. Pub. Nos. 2006/0196518, 2009/0126745, and 2009/0188490 to Hon;
US Pat. Pub. No. 2009/0272379 to Thorens et al.; US Pat. Pub. Nos.
2009/0260641 and 2009/0260642 to Monsees et al.; US Pat. Pub. Nos.
2008/0149118 and 2010/0024834 to Oglesby et al.; US Pat. Pub. No.
2010/0307518 to Wang; and WO 2010/091593 to Hon. Still further
examples include products commercially available under the names
ACCORD.RTM.; HEATBAR.TM.; HYBRID CIGARETTE.RTM., RUYAN VEGAS.TM.;
RUYAN E-GAR.TM.; RUYAN C-GAR.TM.; E-MYSTICK.TM.; and IOLITE.RTM.
Vaporizer.
[0005] Articles that produce the taste and sensation of smoking by
electrically heating tobacco have suffered from inconsistent
release of flavors or other inhalable materials. Electrically
heated smoking devices have further been limited in many instances
to the requirement of an external heating device that was
inconvenient and that detracted from the smoking experience.
Accordingly, it can be desirable to provide a smoking article that
can provide the sensations of cigarette, cigar, or pipe smoking,
that does so without combusting tobacco, that does so without the
need of a combustion heat source, and that does not produce
combustion products.
SUMMARY OF THE INVENTION
[0006] The present invention generally provides articles that may
be used for pulmonary delivery of one or more inhalable substances
(including nicotine). In certain embodiments, the invention relates
to smoking articles that employ an electrical heating element and
an electrical power source to provide the inhalable substance in a
vapor or aerosol form, and also provide other sensations associated
with smoking, preferably without substantially burning or
completely burning tobacco or other substances, producing little or
no combustion or pyrolysis products, including carbon monoxide, and
producing little or no side stream smoke or odor. The electrical
heating member provides for heating almost immediately upon taking
a puff from the article and can provide for delivery of an aerosol
throughout the puff and over about 6 to about 10 puffs on the
article, which is similar to the number of puffs obtained from a
typical cigarette.
[0007] In certain embodiments, the invention thus provides an
article for formation of an inhalable substance. The article can
comprise a substantially tubular shaped cartridge body having an
engaging end, an opposing mouth end configured to allow passage of
the inhalable substance to a consumer, and a wall with an outer
surface and an inner surface. The inner surface of the cartridge
body wall can define an interior cartridge space that includes a
substantially tubular shaped inhalable substance medium having a
wall with an inner surface and an outer surface so as to define an
annular space of a specified volume between the outer surface of
the inhalable substance medium wall and the inner surface of the
cartridge wall. The inhalable substance medium particularly also
can have a first end in proximity to the mouth end of the cartridge
and a second end in proximity to the engaging end of the cartridge.
The article further can comprise an electrical heating member that
heats at least a segment of the inhalable substance medium wall
sufficiently to form a vapor comprising the inhalable substance
within the annular space. The article also can comprise a control
housing having a receiving end that engages the engaging end of the
cartridge. Such receiving end may particularly include a chamber
with an open end for receiving the engaging end of the cartridge.
The control housing further can comprise an electrical energy
source (at least part of which can be positioned at the receiving
end and/or within the receiving chamber) that provides power to the
electrical heating member. In specific embodiments, when the
engaging end of the cartridge engages the receiving end of the
control housing (such as when it slides a defined distance into the
chamber of the control housing), the inhalable substance medium and
the electrical heating member align so as to allow for heating of
at least a segment of the inhalable substance medium. The
electrical energy source (or a component or extension thereof) also
may so align with the inhalable substance medium and the electrical
heating member.
[0008] The inventive article can take on a number of shapes and
sizes. For example, the cartridge can be substantially
cylindrically shaped. Further, the cartridge can have a
cross-section defined by a shape selected from the group consisting
of round, oval, and square. The engaging end of the cartridge also
can include an opening that is sufficiently sized and shaped to
receive at least one component of the electrical energy source. The
cartridge also can comprise an overwrap that can be useful to
provide various properties to the article. For example, the
overwrap may include a filter material positioned in proximity to
the mouth end of the cartridge. Thus, the mouth end of the
cartridge may be characterized as being partially occluded, which
characterization also can relate to further components of the
cartridge, such as the cartridge frame at the mouth end of the
cartridge.
[0009] The inhalable substance medium can comprise a variety of
materials useful for facilitating delivery of one or more inhalable
substances to a consumer. In particular embodiments, the inhalable
substance medium can comprise tobacco and/or a tobacco-derived
material. The inhalable substance medium also may comprise an
aerosol-forming material, which itself may include a
tobacco-derived material. In specific embodiments, the
aerosol-forming material can be a polyhydric alcohol (e.g.,
glycerin). In other embodiments, the inhalable substance medium can
comprise a solid substrate. Such substrate may itself comprise
tobacco (e.g., a tobacco paper formed from reconstituted tobacco),
such that the inhalable substance may be natural to the substrate.
Alternatively, the substrate may simply be a paper material or
other material that has the inhalable substance coated thereon or
that has the inhalable substance absorbed or adsorbed therein. In a
particular embodiment, the inhalable substance medium can comprise
a slurry of tobacco and an aerosol-forming material coated on or
absorbed or adsorbed in the solid substrate. The inhalable
substance medium further may comprise other components, such as a
vapor barrier on one of the inner surface or the outer surface of
the wall. Particularly, the vapor barrier can be positioned on the
surface of the inhalable substance medium wall that is adjacent to
the electrical heating member when the inhalable substance medium
is heated.
[0010] The inhalable substance medium may be attached to the
cartridge body only at the ends of the inhalable substance medium.
In this manner, the inhalable substance medium can be characterized
as being tensioned within the cartridge. The volume of the annular
space between the outer surface of the inhalable substance medium
wall and the inner surface of the cartridge body wall can be about
5 ml to about 100 ml, and can provide a dynamic head space that
provides for passage of a combination of aerosol and air that
substantially corresponds to an average puff volume desired to
deliver a desired amount of the inhalable substance (i.e., in the
form of the aerosol). Moreover, the attachment of the inhalable
substance medium to the engaging end of the cartridge body can be
configured to facilitate movement of air into the annular space so
as to direct the aerosol and the inhalable substance through the
mouth end of the article for inhalation by a consumer.
[0011] The receiving chamber of the control housing can be defined
by a wall with an inner surface and an outer surface, the wall
having a cross-section that is substantially similarly shaped to
the cross-section of the cartridge. The chamber wall also can
include one or more openings therein for allowing entry of ambient
air into the chamber and thus facilitate movement of the inhalable
substance out of the annular space, as described above.
Alternatively, the chamber may be absent from the receiving end of
the control housing or may be replaced with one or more guide
components (e.g., extensions of the casing of the control housing)
that guide the cartridge into a proper alignment with the control
housing. In some embodiments, the walls defining the chamber may be
characterized as examples of a guide component. Thus, the guide
component could be substantially similar in dimensions with the
chamber walls.
[0012] The electrical energy source can essentially be a receptacle
that provides for transmission of electrical current from the power
source to the heating member. In specific embodiments, the
electrical energy source can include a projection that extends from
the control housing (e.g., through the receiving chamber, and
preferably approximately to the open end of the chamber). When the
electrical heating member is a component part of the control
housing, the electrical heating member may be specifically attached
to this projection on the electrical energy source. In such
embodiments, the heating member can include electrical contacts
that extend from the heating member and insert into the receptacle
in the electrical energy source. This can be a permanent,
non-removable connection of the contacts into the receptacle.
[0013] The heating member can specifically be a resistance wire
that generates heat as an electrical current passes therethrough.
In specific embodiments, the heating member may be integral to the
inhalation substance medium.
[0014] In specific embodiments, the heating member can comprise
multiple components. For example, the heating member may comprise a
resistance wire of substantially small dimensions, and a heat
spreading member may be associated therewith to spread the
generated heat across a wider area.
[0015] The electrical heating member (or the heat spreading member)
particularly may be present on the projection only along a segment
of defined length, and such segment particularly may be in
proximity to the end of the projection at the open end of the
chamber. The segment of defined length may encompass about 5% to
about 50% of the length of the projection. In this manner,
segmented heating can be provided in that the heating member will
only encompass an area of the inhalable substance medium that is
less than the entire length of the medium. Preferably, the heating
member (or the heat spreading member) encompasses a length of about
one-sixth to about one-tenth of the inhalable substance medium
whereby the medium can be completely used in about six to about 10
segments or puffs. To achieve this, the cartridge may specifically
index past the projection segment having the electrical heating
member present thereon. Such indexing can be manually controlled by
a consumer, such as using a pushbutton to advance the cartridge
within the receiving chamber or by simply tapping on the cartridge.
In specific embodiments, the article can comprise a puff actuated
switch that automatically indexes the cartridge past the projection
segment. Thereby, the distance traveled by the cartridge during
indexing can be directly related to the duration of the puff.
[0016] In other embodiments, the electrical heating member still
may be positioned in the control housing, but the article may
provide for bulk heating of the inhalable substance medium rather
than segmented heating. For example, the electrical heating member
(or the heat spreading member) may be present on the projection
along a segment that is about 75% to about 125% the length of the
inhalable substance medium. In this manner, the cartridge is
inserted substantially completely into the receiving chamber for
the duration of use, and each puff on the article heats the entire
(or almost entire) length of the inhalable substance medium.
Electrical contacts present on the heating member permanently
engage the receptacle (i.e., the electrical energy source) so that
electrical current can be delivered to the heating member. When the
chamber walls are absent, the cartridge can be characterized as
being combined with the control housing such that the projection is
inserted substantially into the inhalable substance to the full
extent allowed by the specific structure thereof.
[0017] In other embodiments, the heating member can be a component
part of the cartridge rather than the control housing. Such
configuration can allow for bulk heating of the inhalable substance
medium. Specifically, the heating member can be present along
substantially the entire length of the inhalable substrate medium
and can include electrical contacts that engage the receptacle in
the electrical energy source. When heating is activated, heating
occurs along the entire length of the electrical heating member.
Specifically, the electrical heating member (or the heat spreading
component) may be present within the cartridge along a segment that
is about 75% to about 100% the length of the inhalable substance
medium.
[0018] Segmented heating also can be provided when the heating
member is present within the cartridge. To achieve such segmented
heating, it is preferably for the projection of the electrical
energy source to include electrical leads in proximity to the end
of the projection at the open end of the chamber. The electrical
leads form an electrical connection with discrete segments of the
electrical heating member such that when heating occurs, only the
portion of the inhalable substance medium in proximity to the
segment of the electrical heating member in electrical connection
with the projection is heated. The segment of the electrical
heating member that is in electrical connection with the electrical
leads of the projection can encompass about 5% to about 50% of the
length of the inhalable subject medium. Aspects of the invention
described above in relation to the article generally may apply to
any of the embodiments, such as the use of puff actuated
indexing.
[0019] Segmented heating also may be provided by other heating
means. For example, a plurality of heating members may be
positioned in relation to the inhalable substance medium such that
only a specific segment of the inhalable substance medium is heated
by a given heating member. The plurality of heating members may be
components of the control housing or the cartridge, and the
plurality of heating members may be specifically coated with the
inhalable substance. Moreover, a bulk heater structure may be
provided but can be adapted for electronic control such that only
specific segments of the bulk heater are powered at a given time to
heat only specific segments of the inhalable substance medium.
[0020] The control housing may include further components necessary
for function of the article. Specifically, the control housing can
include switching components for actuating flow of electrical
current from the electrical energy source to the heating member
upon application of proper stimulus. Such actuation can be manual
(e.g., use of a pushbutton) or automatic (e.g., puff actuated
heating). In specific embodiments, actuation initiates
uninterrupted current flow to quickly heat the heating member.
[0021] The article preferably includes further components for
controlling current flow. This may include time-based control
wherein current is allowed to flow for a defined period of time
prior to deactuation of the current flow. Such time-based
regulation can include periods of cycling wherein the current flow
is rapidly actuated and deactuated to maintain the heater at a
defined temperature. In other embodiments, once a defined
temperature is achieved, the current regulator may deactuate the
current flow until a new puff initiates actuation again. The
actuation and deactuation achieved by the switching components
preferably provide for a working temperature for the heating member
of about 120.degree. C. to about 300.degree. C.
[0022] The control housing still further includes an electrical
power source to provide power to the electrical energy source. Such
power source may include one or more batteries and/or at least one
capacitor (or other means for providing a stored source of
power).
[0023] In other embodiments, the general components of the article
may exist separately. For example, the invention provides a
disposable unit for use with a reusable smoking article. Such
disposable unit may generally comprise any of the subject matter
described herein in relation to the cartridge.
[0024] In specific embodiments, a disposable unit for use with a
reusable smoking article can comprise a substantially tubular
shaped cartridge body having an engaging end configured to engage
the reusable smoking article, an opposing mouth end configured to
allow passage of an inhalable substance to a consumer, and a wall
with an outer surface and an inner surface that defines an interior
cartridge space that includes a substantially tubular shaped
inhalable substance medium having a wall with an inner surface and
an outer surface so as to define an annular space of a specified
volume between the outer surface of the inhalable substance medium
wall and the inner surface of the cartridge body wall, the
inhalable substance medium having a first end in proximity to the
mouth end of the cartridge and having a second end in proximity to
the engaging end of the cartridge. The disposable unit further can
comprise an electrical heating member that heats at least a segment
of the inhalable substance medium sufficiently to form a vapor
comprising the inhalable substance within the annular space. The
electrical heating member further can comprise contacts for making
electrical connection with an electrical energy source in the
reusable smoking article. Moreover, the electrical heating member
can be positioned within the tubular shaped inhalable substance
medium and, preferably, is in direct contact with the inhalable
substance medium. In certain embodiments, the vapor barrier may
include components so as to function has an electrical heating
member as well. The disposable unit further can comprise an
overwrap that surrounds the cartridge body and which can extend
beyond the engaging end of the cartridge body (e.g., by a distance
that is about 10% to about 90% of the length of the cartridge
body). The overwrap also can include a filter material positioned
in proximity to the mouth end of the cartridge body.
[0025] Likewise, the invention provides a reusable control unit
that can be used with a disposable smoking article. Such reusable
control unit may generally comprise any of the subject matter
described herein in relation to the control housing.
[0026] In specific embodiments, a reusable control unit for use
with a disposable smoking article can comprise a control housing
including: a receiving end for receiving an engaging end of the
disposable smoking article and including an electrical energy
source that delivers power to an electrical heating member, the
electrical energy source including a projection that extends
outward from the receiving end of the control housing and including
a component that forms an electrical connection with electrical
contacts on the electrical heating member; and a control unit
section that houses a power source, a switching component that
actuates flow electrical current from the electrical energy source
to the heating member, and a flow regulating component that
regulates a previously initiated current flow from the electrical
energy source to the electrical heating member. The receiving end
particularly can include a receiving chamber defined by walls that
surround the projection. Exemplary power sources can include a
battery and/or at least one capacitor. The switching component can
comprise a puff-actuated switch or may comprise a pushbutton. The
current regulating component specifically can be a time-based
component. As such, the current regulating component may stop
current to the electrical heating member once a defined temperature
has been achieved. Further, the current regulating component may
cycle the current to the electrical heating member off and on once
a defined temperature has been achieved so as to maintain the
defined temperature for a defined period of time. The component
that forms an electrical connection with the electrical contacts
may be a receptacle that is housed in the electrical energy source.
Alternatively, the component that forms an electrical connection
with the electrical contacts may be located on the projection.
[0027] In another aspect, the invention also relates to kits that
can provide various components of the inventive article, and
accessories therefor, in a variety of combinations. Specifically,
individual kits may include any combination of one or more
cartridges, one or more control units, one or more heating members,
one or more batteries, and one or more charging components. The kit
may include packaging, (e.g., a case or similar item) that can
store one or more of the components of the kit. Particularly, the
case may be sized for carrying in the pocket of a consumer (e.g.,
sized to fit in a typical shirt pocket, trouser pocket, or jacket
pocket). The case may be hard or soft, depending upon the
components of the kit. The case also may be a storage mechanism
that can function as a charging station for the inventive
article.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In order to assist the understanding of embodiments of the
invention, reference will now be made to the appended drawings, in
which like reference numerals refer to like elements and which are
not necessarily drawn to scale. The drawings are exemplary only,
and should not be construed as limiting the invention.
[0029] FIG. 1 is a perspective view of an article according to an
embodiment of the invention comprising a cartridge engaging a
control housing, wherein the cartridge is inserted only a minimum
distance into the control housing;
[0030] FIG. 2 is a perspective view of the article illustrated in
FIG. 1, wherein the cartridge is indexed a further distance into
the control housing;
[0031] FIG. 3 is a perspective view of the article illustrated in
FIG. 1, wherein the cartridge is indexed fully into the control
housing;
[0032] FIG. 4 is a perspective view of a portion of an article
according an embodiment of the invention showing a cartridge
disengaged from the receiving chamber of a control housing (which
is only partially shown), the control housing including a heating
member located on a projection to provide for segmented heating of
the inhalable substance medium in the cartridge, the cartridge and
receiving chamber being partially cut away to reveal the underlying
components of the article;
[0033] FIG. 4a is a cross-section of a cartridge according to an
embodiment of the invention, the cross-section being through the
plane shown by dashed lines in FIG. 4, the cross-section
illustrating the spatial relationship and configuration of certain
components of the cartridge;
[0034] FIG. 4b is a cross-section of an alternate embodiment of a
cartridge according to the invention, the cross-section being
through the plane shown by dashed lines in FIG. 4, the
cross-section illustrating the spatial relationship and
configuration of certain components of the cartridge;
[0035] FIG. 4c is a cross-section of a further alternate embodiment
of a cartridge according to the invention, the cross-section being
through the plane shown by dashed lines in FIG. 4, the
cross-section illustrating the spatial relationship and
configuration of certain components of the cartridge;
[0036] FIG. 5 is a front, plan view of the cartridge frame member
from the mouth end of the cartridge from FIG. 4, the frame member
being illustrated separate from the cartridge to show components
thereof in detail;
[0037] FIG. 6 is a perspective view of an article according to an
embodiment of the invention showing a cartridge engaging a control
housing, wherein a portion of the exterior of the control housing
is removed to reveal interior components thereof;
[0038] FIG. 7 is a perspective view of the article from FIG. 4,
wherein the cartridge is inserted a minimum distance into the
receiving chamber of the control housing, said minimum distance
being a distance such that the heating member on the projection is
positioned within the central cavity of the tubular inhalable
substance medium and in sufficient contact therewith to heat at
least a portion of the inhalable substance medium;
[0039] FIG. 8 is a perspective view of the article from FIG. 7,
wherein the cartridge is indexed into the receiving chamber of the
control housing such that the heating member on the projection is
positioned further into the central cavity of the tubular inhalable
substance medium so as to have moved a distance away from the
engaging end of the cartridge and the same distance toward the
mouth end of the cartridge;
[0040] FIG. 8a is a perspective view of a portion of an article
according an embodiment of the invention showing a cartridge
engaging the receiving end of a control housing (which is only
partially shown), the control housing including a projection with a
heating member thereon to provide for segmented heating of the
inhalable substance medium in the cartridge, the cartridge being
partially cut away to reveal the underlying components of the
article;
[0041] FIG. 8b is a perspective view of a portion of an article
according an embodiment of the invention showing a cartridge
disengaged from the receiving end of a control housing (which is
only partially shown and which does not include walls defining a
chamber), the control housing including a heating member located on
a projection and surrounded by a heat spreading member to provide
for segmented heating of the inhalable substance medium in the
cartridge, the cartridge being partially cut away to reveal the
underlying components of the article;
[0042] FIG. 9 is a perspective view of a portion of an article
according an embodiment of the invention showing a cartridge with a
heating member located therein partially engaging the receiving
chamber of a control housing (which is only partially shown), the
control housing including a projection with electrical leads
thereon that interact with the heating member in the cartridge to
provide for segmented heating of the inhalable substance medium in
the cartridge, the cartridge and receiving chamber being partially
cut away to reveal the underlying components of the article;
[0043] FIG. 10 is a perspective view of a portion of an article
according an embodiment of the invention showing a cartridge
disengaged from the receiving chamber of a control housing (which
is only partially shown), the control housing including a heating
member located on a projection to provide for bulk heating of the
inhalable substance medium in the cartridge, the cartridge and
receiving chamber being partially cut away to reveal the underlying
components of the article;
[0044] FIG. 11 is a perspective view of the article from FIG. 10,
wherein the cartridge is fully inserted into the receiving chamber
of the control housing such that the projection with the heating
member thereon is fully inserted into the central cavity of the
tubular inhalable substance medium and thus positioned to provide
for bulk heating of the inhalable substance medium; and
[0045] FIG. 12 is a perspective view of a portion of an article
according an embodiment of the invention showing a cartridge with a
heating member located therein disengaged from the receptacle in
the receiving chamber of a control housing (which is only partially
shown), the control housing including an electrical energy source
with a receptacle for receiving electrical contacts on the heating
member to provide for bulk heating of the inhalable substance
medium in the cartridge, the cartridge and receiving chamber being
partially cut away to reveal the underlying components of the
article.
DETAILED DESCRIPTION
[0046] The present invention now will be described more fully
hereinafter. This invention may, however, 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 be thorough and complete, and
will fully convey the scope of the invention to those skilled in
the art. It must be noted that, as used in this specification, the
singular forms "a," "an," and "the" include plural referents unless
the context clearly dictates otherwise.
[0047] The present invention provides articles that use electrical
energy to heat a material (preferably without combusting the
material to any significant degree) to form an inhalable substance,
the articles being sufficiently compact to be considered
"hand-held" devices. In certain embodiments, the articles can
particularly be characterized as smoking articles. As used herein,
the term is intended to mean an article that provides the taste
and/or the sensation (e.g., hand-feel or mouth-feel) of smoking a
cigarette, cigar, or pipe without the actual combustion of any
component of the article. The term smoking article does not
necessarily indicate that, in operation, the article produces smoke
in the sense of the by-product of combustion or pyrolysis. Rather,
smoking relates to the physical action of an individual in using
the article--e.g., holding the article in a hand, drawing on one
end of the article, and inhaling from the article. In further
embodiments, the inventive articles can be characterized as being
vapor-producing articles, aerosolization articles, or
pharmaceutical delivery articles. Thus, the articles can be
arranged so as to provide one or more substances in an inhalable
state. In other embodiments, the inhalable substance 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). In
other embodiments, the inhalable substance can be in the form of an
aerosol (i.e., a suspension of fine solid particles or liquid
droplets in a gas). The physical form of the inhalable substance is
not necessarily limited by the nature of the inventive articles but
rather may depend upon the nature of the medium and the inhalable
substance itself as to whether it exists in a vapor state or an
aerosol state. In some embodiments, the terms may be
interchangeable. Thus, for simplicity, the terms as used to
describe the invention are understood to be interchangeable unless
stated otherwise.
[0048] In one aspect, an article according to the invention
generally can comprise an electrical energy source, a heating
member powered by the electrical energy source, a control component
or control housing related to the delivery of electrical energy
from the electrical energy source to the heating member, and an
inhalable substance medium that is positionable in proximity to or
in direct contact with the heating member. When the heating member
heats the inhalable substance medium, an inhalable substance is
formed from, released from, or generated from the inhalable
substance medium 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, the inhalable substance is released in the form of a
vapor or aerosol or mixture thereof.
[0049] Referring now to the appended figures, an article 10
according to the invention generally can comprise a control housing
200 and a cartridge 300. In specific embodiments, the control
housing 200 may be referred to as being reusable, and the cartridge
300 may be referred to as being disposable. In some embodiments,
the entire article 10 may be characterized as being disposable in
that the control housing 200 may be configured for only a limited
number of uses (e.g., until a battery power component no longer
provides sufficient power to the article) with a limited number of
cartridges 300 and, thereafter, the entire article 10, including
the control housing 200, may be discarded. In other embodiments,
the control housing 200 may have a replaceable battery such that
the control housing 200 can be reused through a number of battery
exchanges and with many cartridges 300. Similarly, the article 10
may be rechargeable and thus may be combined with any type of
recharging technology, including connection to a typical electrical
outlet, connection to a car charger (i.e., cigarette lighter
receptacle), and connection to a computer, such as through a USB
cable.
[0050] Although an article according to the invention may take on a
variety of embodiments, as discussed in detail below, the use of
the article by a consumer will be similar in scope. In particular,
the article can be provided as a plurality of components that are
combined by the consumer for use and then are dismantled by the
consumer thereafter. Specifically, a consumer may have a reusable
control housing that is substantially cylindrical in shape having
an open end (or, when chamber walls are absent, a projection end)
and an opposing, closed end. The closed end of the control housing
may include one or more indicators of active use of the article.
The consumer further can have one or more cartridges that engage
the open end of the control housing. To use the article, the
consumer can insert the cartridge into the open end of the control
housing or otherwise combine the cartridge with the control housing
so that the article is operable as discussed herein. In some
embodiments, the cartridge can be inserted as far into the control
housing as allowed by the overall structure of the components.
Typically, a portion of the cartridge that is at least sufficiently
sized for insertion into the mouth of the consumer for puffing
thereon can remain outside of the control housing. This may be
referred to as the mouth end of the cartridge.
[0051] During use, the consumer initiates heating of a heating
member that is adjacent an inhalable substance medium (or a
specific layer thereof), and heating of the medium releases the
inhalable substance within a space inside the cartridge so as to
yield an inhalable substance. When the consumer inhales on the
mouth end of the cartridge, air is drawn into the cartridge through
openings in the control housing and/or the cartridge itself. The
combination of the drawn air and the released inhalable substance
is inhaled by the consumer as the drawn materials exit the mouth
end of the cartridge into the mouth of the consumer. To initiate
heating, the consumer may manually actuate a pushbutton or similar
component that causes the heating member to receive electrical
energy from the battery or other energy source. The electrical
energy may be supplied for a pre-determined length of time or may
be manually controlled. Preferably, flow of electrical energy does
not substantially proceed in between puffs on the article (although
energy flow may proceed to maintain a baseline temperature greater
than ambient temperature--e.g., a temperature that facilitates
rapid heating to the active heating temperature). In further
embodiments, heating may be initiated by the puffing action of the
consumer through use of various sensors, as otherwise described
herein. Once the puff is discontinued, heating will stop or be
reduced. When the consumer has taken a sufficient number of puffs
so as to have released a sufficient amount of the inhalable
substance (e.g., an amount sufficient to equate to a typical
smoking experience), the cartridge can be removed from the control
housing and discarded.
[0052] In other embodiments, the cartridge may initially only be
inserted a short distance into the control housing. During use, the
cartridge can be incrementally pushed further into the control
housing. The number of such indexes into the control housing can
correspond to the number of puffs to be supplied by the individual
cartridge. In relation to each puff, the cartridge is indexed
further into the control housing. Once the cartridge has been fully
indexed into the housing and all puffs have been taken, the
cartridge can be removed from the control housing and discarded.
The foregoing description of use of the article can be applied to
the various embodiments described through minor modifications,
which can be apparent to the person of skill in the art in light of
the further disclosure provided herein. The above description of
use, however, is not intended to limit the use of the inventive
article but is provided to comply with all necessary requirements
of disclosure of the present invention.
[0053] Turning to the specific embodiments, as seen in the
embodiments of FIG. 1 through FIG. 3, an article 10 according to
the invention can have an overall shape that may be defined as
being substantially rod-like or substantially tubular shaped or
substantially cylindrically shaped. In the embodiments of FIG. 1
through FIG. 3, the article 10 has a substantially round
cross-section; however, other cross-sectional shapes (e.g., oval,
square, triangle, etc.) also are encompassed by the present
disclosure. Such language that is descriptive of the physical shape
of the article may also be applied to the individual components
thereof, including the control housing 200 and the cartridge
300.
[0054] The control housing 200 and the cartridge 300 are
specifically configured so as to engage one another in a sliding or
otherwise indexable manner. As seen in FIG. 1, the cartridge 300
slides into an open end of the control housing 200 such that,
during functioning, the cartridge 300 and the control housing 200
are in a coaxial relationship. In such embodiments, the control
housing 200 can comprise a control segment 205 and a receiving
chamber 210 into which the cartridge 300 is inserted. As will be
discussed in greater detail below, FIG. 2 and FIG. 3 illustrate the
nature whereby, in some embodiments, the article 10 may become
gradually shortened during use by a consumer. Specifically, in
certain embodiments, the cartridge 300 can be continually or
segmentally indexed into the control housing 200 such that the
cartridge 300 is understood to have been completely used once the
article 10 has achieved its minimum length. Reverse indexing also
may be used. The cartridge 300 may move continuously without
predetermined stops at defined positions within the receiving
chamber 210. In other embodiments, predetermined stops or
predetermined lengths of movement of the cartridge 300 within the
receiving chamber 210 can be provided such that indexing of the
cartridge 300 results in movement by only the predetermined length.
Various indexing means are encompassed by the invention as further
discussed herein. In some embodiments, the cartridge 300 can be
partially or completely inserted into the control housing 200 at
the beginning of use by a consumer. Although indexing is described
in relation to the cartridge being gradually shortened, the
invention also encompasses embodiments wherein, in use, the
cartridge is fully inserted into the control housing, and the
cartridge indexes outward therefrom.
[0055] An article 10 according to the invention can be further
described in relation to the specific embodiment shown in FIG. 4
wherein a portion of the article is cut away to reveal the interior
components of the cartridge 300 and the receiving chamber 210 of
the control housing 200. The cartridge 300 comprises a cartridge
body 305 formed of a wall having an outer surface and an inner
surface and providing the cartridge body 305 with a substantially
tubular shape. The cartridge body 305 has opposing terminal ends
that define an engaging end 310 that engages the receiving chamber
210 of the control housing 200 and a mouth end 315 configured to
allow passage of an inhalable substance to a consumer. Although not
required, it can be beneficial for the wall of the cartridge body
305 to be reinforced at one or both of the terminal ends, such as
with the flanges 302 illustrated in FIG. 4. When an overwrap 380 is
present, the presence of the flanges can provide for a dead space
389 between the cartridge and the overwrap (as illustrated in FIG.
4a).
[0056] The cartridge body 305 can be formed of any material
suitable for forming and maintaining an appropriate conformation,
such as a tubular shape, and for retaining therein an inhalable
substance medium 350. The cartridge body 305 can be formed of a
single wall, as shown in FIG. 4a. In some embodiments, the
cartridge body 305 is formed of a material (natural or synthetic)
that is heat resistant so as to retain its structural
integrity--e.g., does not degrade--at least at a temperature that
is the heating temperature provided by the electrical heating
member, as further discussed herein. In some embodiments, a heat
resistant polymer may be used. In other embodiments, the cartridge
body 305 may be formed from paper, such as a paper that is
substantially straw-shaped. As further discussed herein, the
cartridge body 305, such as a paper tube, may have one or more
layers associated therewith that function to substantially prevent
movement of vapor therethrough. In one example, an aluminum foil
layer may be laminated to one surface of the cartridge body.
Ceramic materials also may be used. In further embodiments, an
insulating material may be used so as not to unnecessarily move
heat away from the inhalable substance medium. The cartridge body
305, when formed of a single layer, may have a thickness that
preferably is about 0.2 mm to about 5.0 mm, about 0.5 mm to about
4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm to about 3.0
mm. Further exemplary types of components and materials that may be
used to provide the functions described above or be used as
alternatives to the materials and components noted above can be
those of the types set forth in US Pub. Nos. 2010/00186757 to
Crooks et al.; 2010/00186757 to Crooks et al.; and 2011/0041861 to
Sebastian et al.; the disclosures of the documents being
incorporated herein by reference in their entireties.
[0057] The inner surface of the wall of the cartridge body 305
defines an interior cartridge space, and an inhalable substance
medium 350 is included within said space. The inhalable substance
medium 350 can be any material that, when heated, releases an
inhalable substance, such as a flavor-containing substance. In the
embodiment of FIG. 4, the inhalable substance medium 350 is a solid
substrate comprising the inhalable substance. The inhalable
substance specifically may be a tobacco component or a
tobacco-derived material (i.e., a material that is found naturally
in tobacco that may be isolated directly from the tobacco or
synthetically prepared). For example, the inhalable substance
medium can comprise tobacco extracts or fractions thereof combined
with an inert substrate. The inhalable substance medium further may
comprise unburned tobacco or a composition containing unburned
tobacco that, when heated to a temperature below its combustion
temperature, releases an inhalable substance. Although less
preferred, the inhalable substance medium may comprise tobacco
condensates or fractions thereof (i.e., condensed components of the
smoke produced by the combustion of tobacco, leaving flavors and,
possibly, nicotine).
[0058] Tobacco materials useful in the present invention can vary
and can include, for example, flue-cured tobacco, burley tobacco,
Oriental tobacco or Maryland tobacco, dark tobacco, dark-fired
tobacco and Rustica tobaccos, as well as other rare or specialty
tobaccos, or blends thereof. Tobacco materials also can include
so-called "blended" forms and processed forms, such as processed
tobacco stems (e.g., cut-rolled or cut-puffed stems), volume
expanded tobacco (e.g., puffed tobacco, such as dry ice expanded
tobacco (DIET), preferably in cut filler form), reconstituted
tobaccos (e.g., reconstituted tobaccos manufactured using
paper-making type or cast sheet type processes). Various
representative tobacco types, processed types of tobaccos, and
types of tobacco blends are set forth in U.S. Pat. No. 4,836,224 to
Lawson et al.; U.S. Pat. No. 4,924,888 to Perfetti et al.; U.S.
Pat. No. 5,056,537 to Brown et al.; U.S. Pat. No. 5,159,942 to
Brinkley et al.; U.S. Pat. No. 5,220,930 to Gentry; U.S. Pat. No.
5,360,023 to Blakley et al.; U.S. Pat. No. 6,701,936 to Shafer et
al.; U.S. Pat. No. 7,011,096 to Li et al.; and U.S. Pat. No.
7,017,585 to Li et al.; U.S. Pat. No. 7,025,066 to Lawson et al.;
US Pat. App. Pub. No. 2004-0255965 to Perfetti et al.; PCT WO
02/37990 to Bereman; and Bombick et al., Fund. Appl. Toxicol., 39,
p. 11-17 (1997); which are incorporated herein by reference.
Further exemplary tobacco compositions that can be useful in a
smoking device, including according to the present invention, are
disclosed in U.S. Pat. No. 7,726,320 to Robinson et al., which is
incorporated herein by reference in its entirety.
[0059] Still further, the inhalable substance medium 350 may
comprise an inert substrate having the inhalable substance, or a
precursor thereof, integrated therein or otherwise deposited
thereon. For example, a liquid comprising the inhalable substance
may be coated on or absorbed or adsorbed into the inert substrate
such that, upon application of heat, the inhalable substance is
released in a form that can be withdrawn from the inventive article
through application of positive or negative pressure.
[0060] In addition to the inhalable substance (e.g., flavors,
nicotine, or pharmaceuticals generally), the inhalable substance
medium can comprise one or more aerosol-forming or vapor-forming
materials, such as a polyhydric alcohol (e.g., glycerin, propylene
glycol, or a mixture thereof) and/or water. Representative types of
aerosol forming materials are set forth in U.S. Pat. No. 4,793,365
to Sensabaugh, Jr. et al.; and U.S. Pat. No. 5,101,839 to Jakob et
al.; PCT WO 98/57556 to Biggs et al.; and Chemical and Biological
Studies on New Cigarette Prototypes that Heat Instead of Burn
Tobacco, R. J. Reynolds Tobacco Company Monograph (1988); which are
incorporated herein by reference. A preferred aerosol forming
material produces a visible aerosol upon the application of
sufficient heat thereto, and a highly preferred aerosol forming
material produces an aerosol that can be considered to be
"smoke-like." Further tobacco materials, such as a tobacco aroma
oil, a tobacco essence, a spray dried tobacco extract, a freeze
dried tobacco extract, tobacco dust, or the like may be combined
with the vapor-forming or aerosol-forming material. It is also
understood that the inhalable substance itself may be in a form
whereby, upon heating, the inhalable substance is released as a
vapor, aerosol, or combination thereof. In other embodiments, the
inhalable substance may not necessarily release in a vapor or
aerosol form, but the vapor-forming or aerosol-forming material
that may be combined therewith can form a vapor or aerosol upon
heating and function essentially as a carrier for the inhalable
substance itself. Thus, the inhalable substance can be
characterized as being coated on a substrate, as being absorbed in
a substrate, as being adsorbed in a substrate, or as being a
natural component of the substrate (i.e., the material forming the
substrate, such as a tobacco or a tobacco-derived material).
Likewise, an aerosol-forming or vapor-forming material may be
similarly characterized. In certain embodiments, the inhalable
substance medium particularly may comprise a substrate with the
inhalable substance and a separate aerosol forming material
included therewith. As such, in use, the substrate can be heated,
the aerosol forming material can be volatilized into a vapor form
taking with it the inhalable substance. In a specific example, the
inhalable substance medium can comprise a solid substrate with a
slurry of tobacco and an aerosol-forming material and/or
vapor-forming material coated thereon or absorbed or adsorbed
therein. The substrate component may be any material that does not
combust or otherwise degrade at the temperatures described herein
that the heating member achieves to facilitate release of the
inhalable substance. For example, a paper material may be used,
including a tobacco paper (e.g., a paper-like material comprising
tobacco fibers and/or reconstituted tobacco). Thus, in various
embodiments, the inhalable substance medium can be characterized as
comprising the inhalable substance, alternately as comprising the
inhalable substance and a separate aerosol-former or vapor-former,
alternately as comprising the inhalable substance and a substrate,
or alternately as comprising the inhalable substance medium, the
separate aerosol-former or vapor-former, and the substrate. Thus,
the substrate may contain one or both of the inhalable substance
and the aerosol-former or vapor-former.
[0061] If desired, the tobacco material or the inhalable substance
medium generally can further include other components, such as
sugars, glycerin, vanilla, cocoa, licorice, and other flavoring
materials, such as menthol. Exemplary plant-derived compositions
that may be used are disclosed in U.S. application Ser. No.
12/971,746 to Dube et al., and Ser. No. 13/015,744 to Dube et al.
The selection of such further components can vary based upon
factors such as the sensory characteristics that are desired for
the present article, and the present invention is intended to
encompass any such further components that may be readily apparent
to those skilled in the art of tobacco and tobacco-related or
tobacco-derived products. See, Gutcho, Tobacco Flavoring Substances
and Methods, Noyes Data Corp. (1972) and Leffingwell et al.,
Tobacco Flavoring for Smoking Products (1972).
[0062] The inhalable substance and/or the separate vapor forming
material may be provided on the substrate in a variety of
configurations. For example, both materials may be associated with
the substrate such that the concentration of each material along
the length of the substrate is substantially constant (e.g., when
dividing the substrate into a plurality of lengthwise segments, the
total concentration of material in each individual segment can be
substantially similar, such as varying by less than 10%, less than
5%, or less than 2% by mass). In other embodiments, one or both of
the materials may be present in a defined pattern. For example, the
pattern may be a gradient wherein the concentration continually
increases or decreases along the length of the substrate. In this
manner, the first puff on the article may provide an amount of the
inhalable substance that is significantly greater than or less than
the amount of the inhalable substance in the last puff. Moreover,
the pattern may be such that a bolus of inhalable substance is
provided at some point along the length of the substrate (e.g.,
corresponding to the first puff, the last puff, or some
intermediate puff on the article). Any variety of such patterns may
be envisioned in light of the present disclosure, and such
variations are likewise encompassed by the present invention. Such
patterning likewise may apply to further components as described
herein (e.g., flavorants). For example, a bolus of a flavorant may
be provided on the substrate in a position to substantially
correspond to the last puff or the last two or three puffs on the
article. The release of such flavor may signal to the consumer that
the final puff on the device is approaching or has been
achieved.
[0063] Still further, release of the inhalable substance (and any
further components, such as flavorants) may be associated with
activation of specific heating member. For example, a plurality of
heating members may be provided, and at least two different
inhalable substances may be individually associated with two
different heating members. In a non-limiting example, ten heating
members may be provided; nine of the heating members may be
associated with a first inhalable substance (e.g., a tobacco
component); and one of the heating members may be associated with a
specific flavorant (e.g., menthol). Alternately, two heating
members may be provided; the first heating member may provide
heating of an inhalable substance medium for release of aerosol
sufficient for about six to about ten puffs by a consumer; the
second heating member may provide heating to a second inhalable
substance medium for release of aerosol sufficient for about one or
two puffs. Further combinations of individual heating elements with
different inhalable components also are encompassed. If desired,
the inventive article can be equipped with a user controlled
switching mechanism (or even a pre-programmed mechanism for
automatic switching) to allow two or more selected heating members
to be activated at essentially the same time to provide an aerosol
with the sensory components associated with the respective heating
members. For example, one or more flavors may be associated with
individual heating members so that a consumer may obtain aerosol of
a different flavor during individual puffs on the article.
[0064] In specific embodiments, it can be particularly preferable
for the inhalable substance medium to comprise a solid substrate
and have a high surface area to volume ratio. This can be
particularly beneficial to simultaneously increase the volume of
vapor or aerosol that can be released from the substrate and into
an air flow and lower the temperature required to provide the
desired release volume without requiring a high thermal
conductivity material as the substrate. Moreover, increased surface
area allows for a larger area of contact of the substrate with the
heating member, which in turn allows for lower heating
temperatures. More particularly, increases in surface area can
facilitate aerosol formation at lower vapor pressures, thereby
allowing the desired amount of aerosol to be formed at lower
temperature, which can correlate to a reduced energy requirement
and less potential to form unwanted byproducts of heat
decomposition. In particular embodiments, increased surface area
can be provided through use of substrates having a high porosity
and/or having a convoluted surface profile.
[0065] The substrate also may particularly be characterized in
relation to thickness. Preferably, the substrate is relatively thin
so as to facilitate rapid heat transfer from the heating member to
the inhalable substance to be volatilized. For example, the
substrate may have an average thickness of less than 5 mm, less
than 3 mm, less than 2 mm, less than 1 mm, less than 0.75 mm, or
less than 0.5 mm.
[0066] In the embodiment of FIG. 4, the inhalable substance medium
350 is substantially tubular shaped and is formed of a wall 352
with an inner surface and an outer surface. As noted above, the
substrate wall 352 may be formed substantially of a material that
can include the inhalable substance naturally therein (e.g.,
tobacco paper) or may be formed of any further material (e.g.,
paper) that can have the inhalable substance and/or the
vapor-former or aerosol-former entrained therein. In addition to
the inhalable substance and/or the vapor-forming or aerosol-forming
substance, the substrate wall may comprise additional components.
For example, a vapor barrier 375 may be included on the inner
surface of the wall of the inhalable substance medium (as
illustrated in FIG. 4a) to prevent release of vapor or aerosol into
the interior volume of the inhalable substance medium and
facilitate release of the vapor or aerosol into an annular space
319 defined by the outer surface of the inhalable substance medium
wall 352 and the inner surface of the wall of the cartridge body
305. Such annular space can encompass a portion of the interior
cartridge space. Any vapor barrier material, such as a metal foil,
may be used. Alternatively, the vapor barrier may be on the outer
surface of the inhalable substance medium wall 352 in embodiments
where the heating member contacts the outer surface as opposed to
the inner surface of the inhalable substance medium wall 352.
Preferably, the vapor barrier is positioned on the wall surface
that is adjacent (or in contact with) the heating member when the
inhalable substance medium 350 is heated. In particular
embodiments, the vapor barrier may be formed of a material that is
electrical insulating or may comprise a layer of electrically
insulating material that can be in contact with the heating member
400. For example, a metal foil may be used as the vapor barrier,
and the foil may have an insulating monolayer--e.g., a metal oxide
layer--in contact with the heating member.
[0067] In further embodiments, the inhalable substance medium may
be formed of a material that softens or changes phase (especially
from solid to molten) at about the working temperature of the
article. For example, the inhalable substance medium may be a wax
or a gel, and the inhalable substance may be entrained therein. In
such embodiments, it can be particularly useful to include the
vapor barrier (or similar material) that provides support to the
inhalable substance medium and substantially prevents the inhalable
substance medium from contacting the heating member. Likewise, the
inhalable substance medium may comprise a vapor barrier layer
coated with an inhalable substance and/or an aerosol forming
material. For example, one or more of such coating materials may be
in a microencapsulated form that preferably releases its components
at a temperature within one or more of the working ranges otherwise
described herein. Microencapsulation technology that may be useful
in such embodiments is disclosed, for example, in U.S. Pat. No.
4,464,434 to Davis.
[0068] In alternative embodiments (such as shown in FIG. 4b), the
cartridge body 305 may be formed with multiple layers. For example,
FIG. 4b illustrates an alternate embodiment wherein the cartridge
body is formed of a first, outer layer 306 formed of a first
material and a second, inner layer 307 formed of the same or a
different material. Further layers also are envisioned. Preferably,
the first, outer layer 306 is formed of a material with a closed
structure. By closed structure is meant that the material
substantially prevents passage of aerosol or vapor into the
interior of the layer such that the aerosol or vapor may propagate
along the length of the cartridge body 305 to the mouth end 315
thereof. For example, the first, outer layer 306 may comprise a
paper material or a suitable polymer material, as already described
above. Such first, outer layer may have a thickness that preferably
is less than about 1 mm, less than about 0.9 mm, less than about
0.8 mm, less than about 0.7 mm, less than about 0.6 mm, or less
than about 0.5 mm. Alternatively, the first, outer layer may have a
thickness of about 0.1 mm to about 1.0 mm, about 0.2 mm to about
0.8 mm, about 0.25 mm to about 0.75 mm, or about 0.3 mm to about
0.7 mm.
[0069] The second, inner layer 307 preferably has a greater
thickness than the first, outer layer 306, and can be about 0.8 mm
to about 4 mm, about 1 mm to about 3.5 mm, or about 1.2 mm to about
3.0 mm. The second, inner layer may be in direct contact with the
tobacco substrate material 350. As such, it is preferable for the
second, inner layer to have a substantially open structure. By
being in direct contact, the second, inner layer may provide
greater support to the inhalable substance medium 350. Thus, the
cartridge body, and particularly the second, inner layer 307
thereof, may be characterized as providing continuous support for
the inhalable substance medium 350 along substantially the entire
length thereof (e.g., at least about 75%, at least about 85%, at
least about 90%, or at least about 95% of the length thereof). By
having an open structure, the second, inner layer can permit
passage of formed aerosol or vapor from the inhalable substance
medium, and the open structure preferably extends along the length
of the cartridge body to the mouth end 315 thereof. In this manner,
the annular space 319 defined by the inner surface of the cartridge
body and the outer surface of the inhalable substance medium, as
other wise described herein, is replaced by the open structured
second, inner layer of the cartridge body and provides the same
function. Thus, the void in the second, inner layer of the
cartridge may exhibit substantially the same characteristics as
otherwise described herein (e.g., volume, etc.) for the annular
space. In specific embodiments, the open structure of the second,
inner layer is such that at least about 50%, at least about 60%, at
least about 70%, at least about 80%, or at least about 85% of the
layer, based on volume, is the open void space. In specific
embodiments, the open space of the second, inner layer may be about
50% to about 90%, about 60% to about 85%, or about 65% to about 80%
by volume of the second, inner layer. This relatively thick and
porous layer can be characterized as providing an aerosol
collection/generation area and may be, in one example, an accordion
layer of paper or polymeric material. Alternately, the second,
inner layer may be a porous mat of material such as cellulose
acetate tow, cotton fibers, or any number of materials useful to
form a non-woven porous mat such as spun bonded polypropylene, PLA
fibers, PHA fibers, glass fibers, and the like. This may be
described as an open cell material.
[0070] In further embodiments, as seen in FIG. 4c, the cartridge
body may be formed of a first, outer layer 306 that is
substantially closed in structure and a second, inner layer 307
that exhibits an open structure, as described above, and the two
layers may be separated by a void space 308 as otherwise described
herein. In this manner, the inhalable substance medium 350 is
provided substantially continuous support, the generated vapor or
aerosol is allowed to pass therethrough into the void 308, and the
vapor or aerosol can pass along the length of the void to the mouth
end 315 of the cartridge body without substantially permeating
through the first, outer layer. The void space may include one or
more struts 309 interconnecting the first, outer layer with the
second, inner layer without limiting passage of any aerosol or
vapor along the length of the cartridge body within the void
space.
[0071] As with the cartridge 300 generally, the tubular wall 352 of
the inhalable substance medium 350 has opposing terminal ends, the
first end 353 being in proximity to the mouth end 315 of the
cartridge body 305, and the second end 354 being in proximity to
the engaging end 310 of the cartridge body 305. The inhalable
substance medium particularly may be attached to the cartridge body
at the respective terminal ends of each component. Such attachment
may be direct or indirect. For example, in FIG. 4, the second end
354 of the inhalable substance medium 350 is directly attached to
the engaging end 310 of the cartridge body 305 (specifically in the
area of the flange 302). Such direct attachment can be by any
suitable means, such as an adhesive. The first end 353 of the
inhalable substance medium 350, however, is indirectly attached to
the mouth end 315 of the cartridge body 305 via a frame member 360.
In this embodiment, the frame member 360 comprises an outer wall
361, a wall flange 362, a central hub 363, and a plurality of
spokes 364 connecting the central hub 363 to the outer wall 361
such that open space exists between the outer wall 361 and the
central hub 363. For clarity, FIG. 5 provides an end view of the
cartridge (without overwrap 380), and this view essentially shows
the frame member. The central hub 363 has a cross-sectional shape
that is substantially identical to the cross-sectional shape of the
inhalable substance medium (i.e., round in the present embodiment),
and the hub has an outer diameter of a size suitable such that hub
is secured within the first end 353 of the inhalable substance
medium, the wall 352 of the inhalable substance medium at the first
end being in direct contact with the hub and, preferably, being
secured thereto (e.g., by an adhesive or similarly suitable
attachment). The hub specifically may have an elongate outer wall
that provides sufficient area for attachment for the inhalable
substance medium and for attachment to the spokes 364. The hub may
have a thickness that is substantially equal to the length of the
elongate wall, or the elongate wall may have a length that is
greater than the thickness of the hub, the additional length
extending one or both of anterior and posterior to the body of the
hub. In this manner, the inhalable substance medium is suspended
within the cartridge body and is maintained therein through tension
along the length of the tubular shaped inhalable substance medium
originating from the attachments at the first end and second end
thereof to the mouth end 315 and engaging end 310, respectively, of
the cartridge body.
[0072] Tensioning of the inhalable substance medium can be
particularly useful to provide for specific performance of the
inventive article. As otherwise described herein, it can be
beneficial for the inhalable substance medium to have a relatively
small thickness such that heat is efficiently transferred,
particularly when substrates, such as paper, that exhibit
relatively low heat transfer are used. Substrates of small
thickness, however, can have relatively low strength in certain
dimensions while exhibiting relatively high strength in other
dimensions. For example, thin paper, in tension, exhibits high
strength relative to the strength of the same paper in compression.
Tensioning also can facilitate direct contact of the heating member
to the surface of the inhalable substance medium to be heated
(including a substrate that is used or a vapor barrier that may be
present). This further can be facilitated by providing the heating
member with an outer diameter that is greater than the inner
diameter of the inhalable substance medium tube so that the heating
member actually provides tension to the inhalable substance medium
substantially perpendicularly to the lengthwise axis of the
inhalable substance medium. Specifically, the outer diameter of the
heating member may exceed the inner diameter of the inhalable
substance medium (or the inner diameter of any further layer, such
as a vapor barrier, that is interior thereto) by about 1% to about
20%, about 2% to about 15%, about 3% to about 12%, or about 5% to
about 10%.
[0073] As discussed above, the engaging end 310 of the cartridge
300 is sized and shaped for insertion into the control housing 200.
The receiving chamber 210 of the control housing 200 can be
characterized as being defined by a wall 212 with an inner surface
and an outer surface, the inner surface defining the interior
volume of the receiving chamber. Thus, the greatest outer diameter
(or other dimension depending upon the specific cross-sectional
shape of the embodiments) of the cartridge 300 preferably is sized
to be less than the inner diameter (or other dimension) at the
inner surface of the wall of the open end of the receiving chamber
in the control housing. Ideally, the difference in the respective
diameters is sufficiently small so that the cartridge fits snugly
into the receiving chamber, and frictional forces prevent the
cartridge from being moved without an applied force. On the other
hand, the difference should be sufficient to allow the cartridge to
slide or otherwise be indexed within the receiving chamber without
requiring undue force. In alternative embodiments, the article 10
may be configured such that the cartridge (or a portion thereof)
slides over and around the receiving chamber of the control
housing. For example, the cartridge may be configured such that the
cartridge overwrap 380 has an inner diameter that is greater than
the outer diameter of the control housing at the end of the
receiving chamber. In this manner, the cartridge overwrap slides
over the control housing but further components of the cartridge
still can be considered as being inserted into the receiving
chamber of the control housing.
[0074] In preferred embodiments, the article 10 may take on a size
that is comparative to a cigarette or cigar shape. Thus, the
article may have a diameter of about 5 mm to about 25 mm, about 5
mm to about 20 mm, about 6 mm to about 15 mm, or about 6 mm to
about 10 mm. Such dimension may particularly correspond to the
outer diameter of the control housing 200. Thus, the outer diameter
of the cartridge 300 can be sufficiently less so as to allow for
indexing of the cartridge within the receiving chamber 210, as
discussed herein. As seen in FIG. 4, the overwrap 380 of the
cartridge may be formed to have an area of increased diameter at
the mouth-end 315. This area of increased diameter preferably is
such that the diameter is at least the diameter of the receiving
end of the control housing. Thus, a mouth-end wall 316 is formed to
function as a stop to prevent the cartridge from being inserted
entirely into the receiving chamber of the control housing.
[0075] The mouth-end wall may define the mouth-end of the cartridge
as the distance therefrom to the terminal mouth-end of the
cartridge. This may be the area of greater diameter illustrated in
FIG. 4. The length of the mouth-end portion having the area of
greater diameter can vary, such as being about 5 mm to about 25 mm,
about 8 mm to about 22 mm, or about 10 mm to about 20 mm. This area
may include a filter component as otherwise described herein.
Moreover, in other embodiments, the mouth-end of the overwrap or
cartridge may be substantially of the same diameter of the
remaining portion thereof. In such embodiments, the mouth-end could
be defined as the section of the cartridge that is not heated in
use and on which the consumer's lips would be placed. Further, in
such embodiments, a mouth-end wall still may be present to function
as a stop. Alternatively, other stop means may be provided,
including means interior to the cartridge and/or the receiving
chamber of the control housing.
[0076] The control housing 200 and cartridge 300 may likewise be
characterized in relation to overall length. For example, the
control housing may have a length of about 40 mm to about 120 mm,
about 45 mm to about 110 mm, or about 50 mm to about 100 mm. The
cartridge may have a length of about 20 mm to about 60 mm, about 25
mm to about 55 mm, or about 30 mm to about 50 mm. The length of the
control housing may be divided substantially equally between the
control segment 205 and the receiving end (which may be defined by
the receiving chamber 210, or by the projection 225).
Alternatively, one or the other may encompass about 55%, about 60%,
about 65%, or about 70% of the total length of the control housing.
In other embodiments, the receiving chamber may have a length that
is about 70% to about 120%, about 80% to about 110%, or about 85%
to about 100% of the length of the cartridge. The projection
specifically may have a length of about 10 mm to about 50 mm, about
15 mm to about 45 mm, or about 20 mm to about 40 mm.
[0077] The projection may be formed of a variety of materials. In
specific embodiments, it can be useful for the projection to be
formed of a thermal insulator. This can be desirable so as to
maximize heat flow from the heating member to the inhalable
substance medium rather than to the projection.
[0078] The cartridge overwrap 380 may be formed of any material
useful for providing additional structure and/or size to the
cartridge body 305. Preferably the overwrap comprises a material
that resists transfer of heat, which may include a paper or other
fibrous material, such as a cellulose. The overwrap also may be
formed of multiple layers, such as an underlying, bulk layer and an
overlying layer, such as a typical wrapping paper in a cigarette.
The overwrap particularly may comprise a material typically used in
a filter element of a conventional cigarette, such as cellulose
acetate. When the overwrap is present, the overall length thereof
can vary from being substantially identical to the length of the
cartridge body (and the inhalable substance medium 350) up to about
two times the length of the cartridge body. Thus, the overwrap can
be characterized as extending beyond the engaging end 310 of the
cartridge body and/or as extending beyond the mouth end 315 of the
cartridge body. Thus, the cartridge body and the inhalable
substance medium each have a length that is up to about 50%, up to
about 30%, or up to about 10% less than the length of the overwrap.
Preferably, the cartridge body and the inhalable substance medium
each have a length that is at least 10%, at least 15%, or at least
20% less than the length of the overwrap. More specifically, the
distance the overwrap extends beyond the engaging end 310 of the
cartridge body can be about 5%, about 10%, about 15%, about 20%,
about 25%, about 30%, about 40%, about 50%, about 60%, about 70%,
about 80%, about 90%, or about 100% of the length of the cartridge
body. Further, the distance the overwrap extends beyond the
engaging end of the cartridge body can be about 5% to about 100%,
about 10% to about 90%, about 15% to about 80%, about 20% to about
75%, about 25% to about 70%, or about 30% to about 60% of the
length of the cartridge body. The distance the overwrap extends
beyond the mouth end of the cartridge body can be at least about
1%, at least about 2%, at least about 3%, at least about 4%, at
least about 5%, at least about 6%, at least about 7%, at least
about 8%, at least about 9%, or at least about 10% of the length of
the cartridge body. In other embodiments, the distance can be about
2% to about 20%, about 4% to about 18%, or about 5% to about 15% of
the length of the cartridge body. The excess length of the overwrap
at the engaging end of the cartridge can function to protect the
inhalable substance medium within and also to provide structural
integrity to the article 10 when the cartridge is inserted into the
receiving chamber 210 only to a point wherein the heating member
just makes contact with the inhalable substance medium. The excess
length of the overwrap at the mouth end of the cartridge can
function to simply separate the cartridge body from the mouth of a
consumer or to provide space for positioning of a filter material
or to affect draw on the article or to affect flow characteristics
of the vapor or aerosol leaving the article during draw.
[0079] Alternatively, the overwrap may be absent, and the inhalable
substance medium may simply be substantially shorter in length than
the cartridge body. Similarly, the overwrap and the cartridge body
may essentially be combined into a single element that provides the
functions of both elements as otherwise described herein. In such
embodiments, the annular space 319 wherein the vapor is formed may
be the space between the inhalable substance medium and the outer
body (i.e., the combined cartridge body and overwrap). For example,
referring to FIG. 4, the cartridge body 305 may be absent, and the
overwrap 380 can essentially function also as the cartridge
body--i.e., the outer body. Specifically, the second end 354 of the
inhalable substance medium 350 may be attached directly to the
outer body. For example, a ferrule (not shown) may be used to
attach the second end of the inhalable substance medium to the
outer body. The inhalable substance medium may be perforated so as
to allow air flow into the annular space. Alternatively,
perforations may be formed in the outer body (or cartridge and/or
overwrap, depending upon the particular embodiment) in the area of
the annular space. Thus, the invention in all embodiments
encompasses the presence of perforations or apertures in the
components as necessary to allow ambient air to flow directly into
the annular space (e.g., without having to pass through the second
end of the inhalable substance medium).
[0080] The overwrap also can function to provide particular
characteristics at the mouth end of the cartridge. For example, the
construction and/or shape and/or dimension of the overwrap can
function to provide the sensation of a conventional cigarette in
the mouth of a user. Moreover, the overwrap may comprise a filter
390 (e.g., cellulose acetate or polypropylene) positioned in
proximity to the mouth end of the cartridge (such as shown in FIG.
6, wherein the terminus of the mouth end 315 of the cartridge is
removed to reveal the filter underneath) to increase the structural
integrity thereof and/or to provide filtering capacity, if desired,
and/or to provide resistance to draw. For example, an article
according to the invention can exhibit a pressure drop of about 50
to about 250 mm water pressure drop at 17.5 cc/second air flow. In
further embodiments, pressure drop can be about 60 mm to about 180
mm or about 70 mm to about 150 mm. Pressure drop value may be
measured using a Filtrona Filter Test Station (CTS Series)
available from Filtrona Instruments and Automation Ltd or a Quality
Test Module (Q.TM.) available from the Cerulean Division of Molins,
PLC. The thickness of the filter along the length of the cartridge
can vary--e.g., about 2 mm to about 20 mm, about 5 mm to about 20
mm, or about 10 mm to about 15 mm. In some embodiments, the filter
may be separate from the overwrap, and the filter may be held in
position near the cartridge by the overwrap.
[0081] Exemplary types of wrapping materials, wrapping material
components, and treated wrapping materials that may be used in
overwrap 380 in the present invention are described in U.S. Pat.
No. 5,105,838 to White et al.; U.S. Pat. No. 5,271,419 to Arzonico
et al.; U.S. Pat. No. 5,220,930 to Gentry; U.S. Pat. No. 6,908,874
to Woodhead et al.; U.S. Pat. No. 6,929,013 to Ashcraft et al.;
U.S. Pat. No. 7,195,019 to Hancock et al.; U.S. Pat. No. 7,276,120
to Holmes; U.S. Pat. No. 7,275,548 to Hancock et al.; PCT WO
01/08514 to Fournier et al.; and PCT WO 03/043450 to Hajaligol et
al., which are incorporated herein by reference in their
entireties. Representative wrapping materials are commercially
available as R. J. Reynolds Tobacco Company Grades 119, 170, 419,
453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676 and
680 from Schweitzer-Maudit International. The porosity of the
wrapping material can vary, and frequently is between about 5
CORESTA units and about 30,000 CORESTA units, often is between
about 10 CORESTA units and about 90 CORESTA units, and frequently
is between about 8 CORESTA units and about 80 CORESTA units.
[0082] In various embodiments, a wrapping material used in the
overwrap 380 can incorporate a fibrous material and at least one
filler material imbedded or dispersed within the fibrous material.
The fibrous material can vary and can be, for example, a cellulosic
material. The filler material can have the form of essentially
water insoluble particles. Additionally, the filler material can
incorporate inorganic components.
[0083] To maximize aerosol and flavor delivery which otherwise may
be diluted by radial (i.e., outside) air infiltration through the
overwrap 380, one or more layers of non-porous cigarette paper may
be used to envelop the cartridge (with or without the overwrap
present). Examples of suitable non-porous cigarette papers are
commercially available from Kimberly-Clark Corp. as KC-63-5,
P878-5, P878-16-2 and 780-63-5. Preferably, the overwrap is a
material that is substantially impermeable to the vapor formed
during use of the inventive article. If desired, the overwrap can
comprise a resilient paperboard material, foil-lined paperboard,
metal, polymeric materials, or the like, and this material can be
circumscribed by a cigarette paper wrap. Moreover, the overwrap 380
may comprise a tipping paper that circumscribes the component and
optionally may be used to attach a filter material to the cartridge
300, as otherwise described herein.
[0084] Referring again to FIG. 4, it can be seen that the portion
of the overwrap at the mouth end 315 of the cartridge 300 actually
extends beyond the end of the cartridge body 305 and includes an
opening 381 to allow free movement of vapor and/or aerosol from the
article 10 to a consumer. In some embodiments, it may be desirable
to include a filter material specifically in this area of the
article, such as positioned between the mouth end 315 of the
cartridge body 305 and the terminal mouth end of the overwrap 380
(as shown in FIG. 6). Thus, the mouth end of the cartridge may be
characterized as being partially occluded (i.e., by the presence of
the filter material and/or by the size of the opening). This can be
beneficial to limit the concentration of the inhalable substance
that is delivered to the consumer or control resistance to draw.
Alternatively, any filter material that is used may be designed
with relatively low removal efficiency so as not to significantly
limit the aerosol delivered therethrough.
[0085] The control housing 200 includes an electrical energy source
220 that provides power to the electrical heating member 400. The
energy source includes a projection 225 that extends therefrom such
that the terminal end of the projection extends approximately to
the end of the receiving chamber 210. The electrical energy source
is surrounded by a base 230 that can provide insulating properties
and also can function as a dead stop to prevent the cartridge 300
from being inserted into the control housing a distance such that
the projection extends through the mouth end 315 of the cartridge.
The projection is dimensioned to slide inside the interior space
defined by the inner surface of the wall 352 of the inhalable
substance medium 350. The projection also is dimensioned to provide
the electrical heating member in sufficient proximity to the
inhalable substance medium (preferably in direct contact therewith)
to heat the medium and cause release of the inhalable substance.
Thus, the engaging end 310 of the cartridge generally or the
cartridge body 305 specifically can be characterized as including
an opening that is sufficiently sized and shaped to receive at
least one component of the electrical energy source (i.e., the
projection 225).
[0086] The electrical energy source 220 can be characterized as
being an electrical receptacle that is in electrical connection
with a power source 275 (shown in FIG. 6) and that provides for
switch-operated delivery of electrical energy to the heating member
400, such as via the contacts 410, as illustrated in FIG. 4. In
some embodiments, the contacts may be permanently inserted into the
receptacle or electrical energy source 220. In other embodiments,
the electrical energy source may function as a more literal
receptacle in that the contacts are not permanently inserted
therein but only make an electrical connection with the electrical
energy source when the cartridge 300 is inserted into the receiving
chamber 210 sufficiently so that the contacts are moved into
electrical connection with the electrical energy source. In still
other embodiments, the projection 225 can function as an extension
of the electrical energy source in that electrical leads 222 (as
seen in FIG. 9) are present on the projection, and the electrical
heating member 400 receives electrical energy from the electrical
energy source only when the electrical heating member (or a portion
thereof) makes contact with the electrical leads.
[0087] The electrical heating member 400 can be any device suitable
to provide heat sufficient to facilitate release of the inhalable
substance for inhalation by a consumer. In certain embodiments, the
electrical heating member is a resistance heating element. Useful
heating elements can be those having low mass, low density, and
moderate resistivity and that are thermally stable at the
temperatures experienced during use. Useful heating elements heat
and cool rapidly, and thus provide for the efficient use of energy.
Rapid heating of the element also provides almost immediate
volatilization of the aerosol-forming substance. Rapid cooling
prevents substantial volatilization (and hence waste) of the
aerosol-forming substance during periods when aerosol formation is
not desired. Such heating elements also permit relatively precise
control of the temperature range experienced by the aerosol-forming
substance, especially when time based current control is employed.
Useful heating elements also are chemically non-reactive with the
materials comprising the inhalable substance medium being heated so
as not to adversely affect the flavor or content of the aerosol or
vapor that is produced. Exemplary, non-limiting, materials that may
comprise the heating element include carbon, graphite,
carbon/graphite composites, metallic and non-metallic carbides,
nitrides, silicides, inter-metallic compounds, cermets, metal
alloys, and metal foils. In particular, refractory materials may be
useful. Various, different materials can be mixed to achieve the
desired properties of resistivity, mass, thermal conductivity, and
surface properties. As seen in FIG. 4, the electrical heating
member is configured as a coil 405 positioned near the terminal end
of the projection 225 with contacts 410 connecting the coil to the
electrical energy source. Such coil (and optionally the leads) may
be formed of any suitable material, such as described above, and
preferably exhibits properties, such as described above.
[0088] In other embodiments, the heating member 400 can take on
other configurations. For example, the heating member may comprise
an array of individual heating elements that are individually
controlled to heat only the portion of the inhalable substance
medium 350 in direct contact with the individual element. Such
direct contact can be preferred in light of the ability to provide
conduction heating that is more rapid and that requires less
resistance. For example, the projection 225 may comprise such an
array in a shape that corresponds to the shape of the inhalable
substance medium in the cartridge 300. More specifically, when the
inhalable substance medium is tubular, the heating member may be a
tubular member divided into sections along the length thereof to
provide an array of resistive heaters. Alternatively, the tubular
member may be divided into sections around the circumference
thereof to provide an array of resistive heaters. In each
embodiment, the tubular inhalable substance medium can only be
heated in the section corresponding to the section of the heater
array that is heated (only one section being heatable at any one
time). Preferably, such sections of the heater array can be
separated by non-heating or insulative sections so as to avoid
overlap of heated sections on the inhalable substance medium. In
other embodiments, the heater array may be linear, and the
inhalable substance medium may be shaped and dimensioned to
interact with such linear shape. Examples of such heater arrays
that may be adapted for use in the present invention per the
discussion provided above can be found 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., which are incorporated herein by
reference in their entireties.
[0089] In light of the various possible heater configurations, the
invention also encompasses embodiments wherein the inhalable
substance medium 350 may be coated, laminated, or otherwise
attached directly to the heating element(s). In one example, the
heating element may be in the form of a metal foil--e.g., stainless
steel foil, aluminum foil, copper foil, and the like. For example
the foil may have a thickness of about 0.05 mm to about 10 mm,
about 0.1 mm to about 8 mm, about 0.2 mm to about 6 mm, about 0.5
mm to about 5 mm, or about 1 mm to about 4 mm. The foil likewise
may have a length of about 20 mm to about 150 mm, about 40 mm to
about 120 mm, or about 50 mm to about 100 mm. The heating element
foil may be provided in any useful configuration, such as a
significantly straight line or coiled (e.g., having a coil diameter
of about 4 mm to about 15 mm, about 5 mm to about 12 mm, or about 6
mm to about 10 mm) or otherwise provided in a convoluted
configuration. In still other embodiments, the heating element may
be provided as multiple layers of discs (e.g., diameter of about 1
mm to about 6 mm, about 1.5 mm to about 5 mm, or about 2 mm to
about 4 mm) may be arranged in sequence (and optionally activated
in sequence) to release aerosol forming materials coated thereon or
adjacent thereto. The heating element further may comprise a
fibrous material having a high surface area and an adsorbent,
porous, wettable characteristic in order to carry a suitable amount
of the inhalable substance alone or in combination with a separate
aerosol-former. For example, the heating element may be in the form
of porous metal wires or films; carbon yarns, cloths, fibers,
discs, or strips; graphite cylinders, fabrics, or paints;
microporous high temperature polymers having moderate
resistivities; porous substrates in intimate contact with
resistance heating components; and the like. In preferred designs,
it can be useful to maximize heater surface area, which can result
in a reduced heater temperature requirement to achieve the proper
aerosol release. In a specific example, the inhalable substance
medium 350 may comprise a mix of finely ground tobacco, tobacco
extract, spray dried tobacco extract, or other tobacco form mixed
with optional inorganic materials (such as calcium carbonate),
optional flavors, and the aerosol forming materials to form a
substantially solid or moldable (e.g., extrudable) substrate. This
solid or moldable substrate then may be attached directly to the
heating element. As noted above, multiple heater elements with the
inhalable substance medium 350 directly attached thereto may be
arranged in and activated in sequence to release their aerosol
forming materials.
[0090] In particular embodiments, the heating member can be
integral with (e.g., embedded within) the inhalable substance
medium. For example, the inhalable substance medium 350 may be
formed of a material as described above and may include one or more
conductive materials mixed therein. Contacts 410, as described
herein, may be connected directly to the inhalable substance medium
such that, when the cartridge 300 is inserted into the receiving
chamber 210 of the control housing 200, the contacts make
electrical connection with the electrical energy source 220.
Alternatively, the contacts may be integral with the electrical
energy source and extend into the receiving chamber such that, when
the cartridge is inserted into the receiving chamber of the control
housing, the contacts make electrical connection with the inhalable
substance medium. Because of the presence of the conductive
material in the inhalable substance medium, the application of
power from the electrical energy source to the inhalable substance
medium allows electrical current to flow and thus produce heat from
the conductive material. Thus, the heating member may be described
as being integral with the inhalable substance medium. As a
non-limiting example, graphite or other suitable, conductive
material may be mixed with, embedded in, or otherwise present
directly on or within the material forming the inhalable substance
medium to make the heating member integral with the medium.
[0091] In even further embodiments, a conventional heating member
according to the various constructions described herein also may be
combined with the inhalable substance medium so to be at least
partially embedded therein. For example, referring to FIG. 12, the
heating coil 407 may be integrally formed with the inhalable
substance medium 350 so that at least a portion of the heating coil
is fully located within the outer and inner walls of the inhalable
substance medium. In such embodiments, the electrical contacts 410
may extend out of the inhalable substance medium. In even further
embodiments, a vapor barrier that is present on the inhalable
substance medium may function as the heating member also.
[0092] The control housing 200 further can include additional
components that preferably are present in the control segment 205
(although one or more of such additional components may be located
completely or partially within the receiving chamber 210 or be in
communication with the receiving chamber). For example, the control
housing preferably includes a control circuit 260 (which may be
connected to further components, as further described herein) that
is connected by electrically conductive wires (not shown) to a
power source 275. The control circuit particularly can control when
and how the heating member 400 receives electrical energy to heat
the inhalable substance medium 350 for release of the inhalable
substance for inhalation by a consumer. Such control can relate to
actuation of pressure sensitive switches or the like, which are
described in greater detail hereinafter.
[0093] The control components particularly can be configured to
closely control the amount of heat provided to the inhalable
substance medium 350. While the heat needed to volatilize the
aerosol-forming substance in a sufficient volume to provide a
desired dosing of the inhalable substance for a single puff can
vary for each particular substance used, it can be particularly
useful for the heating member to heat to a temperature of at least
120.degree. C., at least 130.degree. C., or at least 140.degree. C.
In some embodiments, in order to volatilize an appropriate amount
of the aerosol-forming substance and thus provide a desired dosing
of the inhalable substance, the heating temperature may be at least
150.degree. C., at least 200.degree. C., at least 300.degree. C.,
or at least 350.degree. C. It can be particularly desirable,
however, to avoid heating to temperatures substantially in excess
of about 550.degree. C. in order to avoid degradation and/or
excessive, premature volatilization of the aerosol-forming
substance. Heating specifically should be at a sufficiently low
temperature and sufficiently short time so as to avoid significant
combustion (preferably any combustion) of the inhalable substance
medium. The present invention particularly can provide the
components of the present article in combinations and modes of use
that will yield the inhalable substance in desired amounts at
relatively low temperatures. As such, yielding can refer to one or
both of generation of the aerosol within the article and delivery
out of the article to a consumer. In specific embodiments, the
heating temperature can be about 120.degree. C. to about
300.degree. C., about 130.degree. C. to about 290.degree. C., about
140.degree. C. to about 280.degree. C., about 150.degree. C. to
about 250.degree. C., or about 160.degree. C. to about 200.degree.
C. The duration of heating can be controlled by a number of
factors, as discussed in greater detail hereinbelow. Heating
temperature and duration may depend upon the desired volume of
aerosol and ambient air that is desired to be drawn through the
annular space 319 defined by the inner surface of the wall of the
cartridge body 305 and the outer surface of the wall 352 of the
inhalable substance medium 350, as further described herein. The
duration, however, may be varied depending upon the heating rate of
the heating member, as the article may be configured such that the
heating member is energized only until a desired temperature is
reached. Alternatively, duration of heating may be coupled to the
duration of a puff on the article by a consumer. Generally, the
temperature and time of heating will be controlled by one or more
components contained in the control housing, as noted above.
[0094] The amount of inhalable material released by the inventive
article 10 can vary based upon the nature of the inhalable
material. Preferably, the article 10 is configured with a
sufficient amount of the inhalable material, with a sufficient
amount of any aerosol-former, and to function at a sufficient
temperature for a sufficient time to release a desired amount over
a course of use. The amount may be provided in a single inhalation
from the article 10 or may be divided so as to be provided through
a number of puffs from the article over a relatively short length
of time (e.g., less than 30 minutes, less than 20 minutes, less
than 15 minutes, less than 10 minutes, or less than 5 minutes). For
example, the article may provide nicotine in an amount of about
0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1
mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg per puff on
the article 10. In other embodiments, a desired amount may be
characterized in relation to the amount of wet total particulate
matter delivered based on puff duration and volume. For example,
the article 10 may deliver at least 1.0 mg of wet total particulate
matter on each puff, for a defined number of puffs (as otherwise
described herein), when smoked under standard FTC smoking
conditions of 2 second, 35 ml puffs. Such testing may be carried
out using any standard smoking machine. In other embodiments, the
amount of wet total particulate matter (WTPM) delivered under the
same conditions on each puff may be at least 1.5 mg, at least 1.7
mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, about 1.0 mg
to about 5.0 mg, about 1.5 mg to about 4.0 mg, about 2.0 mg to
about 4.0 mg, or about 2.0 mg to about 3.0 mg. The same values may
be applied when characterizing the article in terms of the amount
of vapor or aerosol that is yielded per puff.
[0095] Returning to FIG. 4, a particular embodiment of the
inventive article 10 is illustrated wherein the article is
indexable to provide segmented heating of the inhalable substance
medium 350. In use, according to this embodiment, the engaging end
310 (including any overwrap that is present and extending beyond
the end of the cartridge wall 305) of a cartridge 300 is inserted
into the receiving chamber 210 of the control housing 200. As seen
more clearly in FIG. 7, when the engaging end of the cartridge
slides a minimum, operably distance into the receiving chamber, the
inhalable substance medium 350, the electrical heating member 400,
and the electrical energy source 220 align so as to allow for
heating of at least a segment of the inhalable substance medium
350. Such alignment can result from the direct cross-sectional
alignment of the three components (e.g., the inhalable substance
medium 350, the electrical heating member 400, and the projection
225 functioning as an extension of the electrical energy source 220
are all aligned such that a cross-section of the area of alignment
can encompass a portion of all three components). Alternatively,
only the inhalable substance medium 350 and the electrical heating
member 400 may be in a direct cross-sectional alignment, but the
electrical energy source 220 may be considered aligned therewith in
that the electrical heating member is aligned with the electrical
energy source 220 so as to make an electrical connection therewith.
This may be referred to as an operable alignment.
[0096] The embodiment illustrated in FIG. 4 and FIG. 7 provides for
segmented heating of the inhalable substrate medium 350, the
segmented heating proceeding axially from the second end 354 of the
inhalable substrate medium to the first end 353 of the inhalable
substrate medium. As seen in FIG. 7, the cartridge 300 has been
inserted into the receiving chamber 210 of the control housing 200
the minimum distance necessary such that the heating member 400
that is attached to the projection 225 and in electrical connection
with the electrical energy source 220 has been positioned inside
the central cavity 351 of the tubular inhalable substance medium.
In this embodiment, the second end 354 of the inhalable substance
medium has been segmented, the segmented end being the point of
attachment to the engaging end 310 of the cartridge body 305. The
segmented nature of the second end of the inhalable substance
medium can be such that one or more openings are provided in the
engaging end 310 of the cartridge to facilitate air entry into the
annular space 319. In particular embodiments, the segmented end
also can be flared, which can allow for the tubular body of the
inhalable substance medium to have a diameter that is less than the
diameter of the segmented end of the inhalable substance medium.
Such segmented and (optionally) flared arrangement facilitates one
or more of the following: tensioning of the inhalable substance
medium within the cartridge body; configuration of the tubular
inhalable substance medium to have a diameter that is less than the
diameter of the tubular cartridge body; and provision for passage
of air through the annular space defined by the outer surface of
the wall 352 of the inhalable substance medium and the inner
surface of the wall of the cartridge body. Thus, the cartridge can
be characterized as including a flow path therethrough such that
fluid passage from the engaging end of the cartridge to the mouth
end 315 of the cartridge is substantially limited to passage
through the annular space 319 between the inner surface of the
cartridge body wall and the outer surface of the inhalable
substance medium wall.
[0097] In further embodiments, other means can be provided to allow
air flow into the annular space. For example, the inhalable
substance medium may be attached to a ferrule that is directly
attached to the cartridge body. In such embodiments, the ferrule
and/or a portion of the inhalable substance medium near the ferrule
may be perforated. Alternatively, the cartridge (and optionally the
overwrap, when present) may include apertures or perforation that
allow air flow directly into the annular space.
[0098] The configuration of the cartridge body 305 and the
cartridge overwrap 380 preferably is such that air passage around
the cartridge body and between the cartridge body and the overwrap
is significantly prevented. Thus, as seen in FIG. 7, the flange 302
at the engaging end 310 of the cartridge body is sized such that
outer rim of the flange is in direct contact with the cartridge
overwrap around the entire circumference thereof.
[0099] The receiving chamber wall 212 can include one or more
apertures 213 therein for allowing entrance of ambient air into the
interior of the receiving chamber 210. When a consumer draws on the
mouth end of the cartridge 300, air thus can be drawn into the
receiving chamber, pass into the cartridge, be drawn through the
segmented and flared second end 354 of the inhalable substance
medium 350, enter the annular space 319 between the inhalable
substance medium and the cartridge body 305, and pass through the
open space in the cartridge frame member 360 for inhalation by the
consumer. In embodiments wherein the overwrap 380 is present, the
drawn air carries the inhalable substance through the optional
filter 390 (illustrated in FIG. 6) and out of the opening 381 at
the mouth end of the overwrap.
[0100] The wider opening of the cartridge body 305 at the engaging
end 310 thereof (along with the segmented and flared nature of the
second end 354 of the inhalable substance medium 350) facilitates
ease of directing the projection 225 (with the heating member 400
thereon) into the interior space of the tubular inhalable substance
medium 350. With the heating member positioned inside the beginning
section of the tubular portion of the inhalable substance medium,
the heating member can be activated to heat the inhalable substance
medium and cause release of the inhalable substance into the
annular space between the inhalable substance medium and the
cartridge body. Alternatively, in some embodiments, activation of
the heating member may volatilize the aerosol forming material
and/or the inhalable substance of the inhalable substance medium
such that, when ambient air is drawn through the annular space, the
volatilized material(s) become aerosolized and entrained in the air
flowing through the annular space and to the mouth end for
inhalation by the consumer.
[0101] In embodiments wherein segmented heating is provided with a
heating member 400 that is physically a component of the control
housing 200, the heating member typically will be present on the
projection 225 only a long a segment of defined length. As shown in
FIG. 4 and FIG. 7, the segment wherein the heating member is
located can be in proximity to the end of the projection at the
open end of the receiving chamber 210. The relative percentage of
the projection that includes the heating member can be based on the
total length of the inhalable substance medium 350 and the number
of puffs to be delivered by a single cartridge 300. Preferably, a
single cartridge can provide about 4 to about 12, about 5 to about
11, or about 6 to about 10 puffs, which approximates the number of
puffs in a typical cigarette. Thus, for segmented heating, the
segment of the projection that includes the heating member can
encompass about 5% to about 50% of the overall length of the
projection. In other embodiments, the segment can encompass about
5% to about 40%, about 5% to about 30%, about 5% to about 20%, or
about 10% to about 20% of the overall length of the projection.
[0102] As noted above, a vapor barrier 375 (as illustrated in FIG.
4a) may be present on the inner surface of the wall 352 of the
inhalable substance medium 350 to reduce or prevent aerosol or
vapor formation within the interior space of the tubular inhalable
substance medium and maximize aerosol or vapor formation within the
noted annular space. Further, the presence of the heating member
400 within the interior space of the tubular inhalable substance
medium can reduce vapor losses that may result from interaction of
the vapor and the heating member. Still further, such positioning
can function to separate the heating member from the airstream
flowing within the article during draw (as described above). This
can be beneficial to maximize heat delivery from the heating member
to the inhalable substance medium and thus allow for lower heating
temperatures and/or shorter heating duration while still achieving
the desired aerosol formation and release of the inhalable
substance. This configuration likewise can provide for lower energy
consumption necessary to achieve the necessary heating temperature,
and this in turn can facilitate increased battery life (or can
lessen the energy content that must be stored in a capacitor for
complete use of a cartridge).
[0103] The content of aerosol or vapor and the inhalable substance
that is released during heating can be based on a variety of
factors. In some embodiments, it can be useful for the annular
space 319 between the inhalable substance medium 350 and the
cartridge body 305 (or the outer body in embodiments wherein the
cartridge and the overwrap are combined) to be of a defined volume.
For example, the annular space can have a volume of at least 0.25
ml, at least 0.5 ml, at least 0.75 ml, at least 1.0 ml, or at least
1.25 ml. In other embodiments, the volume of the annular space can
be about 0.25 ml to about 5.0 ml, about 0.5 ml to about 3.0 ml,
about 0.7 ml to about 2.0 ml, or about 0.7 ml to about 1.5 ml. In
various embodiments, the total volume of aerosol that is generated
in a single puff may be greater than the annular space volume since
aerosol being formed is continuously swept away with air that is
pulled through the annular space to combine with the aerosol for
passage to the consumer as the total puff volume. For example, in
an average puff time of about 2 seconds, a puff volume of about 25
ml to about 75 ml, about 30 ml to about 70 ml, about 35 ml to about
65 ml, or about 40 ml to about 60 ml may be delivered to the
consumer. Such total puff volume may provide, in certain
embodiments, the WTPM content previously described. Thus, WTPM as
delivered may be characterized in relation to the total puff
volume--e.g., about 1 mg to about 4 mg WTPM in a total puff volume
of about 25 ml to about 75 ml. Such characterization is inclusive
of all puff volume values and WTPM values otherwise described
herein.
[0104] From the above, it is evident that the annular space can be
defined in relation to providing both an actual head space and a
dynamic head space. The annular space provides an actual head space
in that the annular space has a quantifiable volume based upon the
length of the inhalable substance medium, the relative diameters of
the inhalable substance medium and the cartridge, and the actual
shape of each component. By contrast, the annular space can be
defined as a dynamic head space in that the inventive article is
not limited to aerosol production of a volume only sufficient to
fill the actual annular space volume during a single puff. Rather,
during a single puff, aerosol may be formed continuously, and the
formed aerosol is continuously drawn out of the annular space
during the puff. Thus, the annular space provides a dynamic head
space that can be quantified in terms of the total puff volume that
is drawn through the annular space during a single puff. The
dynamic head space may vary between puffs depending upon draw
strength and puff length. The dynamic head space, in certain
embodiments, may have a volume as described above over an average
puff time of about 2 seconds.
[0105] In some embodiments, it may be useful to provide some
indication of when the cartridge 300 has achieved the minimum
distance of insertion into the receiving chamber 210 such that the
heating member 400 on the projection 225 is positioned precisely
into the initial, heatable section or segment of the tubular
inhalable substance medium 350. For example, the cartridge may
include one or more markings (or a graduated scale) on the exterior
thereof (e.g., on the outer surface of the cartridge overwrap 380).
A single mark may indicate the depth of insertion required to
achieve this initial position for use (e.g., as illustrated in FIG.
7). Further marks may indicate the distance the cartridge must be
indexed into the receiving chamber to position the heating member
on a fresh section of the inhalable substance medium that has not
previously been heated for release of the inhalable substance.
Alternatively, the cartridge and the receiving chamber may include
one or a series of grooves (or detents) and projections
(interchangeable between the two components) that provide a tactile
indication of when the initial heating position has been reached
and when the cartridge has been indexed a further distance
necessary to position the heating member on a fresh section of the
inhalable substance medium that has not previously been heated for
release of the inhalable substance. Any such means that can enable
a consumer to recognize and understand that the cartridge has been
indexed sufficiently in the receiving chamber to position the
heating member on a fresh section of the inhalable substance medium
may be used in the present article 10.
[0106] FIG. 8 further illustrates the segmented heating of the
present embodiment. After the heating member 400 has been activated
in relation to FIG. 7 and the inhalable substance on the heated
section of the inhalable substance medium 350 has been released for
inhalation by the consumer, the cartridge 300 is then further
indexed into the receiving chamber 210 such that the cartridge
indexes past the segment of the projection 225 having the
electrical heating member present thereon. FIG. 8 shows the article
10 after said indexing has occurred. The heating member now is
positioned within the tubular inhalable substance medium closer to
the mouth end of the cartridge body 305 and beyond the segment of
the inhalable substance medium that was previously heated. Thus,
the heating member now is positioned near a fresh section of the
inhalable substance medium. This indexing of the cartridge within
the receiving chamber for heating individual segments of the
inhalable substance medium can be achieved via a variety of
mechanisms, any of which can be encompassed by the present
invention. For example, the indexing may be manually controlled by
the consumer such that, after a puff, the cartridge may be manually
pushed further into the receiving chamber by the consumer tapping
on the mouth end of the cartridge or otherwise applying force
manually to push the cartridge further into the receiving chamber.
The consumer may determine the appropriate distance the cartridge
needs to be pushed into the receiving chamber via the graduated
markings on the cartridge, as described, or by the tactile
sensation of the cartridge passing through another notch within the
receiving chamber, both of which are already described above.
[0107] In other embodiments, the article 10 may include further
components useful to facilitate indexing of the cartridge 300
within the receiving chamber 210. For example, the article may
include a pushbutton 15 that may actuate indexing of the cartridge
into the receiving chamber 210 by mechanical means (not shown). In
such embodiments, the control housing 200 may include an engaging
member that removably attaches to the cartridge, and actuation of
the pushbutton may function to move a pawl that allows a spring
attached to the engaging member to move the cartridge one position
further into the receiving chamber and thus move the inhalable
substance medium 350 relative to the heating member 400 such that
the heating member is in position to heat a fresh section of the
inhalable substance medium. In specific embodiments, the pushbutton
may be linked to the control circuit 260 for manual control of the
heating member and, optionally, the actuation of the cartridge. For
example, the consumer may use the pushbutton to energize the
heating member. Optionally, the pushbutton still may be
mechanically linked to the cartridge, such as in the example
described above, so that actuation of the pushbutton moves the
cartridge one segment forward and then energizes the heating member
to heat the fresh segment of the inhalable substance medium.
Alternatively, actuation of the pushbutton may first energize the
heating member (already positioned at a fresh section of the
inhalable substance medium) and then, upon release of the button
(or after a defined delay), the mechanical elements may engage to
move the cartridge one segment forward so that the heating member
is already positioned at a fresh segment of the inhalable substance
medium for when the pushbutton is actuated again to energize the
heating member. Similar functionality tied to the pushbutton may be
achieved by other mechanical means or non-mechanical means (e.g.,
magnetic or electromagnetic). Similar functionality also may be
achieved automatically via an internal switch activated by either
pressure or airflow provided by the consumer during a puff. Thusly,
activation of the heating member and indexing of the cartridge can
be controlled by a single pushbutton. Alternatively, multiple
pushbuttons may be provided to control each action separately. One
or more pushbuttons present may be substantially flush with the
casing of the control housing.
[0108] Instead of (or in addition to) the pushbutton 15, the
inventive article 10 can include components that energize the
heating member 400 in response to the consumer's drawing on the
article (i.e., puff-actuated heating). For example, the article may
include a switch 280 in the control segment 205 of the control
housing 200 that is sensitive either to pressure changes or air
flow changes as the consumer draws on the article (i.e., a
puff-actuated switch). Other suitable current actuation/deactuation
mechanisms may include a temperature actuated on/off switch or a
lip pressure actuated switch. An exemplary mechanism that can
provide such puff-actuation capability includes a Model 163PC01D36
silicon sensor, manufactured by the MicroSwitch division of
Honeywell, Inc., Freeport, Ill. With such sensor, the heating
member is activated rapidly by a change in pressure when the
consumer draws on the article. In addition, flow sensing devices,
such as those using hot-wire anemometry principles, may be used to
cause the energizing of the heater member 400 sufficiently rapidly
after sensing a change in air flow. A further puff actuated switch
that may be used is a pressure differential switch, such as Model
No. MPL-502-V, range A, from Micro Pneumatic Logic, Inc., Ft.
Lauderdale, Fla. Another suitable puff actuated mechanism is a
sensitive pressure transducer (e.g., equipped with an amplifier or
gain stage) which is in turn coupled with a comparator for
detecting a predetermined threshold pressure. Yet another suitable
puff actuated mechanism is a vane which is deflected by airflow,
the motion of which vane is detected by a movement sensing means.
Yet another suitable actuation mechanism is a piezoelectric switch.
Also useful is a suitably connected Honeywell MicroSwitch
Microbridge Airflow Sensor, Part No. AWM 2100V from MicroSwitch
Division of Honeywell, Inc., Freeport, Ill. Further examples of
demand-operated electrical switches that may be employed in a
heating circuit according to the present invention are described in
U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated
herein by reference in its entirety. Other suitable differential
switches, analog pressure sensors, flow rate sensors, or the like,
will be apparent to the skilled artisan with the knowledge of the
present disclosure. A pressure-sensing tube or other passage
providing fluid connection between the puff actuated switch and the
receiving chamber 210 preferably is included in the control housing
200 so that pressure changes during draw are readily identified by
the switch.
[0109] When the consumer draws on the mouth end of the article 10,
the current actuation means can permit unrestricted or
uninterrupted flow of current through the resistance heating member
400 to generate heat rapidly. Because of the rapid heating, it can
be useful to include current regulating components to (i) regulate
current flow through the heating member to control heating of the
resistance element and the temperature experienced thereby, and
(ii) prevent overheating and degradation of the inhalable substance
medium 350.
[0110] The current regulating circuit particularly may be time
based. Specifically, such a circuit includes a means for permitting
uninterrupted current flow through the heating element for an
initial time period during draw, and a timer means for subsequently
regulating current flow until draw is completed. For example, the
subsequent regulation can include the rapid on-off switching of
current flow (e.g., on the order of about every 1 to 50
milliseconds) to maintain the heating element within the desired
temperature range. Further, regulation may comprise simply allowing
uninterrupted current flow until the desired temperature is
achieved then turning off the current flow completely. The heating
member may be reactivated by the consumer initiating another puff
on the article (or manually actuating the pushbutton, depending
upon the specific switch embodiment employed for activating the
heater). Alternatively, the subsequent regulation can involve the
modulation of current flow through the heating element to maintain
the heating element within a desired temperature range. In some
embodiments, so as to release the desired dosing of the inhalable
substance, the heating member may be energized for a duration of
about 0.2 second to about 5.0 seconds, about 0.3 second to about
4.0 seconds, about 0.4 second to about 3.0 seconds, about 0.5
second to about 2.0 seconds, or about 0.6 second to about 1.5
seconds. One exemplary time-based current regulating circuit can
include a transistor, a timer, a comparator, and a capacitor.
Suitable transistors, timers, comparators, and capacitors are
commercially available and will be apparent to the skilled artisan.
Exemplary timers are those available from NEC Electronics as
C-1555C and from General Electric Intersil, Inc. as ICM7555, as
well as various other sizes and configurations of so-called "555
Timers". An exemplary comparator is available from National
Semiconductor as LM311. Further description of such time-based
current regulating circuits is provided in U.S. Pat. No. 4,947,874
to Brooks et al., which is incorporated herein by reference in its
entirety.
[0111] In light of the foregoing, it can be seen that a variety of
mechanisms can be employed to facilitate actuation/deactuation of
current to the heating member 400. For example, the inventive
article 10 can comprise a timer for regulating current flow in the
article (such as during draw by a consumer). The article further
can comprise a timer responsive switch that enables and disables
current flow to the heating member. Current flow regulation also
can comprise use of a capacitor and components for charging and
discharging the capacitor at a defined rate (e.g., a rate that
approximates a rate at which the heating member heats and cools).
Current flow specifically may be regulated such that there is
uninterrupted current flow through the heating member for an
initial time period during draw, but the current flow may be turned
off or cycled alternately off and on after the initial time period
until draw is completed. Such cycling may be controlled by a timer,
as discussed above, which can generate a preset switching cycle. In
specific embodiments, the timer may generate a periodic digital
wave form. The flow during the initial time period further may be
regulated by use of a comparator that compares a first voltage at a
first input to a threshold voltage at a threshold input and
generates an output signal when the first voltage is equal to the
threshold voltage, which enables the timer. Such embodiments
further can include components for generating the threshold voltage
at the threshold input and components for generating the threshold
voltage at the first input upon passage of the initial time
period.
[0112] In further embodiments wherein segmented heating is
provided, puff actuation of the heating member 400 may be coupled
to movement of the cartridge 300 through the receiving chamber 210.
For example, the current regulating component may allow the heating
member to rapidly achieve the desired temperature and then remain
at that temperature for the duration of the puff by the consumer.
Further, puff actuated movement of the cartridge through the
receiving chamber may be continuous for the duration of the puff.
Once the puff ceases, the heating member will be deactivated, and
the cartridge will cease movement within the receiving chamber.
Thus, the distance traveled by the cartridge during automatic
indexing can be directly related to the duration of a puff. In this
manner, the consumer may have control over the amount of the
inhalable substance that is delivered by a single puff. A short
puff can only deliver a small amount of the inhalable substance. A
longer puff can deliver a greater amount of the inhalable
substance. Thus, a large, initial puff may provide a bolus of the
inhalable substance, and shorter puffs thereafter may provide
smaller amounts of the inhalable substance. Exemplary puff
actuation devices that may be useful according to the invention are
disclosed in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,874,
all to Brooks et al., all of which are incorporated herein by
reference in their entireties.
[0113] The power source 275 used to provide power to the various
electrical components of the inventive article 10 can take on
various embodiments. Preferably, the power source is able to
deliver sufficient energy to rapidly heat the heating member 400 in
the manner described above and power the article through use with
multiple cartridges 300 while still fitting conveniently in the
article. One example of a useful power source is a N50-AAA CADNICA
nickel-cadmium cell produced by Sanyo Electric Company, Ltd., of
Japan. A plurality of such batteries, providing 1.2-volts each, may
be connected in series. Other power sources, such as rechargeable
lithium-manganese dioxide batteries, can be used. Any of these
batteries or combinations thereof can be used in the power source,
but rechargeable batteries are preferred because of cost and
disposal considerations associated with disposable batteries. In
addition, if disposable batteries are used, the control segment 205
must be openable for replacement of the battery. In embodiments
where rechargeable batteries are used, the control segment further
can comprise charging contacts 217, as shown in FIG. 1, for
interaction with corresponding contacts in a conventional
recharging unit (not shown) deriving power from a standard 120-volt
AC wall outlet, or other sources such as an automobile electrical
system or a separate portable power supply.
[0114] In further embodiments, the power source 275 also may
comprise a capacitor. Capacitors are capable of discharging more
quickly than batteries and can be charged between puffs, allowing
the battery to discharge into the capacitor at a lower rate than if
it were used to power the heating member 400 directly. For example,
a supercapacitor--i.e., an electric double-layer capacitor
(EDLC)--may be used separate from or in combination with a battery.
When used alone, the supercapacitor may be recharged before each
use of the article 10. Thus, the invention also may include a
charger component that can be attached to the device between uses
to replenish the supercapacitor. Thin film batteries may be used in
certain embodiments of the invention.
[0115] The article 10 also may comprise one or more indicators 219
(as illustrated in FIG. 1). Such indicators 219 may be lights
(e.g., light emitting diodes) that can provide indication of
multiple aspects of use of the inventive article. For example, a
series of lights as shown in FIG. 1 may correspond to the number of
puffs for a given cartridge. Specifically, the lights may become
lit with each puff indicating to a consumer that the cartridge 300
was completely used when all lights were lit. Alternatively, all
lights may be lit upon the cartridge engaging the receiving chamber
210, and a light may turn off with each puff indicating to a
consumer that the cartridge was completely used when all lights
were off. In still other embodiments, only a single indicator may
be present, and lighting thereof may indicate that current was
flowing to the heating member 400 and the article 10 was actively
heating. This may ensure that a consumer did not unknowingly leave
an article unattended in an actively heating mode. In alternative
embodiments, one or more of the indicators may be a component of
the cartridge. Although the indicators are described above in
relation to visual indicators in an on/off method, other indices of
operation also are encompassed. For example, visual indicators also
may include changes in light color or intensity to show progression
of the smoking experience. Tactile indicators and sound indicators
similarly are encompassed by the invention. Moreover, combinations
of such indicators also may be used in a single article.
[0116] Although a variety of materials for use in the present
device, such as heaters, batteries, capacitors, switching
components, and the like have been described, the invention should
not be construed as being limited to only the exemplified
embodiments. Rather, one of skill in the art can recognize based on
the present disclosure similar components in the field that may be
interchanged with any specific component of the present invention.
For example, U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses
piezoelectric sensors that can be associated with the mouth-end of
a device to detect user lip activity associated with taking a draw
and then trigger heating; U.S. Pat. No. 5,372,148 to McCafferty et
al. discloses a puff sensor for controlling energy flow into a
heating load array in response to pressure drop through a
mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses
receptacles in a smoking device that include an identifier that
detects a non-uniformity in infrared transmissivity of an inserted
component and a controller that executes a detection routine as the
component is inserted into the receptacle; U.S. Pat. No. 6,040,560
to Fleischhauer et al. describes a defined executable power cycle
with multiple differential phases; U.S. Pat. No. 5,934,289 to
Watkins et al. discloses photonic-optronic components; U.S. Pat.
No. 5,954,979 to Counts et al. discloses means for altering draw
resistance through a smoking device; U.S. Pat. No. 6,803,545 to
Blake et al. discloses specific battery configurations for use in
smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al.
discloses various charging systems for use with smoking devices; US
2009/0320863 by Fernando et al. discloses computer interfacing
means for smoking devices to facilitate charging and allow computer
control of the device; US 2010/0163063 by Fernando et al. discloses
identification systems for smoking devices; and WO 2010/003480 by
Flick discloses a fluid flow sensing system indicative of a puff in
an aerosol generating system; all of the foregoing disclosures
being incorporated herein by reference in their entireties. Further
examples of components related to electronic aerosol delivery
articles and disclosing materials or components that may be used in
the present article include U.S. Pat. No. 4,735,217 to Gerth et
al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No.
5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et
al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to
Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No.
6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No.
7,513,253 to Kobayashi; U.S. Pat. No. 7,896,006 to Hamano; U.S.
Pat. No. 6,772,756 to Shayan; US Pat. Pub. Nos. 2009/0095311,
2006/0196518, 2009/0126745, and 2009/0188490 to Hon; US Pat. Pub.
No. 2009/0272379 to Thorens et al.; US Pat. Pub. Nos. 2009/0260641
and 2009/0260642 to Monsees et al.; US Pat. Pub. Nos. 2008/0149118
and 2010/0024834 to Oglesby et al.; US Pat. Pub. No. 2010/0307518
to Wang; and WO 2010/091593 to Hon. A variety of the materials
disclosed by the foregoing documents may be incorporated into the
present devices in various embodiments, and all of the foregoing
disclosures are incorporated herein by reference in their
entireties.
[0117] Although the inventive article has been discussed in
relation to certain embodiments, the invention also encompasses a
variety of further embodiments. For example, FIG. 8a illustrates
the embodiment from FIG. 8 but wherein the control housing 200 does
not include a receiving chamber. Rather, the control housing can be
described as comprising a receiving end 211 (as shown in FIG. 8b).
Such receiving end can include all of the components otherwise
described herein in relation to embodiments including the receiving
chamber. The chamber wall is absent, however, such that the further
components (e.g., the projection 225) define the receiving end and
extend from the control segment portion of the control housing.
[0118] While the foregoing has particularly described segmented
heating wherein the electrical heating member 400 is attached to
the projection 225 or is otherwise provided as a component part of
the control housing 200, FIG. 9 illustrates another embodiment of
segmented heating wherein the electrical heating member is a
component part of the cartridge 300. In such embodiments, the
heating member (which in this embodiment is a heating coil 406)
particularly can be present in the interior space of the tubular
inhalable substance medium 350, and the heating member may be
maintained therein by frictional forces, and/or outwardly directed
pressure exerted on the inhalable substance medium by the heating
coil (e.g., wherein the heating coil exhibits springing action and
is compressed to some extent prior to insertion), and/or by being
at least partially embedded within the inhalable substance
medium.
[0119] Use of the article 10 in such embodiments can be
substantially identical to the use as described above. In
particular, a consumer can insert the cartridge 300 into the
receiving chamber 210 of the control housing 200 (or slide the
cartridge over the projection 225 when the chamber walls are
absent). The components of the cartridge can be positioned within
the cartridge to align with and receive the projection 225 as the
cartridge slides into the receiving chamber. The minimum distance
required to align all components for heating of the inhalable
substance medium 350 can be the distance required for the
electrical leads 222 present on the projection to make an
electrical connection with the heating coil 406 (or for an
alternative electrical connection to be operatively engaged).
Segmented heating is provided in that electrical current can only
flow in the portion of the heating coil between the electrical
leads. Indexing of the cartridge can proceed as described above
after the first segment of the inhalable substance medium 350 had
been heated so that the electrical leads may make contact with the
heating coil in the next segment of the cartridge. Puff-actuated
heating followed by indexing may continue until the entire
inhalable substance medium had been used (i.e., the inhalable
substance and the aerosol-forming material released from the
inhalable substance medium).
[0120] Generally, segmented heating embodiments of the invention
can arise from any combination of the heating element and the
inhalable substance medium in a manner wherein only a portion of
the inhalable substance medium is heated at a single time. Thusly,
for each puff on the device, an essentially fresh section of the
inhalable substance medium is in alignment with the heating element
for heating. Accordingly, the invention encompasses any variation
of the segmented heating embodiments described herein wherein one
or both of the inhalable substance medium and the heating member
(which may extend to the cartridge and the control housing as well)
are manipulated such that only a portion of the inhalable substance
medium is heated at any given time and the manipulation positions
the heating member of a fresh portion of the inhalable substance
medium for each subsequent puff. For example, twisting of one of
the control housing or the cartridge (with the other not moving)
may be effective to place the heater on a fresh area of inhalable
substance medium (with optional inward or outward movement of the
cartridge within the receiving chamber control housing). In such
embodiments, the heating member may comprise a lateral heating
element (or series of elements) that may be substantially the same
length as the inhalable substance medium.
[0121] As seen in FIG. 9, it can be preferable for the electrical
leads 222 to be present on the projection 225 in proximity to the
end of the projection 225 at the open end of the receiving chamber
210. Thus, in connection with the description above, the electrical
leads 222 form an electrical connection with discrete segments of
the electrical heating coil 406 such that when heating occurs, only
the portion of the inhalable substance medium 350 in proximity to
the segment of the electrical heating coil 406 in electrical
connection with the projection 225 is heated. In certain
embodiments, the segment of the electrical heating coil 406 that is
in electrical connection with the electrical leads 222 of the
projection 225 encompasses about 5% to about 50% of the length of
the inhalable subject medium 350. In other embodiments, the segment
of the electrical heating coil 406 that is in electrical connection
with the electrical leads 222 of the projection 225 encompasses
about 5% to about 40%, about 5% to about 30%, about 5% to about
20%, or about 10% to about 20% of the length of the inhalable
subject medium 350.
[0122] As seen in relation to the foregoing description, the
invention encompasses articles 10 wherein segmented heating of the
inhalable substance medium 350 is provided. Particularly, the
heating member 400 can be reusable, can be provided as a component
of the control housing 200, and can be provided on only a segment
of the projection 225. Thus, only a segment of the inhalable
substance medium 350 is in contact with the heating member 400 at
any single time during use. Moreover, no portion of the inhalable
substance medium 350 is in physical contact with or in proximity to
with the heating member 400 until the cartridge 300 is inserted
into the receiving chamber 210 of the controller 200 for use by the
consumer. In other embodiments, the heating member 400 can be
disposable and be provided as a component of the cartridge 300. In
both embodiments, the heating member 400 requires only a single set
of contacts 410 or electrical leads 222 for connection to the
electrical energy source 220 (e.g., for direct insertion into a
receptacle in the electrical energy source 220, or formed on the
projection 225 of the electrical energy source 220).
[0123] When segmented heating is used, the inhalable substance
medium 350 can be modified as desired to control various aspects of
release, amount, and flavor. For example, the inhalable substance
may be evenly dispersed on or within the inhalable substance medium
350 so that each respective segment that is heated will release
substantially the same content of the inhalable substance.
Alternatively, the initial area of the inhalable substance medium
350 (i.e., at the second end thereof) that contacts the heating
member 400 may be supercharged with the inhalable substance. For
example, a single segment of the inhalable substance medium 350
corresponding to the size of the area heated by the heating member
400 may comprise about 30% to about 90%, about 35% to about 75%, or
about 40% to about 60% of the total amount of the inhalable
substance present in the inhalable substance medium 350. Similarly,
a single segment, such as the final segment of the inhalable
substance medium 350 heated by the heating member 400, may include
a flavor or other material that is different from the remaining
portion of the inhalable substance medium 350. Such final release
of flavor or other material may function as a signal to a consumer
that the cartridge 300 has been completely used. Thus, it can be
seen that segmented heating can provide for consistent dosing of
the inhalable substance in each heated segment, can provide for
clear indication of progress, and can allow for greater control of
the device by the consumer.
[0124] In various embodiments, the article can be characterized in
relation to the total area of the inhalable substance medium that
is heated or maximally heated at a given time. For example, in
segmented heating embodiments, only a specific segment of the
inhalable substance medium is heated or maximally heated at a given
time (e.g., about one-sixth to about one-tenth of the area of the
inhalable substance medium, or other fraction as necessary to
provide the desired number of puffs from a single inhalable
substance medium). In some embodiments, it may be useful to provide
an electrically resistive heating member, as otherwise described
herein, that encompasses only a small heating area--e.g., on a
single coil or strip). Thus, it also may be useful according to the
invention to include a heat spreading member 401 (as shown in FIG.
8b). The inclusion of such member positioned between the heating
member and the inhalable substance medium can allow for the use of
a relatively small heating member to heat a larger area of the
inhalable substance medium. For example, the heating member
underlying the heat spreading member may have a width as small as
0.5% to 5% of the total length of the projection 225. The heat
spreading member, however, may have a width that is about 10% to
about 30%, about 10% to about 20%, or about 10% to about 15% of the