U.S. patent application number 16/872958 was filed with the patent office on 2020-08-27 for electronic smoking article having a vapor-enhancing apparatus and associated method.
The applicant listed for this patent is RAI Strategic Holdings, Inc.. Invention is credited to Dennis Lee Potter, Stephen Benson Sears.
Application Number | 20200268049 16/872958 |
Document ID | / |
Family ID | 1000004824773 |
Filed Date | 2020-08-27 |
United States Patent
Application |
20200268049 |
Kind Code |
A1 |
Potter; Dennis Lee ; et
al. |
August 27, 2020 |
ELECTRONIC SMOKING ARTICLE HAVING A VAPOR-ENHANCING APPARATUS AND
ASSOCIATED METHOD
Abstract
A vapor-enhancing apparatus is provided for an electronic vapor
smoking article. Such an apparatus includes a filter material and a
tubular housing defining a lumen. The lumen has a mouth-engaging
end and a longitudinally-opposed component-engaging end, and is
configured to receive the filter material therein. The
component-engaging end is adapted to operably engage a control body
portion associated with the electronic vapor smoking article and to
receive a vapor therethrough. A vapor-enhancing element is operably
engaged with the filter material and is configured to enhance the
vapor drawn through the filter material within the lumen, and
through the mouth-engaging end, by application of suction to the
mouth-engaging end of the housing. An associated method is also
provided.
Inventors: |
Potter; Dennis Lee;
(Kernersville, NC) ; Sears; Stephen Benson; (Siler
City, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RAI Strategic Holdings, Inc. |
Winston-Salem |
NC |
US |
|
|
Family ID: |
1000004824773 |
Appl. No.: |
16/872958 |
Filed: |
May 12, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13796725 |
Mar 12, 2013 |
|
|
|
16872958 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 40/40 20200101 |
International
Class: |
A24F 40/40 20200101
A24F040/40 |
Claims
1-29. (canceled)
30. An electronic vapor smoking apparatus, comprising: a control
body portion including a power source; a cartridge body portion
having a mouth-engaging end and a longitudinally-opposed
component-engaging end, the component-engaging end being adapted to
operably engage the control body portion; a reservoir arranged in
the cartridge body portion and arranged to contain a vapor
precursor composition; a heating element arranged in the control
body portion or the cartridge body portion and to heat the vapor
precursor composition from the reservoir to form a vapor; a passage
defined in the cartridge body portion and in fluid communication
with the mouth-engaging end, the vapor being transmitted through
the passage to the mouth-engaging end in response to application of
suction to the passage via the mouth-engaging end of the cartridge
body portion; and a vapor-enhancing element arranged in the
cartridge body portion in communication with the passage, the
vapor-enhancing element being further arranged to release an
enhancement into the vapor drawn along the passage through the
mouth-engaging end.
31. The apparatus according to claim 30, wherein the cartridge body
portion is replaceable with respect to the control body
portion.
32. The apparatus according to claim 30, wherein the cartridge body
portion or the control body portion comprises an indicia indicative
of one or more of: a nature of the enhancement of the vapor
provided by the vapor-enhancing element; a remaining service life
of the vapor-enhancing element in regard to the enhancement
provided to the vapor; an expended service life of the
vapor-enhancing element in regard to the enhancement provided to
the vapor; and compatibility of the cartridge body portion with the
control body portion, upon operable engagement between the
cartridge body portion and the control body portion.
33. The apparatus according to claim 30, wherein the enhancement
released by the vapor-enhancing element does not include nicotine
and includes a flavorant, a medicament, an inhalable material, or
combinations thereof.
34. The apparatus according to claim 30, wherein the
vapor-enhancing element is arranged to be electrically-actuated,
and the cartridge body portion is arranged to form an
electrically-conductive connection between the vapor-enhancing
element and the control body portion upon operable engagement with
the control body portion.
35. The apparatus according to claim 30, wherein the vapor
precursor composition comprises nicotine, and the enhancement
released by the vapor-enhancing element is arranged to alter a
characteristic of the nicotine-including vapor.
36. The apparatus according to claim 30, wherein the heating
element is a resistive heating element comprising a metal coil
electrically connected to the power source.
37. The apparatus according to claim 36, further comprising a wick
or a capillary material arranged to deliver the vapor precursor
composition from the reservoir to the metal coil.
38. The apparatus according to claim 30, wherein the cartridge body
portion comprises an indicator of a vapor precursor composition
level associated with the reservoir therein.
39. The apparatus according to claim 30, further comprising a
sensor associated with a control component arranged to control
actuation of power discharge from the power source in response to
the application of suction to the mouth-engaging end of the
cartridge body portion.
40. The apparatus according to claim 30, further comprising a
filter element attachable to or included in the cartridge body
portion, wherein the vapor-enhancing element is operably engaged
with the filter element.
41. A method of enhancing a vapor produced by an electronic vapor
smoking article, the method comprising: operably engaging a
component-engaging end of a cartridge body portion with a control
body portion including a power source, the cartridge body portion
having a mouth-engaging end longitudinally-opposed to the
component-engaging end; directing a vapor precursor composition
contained in a reservoir arranged in the cartridge body portion to
a heating element arranged in the control body portion or the
cartridge body portion; heating the vapor precursor composition
with the heating element to form a vapor; transmitting the vapor
through a passage to the mouth-engaging end, the passage being
defined in the cartridge body portion and in fluid communication
with the mouth-engaging end, in response to application of suction
to the passage via the mouth-engaging end of the cartridge body
portion; and enhancing the vapor drawn along the passage through
the mouth-engaging end with a vapor-enhancing element arranged in
the cartridge body portion in communication with the passage.
42. The method according to claim 41, wherein operably engaging the
component-engaging end of the cartridge body portion with the
control body portion further comprises removably engaging the
component-engaging end of the cartridge body portion.
43. The method according to claim 41, further comprising displaying
an indicia about one of the cartridge body portion or the control
body portion, the indicia being indicative of one or more of: a
nature of the enhancement of the vapor provided by the
vapor-enhancing element; a remaining service life of the
vapor-enhancing element in regard to the enhancement provided to
the vapor; an expended service life of the vapor-enhancing element
in regard to the enhancement provided to the vapor; and
compatibility of the cartridge body portion with the control body
portion, upon operable engagement between the cartridge body
portion and the control body portion.
44. The method according to claim 41, wherein enhancing the vapor
drawn along the passage further comprises enhancing the vapor drawn
along the passage by the vapor-enhancing element that does not
include nicotine, and includes a flavorant, a medicament, an
inhalable material, or combinations thereof.
45. The method according to claim 41, wherein enhancing the vapor
drawn along the passage further comprises electrically actuating
the vapor-enhancing element, the cartridge body portion being
arranged to form an electrically-conductive connection between the
vapor-enhancing element and the control body portion upon operably
engaging the control body portion
46. The method according to claim 41, wherein the vapor precursor
composition comprises nicotine, and wherein enhancing the vapor
drawn along the passage further comprises altering a characteristic
of the nicotine-including vapor.
47. The method according to claim 41, wherein heating the vapor
precursor composition further comprises heating the vapor precursor
composition with a resistive heating element comprising a metal
coil electrically connected to the power source.
48. The method according to claim 47, wherein directing the vapor
precursor composition to the heating element further comprises
directing the vapor precursor composition to the heating element
using a wick or a capillary material to deliver the vapor precursor
composition from the reservoir to the metal coil.
49. The method according to claim 41, further comprising
controlling actuation of power discharge from the power source
using a sensor associated with a control component in response to
the application of suction to the mouth-engaging end of the
cartridge body portion.
50. The method according to claim 41, further comprising operably
engaging the vapor-enhancing element with a filter element
attachable to or included in the cartridge body portion.
Description
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
[0001] The present disclosure relates to aerosol delivery articles
and uses thereof, and in particular to articles that can be
considered to be smoking articles for purposes of yielding
components of tobacco and other materials in an inhalable form.
Highly preferred components of such articles are made or derived
from tobacco, or those articles can be characterized as otherwise
incorporating tobacco for human consumption.
Description of Related Art
[0002] Many smoking devices have been proposed through the years as
improvements upon, or alternatives to, smoking products that
require combusting tobacco for use. Many of those devices
purportedly have been designed to provide the sensations associated
with cigarette, cigar, or pipe smoking, but without delivering
considerable quantities of incomplete combustion and pyrolysis
products that result from the burning of tobacco. To this end,
there have been proposed numerous smoking products, flavor
generators, and medicinal inhalers that utilize electrical energy
to vaporize or heat a volatile material, or attempt to provide the
sensations of cigarette, cigar, or pipe smoking without burning
tobacco to a significant degree. See, for example, the various
alternative smoking articles, aerosol delivery devices and heat
generating sources set forth in the background art described in
U.S. Pat. No. 7,726,320 to Robinson et al. and U.S. patent
application Ser. No. 13/647,000, filed Oct. 8, 2012, to Sears et
al., which are incorporated herein by reference.
[0003] Certain tobacco products that have employed electrical
energy to produce heat for smoke or aerosol formation, and in
particular, certain products that have been referred to as
electronic cigarette products, have been commercially available
throughout the world. Representative products that resemble many of
the attributes of traditional types of cigarettes, cigars or pipes
have been marketed as ACCORD.RTM. by Philip Morris Incorporated;
ALPHA.TM., JOYE 510.TM. and M4.TM. by InnoVapor LLC; CIRRUS.TM. and
FLING.TM. by White Cloud Cigarettes; COHITA.TM., COLIBRI.TM., ELITE
CLASSIC.TM., MAGNUM.TM., PHANTOM.TM. and SENSE.TM. by Epuffer.RTM.
International Inc.; DUOPRO.TM., STORM.TM. and VAPORKING.RTM. by
Electronic Cigarettes, Inc.; EGAR.TM. by Egar Australia; eGo-C.TM.
and eGo-T.TM. by Joyetech; ELUSION.TM. by Elusion UK Ltd;
EONSMOKE.RTM. by Eonsmoke LLC; GREEN SMOKE.RTM. by Green Smoke Inc.
USA; GREENARETTE.TM. by Greenarette LLC; HALLIGAN.TM., HENDU.TM.,
JET.TM., MAXXQ.TM., PINK.TM. and PITBULL.TM. by Smoke Stik.RTM.;
HEATBAR.TM. by Philip Morris International, Inc.; HYDRO
IMPERIAL.TM. and LXE.TM. from Crown7; LOGIC.TM. and THE CUBAN.TM.
by LOGIC Technology; LUCI.RTM. by Luciano Smokes Inc.; METRO.RTM.
by Nicotek, LLC; NJOY.RTM. and ONEJOY.TM. by Sottera, Inc.; NO.
7.TM. by SS Choice LLC; PREMIUM ELECTRONIC CIGARETTE.TM. by
PremiumEstore LLC; RAPP E-MYSTICK.TM. by Ruyan America, Inc.; RED
DRAGON.TM. by Red Dragon Products, LLC; RUYAN.RTM. by Ruyan Group
(Holdings) Ltd.; SMART SMOKER.RTM. by The Smart Smoking Electronic
Cigarette Company Ltd.; SMOKE ASSIST.RTM. by Coastline Products
LLC; SMOKING EVERYWHERE.RTM. by Smoking Everywhere, Inc.;
V2CIGS.TM. by VMR Products LLC; VAPOR NINE.TM. by VaporNine LLC;
VAPOR4LIFE.RTM. by Vapor 4 Life, Inc.; VEPPO.TM. by
E-CigaretteDirect, LLC and VUSE.RTM. by R. J. Reynolds Vapor
Company. Yet other electrically powered aerosol delivery devices,
and in particular those devices that have been characterized as
so-called electronic cigarettes, have been marketed under the
tradenames BLU.TM.; COOLER VISIONS.TM.; DIRECT E-CIG.TM.;
DRAGONFLY.TM.; EMIST.TM.; EVERSMOKE.TM.; GAMUCCI.RTM.; HYBRID
FLAME.TM.; KNIGHT STICKS.TM.; ROYAL BLUES.TM.; SMOKETIP.RTM. and
SOUTH BEACH SMOKE.TM..
[0004] It would be desirable to provide a smoking article that
employs heat produced by electrical energy to provide the
sensations of cigarette, cigar, or pipe smoking, that does so
without combusting tobacco to any significant degree, that does so
without the need of a combustion heat source, and that does so
without necessarily delivering considerable quantities of
incomplete combustion and pyrolysis products.
BRIEF SUMMARY OF THE DISCLOSURE
[0005] The above and other needs are met by the present disclosure
which, in one aspect, provides a vapor-enhancing apparatus for an
electronic vapor smoking article. Such an apparatus comprises a
filter material and a tubular housing defining a lumen. The tubular
housing has a mouth-engaging end and a longitudinally-opposed
component-engaging end, and the lumen is configured to receive the
filter material therein. The component-engaging end is adapted to
engage a cartridge body portion associated with the electronic
vapor smoking article and to receive a vapor therefrom. A
vapor-enhancing element is operably engaged with the filter
material and is configured to enhance the vapor drawn from the
cartridge body portion associated with the electronic vapor smoking
article through the filter material within the lumen, and through
the mouth-engaging end, by application of a suction to the
mouth-engaging end of the housing.
[0006] Another aspect of the present disclosure provides a method
of enhancing a vapor produced by an electronic vapor smoking
article. Such a method comprises engaging a component-engaging end
of a tubular housing with a cartridge body portion associated with
the electronic vapor smoking article, wherein the tubular housing
has a mouth-engaging end longitudinally-opposed to the
component-engaging end, and defines a lumen configured to receive a
filter material therein. A vapor is received in the lumen of the
housing from the cartridge body portion in response to application
of a suction to the mouth-engaging end of the housing, and the
vapor drawn through the filter material by the suction is enhanced
with a vapor-enhancing element operably engaged with the filter
material.
[0007] Aspects of the present disclosure thus address the
identified needs and provide other advantages as detailed
herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0008] Having thus described the disclosure in the foregoing
general terms, reference will now be made to the accompanying
drawings, which are not necessarily drawn to scale, and
wherein:
[0009] FIG. 1 is a perspective view of an example embodiment of an
electronic vapor smoking article according to the disclosure,
wherein a portion of an outer shell of the article is cut away to
reveal the interior components thereof;
[0010] FIG. 2 is a perspective view of an example embodiment of an
electronic vapor smoking article according to the disclosure,
wherein the article comprises a control body and a cartridge that
are attachable and detachable with respect to each other;
[0011] FIG. 3 is a longitudinal cross-section of an example
embodiment of an electronic vapor smoking article according to
another aspect of the disclosure, wherein the article comprises a
control body and a cartridge that are attachable and detachable
with respect to each other;
[0012] FIG. 4A is a perspective view of an example embodiment of an
electronic vapor smoking article according to the disclosure,
wherein the article comprises a control body and a cartridge that
are attachable and detachable with respect to each other, and
wherein a vapor-enhancing aspect is engaged with a mouth-end
portion of the electronic vapor smoking article;
[0013] FIG. 4B is a perspective view of an example embodiment of an
electronic vapor smoking article according to the disclosure,
wherein the article comprises a control body and a cartridge that
are attachable and detachable with respect to each other, and
wherein a vapor-enhancing aspect is disengaged from a mouth-end
portion of the electronic vapor smoking article; and
[0014] FIG. 5 is a schematic of a method of enhancing a vapor
produced by an electronic vapor smoking article, according to one
aspect of the disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0015] The present disclosure will now be described more fully
hereinafter with reference to exemplary embodiments thereof. These
exemplary embodiments are described so that this disclosure will be
thorough and complete, and will fully convey the scope of the
disclosure to those skilled in the art. Indeed, the disclosure may
be embodied in many different forms and should not be construed as
limited to the embodiments set forth herein; rather, these
embodiments are provided so that this disclosure will satisfy
applicable legal requirements. As used in the specification, and in
the appended claims, the singular forms "a", "an", "the", include
plural referents unless the context clearly dictates otherwise.
[0016] The present disclosure provides descriptions of articles
that use electrical energy to heat a material (preferably without
combusting the material to any significant degree) to form an
inhalable substance; such articles most preferably being
sufficiently compact to be considered "hand-held" devices. In
certain highly preferred embodiments, the articles can be
characterized as smoking articles. As used herein, the term
"smoking article" is intended to mean an article or device that
provides many of the sensations (e.g., inhalation and exhalation
rituals, types of tastes or flavors, organoleptic effects, physical
feel, use rituals, visual cues such as those provided by visible
aerosol, and the like) of smoking a cigarette, cigar, or pipe,
without any substantial degree of combustion of any component of
that article or device. As used herein, the term "smoking article"
does not necessarily mean that, in operation, the article or device
produces smoke in the sense of the aerosol resulting from
by-products of combustion or pyrolysis of tobacco, but rather, that
the article or device yields vapors (including vapors within
aerosols that can be considered to be visible aerosols that might
be considered to be described as smoke-like) resulting from
volatilization or vaporization of certain components of the article
or device. In highly preferred embodiments, articles or devices
characterized as smoking articles incorporate tobacco and/or
components derived from tobacco.
[0017] Articles or devices of the present disclosure also can be
characterized as being vapor-producing articles, aerosol delivery
articles or medicament delivery articles. Thus, such articles or
devices can be adapted so as to provide one or more substances
(e.g., flavors and/or pharmaceutical active ingredients) in an
inhalable form or state. For example, inhalable substances can be
substantially in the form of a vapor (i.e., a substance that is in
the gas phase at a temperature lower than its critical point).
Alternatively, inhalable substances can be in the form of an
aerosol (i.e., a suspension of fine solid particles or liquid
droplets in a gas). For purposes of simplicity, the term "aerosol"
as used herein is meant to include vapors, gases and aerosols of a
form or type suitable for human inhalation, whether or not visible,
and whether or not of a form that might be considered to be
smoke-like.
[0018] In use, smoking articles of the present disclosure are
subjected many of the physical actions of an individual in using a
traditional type of smoking article (e.g., a cigarette, cigar or
pipe that is employed by lighting with a flame and used by inhaling
tobacco that is subsequently burned). For example, the user of a
smoking article of the present disclosure can hold that article
much like a traditional type of smoking article, draw on one end of
that article for inhalation of aerosol produced by that article,
and take puffs at selected intervals of time.
[0019] Smoking articles of the present disclosure generally include
a number of components provided within an outer shell or body. The
overall design of the outer shell or body can vary, and the format
or configuration of the outer body that can define the overall size
and shape of the smoking article can vary. Typically, an elongated
body resembling the shape of a cigarette or cigar can be a formed
from a single, unitary shell; or the elongated body can be formed
of two or more separable pieces. For example, a smoking article can
comprise an elongated shell or body that can be substantially
tubular in shape, and as such, resemble the shape of a conventional
cigarette or cigar. In one embodiment, all of the components of the
smoking article are contained within one outer body or shell.
Alternatively, a smoking article can comprise two shells that are
joined and are separable. For example, a smoking article can
possess at one end a control body comprising a shell containing one
or more reusable components (e.g., a rechargeable battery and
various electronics for controlling the operation of that article),
and at the other end and removably attached thereto a shell
containing a disposable portion (e.g., a disposable
flavor-containing cartridge). More specific formats, configurations
and arrangements of components within the single shell type of unit
or within a multi-piece separable shell type of unit will be
evident in light of the further disclosure provided herein.
Additionally, various smoking article designs and component
arrangements can be appreciated upon consideration of the
commercially available electronic smoking articles, such as those
representative products listed in the background art section of the
present disclosure.
[0020] Smoking articles of the present disclosure most preferably
comprise some combination of a power source (i.e., an electrical
power source), at least one control component (e.g., means for
actuating, controlling, regulating and ceasing power for heat
generation, such as by controlling electrical current flow from the
power source to other components of the article), a heater or heat
generation component (e.g., an electrical resistance heating
element or component commonly referred to as an "atomizer"), and an
aerosol precursor component (e.g., commonly a liquid capable of
yielding an aerosol upon application of sufficient heat, such as
ingredients commonly referred to as "smoke juice," "e-liquid" and
"e-juice"), and a mouth-end region, portion, or tip for allowing
draw upon the smoking article for aerosol inhalation (e.g., a
defined air flow path through the article such that aerosol
generated can be withdrawn therefrom upon draw). Alignment of the
components within the article can vary. In specific embodiments,
the aerosol precursor component can be located near an end of the
article (e.g., with a cartridge which, in certain circumstances,
can be replaceable and disposable) that is proximal to the mouth of
a user so as to maximize aerosol delivery to the user. Other
configurations, however, are not excluded. Generally, the heater
component can be positioned sufficiently near that aerosol
precursor component so that heat from the heater component can
volatilize the aerosol precursor (as well as one or more
flavorants, medicaments, or the like that may likewise be provided
for delivery to a user) and form an aerosol for delivery to the
user. When the heating member heats the aerosol precursor
component, an aerosol is formed, released, or generated in a
physical form suitable for inhalation by a consumer. It should be
noted that the foregoing terms are meant to be interchangeable such
that reference to release, releasing, releases, or released
includes form or generate, forming or generating, forms or
generates, and formed or generated. Specifically, an inhalable
substance is released in the form of a vapor or aerosol or mixture
thereof. Additionally, the selection of various smoking article
components can be appreciated upon consideration of the
commercially available electronic smoking articles, such as those
representative products listed in the background art section of the
present disclosure.
[0021] A smoking article incorporates a battery or other electrical
power source to provide current flow sufficient to provide various
functionalities to the article, such as resistive heating, powering
of control systems, powering of indicators, and the like. The power
source can take on various embodiments. Preferably, the power
source is able to deliver sufficient power to rapidly heat the
heating member to provide for aerosol formation and power the
article through use for the desired duration of time. The power
source preferably is sized to fit conveniently within the article
so that the article can be easily handled; and additionally,
preferred a preferred power source is of a sufficiently light
weight to not detract from a desirable smoking experience.
[0022] Examples of useful power sources include lithium ion
batteries that preferably are rechargeable (e.g., a rechargeable
lithium-manganese dioxide battery). In particular, lithium polymer
batteries can be used as such batteries can provide increased
safety. Other types of batteries--e.g., N50-AAA CADNICA
nickel-cadmium cells--may also be used. Even further examples of
batteries that can be used according to the disclosure are
described in US Pub. App. No. 2010/0028766, the disclosure of which
is incorporated herein by reference in its entirety. Thin film
batteries may be used in certain embodiments of the disclosure. 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 embodiments wherein disposable batteries are provided, smoking
article can include access for removal and replacement of the
battery. Alternatively, in embodiments where rechargeable batteries
are used, the smoking article can comprise charging contacts, for
interaction with corresponding contacts in a conventional
recharging unit 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, including USB connections. Means
for recharging the battery can be provided in a portable charging
case that can include, for example, a relatively larger battery
unit that can provide multiple charges for the relatively smaller
batteries present in the smoking article. The article further can
include components for providing a non-contact inductive recharging
system such that the article can be charged without being
physically connected to an external power source. Thus, the article
can include components to facilitate transfer of energy from an
electromagnetic field to the rechargeable battery within the
article.
[0023] In further embodiments, the power source also can comprise
one or more capacitors. 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 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. Thus, the disclosure also may include a charger
component that can be attached to the smoking article between uses
to replenish the supercapacitor.
[0024] The smoking article can further include a variety of power
management software, hardware, and/or other electronic control
components. For example, such software, hardware, and/or electronic
controls can include carrying out charging of the battery,
detecting the battery charge and discharge status, performing power
save operations, preventing unintentional or over-discharge of the
battery, or the like.
[0025] A "controller" or "control component" according to the
present disclosure can encompass a variety of elements useful in
the present smoking article. Moreover, a smoking article according
to the disclosure can include one, two, or even more control
components that can be combined into a unitary element or that can
be present at separate locations within the smoking article, and
individual control components can be utilized for carrying out
different control aspects. For example, a smoking article can
include a control component that is integral to or otherwise
combined with a battery so as to control power discharge from the
battery. The smoking article separately can include a control
component that controls other aspects of the article.
Alternatively, a single controller may be provided that carries out
multiple control aspects or all control aspects of the article.
Likewise, a sensor (e.g., a puff sensor) used in the article can
include a control component that controls the actuation of power
discharge from the power source in response to a stimulus. The
smoking article separately can include a control component that
controls other aspects of the article. Alternatively, a single
controller may be provided in or otherwise associated with the
sensor for carrying out multiple control aspects or all control
aspects of the article. Thus, it can be seen that a variety of
combinations of controllers may be combined in the present smoking
article to provide the desired level of control of all aspects of
the device.
[0026] The smoking article also can comprise one or more controller
components useful for controlling flow of electrical energy from
the power source to further components of the article, such as to a
resistive heating element. Specifically, the article can comprise a
control component that actuates current flow from the power source,
such as to the resistive heating element. For example, in some
embodiments, the article can include a pushbutton that can be
linked to a control circuit for manual control of power flow,
wherein a consumer can use the pushbutton to turn on the article
and/or to actuate current flow into the resistive heating element.
Multiple buttons can be provided for manual performance of powering
the article on and off, and for activating heating for aerosol
generation. One or more pushbuttons present can be substantially
flush with an outer surface of the smoking article.
[0027] Instead of (or in addition to) the pushbutton, the inventive
article can include one or more control components responsive to
the consumer's drawing on the article (i.e., puff-actuated
heating). For example, the article may include a switch 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 resistive heating element can be 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
resistive heating element 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 disclosure 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 an air flow passage within the
smoking article can be included so that pressure changes during
draw are readily identified by the switch. Further description of
current regulating circuits and other control components, including
microcontrollers, that can be useful in the present smoking article
are provided in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875,
all to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al.,
U.S. Pat. No. 6,040,560 to Fleischhauer et al., and U.S. Pat. No.
7,040,314 to Nguyen et al., all of which are incorporated herein by
reference in their entireties.
[0028] Capacitive sensing components in particular can be
incorporated into the device in a variety of manners to allow for
diverse types of "power-up" and/or "power-down" for one or more
components of the device. Capacitive sensing can include the use of
any sensor incorporating technology based on capacitive coupling
including, but not limited to, sensors that detect and/or measure
proximity, position or displacement, humidity, fluid level,
pressure, or acceleration. Capacitive sensing can arise from
electronic components providing for surface capacitance, projected
capacitance, mutual capacitance, or self capacitance. Capacitive
sensors generally can detect anything that is conductive or has a
dielectric different than that of air. Capacitive sensors, for
example, can replace mechanical buttons (i.e., the push-button
referenced above) with capacitive alternatives. Thus, one specific
application of capacitive sensing according to the disclosure is a
touch capacitive sensor. For example, a touch pad can be present on
the smoking article that allows the user to input a variety of
commands. Most basically, the touch pad can provide for powering
the heating element much in the same manner as a push button, as
already described above. In other embodiments, capacitive sensing
can be applied near the mouth end of the smoking article such that
the pressure of the lips on the smoking article to draw on the
article can signal the device to provide power to the heating
element. In addition to touch capacitance sensors, motion
capacitance sensors, liquid capacitance sensors, and accelerometers
can be utilized according to the disclosure to illicit a variety of
response from the smoking article. Further, photoelectric sensors
also can be incorporated into the inventive smoking article.
[0029] Sensors utilized in the present articles can expressly
signal for power flow to the heating element so as to heat the
substrate including the aerosol precursor material and form a vapor
or aerosol for inhalation by a user. Sensors also can provide
further functions. For example, a "wake-up" sensor can be included.
Other sensing methods providing similar function likewise can be
utilized according to the disclosure.
[0030] When the consumer draws on the mouth end of the smoking
article, the current actuation means can permit unrestricted or
uninterrupted flow of current through the resistive heating member
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
resistive element and the temperature experienced thereby, and (ii)
prevent overheating and degradation of the substrate or other
component carrying the aerosol precursor material and/or other
flavors or inhalable materials.
[0031] 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
4.5 seconds, about 0.5 second to about 4.0 seconds, about 0.5
second to about 3.5 seconds, or about 0.6 second to about 3.0
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 and other control components that can
be useful in the present smoking article are provided in U.S. Pat.
Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., all
of which are incorporated herein by reference in their
entireties.
[0032] The control components particularly can be configured to
closely control the amount of heat provided to the resistive
heating element. In some embodiments, the current regulating
component can function to stop current flow to the resistive
heating element once a defined temperature has been achieved. Such
defined temperature can be in a range that is substantially high
enough to volatilize the aerosol precursor material and any further
inhalable substances and provide an amount of aerosol equivalent to
a typical puff on a conventional cigarette, as otherwise discussed
herein. While the heat needed to volatilize the aerosol precursor
material in a sufficient volume to provide a desired volume for a
single puff can vary, it can be particularly useful for the heating
member to heat to a temperature of about 120.degree. C. or greater,
about 130.degree. C. or greater, about 140.degree. C. or greater,
or about 160.degree. C. In some embodiments, in order to volatilize
an appropriate amount of the aerosol precursor material, the
heating temperature may be about 180.degree. C. or greater, about
200.degree. C. or greater, about 300.degree. C. or greater, or
about 350.degree. C. or greater. In further embodiments, the
defined temperature for aerosol formation can be about 120.degree.
C. to about 350.degree. C., about 140.degree. C. to about
300.degree. C., or about 150.degree. C. to about 250.degree. C. The
temperature and time of heating can be controlled by one or more
components contained in the control housing. The current regulating
component likewise can cycle the current to the resistive heating
element off and on once a defined temperature has been achieved so
as to maintain the defined temperature for a defined period of
time.
[0033] Still further, the current regulating component can cycle
the current to the resistive heating element off and on to maintain
a first temperature that is below an aerosol forming temperature
and then allow an increased current flow in response to a current
actuation control component so as to achieve a second temperature
that is greater than the first temperature and that is an aerosol
forming temperature. Such controlling can improve the response time
of the article for aerosol formation such that aerosol formation
begins almost instantaneously upon initiation of a puff by a
consumer. In some embodiments, the first temperature (which can be
characterized as a standby temperature) can be only slightly less
than the aerosol forming temperature defined above. Specifically,
the standby temperature can be about 50.degree. C. to about
150.degree. C., about 70.degree. C. to about 140.degree. C., about
80.degree. C. to about 120.degree. C., or about 90.degree. C. to
about 110.degree. C.
[0034] In addition to the above control elements, the smoking
article also may comprise one or more indicators. Such indicators
may be lights (e.g., light emitting diodes) that can provide
indication of multiple aspects of use of the inventive article.
Further, LED indicators may be positioned at the distal end of the
smoking article to simulate color changes seen when a conventional
cigarette is lit and drawn on by a user. Other indices of operation
also are encompassed. For example, visual indicators of operation
also may include changes in light color or intensity to show
progression of the smoking experience. Tactile indicators of
operation and sound indicators of operation similarly are
encompassed by the disclosure. Moreover, combinations of such
indicators of operation also may be used in a single article.
[0035] A smoking article according to the disclosure further can
comprise a heating member that heats an aerosol precursor component
to produce an aerosol for inhalation by a user. In various
embodiments, the heating member can be formed of a material that
provides resistive heating when an electrical current is applied
thereto. Preferably, the resistive heating element exhibits an
electrical resistance making the resistive heating element useful
for providing a sufficient quantity of heat when electrical current
flows therethrough. Interaction of the heating member with the
aerosol precursor component/composition may be through, for
example, heat conduction, heat radiation, and/or heat
convection.
[0036] Electrically conductive materials useful as resistive
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 can be beneficial to provide almost
immediate volatilization of an aerosol precursor material in
proximity thereto. Rapid cooling (i.e., to a temperature below the
volatilization temperature of the aerosol precursor
component/composition/material) prevents substantial volatilization
(and hence waste) of the aerosol precursor material during periods
when aerosol formation is not desired. Such heating elements also
permit relatively precise control of the temperature range
experienced by the aerosol precursor material, especially when time
based current control is employed. Useful electrically conductive
materials preferably are chemically non-reactive with the materials
being heated (e.g., aerosol precursor materials and other inhalable
substance materials) so as not to adversely affect the flavor or
content of the aerosol or vapor that is produced. Exemplary,
non-limiting, materials that can be used as the electrically
conductive material include carbon, graphite, carbon/graphite
composites, metals, 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, and thermal conductivity. In
specific embodiments, metals that can be utilized include, for
example, nickel, chromium, alloys of nickel and chromium (e.g.,
nichrome), and steel. Materials that can be useful for providing
resistive heating are described in U.S. Pat. No. 5,060,671 to
Counts et al.; U.S. Pat. No. 5,093,894 to Deevi et al.; U.S. Pat.
No. 5,224,498 to Deevi et al.; U.S. Pat. No. 5,228,460 to Sprinkel
Jr., et al.; U.S. Pat. No. 5,322,075 to Deevi et al.; U.S. Pat. No.
5,353,813 to Deevi et al.; U.S. Pat. No. 5,468,936 to Deevi et al.;
U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 to Das;
U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to
Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No.
5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to
Fleischhauer et al., the disclosures of which are incorporated
herein by reference in their entireties.
[0037] The resistive heating element can be provided in a variety
forms, such as in the form of a foil, a foam, discs, spirals,
fibers, wires, films, yarns, strips, ribbons, or cylinders, as well
as irregular shapes of varying dimensions. In some embodiments, a
resistive heating element according to the present disclosure can
be a conductive substrate, such as described in co-pending U.S.
patent application Ser. No. 13/432,406, filed Mar. 28, 2012, the
disclosure of which is incorporated herein by reference in its
entirety. The resistive heating element also may be present as part
of a microheater component, such as described in co-pending U.S.
patent application Ser. No. 13/602,871, filed Sep. 4, 2012, the
disclosure of which is incorporated herein by reference in its
entirety.
[0038] Beneficially, the resistive heating element can be provided
in a form that enables the heating element to be positioned in
intimate contact with or in close proximity to the aerosol
precursor material (i.e. to provide heat to the aerosol precursor
material through, for example, conduction, radiation, or
convection). In other embodiments, the resistive heating element
can be provided in a form such that the aerosol precursor material
can be delivered to the resistive heating element for
aerosolization. Such delivery can take on a variety of embodiments,
such as wicking of the aerosol precursor to the resistive heating
element and flowing the aerosol precursor to the resistive heating
element, such as through a capillary, which may include valve flow
regulation. As such, the aerosol precursor material may be provided
in liquid form in one or more reservoirs positioned sufficiently
away from the resistive heating element to prevent premature
aerosolization, but positioned sufficiently close to the resistive
heating element to facilitate transport of the aerosol precursor
material, in the desired amount, to the resistive heating element
for aerosolization.
[0039] In certain embodiments, a smoking article according to the
present disclosure can include tobacco, 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). The tobacco that is employed can include,
or can be derived from, tobaccos such as flue-cured tobacco, burley
tobacco, Oriental tobacco, Maryland tobacco, dark tobacco,
dark-fired tobacco and Rustica tobacco, as well as other rare or
specialty tobaccos, or blends thereof. 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.
6,730,832 to Dominguez et al., U.S. Pat. No. 7,011,096 to Li et
al.; 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 Pub. WO 02/37990 to Bereman; and Bombick et al., Fund.
Appl. Toxicol., 39, p. 11-17 (1997); the disclosures of which are
incorporated herein by reference in their entireties.
[0040] The tobacco that is incorporated within the smoking article
can be employed in various forms; and combinations of various forms
of tobacco can be employed, or different forms of tobacco can be
employed at different locations within the smoking article. For
example, the tobacco can be employed in the form of a tobacco
extract. See, for example, U.S. Pat. No. 7,647,932 to Cantrell et
al.; U.S. Pat. No. 8,079,371 to Robinson et al.; and US Pat. Pub.
No. 2007/0215167 to Crooks et al., the disclosures of which are
incorporated herein by reference in their entireties.
[0041] The smoking article can incorporate tobacco additives of the
type that are traditionally used for the manufacture of tobacco
products. Those additives can include the types of materials used
to enhance the flavor and aroma of tobaccos used for the production
of cigars, cigarettes, pipes, and the like. For example, those
additives can include various cigarette casing and/or top dressing
components. See, for example, U.S. Pat. No. 3,419,015 to
Wochnowski; U.S. Pat. No. 4,054,145 to Berndt et al.; U.S. Pat. No.
4,887,619 to Burcham, Jr. et al.; U.S. Pat. No. 5,022,416 to
Watson; U.S. Pat. No. 5,103,842 to Strang et al.; and U.S. Pat. No.
5,711,320 to Martin; the disclosures of which are incorporated
herein by reference in their entireties. Preferred casing materials
include water, sugars and syrups (e.g., sucrose, glucose and high
fructose corn syrup), humectants (e.g. glycerin or propylene
glycol), and flavoring agents (e.g., cocoa and licorice). Those
added components also include top dressing materials (e.g.,
flavoring materials, such as menthol). See, for example, U.S. Pat.
No. 4,449,541 to Mays et al., the disclosure of which is
incorporated herein by reference in its entirety. Further materials
that can be added include those disclosed in U.S. Pat. No.
4,830,028 to Lawson et al. and US Pat. Pub. No. 2008/0245377 to
Marshall et al., the disclosures of which are incorporated herein
by reference in their entireties.
[0042] Various manners and methods for incorporating tobacco into
smoking articles, and particularly smoking articles that are
designed so as to not purposefully burn virtually all of the
tobacco within those smoking articles, are set forth in U.S. Pat.
No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell
et al.; U.S. Pat. No. 8,079,371 to Robinson et al.; US Pat. App.
Pub. No. 2005/0016549 to Banerjee et al.; and US Pat. App. Pub. No.
2007/0215167 to Crooks et al.; the disclosures of which are
incorporated herein by reference in their entireties.
[0043] 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 included in the
vapor precursor or aerosol precursor composition. As used herein,
the term "tobacco extract" means components separated from, removed
from, or derived from, tobacco using tobacco extraction processing
conditions and techniques. Purified extracts of tobacco or other
botanicals specifically can be used. Typically, tobacco extracts
are obtained using solvents, such as solvents having an aqueous
nature (e.g., water) or organic solvents (e.g., alcohols, such as
ethanol or alkanes, such as hexane). As such, extracted tobacco
components are removed from tobacco and separated from the
unextracted tobacco components; and for extracted tobacco
components that are present within a solvent, (i) the solvent can
be removed from the extracted tobacco components, or (ii) the
mixture of extracted tobacco components and solvent can be used as
such. Exemplary types of tobacco extracts, tobacco essences,
solvents, tobacco extraction processing conditions and techniques,
and tobacco extract collection and isolation procedures, are set
forth in Australia Pat. No. 276,250 to Schachner; U.S. Pat. No.
2,805,669 to Meriro; U.S. Pat. No. 3,316,919 to Green et al.; U.S.
Pat. No. 3,398,754 to Tughan; U.S. Pat. No. 3,424,171 to Rooker;
U.S. Pat. No. 3,476,118 to Luttich; U.S. Pat. No. 4,150,677 to
Osborne; U.S. Pat. No. 4,131,117 to Kite; U.S. Pat. No. 4,506,682
to Muller; U.S. Pat. No. 4,986,286 to Roberts et al.; U.S. Pat. No.
5,005,593 to Fagg; U.S. Pat. No. 5,065,775 to Fagg; U.S. Pat. No.
5,060,669 to White et al.; U.S. Pat. No. 5,074,319 to White et al.;
U.S. Pat. No. 5,099,862 to White et al.; U.S. Pat. No. 5,121,757 to
White et al.; U.S. Pat. No. 5,131,415 to Munoz et al.; U.S. Pat.
No. 5,230,354 to Smith et al.; U.S. Pat. No. 5,235,992 to
Sensabaugh; U.S. Pat. No. 5,243,999 to Smith; U.S. Pat. No.
5,301,694 to Raymond; U.S. Pat. No. 5,318,050 to Gonzalez-Parra et
al.; U.S. Pat. No. 5,435,325 to Clapp et al.; and U.S. Pat. No.
5,445,169 to Brinkley et al.; the disclosures of which are
incorporated herein by reference in their entireties.
[0044] The aerosol precursor or vapor precursor material can
comprise one or more different components. For example, the aerosol
precursor can include a polyhydric alcohol (e.g., glycerin,
propylene glycol, or a mixture thereof). Representative types of
further aerosol precursor materials are set forth in U.S. Pat. No.
4,793,365 to Sensabaugh, Jr. et al.; 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); the
disclosures of which are incorporated herein by reference. In some
embodiments, an aerosol precursor composition can produce a visible
aerosol upon the application of sufficient heat thereto (and
cooling with air, if necessary), and the aerosol precursor
composition can produce an aerosol that can be considered to be
"smoke-like." In other embodiments, the aerosol precursor
composition can produce an aerosol that can be substantially
non-visible but can be recognized as present by other
characteristics, such as flavor or texture. Thus, the nature of the
produced aerosol can vary depending upon the specific components of
the aerosol precursor composition. The aerosol precursor
composition can be chemically simple relative to the chemical
nature of the smoke produced by burning tobacco.
[0045] Aerosol precursor materials can be combined with other
liquid materials. For example, aerosol precursor material
formulations can incorporate mixtures of glycerin and water, or
mixtures of propylene glycol and water, or mixtures of propylene
glycol and glycerin, or mixtures of propylene glycol, glycerin, and
water. Exemplary aerosol precursor materials also include those
types of materials incorporated within devices available through
Atlanta Imports Inc., Acworth, Ga., USA., as an electronic cigar
having the brand name E-CIG, which can be employed using associated
Smoking Cartridges Type C1a, C2a, C3a, C4a, C1b, C2b, C3b and C4b;
and as Ruyan Atomizing Electronic Pipe and Ruyan Atomizing
Electronic Cigarette from Ruyan SBT Technology and Development Co.,
Ltd., Beijing, China.
[0046] The smoking article further can comprise one or more
flavors, medicaments, or other inhalable materials. For example,
liquid nicotine can be used. Such further materials may be combined
with the aerosol precursor or vapor precursor material. Thus, the
aerosol precursor or vapor precursor material may be described as
comprising an inhalable substance in addition to the aerosol. Such
inhalable substance can include flavors, medicaments, and other
materials as discussed herein. Particularly, an inhalable substance
delivered using a smoking article according to the present
disclosure can comprise a tobacco component or a tobacco-derived
material. For example, the aerosol precursor material can be in a
slurry with tobacco or a tobacco component, or in solution with a
tobacco-derived material. Alternately, the flavor, medicament, or
other inhalable material can be provided separate from the aerosol
precursor--e.g., in a reservoir. As such, defined aliquots of the
flavor, medicament, or other inhalable material may be separately
or simultaneously delivered to the resistive heating element to
release the flavor, medicament, or other inhalable material into an
air stream to be inhaled by a user along with the aerosol precursor
or vapor precursor material. Alternatively, the flavor, medicament,
or other inhalable material may be provided in a separate portion
of the smoking article or a component thereof. In specific
embodiments, the flavor, medicament, or other inhalable material
can be deposited on a substrate (e.g., a paper or other porous
material) that is located in proximity to the resistive heating
element. The proximity preferably is sufficient such that heating
of the resistive heating element provides heat to the substrate
sufficient to volatilize and release the flavor, medicament, or
other inhalable material from the substrate.
[0047] A wide variety of types of flavoring agents, or materials
that alter the sensory or organoleptic character or nature of the
mainstream aerosol of the smoking article, can be employed. Such
flavoring agents can be provided from sources other than tobacco,
can be natural or artificial in nature, and can be employed as
concentrates or flavor packages. Of particular interest are
flavoring agents that are applied to, or incorporated within, those
regions of the smoking article where aerosol is generated. Again,
such agents can be supplied directly to the resistive heating
element or may be provided on a substrate as already noted above.
Exemplary flavoring agents include vanillin, ethyl vanillin, cream,
tea, coffee, fruit (e.g., apple, cherry, strawberry, peach and
citrus flavors, including lime and lemon), maple, menthol, mint,
peppermint, spearmint, wintergreen, nutmeg, clove, lavender,
cardamom, ginger, honey, anise, sage, cinnamon, sandalwood,
jasmine, cascarilla, cocoa, licorice, and flavorings and flavor
packages of the type and character traditionally used for the
flavoring of cigarette, cigar, and pipe tobaccos. Syrups, such as
high fructose corn syrup, also can be employed. Flavoring agents
also can include acidic or basic characteristics (e.g., organic
acids, such as levulinic acid, succinic acid, and pyruvic acid).
The flavoring agents can be combined with the aerosol-generating
material if desired. Exemplary plant-derived compositions that may
be used are disclosed in U.S. application Ser. No. 12/971,746 to
Dube et al. and U.S. application Ser. No. 13/015,744 to Dube et
al., the disclosures of which are incorporated herein by reference
in their entireties. 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 disclosure 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),
the disclosures of which are incorporated herein by reference in
their entireties. Any of the materials, such as flavorings,
casings, and the like that can be useful in combination with a
tobacco material to affect sensory properties thereof, including
organoleptic properties, such as already described herein, may be
combined with the aerosol precursor material. Organic acids
particularly may be incorporated into the aerosol precursor
composition to affect the flavor, sensation, or organoleptic
properties of medicaments, such as nicotine, that may be combined
with the aerosol precursor composition. For example, organic acids,
such as levulinic acid, lactic acid, and pyruvic acid, may be
included in the aerosol precursor composition with nicotine in
amounts up to being equimolar (based on total organic acid content)
with the nicotine. Any combination of organic acids can be used.
For example, the aerosol precursor composition can include about
0.1 to about 0.5 moles of levulinic acid per one mole of nicotine,
about 0.1 to about 0.5 moles of pyruvic acid per one mole of
nicotine, about 0.1 to about 0.5 moles of lactic acid per one mole
of nicotine, or combinations thereof, up to a concentration wherein
the total amount of organic acid present is equimolar to the total
amount of nicotine present in the aerosol precursor
composition.
[0048] The aerosol precursor material may take on a variety of
conformations based upon the various amounts of materials utilized
therein. For example, a useful aerosol precursor material may
comprise up to about 98% by weight up to about 95% by weight, or up
to about 90% by weight of a polyol. This total amount can be split
in any combination between two or more different polyols. For
example, one polyol can comprise about 50% to about 90%, about 60%
to about 90%, or about 75% to about 90% by weight of the aerosol
precursor material, and a second polyol can comprise about 2% to
about 45%, about 2% to about 25%, or about 2% to about 10% by
weight of the aerosol precursor material. A useful aerosol
precursor material also can comprise up to about 25% by weight,
about 20% by weight or about 15% by weight water--particularly
about 2% to about 25%, about 5% to about 20%, or about 7% to about
15% by weight water. Flavors and the like (which can include
medicaments, such as nicotine) can comprise up to about 10%, up to
about 8%, or up to about 5% by weight of the aerosol precursor
material. In some aspects, the aerosol precursor material may also
include an effervescent material added to the aerosol formation
arrangement, wherein decomposition of the effervescent material may
facilitate aerosol formation.
[0049] As a non-limiting example, an aerosol precursor material
according to the disclosure can comprise glycerol, propylene
glycol, water, nicotine, and one or more flavors. Specifically, the
glycerol can be present in an amount of about 70% to about 90% by
weight, about 70% to about 85% by weight, or about 75% to about 85%
by weight, the propylene glycol can be present in an amount of
about 1% to about 10% by weight, about 1% to about 8% by weight, or
about 2% to about 6% by weight, the water can be present in an
amount of about 10% to about 20% by weight, about 10% to about 18%
by weight, or about 12% to about 16% by weight, the nicotine can be
present in an amount of about 0.1% to about 5% by weight, about
0.5% to about 4% by weight, or about 1% to about 3% by weight, and
the flavors can be present in an amount of up to about 5% by
weight, up to about 3% by weight, or up to about 1% by weight, all
amounts being based on the total weight of the aerosol precursor
material. One specific, non-limiting example of an aerosol
precursor material comprises about 75% to about 80% by weight
glycerol, about 13% to about 15% by weight water, about 4% to about
6% by weight propylene glycol, about 2% to about 3% by weight
nicotine, and about 0.1% to about 0.5% by weight flavors. The
nicotine, for example, can be a high nicotine content tobacco
extract.
[0050] In embodiments of the aerosol precursor material that
contain a tobacco extract, including pharmaceutical grade nicotine
derived from tobacco, it is advantageous for the tobacco extract to
be characterized as substantially free of compounds collectively
known as Hoffmann analytes, including, for example,
tobacco-specific nitrosamines (TSNAs), including
N'-nitrosonornicotine (NNN),
(4-methylnitrosamino)-1-(3-pyridyl)-1-butanone (NNK),
N'-nitrosoanatabine (NAT), and N'-nitrosoanabasine (NAB);
polyaromatic hydrocarbons (PAHs), including benz[a]anthracene,
benzo[a]pyrene, benzo[b]fluoranthene, benzo[k]fluoranthene,
chrysene, dibenz[a,h]anthracene, and indeno[1,2,3-cd]pyrene, and
the like. In certain embodiments, the aerosol precursor material
can be characterized as completely free of any Hoffmann analytes,
including TSNAs and PAHs. Embodiments of the aerosol precursor
material may have TSNA levels (or other Hoffmann analyte levels) in
the range of less than about 5 ppm, less than about 3 ppm, less
than about 1 ppm, or less than about 0.1 ppm, or even below any
detectable limit. Certain extraction processes or treatment
processes can be used to achieve reductions in Hoffmann analyte
concentration. For example, a tobacco extract can be brought into
contact with an imprinted polymer or non-imprinted polymer such as
described, for example, in US Pat. Pub. Nos. 2007/0186940 to
Bhattacharyya et al; 2011/0041859 to Rees et al.; and 2011/0159160
to Jonsson et al; and U.S. patent application Ser. No. 13/111,330
to Byrd et al., filed May 19, 2011, all of which are incorporated
herein by reference. Further, the tobacco extract could be treated
with ion exchange materials having amine functionality, which can
remove certain aldehydes and other compounds. See, for example,
U.S. Pat. No. 4,033,361 to Horsewell et al. and U.S. Pat. No.
6,779,529 to Figlar et al., which are incorporated by reference
herein.
[0051] The amount of aerosol precursor material that is used within
the smoking article is such that the article exhibits acceptable
sensory and organoleptic properties, and desirable performance
characteristics. For example, it is highly preferred that
sufficient aerosol precursor material, such as glycerin and/or
propylene glycol, be employed in order to provide for the
generation of a visible mainstream aerosol that in many regards
resembles the appearance of tobacco smoke. Typically, the amount of
aerosol-generating material incorporated into the smoking article
is in the range of about 1.5 g or less, about 1 g or less, or about
0.5 g or less. The amount of aerosol precursor material can be
dependent upon factors such as the number of puffs desired per
cartridge used with the smoking article. It is desirable for the
aerosol-generating composition not to introduce significant degrees
of unacceptable off-taste, filmy mouth-feel, or an overall sensory
experience that is significantly different from that of a
traditional type of cigarette that generates mainstream smoke by
burning tobacco cut filler. The selection of the particular
aerosol-generating material and reservoir material, the amounts of
those components used, and the types of tobacco material used, can
be altered in order to control the overall chemical composition of
the mainstream aerosol produced by the smoking article.
[0052] The amount of aerosol released by the inventive article can
vary. Preferably, the article is configured with a sufficient
amount of the aerosol precursor material, with a sufficient amount
of any further inhalable substance, and to function at a sufficient
temperature for a sufficient time to release a desired content of
aerosolized materials over a course of use. The content may be
provided in a single inhalation from the article 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 0.01 mg to about 0.5 mg, about 0.05
mg to about 0.3 mg, or about 0.1 mg to about 0.2 mg, per puff on
the article. For purposes of calculations, an average puff time of
about 2 seconds can deliver a puff volume of about 5 ml to about
100 ml, about 15 ml to about 70 ml, about 20 ml to about 60 ml, or
about 25 ml to about 50 ml. A smoking article according to the
disclosure can be configured to provide any number of puffs
calculable by the total amount of aerosol or other inhalable
substance to be delivered divided by the amount to be delivered per
puff. The one or more reservoirs can be loaded with the appropriate
amount of aerosol precursor or other inhalable substance to achieve
the desired number of puffs and/or the desired total amount of
material to be delivered.
[0053] In further embodiments, heating can be characterized in
relation to the amount of aerosol to be generated. Specifically,
the article can be configured to provide an amount of heat
necessary to generate a defined volume of aerosol (e.g., about 5 ml
to about 100 ml, or any other volume deemed useful in a smoking
article, such as otherwise described herein). In certain, the
amount of heat generated can be measured in relation to a two
second puff providing about 35 ml of aerosol at a heater
temperature of about 290.degree. C. In some embodiments, the
article preferably can provide about 1 to about 50 Joules of heat
per second (J/s), about 2 J/s to about 40 J/s, about 3 J/s to about
35 J/s, or about 5 J/s to about 30 J/s.
[0054] The resistive heating element preferably is in electrical
connection with the power source of the smoking article such that
electrical energy can be provided to the resistive heating element
to produce heat and subsequently aerosolize the aerosol precursor
material and any other inhalable substance provided by the smoking
article. Such electrical connection can be permanent (e.g., hard
wired) or can be removable (e.g., wherein the resistive heating
element is provided in a cartridge that can be attached to and
detached from a control body that includes the power source).
[0055] Although a variety of materials for use in a smoking article
according to the present disclosure have been described above--such
as heaters, batteries, capacitors, switching components, aerosol
precursors, and the like, the disclosure 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 disclosure. 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.
[0056] Although an article according to the disclosure 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 single unit or as a plurality of
components that are combined by the consumer for use and then are
dismantled by the consumer thereafter. Generally, a smoking article
according to the disclosure can comprise a first unit that is
engagable and disengageable with a second unit, the first unit
comprising the resistive heating element, and the second unit
comprising the electrical power source. In some embodiments, the
second unit further can comprise one or more control components
that actuate or regulate current flow from the electrical power
source. The first unit can comprise a distal end that engages the
second unit and an opposing, proximate end that includes a
mouthpiece (or simply the mouth end) with an opening at a proximate
end thereof. The first unit can comprise an air flow path opening
into the mouthpiece of the first unit, and the air flow path can
provide for passage of aerosol formed from the resistive heating
element into the mouthpiece. In preferred embodiments, the first
unit can be disposable. Likewise, the second unit can be
reusable.
[0057] More specifically, a smoking article according to the
disclosure can have a reusable control body that is substantially
cylindrical in shape having a connecting 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 article
further can comprise a cartridge with a connecting end that engages
the connecting end of the control body and with an opposing mouth
end. To use the article, the consumer can connect a connecting end
of the cartridge to the connecting end of the control body or
otherwise combine the cartridge with the control body so that the
article is operable as discussed herein. In some embodiments, the
connecting ends of the control body and the cartridge can be
threaded for a screw-type engagement. In other embodiments, the
connecting ends can have a press-fit engagement.
[0058] During use, the consumer initiates heating of the resistive
heating element, the heat produced by the resistive heating element
aerosolizes the aerosol precursor material and, optionally, further
inhalable substances. Such heating releases at least a portion of
the aerosol precursor material in the form of an aerosol (which can
include any further inhalable substances included therewith), and
such aerosol is provided within a space inside the cartridge that
is in fluid communication with the mouth end of the cartridge. When
the consumer inhales on the mouth end of the cartridge, air is
drawn through the cartridge, and the combination of the drawn air
and the aerosol is inhaled by the consumer as the drawn materials
exit the mouth end of the cartridge (and any optional mouthpiece
present) into the mouth of the consumer. To initiate heating, the
consumer may actuate a pushbutton, capacitive sensor, or similar
component that causes the resistive heating element to receive
electrical energy from the battery or other energy source (such as
a capacitor). 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.
Indication that the cartridge is spent (i.e., the aerosol precursor
material has been substantially removed by the consumer) can be
provided. In some embodiments, a single cartridge can provide more
than a single smoking experience and thus may provide a sufficient
content of aerosol precursor material to simulate as much as full
pack of conventional cigarettes or even more. Likewise, a plurality
of individual reservoirs can be provided in a single smoking
article to provide a defined number of puffs, conventional
cigarette equivalents, or the like.
[0059] 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 disclosure.
[0060] Referring now to FIG. 1, a smoking article 10 according to
the disclosure generally can comprise a shell 15 and a plurality of
components provided within the shell. The article can be
characterized as having a mouth end 11 (i.e., the end upon which a
consumer can draw to inhale aerosol from the article), and a distal
end 12. The illustrated article is provided as a single unitary
device (however, line A indicates an optional demarcation whereby
the device can be two separate components that are joined together,
either removably or permanently, such as by gluing). As will be
evident from the further disclosure herein, it can be preferable
for further embodiments of the article to be formed of two or more
detachable units, each housing separate components of the article.
The various components shown in the embodiment of FIG. 1 can be
present in other embodiments, including embodiments formed of
multiple units.
[0061] The article 10 according to the disclosure can have an
overall shape that may be defined as being substantially rod-like
or substantially tubular shaped or substantially cylindrically
shaped. As illustrated in FIG. 1, the article 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 units of the
article in embodiments comprising multiple units, such as a control
body and a cartridge.
[0062] The shell 15 of the smoking article 10 can be formed of any
material suitable for forming and maintaining an appropriate
conformation, such as a tubular shape, and for retaining therein
the suitable components of the article. The shell can be formed of
a single wall, as shown in FIG. 1. In some embodiments, the shell
can be 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 resistive heating element, as further discussed
herein. In some embodiments, a heat resistant polymer may be used.
In other embodiments, the shell can be formed from paper, such as a
paper that is substantially straw-shaped. As further discussed
herein, the shell, 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 shell. Ceramic
materials also may be used.
[0063] The shell 15, when formed of a single layer, can have a
thickness of 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. No. 2010/00186757 to Crooks
et al.; US Pub. No. 2010/00186757 to Crooks et al.; and US Pub. No.
2011/0041861 to Sebastian et al.; the disclosures of which are
incorporated herein by reference in their entireties.
[0064] As seen in the embodiment of FIG. 1, the smoking article 10
generally includes an electronic control component 20, a flow
sensor 30, and a battery 40, and these components can be placed in
a variety of orders within the article. Although not expressly
shown, it is understood that the article 10 can include wiring as
necessary to provide power from the battery 40 to the further
components and to interconnect the components for appropriate
operation of the necessary functions provided by the article. The
article 10 further includes a resistive heating element 50 as
described herein. In the illustrated embodiment, the resistive
heating element 50 is a metal coil that can be electrically
connected to the battery 40 through appropriate wiring of the
terminals 51 to facilitate formation of a closed electrical circuit
with current flow through the heating element. Further wiring (not
illustrated) can be included to provide the necessary electrical
connections within the article. In specific embodiments, the
article 10 can be wired with an electrical circuit such that the
control component 20 delivers, controls, or otherwise modulates
power from the battery 40 for energizing the resistive heating
element 50 according to one or more defined algorithms, such as
already described above. Such electrical circuit can specifically
incorporate the flow sensor 30 such that the article 10 is only
active at times of use by the consumer. For example, when a
consumer puffs on the article 10, the flow sensor detects the puff,
and the control component 20 is then activated to direct power
through the article such that the resistive heating element 50
produces heat and thus provides aerosol for inhalation by the
consumer. The control algorithm may call for power to the resistive
heating element 50 to cycle and thus maintain a defined
temperature. The control algorithm therefore can be programmed to
automatically deactivate the article 10 and discontinue power flow
through the article after a defined time lapse without a puff by a
consumer. Moreover, the article can include a temperature sensor to
provide feedback to the control component. Such sensor can be, for
example, in direct contact with the resistive heating element 50.
Alternative temperature sensing means likewise may be used, such as
relying upon logic control components to evaluate resistance
through the resistive heating element and correlate such resistance
to the temperature of the element. In other embodiments, the flow
sensor 30 may be replaced by appropriate components to provide
alternative sensing means, such as capacitive sensing, as otherwise
described herein. Any variety of sensors and combinations thereof
can be incorporated, as already described herein. Still further,
one or more control buttons 16 can be included to allow for manual
actuation by a consumer to elicit a variety of functions, such as
powering the article 10 on and off, turning on the heating element
50 to generate a vapor or aerosol for inhalation, or the like.
[0065] Additionally, the article can include on or more status
indicators 19 positioned on the shell 15. Such indicators, as
discussed above, can show the number of puffs taken or remaining
from the article, can be indicative of an active or inactive
status, can light up in response to a puff, or the like. Although
six indicators are illustrated, more or fewer indicators can be
present, and the indicators can take on different shapes and can
even being simply an opening in the shell (such as for release of
sound when such indicators are present).
[0066] As illustrated in the embodiment of FIG. 1, a reservoir 205
is shown in proximity to the heating element 50, and a wick 300
extends from the reservoir 205 and into the coil of the resistive
heating element 50. The reservoir is one embodiment illustrating
means of storing an aerosol precursor material. The wick utilizes
capillary action to draw the aerosol precursor material from the
reservoir and into a heating zone defined by the area in and around
the resistive heating element 50 in the form of a metal wire coil.
As such, heat produced by the resistive heating element causes the
aerosol precursor material to aerosolize. The formed aerosol is
then drawn by a user through the mouth end 11 of the smoking
article 10. As the aerosol precursor material in the heating zone
is aerosolized by the heating of the resistive heating element,
further aerosol precursor material is wicked out of the reservoir
205 to the heating zone for aerosolization. The cycle continues
until substantially all of the aerosol precursor material has been
aerosolized.
[0067] As seen in the embodiment of FIG. 1, the mouth end 11 of the
article 10 is substantially an open cavity with the resistive
heating element 50 and the reservoir 205 disposed therein. Such
open cavity provides a volume for release of the aerosol from the
wick 300 as it is withdrawn from the reservoir and heated by the
resistive heating element. The article also includes a mouth
opening 18 in the mouth end 11 to allow for withdrawal of the
aerosol from the cavity around the resistive heating element 50. To
facilitate air flow through the article, an air intake 17 can be
provided and can substantially comprise an aperture in the shell 15
that allows for air flow into the interior of the article. A
plurality of air intakes can be provided, and the air intakes can
be positioned at any location upstream from the mouth end of the
article such that air from the air intake can mingle with and
facilitate removal of the formed aerosol from the cavity around the
resistive heating element/substrate and through the opening in the
mouth end of the article. Although not illustrated, if desired,
structural elements can be provided within the article so as to
effectively isolate one or more components within the article from
the air flowing from the air intake to the opening in the mouth
end. In other words, a defined air flow path can be provided, and
such defined air flow path can substantially avoid air flowing
through the air flow path from coming into physical contact with
one or both of the battery 40 and the control component 20. As
illustrated in FIG. 1, air taken in through the air intake 17
passes the flow sensor 30 before entering the cavity surrounding
the heating element/substrate such that activation of the flow
sensor will facilitate heating of the heating element, as otherwise
described herein.
[0068] 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 shell 15.
[0069] The smoking article 10 in the embodiment illustrated in FIG.
1 can be characterized as a disposable article. Accordingly, it can
be desirable for the reservoir containing the aerosol precursor
material in such embodiments to include a sufficient amount of
aerosol precursor material so that a consumer can obtain more than
a single use of the article. For example, the article can include
sufficient aerosolizable and/or inhalable materials such that the
article can provide a number of puffs substantially equivalent to
the number of puffs (of about two seconds duration) available from
a plurality of conventional cigarettes--e.g., 2 or more, 5 or more,
10 or more, or 20 or more conventional cigarettes. More
particularly, a disposable, single unit article according to the
embodiment of FIG. 1 can provide about 20 or more, about 50 or
more, or about 100 or more puffs, a single puff being measured as
already described herein.
[0070] In particularly preferred embodiments an article according
to the disclosure can comprise two units that are attachable and
detachable from each other. For example, FIG. 2 shows a smoking
article 10 according to one embodiment that is formed of a control
body 80 and a cartridge 90. In specific embodiments, the control
body may be referred to as being reusable, and the cartridge may be
referred to as being disposable. In some embodiments, the entire
article may be characterized as being disposable in that the
control body 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 and, thereafter, the entire article 10, including the
control body, may be discarded. In other embodiments, the control
body may have a replaceable battery such that the control body can
be reused through a number of battery exchanges and with many
cartridges. 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.
[0071] The control body 80 and the cartridge 90 are specifically
configured so as to engage one another and form an interconnected,
functioning device. As illustrated in FIG. 2, the control body 80
includes a proximal attachment end 13 that includes a projection 82
having a reduced diameter in relation to the control body. The
cartridge includes a distal attachment end 14 that engages the
proximal engagement end of the control body 80 to provide the
smoking article 10 in a functioning, usable form. In FIG. 2, the
control body projection 82 includes threads that allow the
cartridge 90 to screw onto the control body 80 via corresponding
threads (not visible in FIG. 2) in the distal attachment end of the
cartridge. Thus, the distal attachment end of the cartridge 90 can
include an open cavity for receiving the control body projection
82. Although a threaded engagement is illustrated in FIG. 2, it is
understood that further means of engagement are encompassed, such
as a press-fit engagement, a magnetic engagement, or the like.
[0072] The functioning relationship between the control body 80 and
the cartridge 90 is further seen in FIG. 3, which shows the two
detached units in cross section. The control body 80 includes the
control component 20, flow sensor 30, and battery 40. Although
these components are illustrated in a specific alignment, it is
understood that various alignments of the components are
encompassed by the disclosure. The control body 80 further includes
a plurality of indicators 19 and an air intake 17 in the control
body shell 81. A variety of positions for one or more air intakes
are encompassed by the disclosure. As shown, the air intake 17 is
positioned such that air drawn through the intake sufficiently
contacts the flow sensor 30 to activate the sensor (although other
positions are encompassed, particular if different sensing means
are provided or if manual actuation, such as with a push button, is
provided). In other instances, the air intake 17 may be positioned,
for example, toward the distal end 12, with the flow sensor 30
being disposed proximally to the distal end 12, toward the proximal
attachment end 13. In such instances, for instance, the disposition
of the air intake toward the distal end 12 may provide additional
lead time from detecting the puff for the heating element 50 to be
actuated, thereby providing a faster response (i.e., delivery of
the aerosol) in response to the puff. The shell 81 can be formed of
materials already described herein in relation to the embodiment of
FIG. 1. A receptacle 60 also is included at the proximal attachment
end 13 of the control body 80 and extends into the control body
projection 82 to allow for ease of electrical connection with the
resistive heating element 50 when the cartridge 90 is attached to
the control body. In the illustrated embodiment, the receptacle 60
includes a central open passage to facilitate air flow from the air
intake in the control body into the cartridge during use of the
article 10.
[0073] The cartridge 90 includes a cartridge shell 91 with a mouth
opening 18 at the mouth end 11 thereof to allow passage of air and
entrained vapor (and further inhalable materials, if present) from
the cartridge to a consumer during draw on the article 10. The
cartridge shell 91 can be formed of materials as already described
herein as being useful for such purpose. The cartridge 90 further
includes a resistive heating element 50 in the form of a metal wire
coil. The resistive heating element includes terminals 51 (e.g.,
positive and negative terminals) at the opposing ends thereof for
facilitating current flow through the resistive heating element and
for attachment of the appropriate wiring (not illustrated) to form
an electrical connection of the resistive heating element with the
battery 40 when the cartridge 90 is connected to the control body
80. Specifically, a plug 65 is positioned at the distal attachment
end 14 of the cartridge. When the cartridge 90 is connected to the
control body 80, the plug 65 engages the receptacle 60 to form an
electrical connection such that current controllably flows from the
battery 40, through the receptacle and plug, and to the resistive
heating element 50. The cartridge shell 91 can continue across the
distal attachment end such that this end of the cartridge is
substantially closed with the plug protruding therefrom. As
illustrated in FIG. 3, the plug 65 includes an open central passage
that aligns with the open central passage in the receptacle 60 to
allow air to flow from the control body 80 and into the cartridge
90.
[0074] A reservoir for use according to the present disclosure can
be any component that functions to store and release one or more
components of the aerosol precursor material. In some embodiments,
such as illustrated in FIG. 1, the reservoir can be a container in
which the aerosol precursor material is stored. The container can
be substantially impermeable in relation to the aerosol precursor
such that the material cannot escape through the walls of the
container. In such embodiments, an opening can be provided for
passage of the aerosol precursor material therefrom. For example,
in FIG. 1, a wick 300 is shown filling an opening in the reservoir
205. In some instances, the reservoir 205 may comprise a "bottle,"
which may generally encompass any container having walls and at
least one opening. The aerosol precursor material in the reservoir
thus moves out of the reservoir by capillary action via the wick.
Other systems for passage of the aerosol precursor material from a
reservoir are also encompassed by the disclosure. For example, a
tube or other conduit can be used for passage of the aerosol
precursor material out of the reservoir and through the tube or
other conduit. Such passage also can occur via capillary action.
Alternately, passive flow of the liquid from the reservoir can be
controlled with an appropriate valve mechanism that can be opened
to allow flow of the aerosol precursor material when the smoking
article is in use and to prevent flow of the aerosol precursor
material when the smoking article is not in use. Active flow
mechanisms incorporating micro-pump devices also are envisioned for
use according to the present disclosure. Such a reservoir can be
formed of any suitable material that is not substantially reactive
with any components of the aerosol precursor material, and is
thermally and mechanically stable, such as glass, metal, low- or
no-porosity ceramics, plastics, and the like.
[0075] In some embodiments, a reservoir can be a container that is
provided without an opening, but a portion or all of the walls of
the container can be porous and thus allow permeation of the
aerosol precursor material out of the container through the walls
thereof. For example, porous ceramics can be useful in such regard.
Any other material of suitable porosity likewise could be used.
[0076] In particular embodiments, a reservoir can be a woven or
non-woven fabric or another mass of fibers suitable for retaining
the aerosol precursor material (e.g., through absorption,
adsorption, or the like) and allowing wicking away of the aerosol
precursor material for transport to the heating zone. For example,
FIG. 3 illustrates a reservoir layer 201 retaining one or more
components of the aerosol precursor material. The reservoir layer
is essentially a non-woven layer of fibers rolled into the form of
a tube that lines a portion of the inner surface of the cartridge
shell 91. Such reservoir layer can be formed of natural fibers,
synthetic fibers, or combinations thereof. Non-limiting examples of
useful materials include cotton, cellulose, cellulose acetate,
polyesters, polyamides, polylactic acids, combinations thereof, and
the like. Similarly, reservoir layers can be formed of
ceramics.
[0077] A wick 301 (as seen in FIG. 3) for use according to the
present disclosure can be any component that functions to transport
one or more aerosol precursor materials from a reservoir to a
heating zone in the smoking article where a resistive heating
element aerosolizes the aerosol precursor material and thus form an
aerosol. A wick particularly can be a component that utilizes
capillary action in the transport of liquids. A wick for use
according to the disclosure thus can be any material that provides
sufficient wicking action to transport one or more components of
the aerosol precursor material to the heating zone. Non-limiting
examples include natural and synthetic fibers, such as cotton,
cellulose, polyesters, polyamides, polyimides, polylactic acids,
glass fibers, combinations thereof, and the like. Wicks further can
be coated with materials that alter the capillary action of the
fibers, and the fibers used in forming wicks can have specific
cross-sectional shape and can be grooved so as to alter the
capillary action of the fibers. Fibers used in forming wicks can be
bundled, provided as a woven fabric, or provided as a non-woven
fabric.
[0078] FIGS. 4A and 4B schematically illustrate alternate aspects
of a smoking article 500 according to the present disclosure. In
such aspects, the smoking article 500 may generally comprise a
shell 510 having a mouth end 511 (i.e., the end upon which a
consumer can draw to inhale aerosol from the article), and an
opposed distal end 512. Such a smoking article 500, in some
aspects, can include a filter material 600 (such as cellulose
acetate or polypropylene) in (see, e.g., FIG. 4A), engaged with
(see, e.g., FIG. 4B), or otherwise associated with the mouth end
511 thereof, for example, to increase the structural integrity
thereof and/or to provide filtering capacity, if desired, and/or to
provide resistance to draw. In some instances, the filter material
600 may be configured to provide an enhancing effect on the
vapor/aerosol drawn through the mouth end 511. For example, in some
aspects, the filter material 600 may include a flavorant,
medicament, or other inhalable material, implemented in a suitable
manner so as to selectively direct the same into an air stream to
be inhaled by a user along with the aerosol precursor or vapor
precursor material.
[0079] In one aspect, such a vapor-enhancing aspect may include the
aforementioned filter material 600 and a tubular housing defining a
lumen 610, with the housing having a mouth-engaging end and a
longitudinally-opposed component-engaging end. The lumen 610 may be
configured to receive the filter material 600 therein, and the
component-engaging end may be adapted to operably engage a control
body portion 506 associated with the smoking article 500, if the
housing comprises a component of the cartridge body portion 505
itself (i.e., is at least partially defined by the shell 510; see,
e.g., FIG. 4A), or the component-engaging end may be adapted to
engage the cartridge body portion 505, if the housing is a discrete
component with respect to the cartridge body portion 505 and the
control body portion 506 (see, e.g., FIG. 4B). In any instance, the
vapor-enhancing aspect may be configured to receive the
vapor/aerosol through the lumen defined thereby. In particular
aspects, the vapor-enhancing aspect may include a vapor-enhancing
element (see, e.g., element 620 in FIGS. 4A and 4B) operably
engaged with the filter material 600 and configured to enhance the
vapor drawn through the filter material 600 within the lumen 610,
and through the mouth-engaging end, by application of a suction to
the mouth-engaging end of the housing of the vapor-enhancing
aspect.
[0080] In some aspects, the filter material 600 may comprise a
suitable filter material such as, for example, cellulose acetate
tow, regenerated cellulose fiber tow, gathered paper, nonwoven
polypropylene web, gathered strands of shredded web, any other
suitable fibrous tow material, and/or combinations thereof, and/or
any such suitable filter material having a coating or film
(reactive or non-reactive) applied thereto. A suitable filter
material, for example, may exhibit a desirable resistance to draw
(suction), may provide an expected taste or other perception,
and/or may be biodegradable. Such example, however, do not preclude
other desirable properties of such filter materials.
[0081] In one aspect, as shown, for example, in FIG. 4A, the
housing is configured as a component of a cartridge body portion
505 (i.e., is at least partially defined by the shell 510) of the
electronic vapor smoking article 500, wherein the cartridge body
portion 505, as disclosed herein, is engaged with the control body
portion 506. In such instances, the mouth-engaging end of the
housing 511 is configured to retain the filter material 600, and
optionally the vapor-enhancing element 620, within the lumen 610.
In another aspect, as shown, for example, in FIG. 4B, the
component-engaging end 630A of the housing 630 is configured to be
removably engaged with a cartridge body portion 505 of the
electronic vapor smoking article 500, wherein the cartridge body
portion 505 is engaged between the housing 630 and the control body
portion 506, such that the housing 630 is replaceable with respect
to the cartridge body portion 505. That is, the housing 630 may
comprise a discrete component with respect to the cartridge body
portion 505 and the control body portion 506. Such a discrete
housing 630 may also be configured to house the vapor-enhancing
element 620. In either instance, the housing 630 may further
comprise a flange 640 disposed about the mouth-engaging end 630B
thereof, wherein the flange 640 extends radially inward with
respect to the housing 630 so as to retain the filter material 600
within the lumen 610.
[0082] In some aspects, the housing 630 (or shell 510 in aspects
where the shell 510 at least partially defines the housing 630)
and/or the filter material 600 may comprise an indicia (see, e.g.,
element 650 in FIGS. 4A and 4B) indicative of a nature of the
enhancement of the vapor provided by the vapor-enhancing element
620 associated therewith. For example, the housing 630 and/or the
filter material 600 may have a particular color to correspond to a
flavor enhancement. In other instances, for example, a graphic may
be provided on the housing 630 to indicate the flavor or other
enhancement provided by the vapor-enhancing element 620. In other
instances, the housing 630 and/or the filter material 600 may
comprise an indicia (see, e.g., element 650 in FIGS. 4A and 4B)
indicative of a remaining service life of the enhancement of the
vapor provided by the vapor-enhancing element 620. For example, a
particular color of the filter material 600 corresponding to a
flavor enhancement may fade to a white color as the service life of
the vapor-enhancing element is expended. In other instances, for
example, the housing may include a gradated level including a
series of markers that successively fade or disappear as the
service life of the vapor-enhancing element is expended. In the
alternative, instead of indicating the remaining service life, the
indicia (see, e.g., element 650 in FIGS. 4A and 4B) may be
indicative of an expended service life of the enhancement of the
vapor provided by the vapor-enhancing element. For example, the
housing 630 may include a numerical indicia that increases in
number as the service life of the vapor-enhancing element is
expended. In yet other instances, the housing and/or the filter
material may comprise an indicia indicative of compatibility of one
of the vapor-enhancing element, the filter material, and the
housing with the control body portion 506, upon operable engagement
between the housing 630 and the control body portion 506 (or upon
operable engagement between the cartridge body portion 505 and the
control body portion 506, when the vapor-enhancing aspect is
integral with the cartridge body portion 505). For example, the
housing 630 may include an electrically-powered indicia that
flashes green upon operable engagement between the housing 630 and
the control body portion 506, wherein, if the housing is not
compatible or authorized for use with the control body portion, the
green light may not flash, or may be replaced with a flashing red
indicia. As such, one skilled in the art will also appreciate that
the example presented herein are not intended to be limiting in any
manner, since such an indicia may take many different forms, as
necessary or appropriate.
[0083] The vapor-enhancing element 620 may take many different
forms. For example, the vapor-enhancing element may comprise a
liquid engaged with the filter material. That is, the filter
material may be treated with the liquid prior to being incorporated
into the housing. In other instances, the liquid may be introduced
to the filter material once the filter material has been inserted
into the housing. In other aspects, the housing 630 (or the shell
510 of the cartridge body portion 505 in instances when the
vapor-enhancing aspect is integral with the cartridge body portion
505) may be configured to be resilient, and the vapor-enhancing
element 620 may comprise a frangible member introduced into the
filter material. The frangible member 620 may be configured to
house or otherwise include an enhancement substance. In such
instances, the frangible member may be further configured to be
responsive to a compressive force applied to the resilient housing
(i.e., a mechanical force such as squeezing or twisting) to rupture
and release the enhancement substance into engagement with the
filter material. That is, in one example, the frangible member 620
may comprise, for example, a capsule member or a plurality of
capsule members (or microcapsule members), wherein each capsule
member may include an enhancement substance comprising, for
example, a liquid flavorant. In such instances, compression or
other mechanical manipulation of the resilient housing may cause
the frangible member to rupture and release the liquid payload
(i.e., a flavorant) into the filter material 600.
[0084] The vapor-enhancing element 620 may, in some aspects,
comprise one element/object, a plurality of elements/objects, or a
combination of elements/objects. In other aspects, the
vapor-enhancing element 620 may comprise one of a thread, a
filament, a microcapsule, a capsule, a pellet, a granule, a
flavorant, and combinations thereof. In some instances, the
vapor-enhancing element 620 may comprise a plurality of
serially-engaged objects. In instances where the vapor comprises a
tobacco component or a tobacco-derived material, the filter
material and/or the vapor-enhancing element, in the form of the one
or more elements/objects or combination of elements/objects, may be
configured to alter a characteristic of the vapor. See, for
example, U.S. Pat. No. 5,724,997 to Smith et al.; U.S. Pat. No.
8,079,369 to Andresen et al.; U.S. Pat. No. 7,972,254 to Stokes et
al.; U.S. Pat. No. 8,262,550 to Barnes et al.; U.S. Pat. No.
7,740,019 to Barnes et al.; U.S. Pat. No. 7,836,895 to Dube et al.;
U.S. Pat. No. 7,793,665 to Dube et al.; U.S. Pat. No. 7,984,719 to
Dube et al.; U.S. Pat. No. 8,066,011 to Clark et al.; U.S. Pat. No.
7,115,085 to Deal; U.S. Pat. No. 7,654,945 to Deal; U.S. Pat. No.
7,833,146 to Deal; and U.S. Pat. No. 7,479,098 to Thomas et al.;
U.S. Patent Application Publication Nos. US2010/0192962 to Barnes
et al.; US2012/0037173 to Clark et al.; US 2008/0142028 to Fagg;
US2010/0101589 to Nelson et al.; and 2011/0271968 to Carpenter et
al.; U.S. patent application Ser. No. 13/248,847 to Novak, III, et
al.; and U.S. patent application Ser. No. 13/675,187 to Ademe, et
al.; each of which is incorporated herein by reference in its
entirety.
[0085] In one aspect, the vapor-enhancing element 620 may be
configured to be electrically-actuated. In such instances, the
housing 630 (or the cartridge body portion 505 in instances when
the vapor-enhancing aspect is integral with the cartridge body
portion 505) may be configured to form an electrically-conductive
connection between the vapor-enhancing element 620 and the control
body portion 506 upon operable engagement of the housing with the
control body portion. For example, the housing may have a
conductive element associated therewith and configured to
complementarily engage a corresponding conductive element
associated with the control body portion and extending into
electrical engagement with the battery 40. Further, the conductive
element of the housing may extend into electrical engagement with
the vapor-enhancing element so as to be capable of actuating the
vapor-enhancing element. For example, the vapor-enhancing element
may have a resistive coil associated therewith wherein, in such
instances, electrical actuation of the resistive element, in turn,
heats the vapor-enhancing element (i.e., a thermal mechanism) to
actuate the vapor enhancement aspect. In other instances, for
example, the electrically-conductive connection may be implemented
to actuate a physical mechanism for releasing the vapor-enhancing
aspect from the vapor-enhancing element 620. More particularly, in
some instances, the vapor-enhancing aspect may comprise a liquid,
vapor, or gas stored in a containing member (not shown) having a
release port, wherein the release port can be electrically
actuated, as necessary or desired, to release the vapor-enhancing
aspect into the filter material 600 for interaction with the vapor
drawn therethrough.
[0086] In summary, or as may otherwise be additionally disclosed
herein, aspects of an electronic vapor smoking article 500
incorporating a filter material 600 having a vapor-enhancing
element 620 associated therewith, may be particularly configured to
provide a vapor enhancement effect (i.e., a flavor) by way of the
filter element through which the vapor is drawn by the user. For
example, menthol or other volatile flavor may be added to the drawn
vapor via a mouth-end portion of the electronic vapor smoking
article 500. In one aspect, the vapor-enhancing element 620 may be,
for instance, liquid menthol or other liquid flavor injected,
dripped, poured, or otherwise introduced into a cellulose acetate
filter material 600 (or a filter material 600 of any other suitable
material or combination of materials) during the process of making
the filter element. In particular aspects, it may be desirable to
implement a relatively high Denier-per-fiber (DPF) filter tow or
other suitable filter material (i.e., between about 4 DPF and about
8 DPF), in order to facilitate maximum throughput of the vapor
(i.e., a filter material configured for minimal removal
efficiency).
[0087] As previously discussed, the filter element may be
configured, for example, to be an integral component of the
electronic vapor smoking article 500 (or "vapor-producing device"),
or otherwise configured to be an addition or supplemental component
to an existing electronic vapor smoking article 500. For example,
in an integral configuration, the filter element (i.e., the filter
material 600 and the vapor-enhancing element 620) may be inserted
into the tubular housing of the electronic vapor smoking article
500. In a two-piece configuration, the filter element may be
inserted into the cartridge body portion 505 or the control body
portion 506, as necessary or desired, such that the filter element
is in communication with the vapor source and disposed within the
vapor pathway between the vapor source and the mouth-end portion of
the electronic vapor smoking article 500. In some instances, the
filter element may be inserted directly into the tubular housing of
the electronic vapor smoking article 500, with the filter element
being longitudinally retained by an appropriate retention element.
For example, the filter element may be separated from the vapor
source by a porous element disposed in the vapor pathway
therebetween. An appropriate porous element is desirably configured
to retain the filter element in a longitudinal position along the
housing, while allowing the vapor to pass therethrough, and may
comprise, for instance, an o-ring, a perforated disc, or any other
suitable porous element for separating the filter element from the
vapor source, vaporizer, or vaporizing liquid. Toward the mouth-end
portion, the filter element may be longitudinally retained by an
appropriate mechanism such as, for example, an end cap engaged with
the housing, a flange, or a crimp in the housing.
[0088] In yet other integral configuration aspects, the filter
element may be self-contained in a filter element housing, wherein
the filter element housing may include a porous or perforated end
configured to be disposed toward the vapor source, and an opposing
crimped, flanged, or capped end configured to be disposed toward
the mouth-end portion. In such instances, the filter element
housing may be configured to be inserted into the tubular housing
and maintained in the desired longitudinal position by an
appropriate mechanism, or even in a friction fit, as will be
appreciated by one skilled in the art.
[0089] In still further aspects, the filter element may be
configured to be engaged with the electronic vapor smoking article
as a supplemental or additional accessory. More particularly, the
filter element may be self-contained in a filter element housing
having a porous or perforated end configured to be disposed toward
the vapor source, and an opposing crimped, flanged, or capped end
configured to be disposed toward the mouth-end portion. The filter
element housing may be further configured, for example, as the
housing 630 previously discussed, or may otherwise be configured to
attach to one end of the cartridge body portion 505 or the control
body portion 506. For example, the filter element housing may be
configured to be attached to the mouth-end portion of the cartridge
body portion 505, as previously disclosed. One skilled in the art
will appreciate, however, that the filter element housing may be
configured to be attached between the cartridge body portion 505
and the control body portion 506 in an appropriately-configured
electronic vapor smoking article. In instances where the filter
element housing is externally exposed, particularly in instances
where the filter element housing is engaged with the mouth-end
portion of the electronic vapor smoking article 500, the filter
element housing may be configured or otherwise comprised of a
material suitable to provide or impart a soft feel or otherwise
pleasingly tactile texture to the lips, teeth, and/or fingers of
the user.
[0090] In such instances wherein the filter element housing is
externally exposed, particularly in instances where the filter
element housing is engaged with the mouth-end portion of the
electronic vapor smoking article 500, the vapor-enhancing element
620 may be further configured to provide pleasing sensations to the
user. For example, as previously disclosed, the vapor-enhancing
element 620 may be configured to be electrically-actuated.
Accordingly, whether the electrical conduction is implemented to
actuate a physical mechanism, or implemented to provide a thermal
mechanism (i.e., heating without decomposition), for providing the
vapor-enhancing aspect, heat may be generated. As such, in those
instances, the filter element housing may be configured to receive
the vapor-enhancing element 620 such that, upon actuation of the
vapor-enhancing element 620 in a manner that generates heat, a
relatively low level of heat is experienced by the user via the
filter element housing. For example, heating menthol, as the
vapor-enhancing element within the filter material, may be
accomplished at relatively low temperatures which, in turn, may
heat the filter element housing, for instance, to a temperature
between about 25.degree. C. and about 60.degree. C. In such an
instance, the "warm" filter element housing may be pleasing to the
user, while the elevated temperature of the filter element housing
may allow the electrical/thermal process associated with actuation
of the vapor-enhancing element 620 to operate at a higher
temperature, thereby possibly enhancing the release/actuation of
the vapor-enhancing aspect.
[0091] In instances where the filter element housing is engaged
with the mouth-end portion of the electronic vapor smoking article
500, the vapor-enhancing element 620 may be further configured to
be actuated upon engagement between the filter element housing and
the mouth end portion. For example, the vapor-enhancing element 620
may be disposed or otherwise arranged about the
interaction/interface between the filter element housing and the
mouth-cnd portion such that engagement therebetween physically
actuates that vapor-enhancing element 620. More particularly, the
vapor-enhancing element may comprise a capsule or other frangible
reservoir, and the filter element housing and the mouth-end portion
may be configured for a threaded engagement therebetween. In such
configurations, the threaded engagement between the filter element
housing and the mouth-end portion may compress, squeeze, pinch,
twist, or otherwise impinge upon the capsule/reservoir and cause
rupture or other mechanical breach thereof, and thereby releasing
the vapor-enhancing aspect into the filter material for interaction
with the vapor.
[0092] In additional aspects, the vapor-enhancing element 620 may
comprise, for example, a crushable capsule containing a flavoring
substance; a plurality of microcapsules, each containing a
flavoring substance, one or more threads of cellulose acetate,
cotton, rayon or other suitable absorbent material, saturated with
a flavoring (liquid) substance.
[0093] In other aspects, the filter material may comprise other
highly porous fibers, tows, films, pellets, threads, or non-woven
materials such as, for example, rayon, polyester, polypropylene, in
addition to or instead of cellulose acetate, wherein the highly
porous fibers may be configured to collect and retain a liquid
flavorant. In other instances, a vapor enhancing element 620
comprising, for example, a flavorant, may be compounded into a
plastic material such as low density or high density polyethylene,
wherein the flavorant would be subject to slow or long term
release. The compounded vapor enhancing element 620 may be
provided, for example, as a pellet, or may be compounded prior to
the plastic (i.e., a non-woven material) being created.
[0094] In yet other aspects, the filter element may be comprised of
cellulose acetate, wherein a hollow center portion therein may be
shaped or otherwise configured to facilitate flow of the vapor
therethrough while still infusing the vapor with the
vapor-enhancing element 620, such as a flavorant. The
vapor-enhancing element 620 may be associated with the filter
material 600, as previously disclosed, or may be disposed within
the hollow center portion of the fitter element. Further, the
vapor-enhancing element 620 may be configured to be responsive to
or actuated by chemicals or moisture in the vapor drawn into
engagement therewith. For example, the vapor may be chemically
reactive with the vapor-enhancing element, wherein the chemical
reaction provides the desired vapor-enhancing effect, or moisture
in the vapor may dissolve or otherwise draw the vapor-enhancing
element into the vapor.
[0095] In other aspects, the filter may be configured to include a
separate heating element configured and disposed to interact with
the vapor-enhancing element 620 so as to, for example, facilitate
release of the vapor enhancement (i.e., a flavorant) into the
filter material 600.
[0096] In still other aspects, the filter element (i.e., the filter
material and/or the vapor-enhancing element 620) may include, for
example, exothermic chemical reactants configured to react with the
vapor to create heat, wherein the heat, in turn may facilitate
release of the vapor enhancement (i.e., a flavorant) into the
filter material 600.
[0097] In some aspects, the vapor-enhancing element 620 may
comprise, for example, an enhancement-impregnated adsorbent
material such as activated carbon, clay, or other suitable
adsorbent material, wherein the enhancement impregnated into the
adsorbent may comprise, for instance, a flavorant.
[0098] In other instances, the vapor-enhancing element 620 may
comprise, for example, a liquid flavorant or other vapor-enhancing
substance contained or otherwise housed in a reservoir. In such
instances, the liquid flavorant or other vapor-enhancing substance
may be configured to wick or otherwise be delivered from the
reservoir and into the filter material 600 to initially treat
filter material 600 or to refresh, supplement, or change the
flavorant already included in the filter material 600. Further, in
such instances, the liquid flavorant or other vapor-enhancing
substance may be manually delivered from the reservoir to the
filter material 600, on demand, by user actuation of an appropriate
mechanism such as, for instance, a squeeze or pump action applied
to the reservoir either directly or via compression of the filter
material 600 or housing of the electronic vapor smoking article
500.
[0099] In still other instances, the vapor-enhancing element 620
may be configured, for example, to facilitate vapor dispersion or
vapor cooling, upon interaction with the vapor drawn through the
filter element by the user, prior to the enhanced vapor entering
the user's mouth.
[0100] In still further aspects, the vapor-enhancing element 620
may comprise or otherwise incorporate, for example, an acidic
coating applied to the filter material 600 or acidic particles
added to the filter material 600, with the acidic substance being
configured to protonate nicotine and impart to the vapor a smoother
vapor sensation or flavor characteristic. In such instances,
suitable acidic substances may include, for example, levulenic
acid, purovic acid, and/or citric acid.
[0101] Of course, one skilled in the art will further appreciate
that the disclosure herein may also be associated with
corresponding methods. In one aspect, as shown in FIG. 5, such a
method may comprise a method of enhancing a vapor produced by an
electronic vapor smoking article (element 700), wherein such a
method may comprise operably engaging a component-engaging end of a
tubular housing with a control body portion associated with the
electronic vapor smoking article, wherein the tubular housing has a
mouth-engaging end longitudinally-opposed to the component-engaging
end, and defines a lumen configured to receive a filter material
therein (block 720). A vapor is received through the lumen of the
housing in response to application of suction to the mouth-engaging
end of the housing (block 740). In doing so, the vapor drawn
through the filter material by the suction is enhanced with a
vapor-enhancing element operably engaged with the filter material
(block 760). The filter material may comprise one of a cellulose
acetate tow, a regenerated cellulose fiber tow, gathered paper, a
nonwoven polypropylene web, gathered strands of shredded web, any
other suitable fibrous tow material, or combinations thereof.
[0102] In some aspects, the methods may further comprise displaying
an indicia about one of the housing and the filter material,
wherein the indicia may be indicative of at least one of a nature
of the enhancement of the vapor provided by the vapor-enhancing
element; a remaining service life of the enhancement of the vapor
provided by the vapor-enhancing element; an expended service life
of the enhancement of the vapor provided by the vapor-enhancing
element; and a compatibility of one of the vapor-enhancing element,
the filter material, and the housing with the control body portion,
upon operable engagement between the housing and the control body
portion. The vapor-enhancing element may comprise, for example, a
liquid engaged with the filter material. In other instances, the
housing may be configured to be resilient, and the vapor-enhancing
element may comprise a frangible member introduced into the filter
material and housing an enhancement substance, wherein the method
further comprises rupturing the frangible member in response to a
compressive force applied to the resilient housing, and releasing
the enhancement substance from the frangible member into engagement
with the filter material.
[0103] In various aspects, the vapor drawn through the filter
material may be enhanced with a vapor-enhancing element comprising
one of a plurality of objects deposited within the filter material,
a thread, a filament, a microcapsule, a capsule, a pellet, a
granule, a flavorant, a plurality of serially-engaged objects, and
combinations thereof. In particular instances, the vapor may be
enhanced by altering a characteristic of the vapor, wherein the
vapor comprises a tobacco component or a tobacco-derived material,
with the filter material and/or the vapor-enhancing element. For
example, a filter material comprising cellulose acetate may provide
a sensory experience, such as by altering the flavor of the tobacco
component or a tobacco-derived material, expected by a user of a
conventional smoking article (i.e., cigarette).
[0104] Many modifications and other embodiments of the disclosure
will come to mind to one skilled in the art to which this
disclosure pertains having the benefit of the teachings presented
in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the disclosure is not to be
limited to the specific embodiments disclosed herein and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *