Electronic cigarette products with improved storage components

Abstract

This disclosure relates to a reservoir for storing products in electronic cigarette products. The reservoir is made of cellulose acetate fiber, thermoplastic fiber, non-thermoplastic fiber, or a combination thereof. The reservoir is substantially tubular in shape and adapted to accommodate internal components of the cigarette product, thereby increasing the reservoir capacity. The internal components may in particular include an atomizer, which may include a braided cord.

Description

Technical Field

[0001] This disclosure relates to aerosol delivery articles and their use, and specifically to articles that can be considered as tobacco articles for obtaining tobacco and other material components in an inhalable form. A very preferred component of said articles is made from or derived from tobacco, or those articles can be described as otherwise combining tobacco for human consumption. Background Technology

[0002] Over the years, numerous smoking devices have been proposed as improvements or alternatives to tobacco products that require the burning of tobacco for use. Many of these devices are reportedly designed to provide the sensations associated with smoking cigarettes, cigars, or pipes, but do not deliver the substantial byproducts of incomplete combustion and pyrolysis produced by tobacco burning. To address this, numerous smoking products, aroma generators, and medical inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensations of smoking cigarettes, cigars, or pipes without significantly burning the tobacco. For example, see the various alternative tobacco products, aerosol delivery devices, and heat sources described in the background art in the following cases: U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0255702 to Griffith, Jr. et al., U.S. Patent Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Publication No. 2014 / 0060554 to Collett et al., and U.S. Patent Application Serial No. 13 / 647,000, filed October 8, 2012, all of which are incorporated herein by reference.

[0003] Certain tobacco products that use electricity to generate heat to form smoke or aerosol, and more specifically, those products already referred to as electronic cigarettes, are available on the market worldwide. Representative products similar to traditional cigarettes, cigars, or pipes in many aspects are already on the market, such as those from Philip Morris Incorporated. ALPHA of InnoVapor LLC TM JOYE 510 TM and M4 TM ;CIRRUS by White Cloud Cigarettes TM and FLING TM ; COHITA International Inc. TM COLIBRI TM ELITECLASSIC TM MAGNUM TMPHANTOM TM and SENSE TM ; DUOPRO by Electronic Cigarettes, Inc. TM STORM TM and Egar Australia's EGAR TM Joyetech's eGo-C TM and eGo-T TM ELUSION UK Ltd TM Eonsmoke LLC's Green Smoke Inc., USA Greenarette LLC's Greenarette TM Smoke HALLIGAN TM HENDU TM JET TM MAXXQ TM PINK TM and Pitbul TM ; HEATBAR by Philip Morris International, Inc. TM Crown7's Hydra Imperial TM and LXE TM LOGIC Technology's LOGIC TM and THE CUBAN TM ;LucianoSmokes Inc. Nicotek, LLC Sottera, Inc. and ONEJOY TM SS Choice LLC's No. 7 TM ; PREMIUM ELECTRONIC CIGARETTE by PremiumEstore LLC TM RAPP E-MYSTICK by Ruyan America, Inc. TM ; RED DRAGON of Red Dragon Products, LLC TM ;RuyanGroup(Holdings)Ltd. SMART by The Smart Smoking Electronic Cigarette CompanyLtd. SMOKE by Coastline Products LLC SMOKING by SmokingEverywhere, Inc. V2CIGS of VMR Products LLC TM VaporNine LLC's Vapor Nine TM Vapor 4Life, Inc. VEPPO, E-CigaretteDirect, LLC TM And RJ Reynolds Vapor Company Other electric aerosol delivery devices, and specifically those described as so-called electronic cigarettes, are sold under the trademark BLU. TM COOLER VISIONS TM DIRECT E-CIG TM DRAGONFLY TM EMIST TM EVERSMOKE TM ; HYBRID FLAME TM KNIGHT STICKS TM ROYAL BLUES TM ; and SOUTHBEACH SMOKE TM .

[0004] It is desirable to provide a tobacco product that uses heat generated by electrical energy to provide the sensation of smoking a cigarette, cigar, or pipe, provides the sensation of smoking a cigarette, cigar, or pipe without burning the tobacco to any significant extent, provides the sensation of smoking a cigarette, cigar, or pipe without requiring a heat source for combustion, and provides the sensation of smoking a cigarette, cigar, or pipe without unnecessarily delivering large amounts of incomplete combustion and pyrolysis products. Summary of the Invention

[0005] This disclosure provides a tobacco product and related components and methods. According to one aspect, an electronic cigarette product is disclosed herein, comprising a power source and a reservoir, the reservoir comprising cellulose acetate and configured to contain a product. The product may include an aerosol precursor composition. The reservoir may be substantially cylindrical, having a hollow internal portion. The reservoir includes an outer surface substantially adapted to conform to the inner surface of the tobacco product. The reservoir may be shaped and sized to accommodate one or more additional components of the tobacco product. The one or more additional components may be an atomizer. The atomizer may include a heater, such as a resistance heating element. The atomizer may further include a liquid delivery element. For example, the liquid delivery element may be a continuous, elongated article. The article may be adapted to aspirate liquid. The heater may be arranged in a heating configuration with at least a portion of the liquid delivery element. For example, the heater may contact the liquid delivery element and may be located approximately at the midpoint of the liquid delivery element. The liquid delivery element may be a braided cord. The braided cord may be a sheath / core type cord, and the sheath may be braided. The core of the sheath / core cord may be a twisted yarn. The atomizer may include conductive terminals extending along at least a portion of the liquid delivery element and electrically arranged with the heater. The hollow interior of the reservoir may include a central cavity defined by an inner wall of the reservoir. The inner wall may include one or more recesses or protrusions formed therein. For example, the inner wall may include fully opposed grooves extending into the reservoir. The grooves (or similar arrangements) may be adapted to mate with at least a portion of the atomizer. The liquid delivery element may be operatively located within the tobacco product to substantially contact the product. The reservoir may be formed from a tow of cellulose acetate fibers. In some embodiments, the cellulose acetate fibers may have a size of about 0.5 dpf or greater, specifically about 0.5 dpf to about 20 dpf. The hollow cellulose acetate reservoir, in the shape of a tube or cylinder, may have a wall thickness of about 1 mm to about 4 mm. The reservoir may comprise about 70% to about 99% cellulose acetate by weight and about 2% to about 25% adhesive by weight. In another embodiment, the reservoir may consist of 100% cellulose acetate. Additional fibers and materials may be included with the cellulose acetate if desired. In some embodiments, the reservoir may be a textile or non-textile fiber pad in the form of a tube or a hollow cylinder.

[0006] This disclosure also provides a cord that can be particularly used in electronic cigarette products. In some embodiments, a cord suitable for use in electronic cigarette products may comprise a braid of at least four individual fibers or yarns. Specifically, at least one of the fibers or yarns forming the braid may be C-glass or E-glass. In other embodiments, the cord may comprise a braid of at least eight individual fibers or yarns. Furthermore, the braided cord may be a sheath / core type cord. Specifically, the braided cord may be a sheath surrounding a core. The core may be unbraided and may be formed of a material different from the braided sheath, or it may be both unbraided and formed of a material different from the braided sheath. In some embodiments, the core may comprise twisted yarn.

[0007] In another embodiment, this disclosure may provide an electronic cigarette article comprising a reservoir in which an aerosol precursor composition (e.g., a liquid composition) is stored, and a braided cord in fluid communication with the reservoir. The braided cord may be as described above. The reservoir may, in particular, be substantially cylindrical or tubular and have a hollow internal portion. The reservoir may, in particular, comprise cellulose acetate. The reservoir may be a molded element. The reservoir may also be a woven or nonwoven fiber pad, such as comprising cellulose acetate fibers. The fiber pad may be rolled or otherwise formed into a tubular or hollow cylindrical shape.

[0008] In other embodiments, this disclosure may provide cartridges for electronic cigarette products. The cartridge may include an atomizer at least partially located within the hollow interior of a tubular reservoir adapted to contain an aerosol precursor composition, the reservoir tube being located within the hollow housing. Specifically, the reservoir tube may be formed of cellulose acetate. The atomizer may specifically include: a continuous, elongated cord having two opposing ends; a heater connected to the cord and located approximately at its midpoint; and conductive terminals positioned in physical contact with the cord and electrically connected to the heater. The hollow housing may include a first end adapted to engage a control assembly (e.g., a controller or power unit of an electronic cigarette product) and an opposing mouthpiece end. The heater of the atomizer may extend beyond the reservoir tube within a cavity formed at the mouthpiece end of the hollow housing. As discussed herein, the cord may be a braided cord.

[0009] In another aspect, a method for manufacturing an electronic cigarette product is provided. The method includes the step of providing a cylinder comprising cellulose acetate having a hollow interior portion. At least a portion of the hollow interior may be shaped and sized to accommodate one or more additional components of the cigarette product. The method further includes the step of inserting an atomizer into the hollow interior of the cellulose acetate cylinder. The method may further include the step of inserting the cylinder and the atomizer into a hollow housing and connecting the atomizer to a power source. The power source may be a battery. The hollow housing may be a cartridge portion of the electronic cigarette product. Attached Figure Description

[0010] Therefore, having already described this disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0011] Figure 1 A cross-sectional view of an embodiment extending through a tobacco product is shown;

[0012] Figure 2 A partial cross-sectional view of an electronic cigarette article containing a reservoir according to an embodiment of the present disclosure is shown;

[0013] Figure 3 An exploded view of an electronic cigarette article containing a reservoir and an atomizer according to an embodiment of the present disclosure is shown;

[0014] Figure 4 A perspective view of a combined reservoir and atomizer according to one embodiment of the present disclosure is provided;

[0015] Figure 5 It is the cross-section of the skin / core type rope according to an exemplary embodiment of the present disclosure;

[0016] Figure 6 and Figure 7 Images of reservoirs according to embodiments of the present disclosure and control reservoirs after being placed in a liquid composition are shown to evaluate the reservoirs’ ability to become saturated with liquid.

[0017] Figure 8 The image shows a reservoir saturated with an aerosol precursor composition according to an embodiment of the present disclosure.

[0018] Figure 9 This occurs after the aerosol precursor composition has been depleted through the use of a reservoir in atomized tobacco products. Figure 8 Image of the storage device;

[0019] Figure 10 This is a graph showing the aerosol formation efficiency of a reservoir according to an embodiment of the present disclosure;

[0020] Figure 11This is a graph showing the change in the average mg number of total particulate matter (TPM) delivered in a puff of an atomized tobacco product utilizing twisted or braided rope according to embodiments of the present disclosure; and

[0021] Figure 12 It is a graph showing the change in the average number of milligrams of total particulate matter (TPM) delivered in a puff of an atomized tobacco product comprising a braided rope formed from 8, 12, or 16 individual glass fiber yarns according to embodiments of the present disclosure. Detailed Implementation

[0022] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the disclosure will be exhaustive and complete, and will fully convey the scope of the disclosure to those skilled in the art. In fact, 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 the disclosure will satisfy applicable legal requirements. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” as used in this specification and the appended claims include the plural referents.

[0023] This disclosure relates to articles that use electrical energy to heat materials (preferably without burning the materials to any significant extent) to form an inhalable substance, said articles being compact enough to be considered "handheld" devices. In particular, this disclosure relates to reservoirs in electronic cigarette articles for storing aerosol precursor compositions. The reservoirs may be fibrous and can be made of various fibers. For example, the reservoirs may be made of cellulose acetate fibers. The reservoirs may be substantially tubular in shape and may be adapted to accommodate additional internal components of the cigarette article.

[0024] This disclosure relates to articles (and their manufacture) that use electrical energy to heat materials (preferably without burning the materials to any significant extent) to form an inhalable substance, said articles being compact enough to be considered “handheld” devices. In some embodiments, said articles may be specifically described as tobacco articles. As used herein, the term “tobacco article” is intended to mean an article that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, type of taste or odor, sensory effects, bodily sensations, usage habits, visual cues (e.g., those provided by visible aerosols), and the like) without any component of said article being burned to any significant extent. As used herein, the term “tobacco article” does not necessarily mean that said article produces smoke in operation in the sense of an aerosol produced by the combustion or pyrolysis of tobacco, but rather that said article yields vapor (including vapor within an aerosol that can be considered as a smoke-like substance) produced by the volatilization or vaporization of certain components of said article or device. In a highly preferred embodiment, the article described as a tobacco article combines tobacco and / or components derived from tobacco.

[0025] In other embodiments, articles made according to this disclosure may be described as vapor-generating articles, atomizing articles, or pharmaceutical delivery articles. Thus, the articles may be arranged to deliver one or more substances (e.g., flavoring agents and / or pharmaceutical active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in the form of a vapor (i.e., a substance that is in the gaseous phase at temperatures below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For simplicity, as used herein, the term "aerosol" is intended to include vapors, gases, and aerosols in forms or types suitable for human inhalation, whether visible or not, and whether or not they can be considered smoke-like forms.

[0026] In use, the tobacco product according to this disclosure may be subjected to many of the bodily actions of an individual using conventional tobacco products (e.g., cigarettes, cigars, or pipes, which are used by lighting them with fire and inhaling the subsequently burning tobacco). For example, the user of the tobacco product of the present invention may hold the product as with conventional tobacco products, inhale from one end of the product to inhale the aerosol produced by the product, and exhale at selected time intervals.

[0027] Tobacco products manufactured according to one aspect of this disclosure may include a number of components disposed within a housing or body. The overall design of the housing or body may vary, and the dimensions or construction of the outer body, which may define the overall size and shape of the tobacco product, may vary. Typically, an elongated body resembling a cigarette or cigar may be formed from a single, monolithic housing; or the elongated body may be formed from two or more separable components. For example, a tobacco product may include an elongated housing or body whose shape may be substantially tubular and thus resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the tobacco product are housed within a single outer body or housing. Alternatively, the tobacco product may include two joined and separable housings. For example, a tobacco product may have: a control body at one end, the control body including a housing housing one or more reusable components (e.g., a rechargeable battery and various electronic devices for controlling the operation of the product); and a housing at the other end and removably attached thereto, the housing housing a disposable portion (e.g., a disposable cartridge containing flavoring). Furthermore, after considering commercially available electronic cigarette products (such as those representative products listed in the background section of this disclosure), one can understand various cigarette product designs and component arrangements.

[0028] A tobacco article made according to one aspect of this disclosure may include a combination of the following: a power source (i.e., an electrical power supply); at least one control component (e.g., a component for actuating, controlling, adjusting, and stopping the electrical power used for heat generation by controlling the current flow from the power source to other components of the article); a heater or heat generation component (e.g., a resistance heating element or component commonly referred to as an "atomizer"); and an aerosol precursor component (e.g., a liquid that is typically capable of producing an aerosol after sufficient heat is applied, such as components commonly referred to as "e-liquid," "e-fluid," and "e-oil"); and a mouthpiece region or tip for allowing inhalation of the tobacco article to inhale the aerosol (e.g., through a defined airflow path of the article such that the generated aerosol can be extracted from it after inhalation). The alignment of the components within the article may vary. In certain embodiments, the aerosol precursor component may be located near one end of the article (e.g., having a cartridge, which in some cases may be replaceable and disposable) close to the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heater assembly may be positioned sufficiently close to the aerosol precursor component such that heat from the heater assembly can vaporize the aerosol precursor (and one or more flavorings, agents, or the like that may be used for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are intended to be interchangeable, such that references to release, released, released out, or released include forming or generating, formed or produced, formed out or produced out, and formed or generated. Specifically, the inhalable substance is released in the form of vapor or aerosol or a mixture thereof. Furthermore, after considering commercially available electronic cigarette products (such as those representative products listed in the background section of this disclosure), one can understand the selection of various cigarette product components.

[0029] Tobacco products manufactured according to one aspect of this disclosure may include a battery or other power source to provide sufficient current to supply various functionalities to the product (e.g., resistance heating, power supply to control systems, power supply to indicators, and the like). The power source may take various embodiments. Preferably, the power source is capable of delivering sufficient power to rapidly heat the heating element to form an aerosol and to power the product by use for the desired duration. The power source is preferably sized to fit conveniently within the product, allowing for easy handling; and additionally, it is preferred that the power source be sufficiently lightweight without compromising the desired smoking experience.

[0030] An exemplary tobacco product 10 according to this disclosure is shown in Figure 1In the middle. As seen in the surface shown therein, the tobacco product 10 may include a control body 80 and a cartridge 90 that can be aligned in a functional relationship. In this respect, the control body 80 and the cartridge 90 may be attachable to and detachable from each other. Although Figure 1 The diagram illustrates a threaded engagement, but it should be understood that other engagement methods are included, such as press-fit engagement, magnetic engagement, or similar. As otherwise described herein, cartridges may specifically include a single-use connector.

[0031] In certain embodiments, the control unit 80 may be described as reusable, and the cartridge 90 as disposable. In some embodiments, the entire tobacco product 10 can be described as disposable because the control unit may be configured to be used only a limited number of times with a limited number of cartridges (e.g., until the battery-powered assembly no longer provides sufficient power to the tobacco product), after which the entire tobacco product 10 (including the control unit) can be discarded. In other embodiments, the control unit may have a replaceable battery, allowing the control unit to be reused through numerous battery replacements and with numerous cartridges. Similarly, the tobacco product 10 may be rechargeable and therefore can be combined with any type of charging technology, including connection to a typical power outlet, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer (e.g., via a USB cable).

[0032] The control body 80 includes a control component 20, a flow sensor 30, and a battery 40. While these components are arranged in a specific alignment as shown, it should be understood that this disclosure includes various alignments of the components. The control body 80 further includes a plurality of indicators 19 at the distal end 12 of the control body housing 81. The indicators 19 may display the number of puffs removed or remaining from the tobacco product, indicate an active or inactive state, illuminate in response to smoke emission, or similarly. The number of indicators may vary, and the indicators may have different shapes, and may even simply be openings in the body (e.g., for emitting sound when the indicator is present).

[0033] This disclosure includes various locations for one or more air inlets 17. As shown, the air inlet 17 may be located within the control body housing 81 such that air drawn through the air inlet sufficiently contacts the flow sensor 30 to activate the sensor (but other locations are included, particularly if different sensing elements are provided or if manual actuation (e.g., via a button) is provided). A socket 60 is also included at the proximal attachment end 13 of the control body 80, and this socket extends into the control body protrusion 82 to facilitate electrical connection with the resistance heating element 50 when the cartridge 90 is attached to the control body. In the illustrated embodiment, the socket 60 includes a centrally opening channel to facilitate the entry of air flowing from the air inlet in the control body into the cartridge during use of the article 10.

[0034] The cartridge 90 includes a cartridge shell 91, with a mouthpiece opening 18 located at the mouthpiece end 11 of the shell to allow air and entrained vapor (i.e., components of the aerosol precursor composition in inhalable form) to be delivered from the cartridge to the consumer during inhalation on the tobacco product 10. The tobacco product 10 according to this disclosure may have an overall shape that can be defined as substantially rod-shaped, substantially tubular, or substantially cylindrical. Figure 1 As shown, the tobacco article 10 has a substantially circular cross-section; however, this disclosure also includes other cross-sectional shapes (e.g., elliptical, square, triangular, etc.). The language used to describe the physical shape of the tobacco article can also be applied to individual units of the tobacco article in embodiments that include multiple units (e.g., control body and cartridge).

[0035] In a preferred embodiment, the tobacco product 10 may be sized and shaped to resemble a cigarette or cigar. Therefore, the tobacco product may have a diameter of approximately 5 mm to approximately 25 mm, approximately 5 mm to approximately 20 mm, approximately 6 mm to approximately 15 mm, or approximately 6 mm to approximately 10 mm. These dimensions may specifically correspond to the outer diameter of the control body housing 81 and / or the cartridge housing 91. The control body may have a length of approximately 50 mm to approximately 110 mm, approximately 60 mm to approximately 100 mm, or approximately 65 mm to approximately 95 mm. The cartridge may have a length of approximately 20 mm to approximately 60 mm, approximately 25 mm to approximately 55 mm, or approximately 30 mm to approximately 50 mm. The overall length of the combined cartridge and control body (or the overall length of the tobacco product formed from a single, monolithic housing according to this disclosure) may be approximately equal to or less than the length of a typical cigarette—for example, approximately 70 mm to approximately 130 mm, approximately 80 mm to approximately 125 mm, or approximately 90 mm to approximately 120 mm.

[0036] The cartridge casing 91 of the tobacco product 10 can be formed of any material suitable for forming and maintaining a proper configuration (e.g., a tubular shape) and for holding suitable components of the tobacco product therein. Figure 1 As shown, the body can be formed from a single wall. The cartridge shell 91 can be formed from a heat-resistant material (natural or synthetic) to maintain its structural integrity (e.g., without degradation) at least at a temperature provided by a resistance heating element. In some embodiments, a heat-resistant polymer can be used. In other embodiments, the body can be formed from paper or from metal (e.g., stainless steel). As further discussed herein, the body (e.g., a paper tube) can have one or more layers associated with it to substantially prevent vapor movement through. In one example, an aluminum foil layer can be laminated to one surface of the body. Ceramic materials can also be used.

[0037] The cartridge 90 further includes a resistance heating element 50 in the form of a metal wire coil. The resistance heating element includes terminals 51 (e.g., positive and negative terminals) at its opposite ends for facilitating current flow through the resistance heating element and attachments for proper wiring (not shown) to form an electrical connection between the resistance heating element and the battery 40 when the cartridge 90 is connected to the control body 80. Specifically, a plug 65 is located 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 socket 60 to form an electrical connection, allowing current to flow controllably from the battery 40 through the socket and the plug to the resistance heating element 50. The cartridge housing 91 may extend across the distal attachment end, such that this end of the cartridge is substantially closed with the plug protruding from it. Figure 1 As shown, the plug 65 includes an open central channel that is aligned with an open central channel in the socket 60 to allow air to flow from the control body 80 and into the cartridge 90.

[0038] Generally, during use, when a consumer inhales at the mouthpiece 11 of the cartridge, the flow sensor 30 detects a change in flow rate and activates the control component 20 to cause current to flow through the resistance heating element 50. Therefore, it is useful for the airflow to pass through the control body 80 in a manner that the flow sensor 30 detects almost immediately.

[0039] The control algorithm may require power to be supplied to the resistance heating element 50 to circulate it and thus maintain a defined temperature. The control algorithm can therefore be programmed to automatically deactivate the tobacco product 10 and stop power flow through the tobacco product after a defined delay if the consumer has not exhaled smoke. Furthermore, the tobacco product may include a temperature sensor to provide feedback to the control components. The sensor may, for example, be in direct contact with the resistance heating element 50. Alternative temperature sensing methods may also be used, such as relying on logic control components to assess the resistance through the resistance heating element and correlate that resistance with the temperature of the element. In other embodiments, the flow sensor 30 may be replaced with suitable components to provide alternative sensing methods, such as capacitive sensing. Additionally, one or more control buttons may be included to allow manual actuation by the consumer to trigger various functions, such as powering on and off the product 10, turning on the heating element 50 to generate vapor or aerosol for inhalation, or similar.

[0040] When the flow sensor 30 is located within the control body 80, it may be useful to have an air inlet 17 on the control body. If desired, a sealed flow path can be provided such that the flow sensor 30 within the control body 80 is fluidly connected to the interior of the cartridge after the cartridge is attached to the control body; this fluid connection is sealed relative to the rest of the components within the control body but extends to the cartridge 90 when attached to the control body. Furthermore, in other embodiments, the flow sensor 30 may be located within the cartridge 90 instead of the control body 80.

[0041] A reservoir can utilize a delivery element to transport an aerosol precursor composition to an atomization zone. As used herein, the term "reservoir" refers to a container or chamber used to contain, store, or retain products such as liquids, fluids, or aerosols. One example is shown in... Figure 1 In this embodiment, the cartridge 90 includes a reservoir layer 201 comprising a layer of non-woven fibers formed in a tubular shape, which encloses the interior of the cartridge housing 91. An aerosol precursor composition is held in the reservoir layer 201. Liquid components (e.g.) may be adsorbently held through the reservoir layer 201. The reservoir layer 201 is fluidly connected to a delivery element 301 (in this embodiment, a cord). The delivery element 301 delivers the aerosol precursor composition stored in the reservoir layer 201 to the atomization zone 400 of the cartridge 90 via capillary action. As shown, the delivery element 301 is in direct contact with a resistance heating element 50, which in this embodiment is in the form of a metal wire coil.

[0042] In use, when a user inhales through the product 10, the resistance heating element 50 is activated (e.g., via a smoke sensor), and the components of the aerosol precursor composition are vaporized in the atomization zone 400. Inhalation through the mouthpiece 11 of the product 10 causes ambient air to enter the air inlet 17 and pass through the central opening in the socket 60 and the central opening in the plug 65. In the cartridge 90, the inhaled air passes through the air passage 230 in the air passage tube 220 and combines with the vapor formed in the atomization zone 400 to form an aerosol. The aerosol is rapidly removed from the atomization zone, passes through the air passage 260 in the air passage tube 250, and exits from the mouth opening 18 in the mouthpiece 11 of the product 10. If desired, the air passage tube 250 may be absent, and the opening cavity may remain in the location to form an aerosol when the aerosol precursor composition is vaporized by the resistance heating element 50.

[0043] Figure 1The tobacco product 10 in the illustrated embodiment can be described as a disposable product. Therefore, it may be desirable for the reservoir 201 in the illustrated embodiment to include sufficient aerosol precursor composition and any additional inhalable material so that the consumer can obtain more than one use of the tobacco product. For example, the tobacco product may include sufficient atomizable and / or inhalable material so that the tobacco product can provide a number of puffs (lasting approximately two seconds) substantially equivalent to those obtainable from multiple conventional cigarettes (e.g., 2 or more, 5 or more, 10 or more, or 20 or more conventional cigarettes). More specifically, according to Figure 1 The disposable single-unit article of the embodiments can provide about 20 or more, about 50 or more, or about 100 or more.

[0044] Although Figure 1 This is an illustrative description of a tobacco product based on the present disclosure; however, the scope of this disclosure should not be construed as limited to the specific combinations and / or arrangements of the components shown therein. Rather, this disclosure may encompass various combinations of components that can be used to form an electronic cigarette product. References are made to tobacco products disclosed, for example, in U.S. Patent Publication No. 2014 / 0000638 to Sebastian et al. and U.S. Patent Publication No. 2013 / 0255702 to Griffith, Jr. et al., the disclosures of which are incorporated herein by reference in their entirety. Furthermore, representative heating elements and materials used therein are described in the following: U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,093,894 to Deevi et al.; U.S. Patent No. 5,224,498 to Deevi et al.; and Sprinkel et al. The disclosures of the following patents are incorporated herein by reference in their entirety: 5,228,460 by Jr. et al.; 5,322,075 by Deevi et al.; 5,353,813 by Deevi et al.; 5,468,936 by Deevi et al.; 5,498,850 by Das et al.; 5,659,656 by Das et al.; 5,498,855 by Deevi et al.; 5,530,225 by Hajaligol; 5,665,262 by Hajaligol; 5,573,692 by Das et al.; and 5,591,368 by Fleischhauer et al.

[0045] Various components of the tobacco products according to the present invention can be selected from those described in the art and those commercially available. Examples of batteries that can be used according to this disclosure are described in U.S. Publication No. 2010 / 0028766, the disclosure of which is incorporated herein by reference in its entirety.

[0046] Exemplary mechanisms that can provide smoke actuation capability include the model 163PC01D36 silicon sensor manufactured by the Microswitches Division of Honeywell, Inc., Freeport, Illinois. Further examples of on-demand operated electrical switches that can be used in heating circuits according to this disclosure are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Further descriptions of current regulation circuits and other control components (including microcontrollers) that can be used in this smoking product are provided in all of the following: U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Patent No. 5,372,148 to McCafferty et al.; U.S. Patent No. 6,040,560 to Fleischhauer et al.; and U.S. Patent No. 7,040,314 to Nguyen et al., all of which are incorporated herein by reference in their entirety.

[0047] Aerosol precursor compositions or vapor precursor compositions may include one or more different components. For example, an aerosol precursor may include a polyol (e.g., glycerol, propylene glycol, or mixtures thereof). Other representative types of aerosol precursor compositions are described in the following: U.S. Patent No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Patent No. 5,101,839 to Jakob et al.; PCT WO 98 / 57556 to Biggs et al.; and chemical and biological studies of novel cigarette prototypes of heated rather than combusted tobacco (RJ, Reynolds Tobacco Company Monograph (1988)); the disclosures of the foregoing are incorporated herein by reference.

[0048] The aerosol precursor composition may include additional liquid materials, such as water. For example, the aerosol precursor composition may combine a mixture of glycerol and water, or a mixture of propylene glycol and water, or a mixture of propylene glycol and glycerol, or a mixture of propylene glycol, glycerol, and water. Exemplary aerosol precursor compositions also include those types of materials incorporated into devices available from Atlanta Imports Inc., Acworth, Ga., USA, such as electronic cigars with the brand name E-CIG, which may be used with associated cartridge types C1a, C2a, C3a, C4a, C1b, C2b, C3b, and C4b; and Ruyan e-cigarettes and e-pipes available from Ruyan SBT Technology and Development Co., Ltd., Beijing, China. Exemplary formulations of aerosol precursor compositions that can be used according to this disclosure are described in U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., the contents of which are incorporated herein by reference in their entirety.

[0049] The aerosol precursor composition used in the disclosed tobacco articles may further include one or more flavoring agents, pharmaceuticals, or other inhalable materials. For example, liquid nicotine may be used. The additional materials may include one or more components of the aerosol precursor or vapor precursor composition. Therefore, the aerosol precursor or vapor precursor composition can be described as comprising an inhalable substance. As discussed herein, the inhalable substance may include flavoring agents, pharmaceuticals, and other materials. Specifically, the inhalable substance delivered using the tobacco articles according to the invention may include tobacco components or tobacco-derived materials. Alternatively, flavoring agents, pharmaceuticals, or other inhalable materials may be provided separately from other aerosol precursor components (e.g., in a reservoir). Thus, defined portions of flavoring agents, pharmaceuticals, or other inhalable materials may be delivered separately or simultaneously to a resistance heating element to release the flavoring agent, pharmaceuticals, or other inhalable material into an airflow for inhalation by the user along with other components of the aerosol precursor or vapor precursor composition.

[0050] Various types of flavor enhancers or materials that alter the sensory or aerosol characteristics or properties of tobacco products can be employed. These flavor enhancers can be supplied from sources other than tobacco, can be natural or artificial in nature, and can be used as concentrates or flavoring packets. Of particular interest are flavor enhancers applied to or incorporated into those aerosol-generating areas of the tobacco product. Furthermore, as noted above, the agents can be supplied directly to the resistance heating element or can be provided on a substrate. Exemplary flavor enhancers include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors (including lime and lemon)), maple, menthol, peppermint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, fennel, sage, cinnamon, sandalwood, jasmine, acerola, cocoa, licorice, and other types and characteristics of flavor enhancers and flavoring packets traditionally used to enhance the flavor of cigarettes, cigars, and pipe tobacco. Syrups, such as high-fructose corn syrup, can also be used. Flavor enhancers may also include acidic or alkaline properties (e.g., organic acids such as levulinic acid, succinic acid, lactic acid, and pyruvic acid). If desired, flavor enhancers can be combined with aerosol-generating materials. Exemplary plant-derived compositions that can be used are disclosed in U.S. Patent Publication Nos. 2012 / 0152265 and 2012 / 0192880 to Dube et al., the disclosures of which are incorporated herein by reference in their entirety.

[0051] Organic acids can be incorporated into aerosol precursors to provide desired alterations to the odor, sensation, or sensory properties of a pharmaceutical agent (e.g., nicotine) that can bind to the aerosol precursor. For example, organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) can be included in an aerosol precursor containing nicotine in an amount equal to that of nicotine (based on the total organic acid content). Any combination of organic acids can be used. For example, the aerosol precursor may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, until a concentration equal to the total amount of organic acids present is achieved as equimolar to the total amount of nicotine present in the aerosol precursor.

[0052] In embodiments of aerosol precursor materials containing tobacco extracts (including pharmaceutical-grade nicotine derived from tobacco), it is advantageous that the tobacco extracts are described as substantially free of compounds collectively referred to as Hoffmann analytes, including (e.g.) tobacco-specific nitrosamines (TSNAs), including N′-nitrosonornicotinamide (NNN), (4-methylnitroso)-1-(3-pyridyl)-1-butanone (NNK), N′-nitrosonechoic acid (NAT), and N′-nitrosopseudoestipine (NAB); polycyclic aromatic hydrocarbons (PAHs), including benzo[a]anthracene, benzo[a]pyrene, benzo[b]fluoranthracene, benzo[k]fluoranthracene, chrysoprase, dibenzo[a,h]anthracene, and indo[1,2,3-cd]pyrene and the like. In some embodiments, the aerosol precursor material may be described as completely free of any Hoffmann analytes, including TSNAs and PAHs. Examples of aerosol precursor materials 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. The reduction in Hoffmann analyte concentration can be achieved using certain extraction or processing methods. For example, the tobacco extract can be contacted with an imprinted or non-imprinted polymer, as described in, for example, the following: U.S. Patent Publication No. 2007 / 0186940 to Bhattacharyya et al.; 2011 / 0041859 to Rees et al.; and 2011 / 0159160 to Jonsson et al.; and U.S. Patent Application No. 13 / 111,330 to Byrd et al., filed May 19, 2011, all of which are incorporated herein by reference. The tobacco extract can be treated with an amine-functional ion exchange material that can remove certain aldehydes and other compounds. For example, see, in connection with, US Patent Nos. 4,033,361 of Horsewell et al. and 6,779,529 of Figlar et al., which are incorporated herein by reference in their entirety.

[0053] In some embodiments, the aerosol precursor may be adapted to increase its surface area during heating to form an aerosol in an electronic cigarette product. The aerosol precursor may include an effervescent material adapted to degrade during heating and release sufficient amounts of carbon dioxide (or other gaseous substances) to cause at least a portion of the aerosol precursor to foam or generate small droplets. Including the effervescent material may be advantageous to reduce the heat required for the aerosol precursor to form an aerosol.

[0054] Aerosol precursor compositions can take on various configurations based on the various amounts of materials used therein. For example, usable aerosol precursor compositions 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 may be distributed among two or more different polyols in any combination. For example, one polyol may comprise about 50% to about 90%, about 60% to about 90%, or about 75% to about 90% by weight of the aerosol precursor, and a second polyol may comprise about 2% to about 45%, about 2% to about 25%, or about 2% to about 10% by weight of the aerosol precursor. Usable aerosol precursors may also comprise up to about 25% by weight, about 20% by weight, or about 15% by weight of water—specifically about 2% to about 25% by weight, about 5% to about 20% by weight, or about 7% to about 15% by weight of water. Flavorings and similar agents (which may include pharmaceuticals such as nicotine) may comprise up to about 10%, up to about 8%, or up to about 5% by weight of the aerosol precursor.

[0055] As a non-limiting example, the aerosol precursor according to the invention may include glycerol, propylene glycol, water, nicotine, and one or more flavoring agents. Specifically, glycerol may 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; propylene glycol may 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; water may 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; nicotine may 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 flavoring agents may 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. A specific, non-limiting example of an aerosol precursor includes about 75% to about 80% by weight of glycerol, about 13% to about 15% by weight of water, about 4% to about 6% by weight of propylene glycol, about 2% to about 3% by weight of nicotine, and about 0.1% to about 0.5% by weight of flavoring agent. Nicotine may, for example, be derived from tobacco extract.

[0056] The amount of aerosol precursor composition used in a tobacco product is such that the product exhibits acceptable sensory and perceptual properties, as well as desired performance characteristics. For example, it is highly preferred to use sufficient aerosol precursor composition components, such as glycerol and / or propylene glycol, to produce a visible mainstream aerosol that resembles tobacco smoke in many respects. Typically, the amount of aerosol-generating material incorporated into the tobacco product 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 composition can depend on various factors, such as the number of puffs required per cartridge used in the tobacco product. The desired outcome is that the aerosol precursor composition does not introduce a significant degree of unacceptable off-flavor, a thin mouthfeel, or an overall sensory experience markedly different from that of conventional types of cigarettes that produce mainstream smoke by burning formulated tobacco. The selection of specific aerosol-generating and reservoir materials, the amounts of those components used, and the type of tobacco material used can be varied to control the overall chemical composition of the mainstream aerosol produced by the tobacco product.

[0057] Other components may be used in the tobacco products disclosed herein. For example, US 5,261,424 of Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouthpiece of a device to detect user lip movements associated with inhalation and then trigger heating; US 5,372,148 of McCafferty et al. discloses a smoke sensor for controlling the flow of energy into a heated load array via a drip tip in response to a pressure drop; US 5,967,148 of Harris et al. discloses a socket in a smoking device including a recognizer that detects non-uniformity of infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the socket; US 6,040,560 of Fleischhauer et al. describes a defined executable electrical cycle with multiple differential phases; US 5,934,289 of Watkins et al. discloses a photonic light guide luminescent component; US 5,954,979 of Counts et al. discloses a component for changing the draw resistance through a smoking device; and US 5,934,289 of Blake et al. discloses a component for changing the draw resistance through a smoking device. US 6,803,545 discloses a specific battery configuration used in a smoke device; US 7,293,565 by Griffen et al. discloses various charging systems for use with smoke devices; US 2009 / 0320863 by Fernando et al. discloses a computer interface component for smoke devices to facilitate charging and enable computer control of the devices; US 2010 / 0163063 by Fernando et al. discloses an identification system for smoke devices; and WO2010 / 003480 by Flick discloses a fluid flow sensing system for indicating smoke emission in an aerosol generation system; all of the foregoing disclosures are incorporated herein by reference in their entirety.Further examples of components relating to electronic aerosol delivery articles and disclosing materials or components that can be used in the articles include U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patent No. 5,249,586 to Morgan et al.; U.S. Patent No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; and White's U.S. Patent No. 4,735,217 to White et al. U.S. Patent No. 6,164,287; Voges's U.S. Patent No. 6,196,218; Felter et al.'s U.S. Patent No. 6,810,883; Nichols's U.S. Patent No. 6,854,461; Hon's U.S. Patent No. 7,832,410; Kobayashi's U.S. Patent No. 7,513,253; Hamano's U.S. Patent No. 7,896,006; Shayan's U.S. Patent No. 6,772,756; Hon's U.S. Patent Publications 2009 / 0095311 and 2006 / 0196518. U.S. Patent Publications 2009 / 0126745 and 2009 / 0188490; Thorens et al., U.S. Patent Publications 2009 / 0272379; Monsees et al., U.S. Patent Publications 2009 / 0260641 and 2009 / 0260642; Oglesby et al., U.S. Patent Publications 2008 / 0149118 and 2010 / 0024834; Wang, U.S. Patent Publication 2010 / 0307518; Worm et al., U.S. Patent Publication 2013 / 0037041; and Hon, WO 2010 / 091593. The various materials disclosed in the foregoing documents can be incorporated into the apparatus of the present invention in various embodiments, and the entire foregoing disclosure is incorporated herein by reference in its entirety.

[0058] While the articles of manufacture according to this disclosure may be presented in various embodiments, consumer use of the articles will be similar in scope, as discussed in detail below. Specifically, the articles may be provided as a single unit or as multiple components assembled by the consumer for use and subsequently disassembled by the consumer. Generally, a tobacco article according to this disclosure may include a first unit that is engageable and detachable from a second unit, the first unit including a resistance heating element, and the second unit including a power source. In some embodiments, the second unit may further include one or more control components that actuate or adjust current from the power source. The first unit may include a distal end engaging the second unit and an opposing proximal end (or simply mouthpiece) including a drip tip having an opening at its proximal end. The first unit may include an airflow path leading to the drip tip of the first unit, and the airflow path may allow the formed aerosol to be transferred from the resistance heating element to the drip tip. In a preferred embodiment, the first unit may be disposable. Similarly, the second unit may be reusable.

[0059] During use, the consumer initiates heating by the resistance heating element, the heat generated by which atomizes the aerosol precursor composition and (optionally) additional inhalable material. This heating causes at least a portion of the aerosol precursor composition to be released as an aerosol (which may include any additional inhalable material included therein), and this aerosol is provided within a space inside the cartridge, which is in fluid communication with the mouthpiece of the cartridge. When the consumer inhales at the mouthpiece of the cartridge, air is drawn through the cartridge, and the combination of the drawn air and aerosol is inhaled as the inhaled material exits from the mouthpiece of the cartridge (and any optional drip tip present) and enters the consumer's mouth. To initiate heating, the consumer can actuate a button, a capacitive sensor, or a similar component that causes the resistance heating element to receive electrical energy from a battery or other energy source (e.g., a capacitor). The electrical energy can be supplied for a predetermined duration or can be manually controlled. Preferably, the flow of electrical energy on the article is substantially discontinued between puffs (but the energy flow may continue to maintain a baseline temperature higher than the ambient temperature—e.g., a temperature that promotes rapid heating to an effective heating temperature). In another embodiment, as further described herein, heating can be initiated by the consumer's puffing action using various sensors. Once puffing ceases, heating will stop or decrease. When the consumer has puffed a sufficient number of times to release a sufficient amount of inhalable material (e.g., an amount sufficient to equivalent to a typical smoking experience), the cartridge can be removed from the control housing and discarded. An indication of cartridge disposal (i.e., that the aerosol precursor composition has been substantially removed by the consumer) can be provided. In some embodiments, a single cartridge can provide more than one smoking experience and thus provide a sufficient amount of aerosol precursor composition to simulate as much as a pack of regular cigarettes or even more.

[0060] The foregoing description of the use of the article of manufacture can be applied to the various embodiments described with minor modifications, which will be apparent to those skilled in the art given the further disclosure provided herein. However, the foregoing description of its use is not intended to limit the use of the article of manufacture, but is provided to comply with all necessary disclosure requirements of this disclosure.

[0061] In various embodiments, this disclosure particularly provides a reservoir that can be easily combined with other elements of a tobacco product (especially cartridges). For example, Figure 2A cross-sectional view of a cartridge 500 that may be included in an electronic cigarette product is provided. According to one embodiment, the cartridge 500 includes a reservoir 501. As described herein, the cartridge 500 may be substantially tubular in shape and may be formed from a reservoir wall 502. As shown, the reservoir 501 may have a generally hollow tube shape, said tube being concentric with the cartridge wall 502. The reservoir 501 may be substantially rod-shaped, substantially tubular, or substantially cylindrical. Thus, the reservoir 501 may have a diameter that allows the reservoir 501 to be adapted to fit within the cartridge 500. The reservoir 501 may be formed from a plurality of combined layers, said layers may be concentric or overlapping. For example, the reservoir 501 may be a continuous sheet of material rolled up to form a hollow tube. The reservoir may also be a pad formed of a non-woven material. In other embodiments, the reservoir 501 may be a substantially monolithic component. For example, the reservoir 501 can be shaped or molded into a unit component in the form of a substantially hollow tube, the composition of which is substantially continuous in its length and thickness. The reservoir 501 can be rigid or semi-rigid. The reservoir 501 may include a first end 503 and an opposing second end 504. The reservoir 501 includes an outer surface 505, which can be significantly shaped and adapted to conform to the inner surface 506 of the cartridge wall 502. If desired, one or more additional components of the tobacco article according to this disclosure can be accommodated within or around the reservoir 501. Although the reservoir 501 is in Figure 2 The image is shown in part 500 of a tobacco cartridge in a tobacco product, but those skilled in the art will understand that the reservoir 501 may be located in any part of the tobacco product to avoid obstructing the storage and delivery of the aerosol precursor composition stored therein.

[0062] In some embodiments, the reservoir according to this disclosure may be provided in a manner such that at least a portion of its hollow interior is shaped and sized to accommodate one or more additional components of a tobacco article. In some embodiments, the term "shaped and sized" may indicate that the walls of the hollow interior include one or more notches or protrusions that give the interior a shape other than that of a substantially smooth and continuous form. In other embodiments, the hollow nature of the reservoir may be sufficient to accommodate additional components of a tobacco article without forming cavities or protrusions.

[0063] The article of this disclosure may be particularly advantageous because the reservoir can be preformed and can have a hollow interior with walls that are shaped and sized to accommodate additional components for housing the tobacco article. This particularly facilitates easy assembly of the tobacco article and can maximize the reservoir volume while also providing sufficient space for aerosol formation. An embodiment of the tobacco cartridge according to this disclosure is shown in... Figure 3 middle, Figure 3An exploded view of the cartridge 500 is provided. As seen therein and as described herein, the cartridge wall 502 can be adapted to enclose the reservoir 501. The outer surface 505 of the reservoir 501 can be adapted to conform to the inner surface 506 of the cartridge wall 502.

[0064] The reservoir 501 also has an inner surface 508 that defines a central cavity 507 within the reservoir. In the illustrated embodiment, the inner surface 508 of the reservoir 501 includes two completely opposite grooves (515, 516) that extend inwardly from the central cavity into the reservoir. As shown, the grooves extend substantially the entire length of the reservoir 501 from a first end 503 to a second end 504. In other embodiments, the grooves may be absent, and the inner surface of the reservoir may still be described as shaped and sized to accommodate an atomizer, since the atomizer can be positioned together with the central cavity such that a portion of the atomizer is in fluid contact with the reservoir.

[0065] exist Figure 3 In some embodiments, the atomizer specifically includes a heater, a liquid delivery element, and conductive terminals. For example... Figure 3 As shown, the liquid delivery element is a continuous, elongated cord 509, and the heater is a resistance heating coil 510 connected to the cord and located approximately at the midpoint of the cord. The portion of the cord extending beyond the resistance heating coil can be referred to as the distal arm of the cord. The conductive terminal 511 of the atomizer 520 is positioned to contact the cord 509 at the distal end of the resistance heating coil 510. The conductive terminal can be specifically described as contacting the cord at one or more portions of the cord at the distal end of the resistance heating coil. As shown, the conductive terminal 511 extends beyond the end of the cord 509. This extension is not necessarily required. Given the hollow interior of the reservoir 501, the atomizer can be easily positioned inside the reservoir during the assembly of the tobacco product. Similarly, since the hollow interior can be shaped and sized to fit the atomizer, the assembly can be easily assembled, and the atomizer can fit snugly against the reservoir while the cord is positioned in fluid connection with the reservoir.

[0066] The above structure is further shown in Figure 4 middle, Figure 4A perspective view of a reservoir 501, according to one embodiment, is provided in combination with an atomizer 520. The reservoir 501 includes a central cavity 507, which may be fibrous-free and capable of storing, containing, or retaining products such as aerosol precursor compositions. The atomizer 520 is combined with the reservoir 501 because the distal arm of the cord 509 mates with and engages with fully opposed grooves (515, 516). These grooves may be pre-formed in the reservoir, or they may be formed by engaging the atomizer cord with the inner wall of the reservoir, such that the fiber reservoir is locally compressed by the atomizer cord. By adapting the inner surface 508 of the central cavity 507 of the reservoir 501 to accommodate various tobacco product components, the available open space in the tobacco product can be fully maximized by extending the reservoir 501 into a previously open space. Therefore, the overall size and capacity of the reservoir 501 can be increased compared to conventional textile or non-textile fiber pads typically used in e-cigarette products. The increased capacity allows the reservoir 501 to hold an increased amount of aerosol precursor composition, which in turn leads to a longer period of use and enjoyment of the tobacco product by the end user.

[0067] like Figure 4 As shown, the portion of the atomizer 520 including the resistance heating element extends beyond the second end 504 of the reservoir 501. When assembled with a cartridge, the second end 504 of the reservoir 501 can be located at the mouthpiece end of the cartridge (see...). Figure 1 The proximal end of element 11). Ideally, the mouthpiece end of the cartridge may include an open cavity in which an aerosol can be formed when the aerosol precursor composition is vaporized by the resistance heating element. In other embodiments, the atomizer does not necessarily extend beyond the end of the reservoir, and the atomizer may be positioned relative to the reservoir such that the resistance heating element is located within the hollow cavity of the reservoir.

[0068] The reservoir can be made of any material capable of being shaped into a rigid or semi-rigid hollow tube while retaining the ability to store liquid products (e.g., aerosol precursor compositions). In some embodiments, the reservoir material can be absorbent, adsorbent, or porous to provide the ability to retain the aerosol precursor composition. Thus, the aerosol precursor composition can be described as being coated on, adsorbed by, or absorbed within the reservoir material. The reservoir can be located within the tobacco article to be substantially in contact with one or more delivery elements (e.g., a rope). More specifically, the reservoir can be made of any material suitable for retaining the aerosol precursor composition (e.g., by absorption, adsorption, or the like) and allowing the precursor composition to be drawn away by the rope for delivery to a resistance heating element.

[0069] The reservoir material is adapted to form and maintain a suitable configuration (e.g., a substantially tubular shape) and to accommodate suitable components of an e-cigarette product therein. The reservoir material may be heat-resistant to maintain its structural integrity (e.g., without degradation) at least at a temperature received near the end of a heating temperature provided by a resistance heating element. The size and strength of the reservoir can vary depending on the characteristics and requirements of the respective e-cigarette product. In some embodiments, the reservoir may be made of a material suitable for high-speed, automated manufacturing processes. In some embodiments, the reservoir may comprise a woven or non-woven fiber pad that may be rolled up or otherwise formed into a tubular or hollow cylindrical shape. In other embodiments, the reservoir may be a molded tube or a hollow cylinder.

[0070] According to one embodiment, the reservoir can be made of cellulose acetate tow, which can be treated to form hollow acetate tubes. Cellulose acetate tow can be prepared according to various methods known to those skilled in the art. For example, see the methods set forth in U.S. Patent No. 4,439,605 to Yabune, U.S. Patent No. 5,167,764 to Nielsen et al., and U.S. Patent No. 6,803,458 to Ozaki, all of which are incorporated herein by reference in their entirety. Typically, cellulose acetate is obtained from cellulose by reacting pure cellulose from wood pulp with acetic acid and acetic anhydride in the presence of sulfuric acid. The resulting product is then subjected to controlled partial hydrolysis to remove sulfate groups and a sufficient number of acetate groups to produce cellulose acetate with the desired properties capable of ultimately forming rigid or semi-rigid hollow tubes. The cellulose acetate can then be extruded, spun, and arranged into tows. Cellulose acetate fibers can be open, crimped, or continuous filaments.

[0071] In another embodiment, cellulose acetate can be any acetate material suitable for providing tobacco smoke filters for cigarettes. Conventional cigarette filter materials can be used, such as cellulose acetate tow, aggregated cellulose acetate web, or aggregated cellulose acetate mesh. Examples of materials that can be used as alternatives to cellulose acetate include polypropylene tow, aggregated paper, recycled tobacco bundles, or the like. One filter material that can provide suitable filter rods and thus suitable hollow tube reservoirs is cellulose acetate tow having 3 fineness per filament and 40,000 total fineness. As another example, cellulose acetate tow having 3 fineness per filament and 35,000 total fineness can be used. As yet another example, cellulose acetate tow having 8 fineness per filament and 40,000 total fineness can be used. Other examples include the types of filter materials stated in the following cases: U.S. Patent No. 3,424,172 to Neurath; U.S. Patent No. 4,811,745 to Cohen et al.; U.S. Patent No. 4,925,602 to Hill et al.; U.S. Patent No. 5,225,277 to Takegawa et al.; and U.S. Patent No. 5,271,419 to Arzonico et al.; each of these cases is incorporated herein by reference.

[0072] Cellulose acetate fibers can be blended with other materials, such as cellulose, viscose, cotton, cellulose acetate butyrate, cellulose propionate, polyester (e.g., polyethylene terephthalate (PET)), polylactic acid (PLA), activated carbon, glass fiber, metal fiber, wood fiber, and the like. The fibers of the cellulose acetate tow emerging from the spinneret can be aggregated together to form a “raw tow,” which can then be bundled into bales for subsequent processing into tubes as described herein. Additional examples of fibrous materials suitable for use in reservoirs according to this disclosure are described in U.S. Patent Publication No. 2013 / 0025610 to Sebastian et al., the disclosure of which is incorporated herein by reference.

[0073] Cellulose acetate can be treated and formed into tubes using conventional filter tow processing methods. For example, a steam-bonded method can be used to produce hollow cellulose acetate tubes. Exemplary methods for forming cellulose acetate tubes can be found in U.S. Patent Publication No. 2012 / 0255569 by Beard et al. In another embodiment, cellulose acetate can be treated using a conventional filter tow processing unit. For example, a Bassell jetting method or a threaded roll method can be used to separate the filter tow. Exemplary tow processing units are commercially available, such as the E-60 supplied by Arjay Equipment Corp., Winston-Salem, NC. Other exemplary tow processing units are commercially available, such as the AF-2, AF-3, and AF-4 from Hauni-Werke Korber & Co.KG., and the Candor-ITM tow processor from International Tobacco Machinery. Other types of commercially available tow processing equipment known to those skilled in the art can be employed. The types of materials, apparatus, and techniques described in U.S. Patent Nos. 4,807,809 to Pryor et al. and 5,025,814 to Raker can be used to provide alternative materials for forming hollow tube reservoirs, such as aggregated paper, nonwoven polypropylene mesh, or aggregated bundles of wire mesh. Additionally, representative manners and methods for operating the filter material supply unit and the filter manufacturing unit are described in the following cases: U.S. Patent No. 4,281,671 to Bynre; U.S. Patent No. 4,850,301 to Green, Jr. et al.; U.S. Patent No. 4,862,905 to Green, Jr. et al.; U.S. Patent No. 5,060,664 to Siems et al.; U.S. Patent No. 5,387,285 to Rivers; and U.S. Patent No. 7,074,170 to Lanier, Jr. et al.

[0074] Hollow acetate tubes as described herein may be particularly useful due to their surprisingly efficient liquid storage capacity. According to one embodiment, the cellulose acetate tow may have a linear mass density of about 0.5 dpf or greater, about 1 dpf or greater, or about 2 dpf or greater. In other embodiments, the cellulose acetate tow may have a linear mass density of about 0.5 dpf to about 20 dpf, about 0.75 dpf to about 15 dpf, about 1 dpf to about 10 dpf, or about 2 dpf to about 6 dpf. Cellulose acetate as used in this disclosure may comprise short fibers. The stable fibers may have an average length of about 0.1 inches to about 6 inches, about 0.2 inches to about 5 inches, or about 0.25 inches to about 3 inches.

[0075] Reservoirs comprising cellulose acetate can be formed from various compositions and in various ways. In a particular embodiment, the reservoir may include cellulose acetate fibers. If desired, the reservoir may include an adhesive. Fillers (e.g., cellulose) and fibers formed from different materials may also be used. The reservoir may include about 70% to about 99% cellulose acetate fibers by weight, and the weight indicated herein is measured on a dry weight basis. More specifically, the reservoir may include about 75% to about 98%, about 80% to about 97.5%, or about 90% to about 97% cellulose acetate fibers by weight. The reservoir may include about 1% to about 30% adhesive by weight. More specifically, the reservoir may include about 2% to about 25%, about 2.5% to about 20%, or about 3% to about 10% adhesive by weight. In a particular embodiment, the reservoir according to this disclosure may include about 95% to about 97% cellulose acetate fibers by weight and about 3% to about 5% adhesive by weight. In other specific embodiments, the reservoir according to this disclosure may include about 80% to about 85% by weight of cellulose acetate fibers and about 15% to about 20% by weight of an adhesive. An adhesive is understood to be a material that imparts an adhesive effect to the fibers used in forming the disclosed reservoir. For example, an adhesive may be a material that partially dissolves the cellulose acetate fibers such that the fibers adhere to each other or to other fibrous materials included in a textile or non-textile reservoir. Exemplary adhesives that may be used include polyvinyl acetate (PVA) adhesives, pastes, and triacetin. Those skilled in the art of cigarette filter manufacturing will recognize triacetin as a plasticizer for said filters. Therefore, it should be understood that there may be overlap between the group of adhesives available according to this disclosure and materials that may be considered plasticizers in other fields. Therefore, adhesives used and described herein as adhesives may include materials that may be considered plasticizers in other fields. Furthermore, materials considered plasticizers of cellulose acetate in the field of cigarette filters may be included by the use of the term adhesive herein.

[0076] Cellulose acetate fibers can have various cross-sectional shapes, such as circular, elongated, or multi-lobed. In certain embodiments, cellulose acetate with a three-lobed or Y-shaped cross-sectional shape can be used.

[0077] In some embodiments, the nonwoven fiber pad reservoir according to this disclosure can be formed by a wet-laid method or by a dry-laid method. When using a wet-laid method, it may be advantageous to use cellulose acetate fibers with a shorter length (e.g., in the range of about 0.25 inches to about 2 inches). When using a dry-laid method, it may be advantageous to use cellulose acetate fibers with a longer length (e.g., in the range of about 2.5 inches to about 3 inches). In each case, the thickness of the resulting pad including cellulose acetate fibers can be about 1 mm to about 4 mm, about 1.25 mm to about 3.5 mm, or about 1.5 mm to about 3 mm. The cellulose acetate pad can have a basic weight of about 70 gsm to about 240 gsm, about 80 gsm to about 220 gsm, or about 90 gsm to about 200 gsm. The cellulose acetate pad can be set to the desired width. In various embodiments, the width can be from about 10 mm to about 25 mm, from about 15 mm to about 24 mm, or from about 20 mm to about 23 mm. The cellulose acetate pad can be cut to a length suitable for rolling into a tube having an outer diameter suitable for insertion into a tobacco product as described herein and an inner diameter suitable for allowing insertion of an atomizer according to this disclosure. The ends of the rolled pad can form butt joints or can overlap. In another embodiment, the cellulose acetate composition can be molded into a substantially tubular shape. The shaped hollow acetate tube can have one or more shapes formed into its inner wall, such as the fully opposed grooves discussed above.

[0078] In some embodiments, the fibers of the formed pad can be entangled. For example, hydraulic entanglement and needle punching can be used individually or in combination. In certain embodiments, needle punching can be used at a rate of at least 250, at least 500, at least 1,000, or at least 1,500 needles per square inch (NPPSI). Specifically, rates of about 250 to about 2,500, about 500 to about 2,000, or about 750 to about 1,500 NPPSI can be used.

[0079] According to one embodiment, the reservoir may comprise a mixture of different types of fibers. Suitable fibers for forming the mixture include, but are not limited to, fibers formed from cellulose acetate, wood pulp, wool, silk, polyester (e.g., polyethylene terephthalate), polyamide (e.g., nylon), polyolefins, polyvinyl alcohol, and the like.

[0080] As discovered in this disclosure, hydrophilic fibers, particularly cellulose acetate, can be particularly used to form reservoirs for aerosol precursor compositions (especially compositions mainly composed of polyols, such as glycerol). These reservoirs can provide improved storage and release of the aerosol precursor compositions. For example, the reservoirs can achieve faster loading of the aerosol precursor compositions, more consistent release of the aerosol precursor compositions as they are inhaled (e.g., through a cord) during use of the tobacco product, and a reduction in the overall volume of the aerosol precursor compositions that must be loaded into the reservoir.

[0081] The filaments used in the rope according to this disclosure can be formed of any material that provides sufficient capillary action to transport one or more components of the aerosol precursor composition along the length of the filament. Non-limiting examples include natural and synthetic fibers such as cotton, cellulose, polyester, polyamide, polylactic acid, glass fiber, combinations thereof, and the like. Other exemplary materials that can be used in the rope include metals, ceramics, and carbonized filaments (e.g., materials formed from carbon-containing materials that have been calcined to drive away non-carbon components of the material).

[0082] The filaments (or generally ropes) can be coated with materials that alter the capillary action of the filaments, i.e., to increase (or decrease) the capillary action of the filaments if desired. Furthermore, the selection of fiber materials can be used to increase or decrease capillary action and thus control the adsorption rate of specific components of the aerosol precursor composition. The capillary action can also be customized by selecting the size of the fibers used in the rope and the overall dimensions of the rope (including rope length and rope diameter).

[0083] The filaments used to form the rope can have a specific cross-sectional shape and / or can be grooved to alter the capillary action of the fiber. The filaments can have a substantially circular cross-section, and altering the cross-sectional shape of the fiber can increase the surface area per fineness of the fiber and thus improve capillary action along the filament. For example, the filaments can be formed with longitudinal grooves intended to promote capillary action, such as 4DG fibers (available from Fiber Innovation Technology) and winged fibers (available from Alasso Industries). Similarly, filaments formed with “X” or “Y” shaped cross-sections can provide the desired capillary properties.

[0084] In other embodiments, at least a portion of the filaments used in the rope can be designed to promote radial suction. Continuous filament fibers, such as glass fibers, tend to promote suction primarily along the axis of the filament, i.e., axial suction. With appropriate design, the filaments can also promote radial suction, i.e., from the axis of the filament outwards. For example, radial suction can be promoted by using filaments with fibrillated fiber surfaces. This design is particularly useful in areas of the filaments near or in contact with the heater, as it allows more of the precursor composition to be atomized in a specific area of ​​the heater. Similarly, particles or beads can be sintered or otherwise interconnected to provide a continuous rope structure with similar effects.

[0085] The filaments used to form the rope can be provided individually or bundled together (including nets and braids). The filaments can be single fibers or formed from a group of fibers providing a larger mass. The porosity of the filaments used in the rope can also be controlled to alter capillary action, and may include controlling the average pore size and total porosity, controlling the filament geometry, controlling the overall rope shape, and controlling surface properties. Individual filaments can also have different lengths. Changing the properties of the filaments can be used to tailor vapor formation. For example, filaments with a greater drawdown capacity can be used to transport components in an aerosol precursor composition that will be vaporized in large quantities, while filaments with a reduced drawdown capacity can be used to transport components in an aerosol precursor composition that are desired to be vaporized in smaller quantities.

[0086] The type of material used to form the individual filaments of the rope can also be customized to transport specific types of compounds. For example, one or more ropes can be formed from filaments made of hydrophobic materials to preferentially absorb hydrophobic liquids. Alternatively, one or more ropes can be formed from filaments made of hydrophilic materials to preferentially absorb hydrophilic liquids. Furthermore, one or more ropes may include filaments formed from materials that are neither hydrophilic nor hydrophobic (e.g., natural materials) to preferentially absorb liquids that are neither distinctly polar nor distinctly nonpolar.

[0087] In certain embodiments, the rope that can be used as a liquid delivery component is a braided rope. The braided rope may be formed from at least three individual fibers or yarns. Furthermore, the braided rope may be formed from at least four, six, eight, ten, twelve, fourteen, or sixteen individual fibers or yarns. Each of the individual fibers or yarns may have the same composition. Alternatively, the individual fibers or yarns may comprise fibers or yarns formed from two or more different compositions (e.g., glass fiber yarn braided together with cotton yarn). Therefore, the braided rope may be formed from a combination of various synthetic fibers or yarns, various natural fibers or yarns, at least one synthetic fiber or yarn, and at least one antenna fiber or yarn. In some embodiments, E-glass may be used. In a preferred embodiment, C-glass may be used. The use of C-glass has been identified as a particular use because it has higher solubility in lung fluid compared to other materials, particularly other glass fiber materials.

[0088] Specifically, the braided cord can be provided as a core / sheath yarn assembly. Specifically, a first cord material can form the yarn core, while a second cord material can surround the core to form the yarn sheath. The sheath and core may differ in at least one of their physical structure and the materials forming the yarn. In a preferred embodiment, the twisted yarn may comprise the core, while the braided yarn may form the sheath.

[0089] Examples of sheath / core cords according to some embodiments of this disclosure are shown in Figure 5 In the cross-sectional view, Figure 5 In this embodiment, the sheath / core cord 202 can be formed from a sheath assembly 203 and a core assembly 204. As further described herein, the sheath 203 is formed from braided fibers or yarns. The core 204 is formed from unbraided yarns. In some embodiments, the relative dimensions of the cross-section of the sheath / core cord can vary. The core can be in direct contact with the sheath, or a space can be provided between the sheath and the core.

[0090] A method for manufacturing an electronic cigarette product is provided. The method includes the step of providing a cylinder comprising cellulose acetate and having a hollow interior portion. At least a portion of the hollow interior may be shaped and sized to accommodate one or more additional components of the cigarette product. The method may further include the step of inserting an atomizer into the hollow interior of the cellulose acetate cylinder. The atomizer may include a liquid delivery element, a heater, and electrical contacts. The method may further include the step of inserting the cylinder and the atomizer into a hollow housing and connecting the atomizer to a power source. The power source may be a battery. A portion of the liquid delivery element may be attached to or embedded in a reservoir to form a fluid connection enabling the delivery of an aerosol precursor composition to the outside of the reservoir. The atomizer may include a continuous, elongated cord having two opposing ends. The cord may particularly be a braided cord and may include C-glass. The atomizer may further include a heater connected to the cord and located approximately at its midpoint. The atomizer may also include conductive terminals positioned in physical contact with the cord and in electrical contact with the heater. According to one embodiment, the heater may be a resistance heating element. In some embodiments, the step of inserting the atomizer into the cellulose acetate cylinder may include extending a portion of the atomizer beyond the end of the cellulose acetate cylinder.

[0091] experiment

[0092] The following examples further illustrate the currently disclosed subject matter. These examples are stated to illustrate the currently disclosed subject matter and to provide sufficient disclosure, and they are not to be construed as limiting the subject matter.

[0093] Example 1

[0094] Preparation of cellulose acetate reservoir

[0095] A dry-laid cellulose acetate (CA) substrate was constructed from conventional cigarette filter tow (Eastman Estron acetate tow, 3.0 dpf, 40,000 total fineness, Y-shaped cross-section) cut to 2.5-inch fiber lengths to evaluate its suitability as a reservoir according to this disclosure. The sheet was mechanically entangled in a needle-punching process. No additional fibers or adhesives were added to the sheet. Other CA fibers and tow sizes, as well as various fiber cross-sections and fiber lengths compatible with carding / needling, can be used. Needling at 500, 1000, and 1500 needles per square inch (NPPSI) all produced usable sheets. Finished substrate sheets of approximately 70 gsm to approximately 240 gsm were produced, resulting in a thickness of approximately 1 mm to approximately 4 mm. A preferred embodiment has a base weight of 150 gsm at a thickness of approximately 2 mm and 1000 NPPSI. All other things being equal, a lighter base weight substrate results in a larger amount of aerosol generated by the product. These sheet parameters are selected in part to suit the needs of the cartridge design and assembly process. They can be adjusted to match larger or smaller liquid loads and / or physical cartridge sizes.

[0096] The hydroentanglement method was also tested as a way to entangle short fibers to create an adhesive sheet. Other methods can also be used, such as stitch bonding, ultrasonic bonding, or thermal bonding. Triacetin or other plasticizers, or spray bonding agents, can also be used. Fiber blends can also be used to adjust sheet properties for liquid affinity, capillary action, strength, elongation, and stiffness.

[0097] Non-crimped CA yarns, manufactured by Celanese and Eastman Chemical, are used to construct wet-laid CA substrates. The Eastman yarns are 4.0 dpf and 150 total fineness, with a regular (circular) cross-section, producing a standard cigarette tow finish. The yarns are cut to lengths of 0.25 inches and 0.5 inches for use in the wet-laid process. In testing, the 0.5-inch cut was preferred due to increased sheet integrity. Longer fiber lengths can also be used to improve this. Other filament fineness, total fineness, or cross-sections can also be used.

[0098] Several sheet compositions were tested. All compositions used a majority of CA fibers, ranging from approximately 75% to approximately 92% of the total dry weight. Additional fibers (alone or in combination) were added, ranging from approximately 8% to approximately 25% of the total dry weight, to reinforce the sheets. These additional fibers included: HP-11 wood pulp from Buckeye Technologies; DPL-2607, a PET (polyethylene terephthalate) bicomponent fiber from Fiber Innovation Technologies; and Kuralon VPB 105-2x4, PVOH (polyvinyl alcohol) fiber from Kuraray Co., Ltd. The final material selected for production had a composition of 92% CA, 4% wood pulp, and 4% PVOH.

[0099] Finished substrate sheets are produced with a thickness of approximately 0.7 mm to approximately 3 mm, ranging from approximately 70 gsm to approximately 160 gsm. An exemplary material is approximately 115 gsm and approximately 1.5 mm thick. These sheet parameters are selected in part to suit the needs of the cartridge design and assembly process. They can be adjusted to match larger or smaller liquid loads and / or physical cartridge sizes. The substrate sheets can be used to form hollow tube reservoirs.

[0100] Other cellulosic fibers, including rayon or cotton, can be used to replace wood pulp, or other cellulosic fibers, including rayon or cotton, can be used in addition to wood pulp to achieve substantially the same effect. Other methods of bonding the sheets may include spray adhesives, such as latex or solvents combined with triacetin or other plasticizers.

[0101] The advantage of wet web forming is its ability to adjust fiber orientation to change the "squareness" of the sheet. This can be used to reduce machine-directed elongation, which in turn improves the uniformity of slit width.

[0102] Example 2

[0103] Improved adsorption and release of aerosol precursor compositions

[0104] It is known that reservoirs in atomizing devices are typically formed from nonwoven pads of polyester (PET) fibers. This has the advantage of being a relatively inexpensive and widely available material; however, the hydrophobic nature of this material has been found to cause disadvantages, particularly when the aerosol precursor composition is primarily formed from hydrophilic materials. For example, PET nonwoven sheets cause little or no movement of the liquid precursor composition, and it can take approximately several hours for the liquid precursor composition to move completely through the entire reservoir.

[0105] Experiments were conducted to evaluate cellulose acetate (CA) substrates as reservoirs. Dry-laid, nonwoven cellulose acetate reservoirs (100% CA, 2.5-inch average fiber length, 150 gsm weight) were compared with PET reservoirs of similar size. Figure 6 The two reservoirs are shown one minute after the dry reservoirs were placed on a liquid substrate containing glycerin. Figure 7 The reservoir is shown two minutes after placement. At one minute, the CA tube has absorbed a significant amount of liquid, while the PET tube absorbs very little to no liquid. At two minutes, the CA tube is saturated, while the PET tube still absorbs very little to no liquid. This higher affinity for liquids affects the product in several ways. For manufacturing, it allows for the rapid filling of cartridges with substrates that absorb liquid more easily and uniformly. For product use, it allows the liquid in the cartridge to migrate more easily to the cord, resulting in more efficient use of the liquid in the cartridge.

[0106] The CA substrate was also tested against a PET substrate to evaluate its filling time when used as a reservoir in tobacco cartridges. When liquid was applied to the top of the substrate in the cartridge, the PET substrate had a filling time of more than 30 minutes. Under the same conditions, the CA substrate had a filling time of less than two minutes.

[0107] In the case of PET substrates, it is often observed that at the end of the product's lifespan, the areas of the substrate not in contact with the cord remain saturated with liquid, while the areas in contact with the cord have become depleted. This is an inefficient system because more liquid than can be efficiently converted into aerosol must be added to the cartridge. Figure 8 and Figure 9 The image in the image shows the product before use. Figure 8 ) and after use ( Figure 9 The figure shows a CA substrate. The figure illustrates that when a CA reservoir is used in a tobacco product, the applied aerosol precursor composition is uniformly depleted throughout the reservoir. This advantageously allows for the use of a smaller reservoir and a smaller volume of aerosol precursor composition to achieve the desired puff count in a tobacco product incorporating a CA reservoir. Figure 10 As observed, the aerosol formation efficiency increases as the size of the reservoir (saturated with the aerosol precursor composition) decreases, indicating that the aerosol precursor composition is efficiently and uniformly transferred from the reservoir for atomization.

[0108] Example 3

[0109] Improved suction and release of liquid delivery components

[0110] One of the main identified defects in many known atomized tobacco products is the alteration of aerosol delivery over the product's lifespan. When comparing initial performance (e.g., 1 to 20 puffs) with performance at the end of the product's lifespan (e.g., 180 to 200 puffs), most products show a 25% to 60% reduction in aerosol delivery. Ideally, performance should be consistent throughout the product's lifespan. Tests are conducted to evaluate improvements in performance based on the properties of the liquid delivery components (i.e., the cord) within the tobacco product.

[0111] A control rope was formed from twisted glass fiber yarn (9-micron E-glass) with a diameter of approximately 0.054 inches and a linear mass of approximately 2.15 mg / mm. The twisted yarn exhibited very little adhesive structure, especially when cut to short lengths. The yarn was easily compressed, which was considered a disadvantage for maintaining good contact with the resistance wire heater. Upon cutting, the ends of the yarn tended to disperse when the tension or torque applied during the twisting process was released. This was expected to reduce the rope's efficiency in fluid transport.

[0112] To address these physical limitations, a braided glass fiber rope with approximately the same specifications was developed: 9-micron E-glass, 0.052-inch diameter, and 2.47 mg / mm linear mass. This braided rope performs similarly to the original twisted rope. In both designs, the average mg of total particulate matter per pore (TPM) was reduced by approximately 25% from the initial number of pores to the number of pores at the end of its service life. This is shown in... Figure 11 middle.

[0113] In another test, a braided sheath was formed around the twisted core. The rope diameter and mass were also reduced. Three sheath / core type ropes were formed with diameters ranging from 0.043 inches to 0.047 inches and thread masses from 1.65 mg / mm to 1.85 mg / mm. The braided exterior of the sheath / core type ropes was formed using 8, 12, and 16 bobbins respectively, and is therefore described as comprising 8, 12, or 16 braids. Each of the three sheath / core type ropes provided a significantly higher TPM yield. See also Figure 12 The sheath / core type rope also exhibited smaller TPM changes over the product's lifespan, reduced by approximately 20% in both cases. All braid designs demonstrated greater physical integrity compared to the original twisted rope, rarely unraveling or unraveling upon cutting. The braid designs were also more robust, potentially improving the contact between the yarn heater and the braid.

[0114] Many modifications and other embodiments of this disclosure will arise to those skilled in the art upon understanding the teachings set forth in the foregoing description and associated drawings. Therefore, it will be understood that this disclosure is not 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. While specific terminology is used herein, it is used in a general and descriptive sense only and not for limitation.

Examples

example 1

[0094] Preparation of cellulose acetate reservoirs

[0095] A dry-laid cellulose acetate (CA) substrate was constructed from conventional cigarette filter tow (Eastman Estron acetate tow, 3.0 dpf, 40,000 total denier, Y-shaped cross-section) cut to a fiber length of 2.5 inches to Suitability for use as a reservoir according to the present disclosure was assessed. The sheets are mechanically entangled in the needling process. No additional fibers or binders are added to the sheet. Other CA fibers and tow sizes can be used, as well as various fiber cross-sections and carding / needling compatible fiber lengths. Needling at 500, 1000 and 1500 needle punches per square inch (NPPSI) all produced usable sheets. A finished substrate sheet of about 70 gsm to about 240 gsm is produced, which gives a thickness of about 1 mm to about 4 mm. A preferred embodiment has a basis weight of 150 gsm at about 2 mm thickness and 1000 NPPSI. All other factors being equal, a lower basis weight su...

example 2

[0103] Improved uptake and release of aerosol precursor compositions

[0104] The reservoirs in known nebulizing devices are usually formed from non-woven mats of polyester (PET) fibres. This has the advantage that this is a relatively cheap and widely available material; however, it has been found that the hydrophobic nature of the material can lead to disadvantages, especially when the aerosol precursor composition is formed primarily of hydrophilic materials Time. For example, the PET nonwoven sheet facilitates little or no movement of the liquid precursor composition, and it may take several hours for the liquid precursor composition to move completely through the entire reservoir.

[0105] Experiments were performed to evaluate cellulose acetate (CA) based substrates as reservoirs. Dry-laid, non-woven cellulose acetate reservoirs (100% CA, 2.5 inches average fiber length, 150 gsm weight) were compared to PET reservoirs of similar size. Figure 6 The two reservoirs are ...

example 3

[0109] Improved intake and release of liquid delivery components

[0110] One of the major deficiencies identified with many known vaping articles is the change in aerosol delivery over the lifetime of the article. When comparing initial performance (eg, 1 to 20 puffs) to end-of-life performance (eg, 180 to 200 puffs), most articles show a 25% to 60% reduction in aerosol delivery. Ideally, performance will be consistent over the life of the product. Tests were performed to evaluate enhanced performance based on the properties of the liquid delivery component (ie the cord) in the smoking article.

[0111] A control cord was formed from twisted fiberglass yarn (9 micron E-glass) with a diameter of approximately 0.054 inches and a thread mass of approximately 2.15 mg / mm. Twisted yarns exhibit little cohesive structure, especially when cut to short lengths. The yarn is easily compressed, which is considered a disadvantage for maintaining good contact with the resistance wire he...

Technical Field

[0001] This disclosure relates to aerosol delivery articles and their use, and specifically to articles that can be considered as tobacco articles for obtaining tobacco and other material components in an inhalable form. A very preferred component of said articles is made from or derived from tobacco, or those articles can be described as otherwise combining tobacco for human consumption. Background Technology

[0002] Over the years, numerous smoking devices have been proposed as improvements or alternatives to tobacco products that require the burning of tobacco for use. Many of these devices are reportedly designed to provide the sensations associated with smoking cigarettes, cigars, or pipes, but do not deliver the substantial byproducts of incomplete combustion and pyrolysis produced by tobacco burning. To address this, numerous smoking products, aroma generators, and medical inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensations of smoking cigarettes, cigars, or pipes without significantly burning the tobacco. For example, see the various alternative tobacco products, aerosol delivery devices, and heat sources described in the background art in the following cases: U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0255702 to Griffith, Jr. et al., U.S. Patent Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Publication No. 2014 / 0060554 to Collett et al., and U.S. Patent Application Serial No. 13 / 647,000, filed October 8, 2012, all of which are incorporated herein by reference.

[0003] Certain tobacco products that use electricity to generate heat to form smoke or aerosol, and more specifically, those products already referred to as electronic cigarettes, are available on the market worldwide. Representative products similar to traditional cigarettes, cigars, or pipes in many aspects are already on the market, such as those from Philip Morris Incorporated. ALPHA of InnoVapor LLC TM JOYE 510 TM and M4 TM ;CIRRUS by White Cloud Cigarettes TM and FLING TM ; COHITA International Inc. TM COLIBRI TM ELITECLASSIC TM MAGNUM TMPHANTOM TM and SENSE TM ; DUOPRO by Electronic Cigarettes, Inc. TM STORM TM and Egar Australia's EGAR TM Joyetech's eGo-C TM and eGo-T TM ELUSION UK Ltd TM Eonsmoke LLC's Green Smoke Inc., USA Greenarette LLC's Greenarette TM Smoke HALLIGAN TM HENDU TM JET TM MAXXQ TM PINK TM and Pitbul TM ; HEATBAR by Philip Morris International, Inc. TM Crown7's Hydra Imperial TM and LXE TM LOGIC Technology's LOGIC TM and THE CUBAN TM ;LucianoSmokes Inc. Nicotek, LLC Sottera, Inc. and ONEJOY TM SS Choice LLC's No. 7 TM ; PREMIUM ELECTRONIC CIGARETTE by PremiumEstore LLC TM RAPP E-MYSTICK by Ruyan America, Inc. TM ; RED DRAGON of Red Dragon Products, LLC TM ;RuyanGroup(Holdings)Ltd. SMART by The Smart Smoking Electronic Cigarette CompanyLtd. SMOKE by Coastline Products LLC SMOKING by SmokingEverywhere, Inc. V2CIGS of VMR Products LLC TM VaporNine LLC's Vapor Nine TM Vapor 4Life, Inc. VEPPO, E-CigaretteDirect, LLC TM And RJ Reynolds Vapor Company Other electric aerosol delivery devices, and specifically those described as so-called electronic cigarettes, are sold under the trademark BLU. TM COOLER VISIONS TM DIRECT E-CIG TM DRAGONFLY TM EMIST TM EVERSMOKE TM ; HYBRID FLAME TM KNIGHT STICKS TM ROYAL BLUES TM ; and SOUTHBEACH SMOKE TM .

[0004] It is desirable to provide a tobacco product that uses heat generated by electrical energy to provide the sensation of smoking a cigarette, cigar, or pipe, provides the sensation of smoking a cigarette, cigar, or pipe without burning the tobacco to any significant extent, provides the sensation of smoking a cigarette, cigar, or pipe without requiring a heat source for combustion, and provides the sensation of smoking a cigarette, cigar, or pipe without unnecessarily delivering large amounts of incomplete combustion and pyrolysis products. Summary of the Invention

[0005] This disclosure provides a tobacco product and related components and methods. According to one aspect, an electronic cigarette product is disclosed herein, comprising a power source and a reservoir, the reservoir comprising cellulose acetate and configured to contain a product. The product may include an aerosol precursor composition. The reservoir may be substantially cylindrical, having a hollow internal portion. The reservoir includes an outer surface substantially adapted to conform to the inner surface of the tobacco product. The reservoir may be shaped and sized to accommodate one or more additional components of the tobacco product. The one or more additional components may be an atomizer. The atomizer may include a heater, such as a resistance heating element. The atomizer may further include a liquid delivery element. For example, the liquid delivery element may be a continuous, elongated article. The article may be adapted to aspirate liquid. The heater may be arranged in a heating configuration with at least a portion of the liquid delivery element. For example, the heater may contact the liquid delivery element and may be located approximately at the midpoint of the liquid delivery element. The liquid delivery element may be a braided cord. The braided cord may be a sheath / core type cord, and the sheath may be braided. The core of the sheath / core cord may be a twisted yarn. The atomizer may include conductive terminals extending along at least a portion of the liquid delivery element and electrically arranged with the heater. The hollow interior of the reservoir may include a central cavity defined by an inner wall of the reservoir. The inner wall may include one or more recesses or protrusions formed therein. For example, the inner wall may include fully opposed grooves extending into the reservoir. The grooves (or similar arrangements) may be adapted to mate with at least a portion of the atomizer. The liquid delivery element may be operatively located within the tobacco product to substantially contact the product. The reservoir may be formed from a tow of cellulose acetate fibers. In some embodiments, the cellulose acetate fibers may have a size of about 0.5 dpf or greater, specifically about 0.5 dpf to about 20 dpf. The hollow cellulose acetate reservoir, in the shape of a tube or cylinder, may have a wall thickness of about 1 mm to about 4 mm. The reservoir may comprise about 70% to about 99% cellulose acetate by weight and about 2% to about 25% adhesive by weight. In another embodiment, the reservoir may consist of 100% cellulose acetate. Additional fibers and materials may be included with the cellulose acetate if desired. In some embodiments, the reservoir may be a textile or non-textile fiber pad in the form of a tube or a hollow cylinder.

[0006] This disclosure also provides a cord that can be particularly used in electronic cigarette products. In some embodiments, a cord suitable for use in electronic cigarette products may comprise a braid of at least four individual fibers or yarns. Specifically, at least one of the fibers or yarns forming the braid may be C-glass or E-glass. In other embodiments, the cord may comprise a braid of at least eight individual fibers or yarns. Furthermore, the braided cord may be a sheath / core type cord. Specifically, the braided cord may be a sheath surrounding a core. The core may be unbraided and may be formed of a material different from the braided sheath, or it may be both unbraided and formed of a material different from the braided sheath. In some embodiments, the core may comprise twisted yarn.

[0007] In another embodiment, this disclosure may provide an electronic cigarette article comprising a reservoir in which an aerosol precursor composition (e.g., a liquid composition) is stored, and a braided cord in fluid communication with the reservoir. The braided cord may be as described above. The reservoir may, in particular, be substantially cylindrical or tubular and have a hollow internal portion. The reservoir may, in particular, comprise cellulose acetate. The reservoir may be a molded element. The reservoir may also be a woven or nonwoven fiber pad, such as comprising cellulose acetate fibers. The fiber pad may be rolled or otherwise formed into a tubular or hollow cylindrical shape.

[0008] In other embodiments, this disclosure may provide cartridges for electronic cigarette products. The cartridge may include an atomizer at least partially located within the hollow interior of a tubular reservoir adapted to contain an aerosol precursor composition, the reservoir tube being located within the hollow housing. Specifically, the reservoir tube may be formed of cellulose acetate. The atomizer may specifically include: a continuous, elongated cord having two opposing ends; a heater connected to the cord and located approximately at its midpoint; and conductive terminals positioned in physical contact with the cord and electrically connected to the heater. The hollow housing may include a first end adapted to engage a control assembly (e.g., a controller or power unit of an electronic cigarette product) and an opposing mouthpiece end. The heater of the atomizer may extend beyond the reservoir tube within a cavity formed at the mouthpiece end of the hollow housing. As discussed herein, the cord may be a braided cord.

[0009] In another aspect, a method for manufacturing an electronic cigarette product is provided. The method includes the step of providing a cylinder comprising cellulose acetate having a hollow interior portion. At least a portion of the hollow interior may be shaped and sized to accommodate one or more additional components of the cigarette product. The method further includes the step of inserting an atomizer into the hollow interior of the cellulose acetate cylinder. The method may further include the step of inserting the cylinder and the atomizer into a hollow housing and connecting the atomizer to a power source. The power source may be a battery. The hollow housing may be a cartridge portion of the electronic cigarette product. Attached Figure Description

[0010] Therefore, having already described this disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0011] Figure 1 A cross-sectional view of an embodiment extending through a tobacco product is shown;

[0012] Figure 2 A partial cross-sectional view of an electronic cigarette article containing a reservoir according to an embodiment of the present disclosure is shown;

[0013] Figure 3 An exploded view of an electronic cigarette article containing a reservoir and an atomizer according to an embodiment of the present disclosure is shown;

[0014] Figure 4 A perspective view of a combined reservoir and atomizer according to one embodiment of the present disclosure is provided;

[0015] Figure 5 It is the cross-section of the skin / core type rope according to an exemplary embodiment of the present disclosure;

[0016] Figure 6 and Figure 7 Images of reservoirs according to embodiments of the present disclosure and control reservoirs after being placed in a liquid composition are shown to evaluate the reservoirs’ ability to become saturated with liquid.

[0017] Figure 8 The image shows a reservoir saturated with an aerosol precursor composition according to an embodiment of the present disclosure.

[0018] Figure 9 This occurs after the aerosol precursor composition has been depleted through the use of a reservoir in atomized tobacco products. Figure 8 Image of the storage device;

[0019] Figure 10 This is a graph showing the aerosol formation efficiency of a reservoir according to an embodiment of the present disclosure;

[0020] Figure 11This is a graph showing the change in the average mg number of total particulate matter (TPM) delivered in a puff of an atomized tobacco product utilizing twisted or braided rope according to embodiments of the present disclosure; and

[0021] Figure 12 It is a graph showing the change in the average number of milligrams of total particulate matter (TPM) delivered in a puff of an atomized tobacco product comprising a braided rope formed from 8, 12, or 16 individual glass fiber yarns according to embodiments of the present disclosure. Detailed Implementation

[0022] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the disclosure will be exhaustive and complete, and will fully convey the scope of the disclosure to those skilled in the art. In fact, 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 the disclosure will satisfy applicable legal requirements. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” as used in this specification and the appended claims include the plural referents.

[0023] This disclosure relates to articles that use electrical energy to heat materials (preferably without burning the materials to any significant extent) to form an inhalable substance, said articles being compact enough to be considered "handheld" devices. In particular, this disclosure relates to reservoirs in electronic cigarette articles for storing aerosol precursor compositions. The reservoirs may be fibrous and can be made of various fibers. For example, the reservoirs may be made of cellulose acetate fibers. The reservoirs may be substantially tubular in shape and may be adapted to accommodate additional internal components of the cigarette article.

[0024] This disclosure relates to articles (and their manufacture) that use electrical energy to heat materials (preferably without burning the materials to any significant extent) to form an inhalable substance, said articles being compact enough to be considered “handheld” devices. In some embodiments, said articles may be specifically described as tobacco articles. As used herein, the term “tobacco article” is intended to mean an article that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, type of taste or odor, sensory effects, bodily sensations, usage habits, visual cues (e.g., those provided by visible aerosols), and the like) without any component of said article being burned to any significant extent. As used herein, the term “tobacco article” does not necessarily mean that said article produces smoke in operation in the sense of an aerosol produced by the combustion or pyrolysis of tobacco, but rather that said article yields vapor (including vapor within an aerosol that can be considered as a smoke-like substance) produced by the volatilization or vaporization of certain components of said article or device. In a highly preferred embodiment, the article described as a tobacco article combines tobacco and / or components derived from tobacco.

[0025] In other embodiments, articles made according to this disclosure may be described as vapor-generating articles, atomizing articles, or pharmaceutical delivery articles. Thus, the articles may be arranged to deliver one or more substances (e.g., flavoring agents and / or pharmaceutical active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in the form of a vapor (i.e., a substance that is in the gaseous phase at temperatures below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For simplicity, as used herein, the term "aerosol" is intended to include vapors, gases, and aerosols in forms or types suitable for human inhalation, whether visible or not, and whether or not they can be considered smoke-like forms.

[0026] In use, the tobacco product according to this disclosure may be subjected to many of the bodily actions of an individual using conventional tobacco products (e.g., cigarettes, cigars, or pipes, which are used by lighting them with fire and inhaling the subsequently burning tobacco). For example, the user of the tobacco product of the present invention may hold the product as with conventional tobacco products, inhale from one end of the product to inhale the aerosol produced by the product, and exhale at selected time intervals.

[0027] Tobacco products manufactured according to one aspect of this disclosure may include a number of components disposed within a housing or body. The overall design of the housing or body may vary, and the dimensions or construction of the outer body, which may define the overall size and shape of the tobacco product, may vary. Typically, an elongated body resembling a cigarette or cigar may be formed from a single, monolithic housing; or the elongated body may be formed from two or more separable components. For example, a tobacco product may include an elongated housing or body whose shape may be substantially tubular and thus resemble the shape of a conventional cigarette or cigar. In one embodiment, all components of the tobacco product are housed within a single outer body or housing. Alternatively, the tobacco product may include two joined and separable housings. For example, a tobacco product may have: a control body at one end, the control body including a housing housing one or more reusable components (e.g., a rechargeable battery and various electronic devices for controlling the operation of the product); and a housing at the other end and removably attached thereto, the housing housing a disposable portion (e.g., a disposable cartridge containing flavoring). Furthermore, after considering commercially available electronic cigarette products (such as those representative products listed in the background section of this disclosure), one can understand various cigarette product designs and component arrangements.

[0028] A tobacco article made according to one aspect of this disclosure may include a combination of the following: a power source (i.e., an electrical power supply); at least one control component (e.g., a component for actuating, controlling, adjusting, and stopping the electrical power used for heat generation by controlling the current flow from the power source to other components of the article); a heater or heat generation component (e.g., a resistance heating element or component commonly referred to as an "atomizer"); and an aerosol precursor component (e.g., a liquid that is typically capable of producing an aerosol after sufficient heat is applied, such as components commonly referred to as "e-liquid," "e-fluid," and "e-oil"); and a mouthpiece region or tip for allowing inhalation of the tobacco article to inhale the aerosol (e.g., through a defined airflow path of the article such that the generated aerosol can be extracted from it after inhalation). The alignment of the components within the article may vary. In certain embodiments, the aerosol precursor component may be located near one end of the article (e.g., having a cartridge, which in some cases may be replaceable and disposable) close to the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heater assembly may be positioned sufficiently close to the aerosol precursor component such that heat from the heater assembly can vaporize the aerosol precursor (and one or more flavorings, agents, or the like that may be used for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are intended to be interchangeable, such that references to release, released, released out, or released include forming or generating, formed or produced, formed out or produced out, and formed or generated. Specifically, the inhalable substance is released in the form of vapor or aerosol or a mixture thereof. Furthermore, after considering commercially available electronic cigarette products (such as those representative products listed in the background section of this disclosure), one can understand the selection of various cigarette product components.

[0029] Tobacco products manufactured according to one aspect of this disclosure may include a battery or other power source to provide sufficient current to supply various functionalities to the product (e.g., resistance heating, power supply to control systems, power supply to indicators, and the like). The power source may take various embodiments. Preferably, the power source is capable of delivering sufficient power to rapidly heat the heating element to form an aerosol and to power the product by use for the desired duration. The power source is preferably sized to fit conveniently within the product, allowing for easy handling; and additionally, it is preferred that the power source be sufficiently lightweight without compromising the desired smoking experience.

[0030] An exemplary tobacco product 10 according to this disclosure is shown in Figure 1In the middle. As seen in the surface shown therein, the tobacco product 10 may include a control body 80 and a cartridge 90 that can be aligned in a functional relationship. In this respect, the control body 80 and the cartridge 90 may be attachable to and detachable from each other. Although Figure 1 The diagram illustrates a threaded engagement, but it should be understood that other engagement methods are included, such as press-fit engagement, magnetic engagement, or similar. As otherwise described herein, cartridges may specifically include a single-use connector.

[0031] In certain embodiments, the control unit 80 may be described as reusable, and the cartridge 90 as disposable. In some embodiments, the entire tobacco product 10 can be described as disposable because the control unit may be configured to be used only a limited number of times with a limited number of cartridges (e.g., until the battery-powered assembly no longer provides sufficient power to the tobacco product), after which the entire tobacco product 10 (including the control unit) can be discarded. In other embodiments, the control unit may have a replaceable battery, allowing the control unit to be reused through numerous battery replacements and with numerous cartridges. Similarly, the tobacco product 10 may be rechargeable and therefore can be combined with any type of charging technology, including connection to a typical power outlet, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer (e.g., via a USB cable).

[0032] The control body 80 includes a control component 20, a flow sensor 30, and a battery 40. While these components are arranged in a specific alignment as shown, it should be understood that this disclosure includes various alignments of the components. The control body 80 further includes a plurality of indicators 19 at the distal end 12 of the control body housing 81. The indicators 19 may display the number of puffs removed or remaining from the tobacco product, indicate an active or inactive state, illuminate in response to smoke emission, or similarly. The number of indicators may vary, and the indicators may have different shapes, and may even simply be openings in the body (e.g., for emitting sound when the indicator is present).

[0033] This disclosure includes various locations for one or more air inlets 17. As shown, the air inlet 17 may be located within the control body housing 81 such that air drawn through the air inlet sufficiently contacts the flow sensor 30 to activate the sensor (but other locations are included, particularly if different sensing elements are provided or if manual actuation (e.g., via a button) is provided). A socket 60 is also included at the proximal attachment end 13 of the control body 80, and this socket extends into the control body protrusion 82 to facilitate electrical connection with the resistance heating element 50 when the cartridge 90 is attached to the control body. In the illustrated embodiment, the socket 60 includes a centrally opening channel to facilitate the entry of air flowing from the air inlet in the control body into the cartridge during use of the article 10.

[0034] The cartridge 90 includes a cartridge shell 91, with a mouthpiece opening 18 located at the mouthpiece end 11 of the shell to allow air and entrained vapor (i.e., components of the aerosol precursor composition in inhalable form) to be delivered from the cartridge to the consumer during inhalation on the tobacco product 10. The tobacco product 10 according to this disclosure may have an overall shape that can be defined as substantially rod-shaped, substantially tubular, or substantially cylindrical. Figure 1 As shown, the tobacco article 10 has a substantially circular cross-section; however, this disclosure also includes other cross-sectional shapes (e.g., elliptical, square, triangular, etc.). The language used to describe the physical shape of the tobacco article can also be applied to individual units of the tobacco article in embodiments that include multiple units (e.g., control body and cartridge).

[0035] In a preferred embodiment, the tobacco product 10 may be sized and shaped to resemble a cigarette or cigar. Therefore, the tobacco product may have a diameter of approximately 5 mm to approximately 25 mm, approximately 5 mm to approximately 20 mm, approximately 6 mm to approximately 15 mm, or approximately 6 mm to approximately 10 mm. These dimensions may specifically correspond to the outer diameter of the control body housing 81 and / or the cartridge housing 91. The control body may have a length of approximately 50 mm to approximately 110 mm, approximately 60 mm to approximately 100 mm, or approximately 65 mm to approximately 95 mm. The cartridge may have a length of approximately 20 mm to approximately 60 mm, approximately 25 mm to approximately 55 mm, or approximately 30 mm to approximately 50 mm. The overall length of the combined cartridge and control body (or the overall length of the tobacco product formed from a single, monolithic housing according to this disclosure) may be approximately equal to or less than the length of a typical cigarette—for example, approximately 70 mm to approximately 130 mm, approximately 80 mm to approximately 125 mm, or approximately 90 mm to approximately 120 mm.

[0036] The cartridge casing 91 of the tobacco product 10 can be formed of any material suitable for forming and maintaining a proper configuration (e.g., a tubular shape) and for holding suitable components of the tobacco product therein. Figure 1 As shown, the body can be formed from a single wall. The cartridge shell 91 can be formed from a heat-resistant material (natural or synthetic) to maintain its structural integrity (e.g., without degradation) at least at a temperature provided by a resistance heating element. In some embodiments, a heat-resistant polymer can be used. In other embodiments, the body can be formed from paper or from metal (e.g., stainless steel). As further discussed herein, the body (e.g., a paper tube) can have one or more layers associated with it to substantially prevent vapor movement through. In one example, an aluminum foil layer can be laminated to one surface of the body. Ceramic materials can also be used.

[0037] The cartridge 90 further includes a resistance heating element 50 in the form of a metal wire coil. The resistance heating element includes terminals 51 (e.g., positive and negative terminals) at its opposite ends for facilitating current flow through the resistance heating element and attachments for proper wiring (not shown) to form an electrical connection between the resistance heating element and the battery 40 when the cartridge 90 is connected to the control body 80. Specifically, a plug 65 is located 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 socket 60 to form an electrical connection, allowing current to flow controllably from the battery 40 through the socket and the plug to the resistance heating element 50. The cartridge housing 91 may extend across the distal attachment end, such that this end of the cartridge is substantially closed with the plug protruding from it. Figure 1 As shown, the plug 65 includes an open central channel that is aligned with an open central channel in the socket 60 to allow air to flow from the control body 80 and into the cartridge 90.

[0038] Generally, during use, when a consumer inhales at the mouthpiece 11 of the cartridge, the flow sensor 30 detects a change in flow rate and activates the control component 20 to cause current to flow through the resistance heating element 50. Therefore, it is useful for the airflow to pass through the control body 80 in a manner that the flow sensor 30 detects almost immediately.

[0039] The control algorithm may require power to be supplied to the resistance heating element 50 to circulate it and thus maintain a defined temperature. The control algorithm can therefore be programmed to automatically deactivate the tobacco product 10 and stop power flow through the tobacco product after a defined delay if the consumer has not exhaled smoke. Furthermore, the tobacco product may include a temperature sensor to provide feedback to the control components. The sensor may, for example, be in direct contact with the resistance heating element 50. Alternative temperature sensing methods may also be used, such as relying on logic control components to assess the resistance through the resistance heating element and correlate that resistance with the temperature of the element. In other embodiments, the flow sensor 30 may be replaced with suitable components to provide alternative sensing methods, such as capacitive sensing. Additionally, one or more control buttons may be included to allow manual actuation by the consumer to trigger various functions, such as powering on and off the product 10, turning on the heating element 50 to generate vapor or aerosol for inhalation, or similar.

[0040] When the flow sensor 30 is located within the control body 80, it may be useful to have an air inlet 17 on the control body. If desired, a sealed flow path can be provided such that the flow sensor 30 within the control body 80 is fluidly connected to the interior of the cartridge after the cartridge is attached to the control body; this fluid connection is sealed relative to the rest of the components within the control body but extends to the cartridge 90 when attached to the control body. Furthermore, in other embodiments, the flow sensor 30 may be located within the cartridge 90 instead of the control body 80.

[0041] A reservoir can utilize a delivery element to transport an aerosol precursor composition to an atomization zone. As used herein, the term "reservoir" refers to a container or chamber used to contain, store, or retain products such as liquids, fluids, or aerosols. One example is shown in... Figure 1 In this embodiment, the cartridge 90 includes a reservoir layer 201 comprising a layer of non-woven fibers formed in a tubular shape, which encloses the interior of the cartridge housing 91. An aerosol precursor composition is held in the reservoir layer 201. Liquid components (e.g.) may be adsorbently held through the reservoir layer 201. The reservoir layer 201 is fluidly connected to a delivery element 301 (in this embodiment, a cord). The delivery element 301 delivers the aerosol precursor composition stored in the reservoir layer 201 to the atomization zone 400 of the cartridge 90 via capillary action. As shown, the delivery element 301 is in direct contact with a resistance heating element 50, which in this embodiment is in the form of a metal wire coil.

[0042] In use, when a user inhales through the product 10, the resistance heating element 50 is activated (e.g., via a smoke sensor), and the components of the aerosol precursor composition are vaporized in the atomization zone 400. Inhalation through the mouthpiece 11 of the product 10 causes ambient air to enter the air inlet 17 and pass through the central opening in the socket 60 and the central opening in the plug 65. In the cartridge 90, the inhaled air passes through the air passage 230 in the air passage tube 220 and combines with the vapor formed in the atomization zone 400 to form an aerosol. The aerosol is rapidly removed from the atomization zone, passes through the air passage 260 in the air passage tube 250, and exits from the mouth opening 18 in the mouthpiece 11 of the product 10. If desired, the air passage tube 250 may be absent, and the opening cavity may remain in the location to form an aerosol when the aerosol precursor composition is vaporized by the resistance heating element 50.

[0043] Figure 1The tobacco product 10 in the illustrated embodiment can be described as a disposable product. Therefore, it may be desirable for the reservoir 201 in the illustrated embodiment to include sufficient aerosol precursor composition and any additional inhalable material so that the consumer can obtain more than one use of the tobacco product. For example, the tobacco product may include sufficient atomizable and / or inhalable material so that the tobacco product can provide a number of puffs (lasting approximately two seconds) substantially equivalent to those obtainable from multiple conventional cigarettes (e.g., 2 or more, 5 or more, 10 or more, or 20 or more conventional cigarettes). More specifically, according to Figure 1 The disposable single-unit article of the embodiments can provide about 20 or more, about 50 or more, or about 100 or more.

[0044] Although Figure 1 This is an illustrative description of a tobacco product based on the present disclosure; however, the scope of this disclosure should not be construed as limited to the specific combinations and / or arrangements of the components shown therein. Rather, this disclosure may encompass various combinations of components that can be used to form an electronic cigarette product. References are made to tobacco products disclosed, for example, in U.S. Patent Publication No. 2014 / 0000638 to Sebastian et al. and U.S. Patent Publication No. 2013 / 0255702 to Griffith, Jr. et al., the disclosures of which are incorporated herein by reference in their entirety. Furthermore, representative heating elements and materials used therein are described in the following: U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,093,894 to Deevi et al.; U.S. Patent No. 5,224,498 to Deevi et al.; and Sprinkel et al. The disclosures of the following patents are incorporated herein by reference in their entirety: 5,228,460 by Jr. et al.; 5,322,075 by Deevi et al.; 5,353,813 by Deevi et al.; 5,468,936 by Deevi et al.; 5,498,850 by Das et al.; 5,659,656 by Das et al.; 5,498,855 by Deevi et al.; 5,530,225 by Hajaligol; 5,665,262 by Hajaligol; 5,573,692 by Das et al.; and 5,591,368 by Fleischhauer et al.

[0045] Various components of the tobacco products according to the present invention can be selected from those described in the art and those commercially available. Examples of batteries that can be used according to this disclosure are described in U.S. Publication No. 2010 / 0028766, the disclosure of which is incorporated herein by reference in its entirety.

[0046] Exemplary mechanisms that can provide smoke actuation capability include the model 163PC01D36 silicon sensor manufactured by the Microswitches Division of Honeywell, Inc., Freeport, Illinois. Further examples of on-demand operated electrical switches that can be used in heating circuits according to this disclosure are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Further descriptions of current regulation circuits and other control components (including microcontrollers) that can be used in this smoking product are provided in all of the following: U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Patent No. 5,372,148 to McCafferty et al.; U.S. Patent No. 6,040,560 to Fleischhauer et al.; and U.S. Patent No. 7,040,314 to Nguyen et al., all of which are incorporated herein by reference in their entirety.

[0047] Aerosol precursor compositions or vapor precursor compositions may include one or more different components. For example, an aerosol precursor may include a polyol (e.g., glycerol, propylene glycol, or mixtures thereof). Other representative types of aerosol precursor compositions are described in the following: U.S. Patent No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Patent No. 5,101,839 to Jakob et al.; PCT WO 98 / 57556 to Biggs et al.; and chemical and biological studies of novel cigarette prototypes of heated rather than combusted tobacco (RJ, Reynolds Tobacco Company Monograph (1988)); the disclosures of the foregoing are incorporated herein by reference.

[0048] The aerosol precursor composition may include additional liquid materials, such as water. For example, the aerosol precursor composition may combine a mixture of glycerol and water, or a mixture of propylene glycol and water, or a mixture of propylene glycol and glycerol, or a mixture of propylene glycol, glycerol, and water. Exemplary aerosol precursor compositions also include those types of materials incorporated into devices available from Atlanta Imports Inc., Acworth, Ga., USA, such as electronic cigars with the brand name E-CIG, which may be used with associated cartridge types C1a, C2a, C3a, C4a, C1b, C2b, C3b, and C4b; and Ruyan e-cigarettes and e-pipes available from Ruyan SBT Technology and Development Co., Ltd., Beijing, China. Exemplary formulations of aerosol precursor compositions that can be used according to this disclosure are described in U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., the contents of which are incorporated herein by reference in their entirety.

[0049] The aerosol precursor composition used in the disclosed tobacco articles may further include one or more flavoring agents, pharmaceuticals, or other inhalable materials. For example, liquid nicotine may be used. The additional materials may include one or more components of the aerosol precursor or vapor precursor composition. Therefore, the aerosol precursor or vapor precursor composition can be described as comprising an inhalable substance. As discussed herein, the inhalable substance may include flavoring agents, pharmaceuticals, and other materials. Specifically, the inhalable substance delivered using the tobacco articles according to the invention may include tobacco components or tobacco-derived materials. Alternatively, flavoring agents, pharmaceuticals, or other inhalable materials may be provided separately from other aerosol precursor components (e.g., in a reservoir). Thus, defined portions of flavoring agents, pharmaceuticals, or other inhalable materials may be delivered separately or simultaneously to a resistance heating element to release the flavoring agent, pharmaceuticals, or other inhalable material into an airflow for inhalation by the user along with other components of the aerosol precursor or vapor precursor composition.

[0050] Various types of flavor enhancers or materials that alter the sensory or aerosol characteristics or properties of tobacco products can be employed. These flavor enhancers can be supplied from sources other than tobacco, can be natural or artificial in nature, and can be used as concentrates or flavoring packets. Of particular interest are flavor enhancers applied to or incorporated into those aerosol-generating areas of the tobacco product. Furthermore, as noted above, the agents can be supplied directly to the resistance heating element or can be provided on a substrate. Exemplary flavor enhancers include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors (including lime and lemon)), maple, menthol, peppermint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, fennel, sage, cinnamon, sandalwood, jasmine, acerola, cocoa, licorice, and other types and characteristics of flavor enhancers and flavoring packets traditionally used to enhance the flavor of cigarettes, cigars, and pipe tobacco. Syrups, such as high-fructose corn syrup, can also be used. Flavor enhancers may also include acidic or alkaline properties (e.g., organic acids such as levulinic acid, succinic acid, lactic acid, and pyruvic acid). If desired, flavor enhancers can be combined with aerosol-generating materials. Exemplary plant-derived compositions that can be used are disclosed in U.S. Patent Publication Nos. 2012 / 0152265 and 2012 / 0192880 to Dube et al., the disclosures of which are incorporated herein by reference in their entirety.

[0051] Organic acids can be incorporated into aerosol precursors to provide desired alterations to the odor, sensation, or sensory properties of a pharmaceutical agent (e.g., nicotine) that can bind to the aerosol precursor. For example, organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) can be included in an aerosol precursor containing nicotine in an amount equal to that of nicotine (based on the total organic acid content). Any combination of organic acids can be used. For example, the aerosol precursor may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, until a concentration equal to the total amount of organic acids present is achieved as equimolar to the total amount of nicotine present in the aerosol precursor.

[0052] In embodiments of aerosol precursor materials containing tobacco extracts (including pharmaceutical-grade nicotine derived from tobacco), it is advantageous that the tobacco extracts are described as substantially free of compounds collectively referred to as Hoffmann analytes, including (e.g.) tobacco-specific nitrosamines (TSNAs), including N′-nitrosonornicotinamide (NNN), (4-methylnitroso)-1-(3-pyridyl)-1-butanone (NNK), N′-nitrosonechoic acid (NAT), and N′-nitrosopseudoestipine (NAB); polycyclic aromatic hydrocarbons (PAHs), including benzo[a]anthracene, benzo[a]pyrene, benzo[b]fluoranthracene, benzo[k]fluoranthracene, chrysoprase, dibenzo[a,h]anthracene, and indo[1,2,3-cd]pyrene and the like. In some embodiments, the aerosol precursor material may be described as completely free of any Hoffmann analytes, including TSNAs and PAHs. Examples of aerosol precursor materials 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. The reduction in Hoffmann analyte concentration can be achieved using certain extraction or processing methods. For example, the tobacco extract can be contacted with an imprinted or non-imprinted polymer, as described in, for example, the following: U.S. Patent Publication No. 2007 / 0186940 to Bhattacharyya et al.; 2011 / 0041859 to Rees et al.; and 2011 / 0159160 to Jonsson et al.; and U.S. Patent Application No. 13 / 111,330 to Byrd et al., filed May 19, 2011, all of which are incorporated herein by reference. The tobacco extract can be treated with an amine-functional ion exchange material that can remove certain aldehydes and other compounds. For example, see, in connection with, US Patent Nos. 4,033,361 of Horsewell et al. and 6,779,529 of Figlar et al., which are incorporated herein by reference in their entirety.

[0053] In some embodiments, the aerosol precursor may be adapted to increase its surface area during heating to form an aerosol in an electronic cigarette product. The aerosol precursor may include an effervescent material adapted to degrade during heating and release sufficient amounts of carbon dioxide (or other gaseous substances) to cause at least a portion of the aerosol precursor to foam or generate small droplets. Including the effervescent material may be advantageous to reduce the heat required for the aerosol precursor to form an aerosol.

[0054] Aerosol precursor compositions can take on various configurations based on the various amounts of materials used therein. For example, usable aerosol precursor compositions 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 may be distributed among two or more different polyols in any combination. For example, one polyol may comprise about 50% to about 90%, about 60% to about 90%, or about 75% to about 90% by weight of the aerosol precursor, and a second polyol may comprise about 2% to about 45%, about 2% to about 25%, or about 2% to about 10% by weight of the aerosol precursor. Usable aerosol precursors may also comprise up to about 25% by weight, about 20% by weight, or about 15% by weight of water—specifically about 2% to about 25% by weight, about 5% to about 20% by weight, or about 7% to about 15% by weight of water. Flavorings and similar agents (which may include pharmaceuticals such as nicotine) may comprise up to about 10%, up to about 8%, or up to about 5% by weight of the aerosol precursor.

[0055] As a non-limiting example, the aerosol precursor according to the invention may include glycerol, propylene glycol, water, nicotine, and one or more flavoring agents. Specifically, glycerol may 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; propylene glycol may 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; water may 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; nicotine may 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 flavoring agents may 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. A specific, non-limiting example of an aerosol precursor includes about 75% to about 80% by weight of glycerol, about 13% to about 15% by weight of water, about 4% to about 6% by weight of propylene glycol, about 2% to about 3% by weight of nicotine, and about 0.1% to about 0.5% by weight of flavoring agent. Nicotine may, for example, be derived from tobacco extract.

[0056] The amount of aerosol precursor composition used in a tobacco product is such that the product exhibits acceptable sensory and perceptual properties, as well as desired performance characteristics. For example, it is highly preferred to use sufficient aerosol precursor composition components, such as glycerol and / or propylene glycol, to produce a visible mainstream aerosol that resembles tobacco smoke in many respects. Typically, the amount of aerosol-generating material incorporated into the tobacco product 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 composition can depend on various factors, such as the number of puffs required per cartridge used in the tobacco product. The desired outcome is that the aerosol precursor composition does not introduce a significant degree of unacceptable off-flavor, a thin mouthfeel, or an overall sensory experience markedly different from that of conventional types of cigarettes that produce mainstream smoke by burning formulated tobacco. The selection of specific aerosol-generating and reservoir materials, the amounts of those components used, and the type of tobacco material used can be varied to control the overall chemical composition of the mainstream aerosol produced by the tobacco product.

[0057] Other components may be used in the tobacco products disclosed herein. For example, US 5,261,424 of Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouthpiece of a device to detect user lip movements associated with inhalation and then trigger heating; US 5,372,148 of McCafferty et al. discloses a smoke sensor for controlling the flow of energy into a heated load array via a drip tip in response to a pressure drop; US 5,967,148 of Harris et al. discloses a socket in a smoking device including a recognizer that detects non-uniformity of infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the socket; US 6,040,560 of Fleischhauer et al. describes a defined executable electrical cycle with multiple differential phases; US 5,934,289 of Watkins et al. discloses a photonic light guide luminescent component; US 5,954,979 of Counts et al. discloses a component for changing the draw resistance through a smoking device; and US 5,934,289 of Blake et al. discloses a component for changing the draw resistance through a smoking device. US 6,803,545 discloses a specific battery configuration used in a smoke device; US 7,293,565 by Griffen et al. discloses various charging systems for use with smoke devices; US 2009 / 0320863 by Fernando et al. discloses a computer interface component for smoke devices to facilitate charging and enable computer control of the devices; US 2010 / 0163063 by Fernando et al. discloses an identification system for smoke devices; and WO2010 / 003480 by Flick discloses a fluid flow sensing system for indicating smoke emission in an aerosol generation system; all of the foregoing disclosures are incorporated herein by reference in their entirety.Further examples of components relating to electronic aerosol delivery articles and disclosing materials or components that can be used in the articles include U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patent No. 5,249,586 to Morgan et al.; U.S. Patent No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; and White's U.S. Patent No. 4,735,217 to White et al. U.S. Patent No. 6,164,287; Voges's U.S. Patent No. 6,196,218; Felter et al.'s U.S. Patent No. 6,810,883; Nichols's U.S. Patent No. 6,854,461; Hon's U.S. Patent No. 7,832,410; Kobayashi's U.S. Patent No. 7,513,253; Hamano's U.S. Patent No. 7,896,006; Shayan's U.S. Patent No. 6,772,756; Hon's U.S. Patent Publications 2009 / 0095311 and 2006 / 0196518. U.S. Patent Publications 2009 / 0126745 and 2009 / 0188490; Thorens et al., U.S. Patent Publications 2009 / 0272379; Monsees et al., U.S. Patent Publications 2009 / 0260641 and 2009 / 0260642; Oglesby et al., U.S. Patent Publications 2008 / 0149118 and 2010 / 0024834; Wang, U.S. Patent Publication 2010 / 0307518; Worm et al., U.S. Patent Publication 2013 / 0037041; and Hon, WO 2010 / 091593. The various materials disclosed in the foregoing documents can be incorporated into the apparatus of the present invention in various embodiments, and the entire foregoing disclosure is incorporated herein by reference in its entirety.

[0058] While the articles of manufacture according to this disclosure may be presented in various embodiments, consumer use of the articles will be similar in scope, as discussed in detail below. Specifically, the articles may be provided as a single unit or as multiple components assembled by the consumer for use and subsequently disassembled by the consumer. Generally, a tobacco article according to this disclosure may include a first unit that is engageable and detachable from a second unit, the first unit including a resistance heating element, and the second unit including a power source. In some embodiments, the second unit may further include one or more control components that actuate or adjust current from the power source. The first unit may include a distal end engaging the second unit and an opposing proximal end (or simply mouthpiece) including a drip tip having an opening at its proximal end. The first unit may include an airflow path leading to the drip tip of the first unit, and the airflow path may allow the formed aerosol to be transferred from the resistance heating element to the drip tip. In a preferred embodiment, the first unit may be disposable. Similarly, the second unit may be reusable.

[0059] During use, the consumer initiates heating by the resistance heating element, the heat generated by which atomizes the aerosol precursor composition and (optionally) additional inhalable material. This heating causes at least a portion of the aerosol precursor composition to be released as an aerosol (which may include any additional inhalable material included therein), and this aerosol is provided within a space inside the cartridge, which is in fluid communication with the mouthpiece of the cartridge. When the consumer inhales at the mouthpiece of the cartridge, air is drawn through the cartridge, and the combination of the drawn air and aerosol is inhaled as the inhaled material exits from the mouthpiece of the cartridge (and any optional drip tip present) and enters the consumer's mouth. To initiate heating, the consumer can actuate a button, a capacitive sensor, or a similar component that causes the resistance heating element to receive electrical energy from a battery or other energy source (e.g., a capacitor). The electrical energy can be supplied for a predetermined duration or can be manually controlled. Preferably, the flow of electrical energy on the article is substantially discontinued between puffs (but the energy flow may continue to maintain a baseline temperature higher than the ambient temperature—e.g., a temperature that promotes rapid heating to an effective heating temperature). In another embodiment, as further described herein, heating can be initiated by the consumer's puffing action using various sensors. Once puffing ceases, heating will stop or decrease. When the consumer has puffed a sufficient number of times to release a sufficient amount of inhalable material (e.g., an amount sufficient to equivalent to a typical smoking experience), the cartridge can be removed from the control housing and discarded. An indication of cartridge disposal (i.e., that the aerosol precursor composition has been substantially removed by the consumer) can be provided. In some embodiments, a single cartridge can provide more than one smoking experience and thus provide a sufficient amount of aerosol precursor composition to simulate as much as a pack of regular cigarettes or even more.

[0060] The foregoing description of the use of the article of manufacture can be applied to the various embodiments described with minor modifications, which will be apparent to those skilled in the art given the further disclosure provided herein. However, the foregoing description of its use is not intended to limit the use of the article of manufacture, but is provided to comply with all necessary disclosure requirements of this disclosure.

[0061] In various embodiments, this disclosure particularly provides a reservoir that can be easily combined with other elements of a tobacco product (especially cartridges). For example, Figure 2A cross-sectional view of a cartridge 500 that may be included in an electronic cigarette product is provided. According to one embodiment, the cartridge 500 includes a reservoir 501. As described herein, the cartridge 500 may be substantially tubular in shape and may be formed from a reservoir wall 502. As shown, the reservoir 501 may have a generally hollow tube shape, said tube being concentric with the cartridge wall 502. The reservoir 501 may be substantially rod-shaped, substantially tubular, or substantially cylindrical. Thus, the reservoir 501 may have a diameter that allows the reservoir 501 to be adapted to fit within the cartridge 500. The reservoir 501 may be formed from a plurality of combined layers, said layers may be concentric or overlapping. For example, the reservoir 501 may be a continuous sheet of material rolled up to form a hollow tube. The reservoir may also be a pad formed of a non-woven material. In other embodiments, the reservoir 501 may be a substantially monolithic component. For example, the reservoir 501 can be shaped or molded into a unit component in the form of a substantially hollow tube, the composition of which is substantially continuous in its length and thickness. The reservoir 501 can be rigid or semi-rigid. The reservoir 501 may include a first end 503 and an opposing second end 504. The reservoir 501 includes an outer surface 505, which can be significantly shaped and adapted to conform to the inner surface 506 of the cartridge wall 502. If desired, one or more additional components of the tobacco article according to this disclosure can be accommodated within or around the reservoir 501. Although the reservoir 501 is in Figure 2 The image is shown in part 500 of a tobacco cartridge in a tobacco product, but those skilled in the art will understand that the reservoir 501 may be located in any part of the tobacco product to avoid obstructing the storage and delivery of the aerosol precursor composition stored therein.

[0062] In some embodiments, the reservoir according to this disclosure may be provided in a manner such that at least a portion of its hollow interior is shaped and sized to accommodate one or more additional components of a tobacco article. In some embodiments, the term "shaped and sized" may indicate that the walls of the hollow interior include one or more notches or protrusions that give the interior a shape other than that of a substantially smooth and continuous form. In other embodiments, the hollow nature of the reservoir may be sufficient to accommodate additional components of a tobacco article without forming cavities or protrusions.

[0063] The article of this disclosure may be particularly advantageous because the reservoir can be preformed and can have a hollow interior with walls that are shaped and sized to accommodate additional components for housing the tobacco article. This particularly facilitates easy assembly of the tobacco article and can maximize the reservoir volume while also providing sufficient space for aerosol formation. An embodiment of the tobacco cartridge according to this disclosure is shown in... Figure 3 middle, Figure 3An exploded view of the cartridge 500 is provided. As seen therein and as described herein, the cartridge wall 502 can be adapted to enclose the reservoir 501. The outer surface 505 of the reservoir 501 can be adapted to conform to the inner surface 506 of the cartridge wall 502.

[0064] The reservoir 501 also has an inner surface 508 that defines a central cavity 507 within the reservoir. In the illustrated embodiment, the inner surface 508 of the reservoir 501 includes two completely opposite grooves (515, 516) that extend inwardly from the central cavity into the reservoir. As shown, the grooves extend substantially the entire length of the reservoir 501 from a first end 503 to a second end 504. In other embodiments, the grooves may be absent, and the inner surface of the reservoir may still be described as shaped and sized to accommodate an atomizer, since the atomizer can be positioned together with the central cavity such that a portion of the atomizer is in fluid contact with the reservoir.

[0065] exist Figure 3 In some embodiments, the atomizer specifically includes a heater, a liquid delivery element, and conductive terminals. For example... Figure 3 As shown, the liquid delivery element is a continuous, elongated cord 509, and the heater is a resistance heating coil 510 connected to the cord and located approximately at the midpoint of the cord. The portion of the cord extending beyond the resistance heating coil can be referred to as the distal arm of the cord. The conductive terminal 511 of the atomizer 520 is positioned to contact the cord 509 at the distal end of the resistance heating coil 510. The conductive terminal can be specifically described as contacting the cord at one or more portions of the cord at the distal end of the resistance heating coil. As shown, the conductive terminal 511 extends beyond the end of the cord 509. This extension is not necessarily required. Given the hollow interior of the reservoir 501, the atomizer can be easily positioned inside the reservoir during the assembly of the tobacco product. Similarly, since the hollow interior can be shaped and sized to fit the atomizer, the assembly can be easily assembled, and the atomizer can fit snugly against the reservoir while the cord is positioned in fluid connection with the reservoir.

[0066] The above structure is further shown in Figure 4 middle, Figure 4A perspective view of a reservoir 501, according to one embodiment, is provided in combination with an atomizer 520. The reservoir 501 includes a central cavity 507, which may be fibrous-free and capable of storing, containing, or retaining products such as aerosol precursor compositions. The atomizer 520 is combined with the reservoir 501 because the distal arm of the cord 509 mates with and engages with fully opposed grooves (515, 516). These grooves may be pre-formed in the reservoir, or they may be formed by engaging the atomizer cord with the inner wall of the reservoir, such that the fiber reservoir is locally compressed by the atomizer cord. By adapting the inner surface 508 of the central cavity 507 of the reservoir 501 to accommodate various tobacco product components, the available open space in the tobacco product can be fully maximized by extending the reservoir 501 into a previously open space. Therefore, the overall size and capacity of the reservoir 501 can be increased compared to conventional textile or non-textile fiber pads typically used in e-cigarette products. The increased capacity allows the reservoir 501 to hold an increased amount of aerosol precursor composition, which in turn leads to a longer period of use and enjoyment of the tobacco product by the end user.

[0067] like Figure 4 As shown, the portion of the atomizer 520 including the resistance heating element extends beyond the second end 504 of the reservoir 501. When assembled with a cartridge, the second end 504 of the reservoir 501 can be located at the mouthpiece end of the cartridge (see...). Figure 1 The proximal end of element 11). Ideally, the mouthpiece end of the cartridge may include an open cavity in which an aerosol can be formed when the aerosol precursor composition is vaporized by the resistance heating element. In other embodiments, the atomizer does not necessarily extend beyond the end of the reservoir, and the atomizer may be positioned relative to the reservoir such that the resistance heating element is located within the hollow cavity of the reservoir.

[0068] The reservoir can be made of any material capable of being shaped into a rigid or semi-rigid hollow tube while retaining the ability to store liquid products (e.g., aerosol precursor compositions). In some embodiments, the reservoir material can be absorbent, adsorbent, or porous to provide the ability to retain the aerosol precursor composition. Thus, the aerosol precursor composition can be described as being coated on, adsorbed by, or absorbed within the reservoir material. The reservoir can be located within the tobacco article to be substantially in contact with one or more delivery elements (e.g., a rope). More specifically, the reservoir can be made of any material suitable for retaining the aerosol precursor composition (e.g., by absorption, adsorption, or the like) and allowing the precursor composition to be drawn away by the rope for delivery to a resistance heating element.

[0069] The reservoir material is adapted to form and maintain a suitable configuration (e.g., a substantially tubular shape) and to accommodate suitable components of an e-cigarette product therein. The reservoir material may be heat-resistant to maintain its structural integrity (e.g., without degradation) at least at a temperature received near the end of a heating temperature provided by a resistance heating element. The size and strength of the reservoir can vary depending on the characteristics and requirements of the respective e-cigarette product. In some embodiments, the reservoir may be made of a material suitable for high-speed, automated manufacturing processes. In some embodiments, the reservoir may comprise a woven or non-woven fiber pad that may be rolled up or otherwise formed into a tubular or hollow cylindrical shape. In other embodiments, the reservoir may be a molded tube or a hollow cylinder.

[0070] According to one embodiment, the reservoir can be made of cellulose acetate tow, which can be treated to form hollow acetate tubes. Cellulose acetate tow can be prepared according to various methods known to those skilled in the art. For example, see the methods set forth in U.S. Patent No. 4,439,605 to Yabune, U.S. Patent No. 5,167,764 to Nielsen et al., and U.S. Patent No. 6,803,458 to Ozaki, all of which are incorporated herein by reference in their entirety. Typically, cellulose acetate is obtained from cellulose by reacting pure cellulose from wood pulp with acetic acid and acetic anhydride in the presence of sulfuric acid. The resulting product is then subjected to controlled partial hydrolysis to remove sulfate groups and a sufficient number of acetate groups to produce cellulose acetate with the desired properties capable of ultimately forming rigid or semi-rigid hollow tubes. The cellulose acetate can then be extruded, spun, and arranged into tows. Cellulose acetate fibers can be open, crimped, or continuous filaments.

[0071] In another embodiment, cellulose acetate can be any acetate material suitable for providing tobacco smoke filters for cigarettes. Conventional cigarette filter materials can be used, such as cellulose acetate tow, aggregated cellulose acetate web, or aggregated cellulose acetate mesh. Examples of materials that can be used as alternatives to cellulose acetate include polypropylene tow, aggregated paper, recycled tobacco bundles, or the like. One filter material that can provide suitable filter rods and thus suitable hollow tube reservoirs is cellulose acetate tow having 3 fineness per filament and 40,000 total fineness. As another example, cellulose acetate tow having 3 fineness per filament and 35,000 total fineness can be used. As yet another example, cellulose acetate tow having 8 fineness per filament and 40,000 total fineness can be used. Other examples include the types of filter materials stated in the following cases: U.S. Patent No. 3,424,172 to Neurath; U.S. Patent No. 4,811,745 to Cohen et al.; U.S. Patent No. 4,925,602 to Hill et al.; U.S. Patent No. 5,225,277 to Takegawa et al.; and U.S. Patent No. 5,271,419 to Arzonico et al.; each of these cases is incorporated herein by reference.

[0072] Cellulose acetate fibers can be blended with other materials, such as cellulose, viscose, cotton, cellulose acetate butyrate, cellulose propionate, polyester (e.g., polyethylene terephthalate (PET)), polylactic acid (PLA), activated carbon, glass fiber, metal fiber, wood fiber, and the like. The fibers of the cellulose acetate tow emerging from the spinneret can be aggregated together to form a “raw tow,” which can then be bundled into bales for subsequent processing into tubes as described herein. Additional examples of fibrous materials suitable for use in reservoirs according to this disclosure are described in U.S. Patent Publication No. 2013 / 0025610 to Sebastian et al., the disclosure of which is incorporated herein by reference.

[0073] Cellulose acetate can be treated and formed into tubes using conventional filter tow processing methods. For example, a steam-bonded method can be used to produce hollow cellulose acetate tubes. Exemplary methods for forming cellulose acetate tubes can be found in U.S. Patent Publication No. 2012 / 0255569 by Beard et al. In another embodiment, cellulose acetate can be treated using a conventional filter tow processing unit. For example, a Bassell jetting method or a threaded roll method can be used to separate the filter tow. Exemplary tow processing units are commercially available, such as the E-60 supplied by Arjay Equipment Corp., Winston-Salem, NC. Other exemplary tow processing units are commercially available, such as the AF-2, AF-3, and AF-4 from Hauni-Werke Korber & Co.KG., and the Candor-ITM tow processor from International Tobacco Machinery. Other types of commercially available tow processing equipment known to those skilled in the art can be employed. The types of materials, apparatus, and techniques described in U.S. Patent Nos. 4,807,809 to Pryor et al. and 5,025,814 to Raker can be used to provide alternative materials for forming hollow tube reservoirs, such as aggregated paper, nonwoven polypropylene mesh, or aggregated bundles of wire mesh. Additionally, representative manners and methods for operating the filter material supply unit and the filter manufacturing unit are described in the following cases: U.S. Patent No. 4,281,671 to Bynre; U.S. Patent No. 4,850,301 to Green, Jr. et al.; U.S. Patent No. 4,862,905 to Green, Jr. et al.; U.S. Patent No. 5,060,664 to Siems et al.; U.S. Patent No. 5,387,285 to Rivers; and U.S. Patent No. 7,074,170 to Lanier, Jr. et al.

[0074] Hollow acetate tubes as described herein may be particularly useful due to their surprisingly efficient liquid storage capacity. According to one embodiment, the cellulose acetate tow may have a linear mass density of about 0.5 dpf or greater, about 1 dpf or greater, or about 2 dpf or greater. In other embodiments, the cellulose acetate tow may have a linear mass density of about 0.5 dpf to about 20 dpf, about 0.75 dpf to about 15 dpf, about 1 dpf to about 10 dpf, or about 2 dpf to about 6 dpf. Cellulose acetate as used in this disclosure may comprise short fibers. The stable fibers may have an average length of about 0.1 inches to about 6 inches, about 0.2 inches to about 5 inches, or about 0.25 inches to about 3 inches.

[0075] Reservoirs comprising cellulose acetate can be formed from various compositions and in various ways. In a particular embodiment, the reservoir may include cellulose acetate fibers. If desired, the reservoir may include an adhesive. Fillers (e.g., cellulose) and fibers formed from different materials may also be used. The reservoir may include about 70% to about 99% cellulose acetate fibers by weight, and the weight indicated herein is measured on a dry weight basis. More specifically, the reservoir may include about 75% to about 98%, about 80% to about 97.5%, or about 90% to about 97% cellulose acetate fibers by weight. The reservoir may include about 1% to about 30% adhesive by weight. More specifically, the reservoir may include about 2% to about 25%, about 2.5% to about 20%, or about 3% to about 10% adhesive by weight. In a particular embodiment, the reservoir according to this disclosure may include about 95% to about 97% cellulose acetate fibers by weight and about 3% to about 5% adhesive by weight. In other specific embodiments, the reservoir according to this disclosure may include about 80% to about 85% by weight of cellulose acetate fibers and about 15% to about 20% by weight of an adhesive. An adhesive is understood to be a material that imparts an adhesive effect to the fibers used in forming the disclosed reservoir. For example, an adhesive may be a material that partially dissolves the cellulose acetate fibers such that the fibers adhere to each other or to other fibrous materials included in a textile or non-textile reservoir. Exemplary adhesives that may be used include polyvinyl acetate (PVA) adhesives, pastes, and triacetin. Those skilled in the art of cigarette filter manufacturing will recognize triacetin as a plasticizer for said filters. Therefore, it should be understood that there may be overlap between the group of adhesives available according to this disclosure and materials that may be considered plasticizers in other fields. Therefore, adhesives used and described herein as adhesives may include materials that may be considered plasticizers in other fields. Furthermore, materials considered plasticizers of cellulose acetate in the field of cigarette filters may be included by the use of the term adhesive herein.

[0076] Cellulose acetate fibers can have various cross-sectional shapes, such as circular, elongated, or multi-lobed. In certain embodiments, cellulose acetate with a three-lobed or Y-shaped cross-sectional shape can be used.

[0077] In some embodiments, the nonwoven fiber pad reservoir according to this disclosure can be formed by a wet-laid method or by a dry-laid method. When using a wet-laid method, it may be advantageous to use cellulose acetate fibers with a shorter length (e.g., in the range of about 0.25 inches to about 2 inches). When using a dry-laid method, it may be advantageous to use cellulose acetate fibers with a longer length (e.g., in the range of about 2.5 inches to about 3 inches). In each case, the thickness of the resulting pad including cellulose acetate fibers can be about 1 mm to about 4 mm, about 1.25 mm to about 3.5 mm, or about 1.5 mm to about 3 mm. The cellulose acetate pad can have a basic weight of about 70 gsm to about 240 gsm, about 80 gsm to about 220 gsm, or about 90 gsm to about 200 gsm. The cellulose acetate pad can be set to the desired width. In various embodiments, the width can be from about 10 mm to about 25 mm, from about 15 mm to about 24 mm, or from about 20 mm to about 23 mm. The cellulose acetate pad can be cut to a length suitable for rolling into a tube having an outer diameter suitable for insertion into a tobacco product as described herein and an inner diameter suitable for allowing insertion of an atomizer according to this disclosure. The ends of the rolled pad can form butt joints or can overlap. In another embodiment, the cellulose acetate composition can be molded into a substantially tubular shape. The shaped hollow acetate tube can have one or more shapes formed into its inner wall, such as the fully opposed grooves discussed above.

[0078] In some embodiments, the fibers of the formed pad can be entangled. For example, hydraulic entanglement and needle punching can be used individually or in combination. In certain embodiments, needle punching can be used at a rate of at least 250, at least 500, at least 1,000, or at least 1,500 needles per square inch (NPPSI). Specifically, rates of about 250 to about 2,500, about 500 to about 2,000, or about 750 to about 1,500 NPPSI can be used.

[0079] According to one embodiment, the reservoir may comprise a mixture of different types of fibers. Suitable fibers for forming the mixture include, but are not limited to, fibers formed from cellulose acetate, wood pulp, wool, silk, polyester (e.g., polyethylene terephthalate), polyamide (e.g., nylon), polyolefins, polyvinyl alcohol, and the like.

[0080] As discovered in this disclosure, hydrophilic fibers, particularly cellulose acetate, can be particularly used to form reservoirs for aerosol precursor compositions (especially compositions mainly composed of polyols, such as glycerol). These reservoirs can provide improved storage and release of the aerosol precursor compositions. For example, the reservoirs can achieve faster loading of the aerosol precursor compositions, more consistent release of the aerosol precursor compositions as they are inhaled (e.g., through a cord) during use of the tobacco product, and a reduction in the overall volume of the aerosol precursor compositions that must be loaded into the reservoir.

[0081] The filaments used in the rope according to this disclosure can be formed of any material that provides sufficient capillary action to transport one or more components of the aerosol precursor composition along the length of the filament. Non-limiting examples include natural and synthetic fibers such as cotton, cellulose, polyester, polyamide, polylactic acid, glass fiber, combinations thereof, and the like. Other exemplary materials that can be used in the rope include metals, ceramics, and carbonized filaments (e.g., materials formed from carbon-containing materials that have been calcined to drive away non-carbon components of the material).

[0082] The filaments (or generally ropes) can be coated with materials that alter the capillary action of the filaments, i.e., to increase (or decrease) the capillary action of the filaments if desired. Furthermore, the selection of fiber materials can be used to increase or decrease capillary action and thus control the adsorption rate of specific components of the aerosol precursor composition. The capillary action can also be customized by selecting the size of the fibers used in the rope and the overall dimensions of the rope (including rope length and rope diameter).

[0083] The filaments used to form the rope can have a specific cross-sectional shape and / or can be grooved to alter the capillary action of the fiber. The filaments can have a substantially circular cross-section, and altering the cross-sectional shape of the fiber can increase the surface area per fineness of the fiber and thus improve capillary action along the filament. For example, the filaments can be formed with longitudinal grooves intended to promote capillary action, such as 4DG fibers (available from Fiber Innovation Technology) and winged fibers (available from Alasso Industries). Similarly, filaments formed with “X” or “Y” shaped cross-sections can provide the desired capillary properties.

[0084] In other embodiments, at least a portion of the filaments used in the rope can be designed to promote radial suction. Continuous filament fibers, such as glass fibers, tend to promote suction primarily along the axis of the filament, i.e., axial suction. With appropriate design, the filaments can also promote radial suction, i.e., from the axis of the filament outwards. For example, radial suction can be promoted by using filaments with fibrillated fiber surfaces. This design is particularly useful in areas of the filaments near or in contact with the heater, as it allows more of the precursor composition to be atomized in a specific area of ​​the heater. Similarly, particles or beads can be sintered or otherwise interconnected to provide a continuous rope structure with similar effects.

[0085] The filaments used to form the rope can be provided individually or bundled together (including nets and braids). The filaments can be single fibers or formed from a group of fibers providing a larger mass. The porosity of the filaments used in the rope can also be controlled to alter capillary action, and may include controlling the average pore size and total porosity, controlling the filament geometry, controlling the overall rope shape, and controlling surface properties. Individual filaments can also have different lengths. Changing the properties of the filaments can be used to tailor vapor formation. For example, filaments with a greater drawdown capacity can be used to transport components in an aerosol precursor composition that will be vaporized in large quantities, while filaments with a reduced drawdown capacity can be used to transport components in an aerosol precursor composition that are desired to be vaporized in smaller quantities.

[0086] The type of material used to form the individual filaments of the rope can also be customized to transport specific types of compounds. For example, one or more ropes can be formed from filaments made of hydrophobic materials to preferentially absorb hydrophobic liquids. Alternatively, one or more ropes can be formed from filaments made of hydrophilic materials to preferentially absorb hydrophilic liquids. Furthermore, one or more ropes may include filaments formed from materials that are neither hydrophilic nor hydrophobic (e.g., natural materials) to preferentially absorb liquids that are neither distinctly polar nor distinctly nonpolar.

[0087] In certain embodiments, the rope that can be used as a liquid delivery component is a braided rope. The braided rope may be formed from at least three individual fibers or yarns. Furthermore, the braided rope may be formed from at least four, six, eight, ten, twelve, fourteen, or sixteen individual fibers or yarns. Each of the individual fibers or yarns may have the same composition. Alternatively, the individual fibers or yarns may comprise fibers or yarns formed from two or more different compositions (e.g., glass fiber yarn braided together with cotton yarn). Therefore, the braided rope may be formed from a combination of various synthetic fibers or yarns, various natural fibers or yarns, at least one synthetic fiber or yarn, and at least one antenna fiber or yarn. In some embodiments, E-glass may be used. In a preferred embodiment, C-glass may be used. The use of C-glass has been identified as a particular use because it has higher solubility in lung fluid compared to other materials, particularly other glass fiber materials.

[0088] Specifically, the braided cord can be provided as a core / sheath yarn assembly. Specifically, a first cord material can form the yarn core, while a second cord material can surround the core to form the yarn sheath. The sheath and core may differ in at least one of their physical structure and the materials forming the yarn. In a preferred embodiment, the twisted yarn may comprise the core, while the braided yarn may form the sheath.

[0089] Examples of sheath / core cords according to some embodiments of this disclosure are shown in Figure 5 In the cross-sectional view, Figure 5 In this embodiment, the sheath / core cord 202 can be formed from a sheath assembly 203 and a core assembly 204. As further described herein, the sheath 203 is formed from braided fibers or yarns. The core 204 is formed from unbraided yarns. In some embodiments, the relative dimensions of the cross-section of the sheath / core cord can vary. The core can be in direct contact with the sheath, or a space can be provided between the sheath and the core.

[0090] A method for manufacturing an electronic cigarette product is provided. The method includes the step of providing a cylinder comprising cellulose acetate and having a hollow interior portion. At least a portion of the hollow interior may be shaped and sized to accommodate one or more additional components of the cigarette product. The method may further include the step of inserting an atomizer into the hollow interior of the cellulose acetate cylinder. The atomizer may include a liquid delivery element, a heater, and electrical contacts. The method may further include the step of inserting the cylinder and the atomizer into a hollow housing and connecting the atomizer to a power source. The power source may be a battery. A portion of the liquid delivery element may be attached to or embedded in a reservoir to form a fluid connection enabling the delivery of an aerosol precursor composition to the outside of the reservoir. The atomizer may include a continuous, elongated cord having two opposing ends. The cord may particularly be a braided cord and may include C-glass. The atomizer may further include a heater connected to the cord and located approximately at its midpoint. The atomizer may also include conductive terminals positioned in physical contact with the cord and in electrical contact with the heater. According to one embodiment, the heater may be a resistance heating element. In some embodiments, the step of inserting the atomizer into the cellulose acetate cylinder may include extending a portion of the atomizer beyond the end of the cellulose acetate cylinder.

[0091] experiment

[0092] The following examples further illustrate the currently disclosed subject matter. These examples are stated to illustrate the currently disclosed subject matter and to provide sufficient disclosure, and they are not to be construed as limiting the subject matter.

[0093] Example 1

[0094] Preparation of cellulose acetate reservoir

[0095] A dry-laid cellulose acetate (CA) substrate was constructed from conventional cigarette filter tow (Eastman Estron acetate tow, 3.0 dpf, 40,000 total fineness, Y-shaped cross-section) cut to 2.5-inch fiber lengths to evaluate its suitability as a reservoir according to this disclosure. The sheet was mechanically entangled in a needle-punching process. No additional fibers or adhesives were added to the sheet. Other CA fibers and tow sizes, as well as various fiber cross-sections and fiber lengths compatible with carding / needling, can be used. Needling at 500, 1000, and 1500 needles per square inch (NPPSI) all produced usable sheets. Finished substrate sheets of approximately 70 gsm to approximately 240 gsm were produced, resulting in a thickness of approximately 1 mm to approximately 4 mm. A preferred embodiment has a base weight of 150 gsm at a thickness of approximately 2 mm and 1000 NPPSI. All other things being equal, a lighter base weight substrate results in a larger amount of aerosol generated by the product. These sheet parameters are selected in part to suit the needs of the cartridge design and assembly process. They can be adjusted to match larger or smaller liquid loads and / or physical cartridge sizes.

[0096] The hydroentanglement method was also tested as a way to entangle short fibers to create an adhesive sheet. Other methods can also be used, such as stitch bonding, ultrasonic bonding, or thermal bonding. Triacetin or other plasticizers, or spray bonding agents, can also be used. Fiber blends can also be used to adjust sheet properties for liquid affinity, capillary action, strength, elongation, and stiffness.

[0097] Non-crimped CA yarns, manufactured by Celanese and Eastman Chemical, are used to construct wet-laid CA substrates. The Eastman yarns are 4.0 dpf and 150 total fineness, with a regular (circular) cross-section, producing a standard cigarette tow finish. The yarns are cut to lengths of 0.25 inches and 0.5 inches for use in the wet-laid process. In testing, the 0.5-inch cut was preferred due to increased sheet integrity. Longer fiber lengths can also be used to improve this. Other filament fineness, total fineness, or cross-sections can also be used.

[0098] Several sheet compositions were tested. All compositions used a majority of CA fibers, ranging from approximately 75% to approximately 92% of the total dry weight. Additional fibers (alone or in combination) were added, ranging from approximately 8% to approximately 25% of the total dry weight, to reinforce the sheets. These additional fibers included: HP-11 wood pulp from Buckeye Technologies; DPL-2607, a PET (polyethylene terephthalate) bicomponent fiber from Fiber Innovation Technologies; and Kuralon VPB 105-2x4, PVOH (polyvinyl alcohol) fiber from Kuraray Co., Ltd. The final material selected for production had a composition of 92% CA, 4% wood pulp, and 4% PVOH.

[0099] Finished substrate sheets are produced with a thickness of approximately 0.7 mm to approximately 3 mm, ranging from approximately 70 gsm to approximately 160 gsm. An exemplary material is approximately 115 gsm and approximately 1.5 mm thick. These sheet parameters are selected in part to suit the needs of the cartridge design and assembly process. They can be adjusted to match larger or smaller liquid loads and / or physical cartridge sizes. The substrate sheets can be used to form hollow tube reservoirs.

[0100] Other cellulosic fibers, including rayon or cotton, can be used to replace wood pulp, or other cellulosic fibers, including rayon or cotton, can be used in addition to wood pulp to achieve substantially the same effect. Other methods of bonding the sheets may include spray adhesives, such as latex or solvents combined with triacetin or other plasticizers.

[0101] The advantage of wet web forming is its ability to adjust fiber orientation to change the "squareness" of the sheet. This can be used to reduce machine-directed elongation, which in turn improves the uniformity of slit width.

[0102] Example 2

[0103] Improved adsorption and release of aerosol precursor compositions

[0104] It is known that reservoirs in atomizing devices are typically formed from nonwoven pads of polyester (PET) fibers. This has the advantage of being a relatively inexpensive and widely available material; however, the hydrophobic nature of this material has been found to cause disadvantages, particularly when the aerosol precursor composition is primarily formed from hydrophilic materials. For example, PET nonwoven sheets cause little or no movement of the liquid precursor composition, and it can take approximately several hours for the liquid precursor composition to move completely through the entire reservoir.

[0105] Experiments were conducted to evaluate cellulose acetate (CA) substrates as reservoirs. Dry-laid, nonwoven cellulose acetate reservoirs (100% CA, 2.5-inch average fiber length, 150 gsm weight) were compared with PET reservoirs of similar size. Figure 6 The two reservoirs are shown one minute after the dry reservoirs were placed on a liquid substrate containing glycerin. Figure 7 The reservoir is shown two minutes after placement. At one minute, the CA tube has absorbed a significant amount of liquid, while the PET tube absorbs very little to no liquid. At two minutes, the CA tube is saturated, while the PET tube still absorbs very little to no liquid. This higher affinity for liquids affects the product in several ways. For manufacturing, it allows for the rapid filling of cartridges with substrates that absorb liquid more easily and uniformly. For product use, it allows the liquid in the cartridge to migrate more easily to the cord, resulting in more efficient use of the liquid in the cartridge.

[0106] The CA substrate was also tested against a PET substrate to evaluate its filling time when used as a reservoir in tobacco cartridges. When liquid was applied to the top of the substrate in the cartridge, the PET substrate had a filling time of more than 30 minutes. Under the same conditions, the CA substrate had a filling time of less than two minutes.

[0107] In the case of PET substrates, it is often observed that at the end of the product's lifespan, the areas of the substrate not in contact with the cord remain saturated with liquid, while the areas in contact with the cord have become depleted. This is an inefficient system because more liquid than can be efficiently converted into aerosol must be added to the cartridge. Figure 8 and Figure 9 The image in the image shows the product before use. Figure 8 ) and after use ( Figure 9 The figure shows a CA substrate. The figure illustrates that when a CA reservoir is used in a tobacco product, the applied aerosol precursor composition is uniformly depleted throughout the reservoir. This advantageously allows for the use of a smaller reservoir and a smaller volume of aerosol precursor composition to achieve the desired puff count in a tobacco product incorporating a CA reservoir. Figure 10 As observed, the aerosol formation efficiency increases as the size of the reservoir (saturated with the aerosol precursor composition) decreases, indicating that the aerosol precursor composition is efficiently and uniformly transferred from the reservoir for atomization.

[0108] Example 3

[0109] Improved suction and release of liquid delivery components

[0110] One of the main identified defects in many known atomized tobacco products is the alteration of aerosol delivery over the product's lifespan. When comparing initial performance (e.g., 1 to 20 puffs) with performance at the end of the product's lifespan (e.g., 180 to 200 puffs), most products show a 25% to 60% reduction in aerosol delivery. Ideally, performance should be consistent throughout the product's lifespan. Tests are conducted to evaluate improvements in performance based on the properties of the liquid delivery components (i.e., the cord) within the tobacco product.

[0111] A control rope was formed from twisted glass fiber yarn (9-micron E-glass) with a diameter of approximately 0.054 inches and a linear mass of approximately 2.15 mg / mm. The twisted yarn exhibited very little adhesive structure, especially when cut to short lengths. The yarn was easily compressed, which was considered a disadvantage for maintaining good contact with the resistance wire heater. Upon cutting, the ends of the yarn tended to disperse when the tension or torque applied during the twisting process was released. This was expected to reduce the rope's efficiency in fluid transport.

[0112] To address these physical limitations, a braided glass fiber rope with approximately the same specifications was developed: 9-micron E-glass, 0.052-inch diameter, and 2.47 mg / mm linear mass. This braided rope performs similarly to the original twisted rope. In both designs, the average mg of total particulate matter per pore (TPM) was reduced by approximately 25% from the initial number of pores to the number of pores at the end of its service life. This is shown in... Figure 11 middle.

[0113] In another test, a braided sheath was formed around the twisted core. The rope diameter and mass were also reduced. Three sheath / core type ropes were formed with diameters ranging from 0.043 inches to 0.047 inches and thread masses from 1.65 mg / mm to 1.85 mg / mm. The braided exterior of the sheath / core type ropes was formed using 8, 12, and 16 bobbins respectively, and is therefore described as comprising 8, 12, or 16 braids. Each of the three sheath / core type ropes provided a significantly higher TPM yield. See also Figure 12 The sheath / core type rope also exhibited smaller TPM changes over the product's lifespan, reduced by approximately 20% in both cases. All braid designs demonstrated greater physical integrity compared to the original twisted rope, rarely unraveling or unraveling upon cutting. The braid designs were also more robust, potentially improving the contact between the yarn heater and the braid.

[0114] Many modifications and other embodiments of this disclosure will arise to those skilled in the art upon understanding the teachings set forth in the foregoing description and associated drawings. Therefore, it will be understood that this disclosure is not 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. While specific terminology is used herein, it is used in a general and descriptive sense only and not for limitation.

Examples

example 1

[0094] Preparation of cellulose acetate reservoirs

[0095] A dry-laid cellulose acetate (CA) substrate was constructed from conventional cigarette filter tow (Eastman Estron acetate tow, 3.0 dpf, 40,000 total denier, Y-shaped cross-section) cut to a fiber length of 2.5 inches to Suitability for use as a reservoir according to the present disclosure was assessed. The sheets are mechanically entangled in the needling process. No additional fibers or binders are added to the sheet. Other CA fibers and tow sizes can be used, as well as various fiber cross-sections and carding / needling compatible fiber lengths. Needling at 500, 1000 and 1500 needle punches per square inch (NPPSI) all produced usable sheets. A finished substrate sheet of about 70 gsm to about 240 gsm is produced, which gives a thickness of about 1 mm to about 4 mm. A preferred embodiment has a basis weight of 150 gsm at about 2 mm thickness and 1000 NPPSI. All other factors being equal, a lower basis weight su...

example 2

[0103] Improved uptake and release of aerosol precursor compositions

[0104] The reservoirs in known nebulizing devices are usually formed from non-woven mats of polyester (PET) fibres. This has the advantage that this is a relatively cheap and widely available material; however, it has been found that the hydrophobic nature of the material can lead to disadvantages, especially when the aerosol precursor composition is formed primarily of hydrophilic materials Time. For example, the PET nonwoven sheet facilitates little or no movement of the liquid precursor composition, and it may take several hours for the liquid precursor composition to move completely through the entire reservoir.

[0105] Experiments were performed to evaluate cellulose acetate (CA) based substrates as reservoirs. Dry-laid, non-woven cellulose acetate reservoirs (100% CA, 2.5 inches average fiber length, 150 gsm weight) were compared to PET reservoirs of similar size. Figure 6 The two reservoirs are ...

example 3

[0109] Improved intake and release of liquid delivery components

[0110] One of the major deficiencies identified with many known vaping articles is the change in aerosol delivery over the lifetime of the article. When comparing initial performance (eg, 1 to 20 puffs) to end-of-life performance (eg, 180 to 200 puffs), most articles show a 25% to 60% reduction in aerosol delivery. Ideally, performance will be consistent over the life of the product. Tests were performed to evaluate enhanced performance based on the properties of the liquid delivery component (ie the cord) in the smoking article.

[0111] A control cord was formed from twisted fiberglass yarn (9 micron E-glass) with a diameter of approximately 0.054 inches and a thread mass of approximately 2.15 mg / mm. Twisted yarns exhibit little cohesive structure, especially when cut to short lengths. The yarn is easily compressed, which is considered a disadvantage for maintaining good contact with the resistance wire he...

Claims

1. An electronic cigarette product, comprising: Power source; A reservoir comprising cellulose acetate, the reservoir being substantially shaped like a cylinder having a hollow central cavity; An aerosol precursor composition, wherein the aerosol precursor composition is coated on the cellulose acetate reservoir and adsorbed or absorbed in the cellulose acetate reservoir, the aerosol precursor composition comprising a polyol. heater; Two conductive terminals, which are electrically connected to the heater; and A liquid delivery element configured such that the reservoir is in fluid connection with the heater; The liquid delivery element is shaped like a continuous, elongated rope having two opposing ends. A heater is connected to the rope and located approximately at its midpoint. Two conductive terminals independently contact the two opposing ends of the elongated rope and extend beyond the two opposing ends. The rope, the two conductive terminals, and the heater are positioned such that the opposing ends of the rope and the two conductive terminals extend into the hollow central cavity, and the heater extends beyond the end of the reservoir and into a cavity formed at the mouthpiece of the electronic cigarette.

2. The electronic cigarette article of claim 1, wherein the liquid delivery element comprises a braided cord, the cord being a braid of three or more individual fibers or yarns.

3. The electronic cigarette product as claimed in claim 2, wherein the liquid delivery element is in the form of a leather / core cord.

4. The electronic cigarette article of claim 3, wherein the leather portion of the rope is braided.

5. The electronic cigarette article of claim 4, wherein the core portion of the cord is unbraided or formed of a material different from the braided leather, or both.

6. The electronic cigarette article of claim 2, wherein the braided cord is a braid of at least four individual fibers or yarns.

7. The electronic cigarette product of claim 1, wherein the liquid delivery element comprises glass fiber.

8. The electronic cigarette article of claim 1, wherein the hollow interior of the reservoir includes a central cavity having a fully opposing groove extending into the reservoir, and wherein the groove is adapted to engage with the opposing end of the cord.

9. The electronic cigarette product of claim 1, wherein the cellulose acetate fiber has a linear mass density of 0.5 dpf or greater.

10. The electronic cigarette article of claim 1, wherein the reservoir comprises 75% to 98% cellulose acetate by weight and 2% to 25% adhesive by weight.

11. The electronic cigarette product of claim 1, wherein the aerosol precursor composition further comprises an organic acid.

12. The electronic cigarette product of claim 7, wherein the glass fiber is C-glass.

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