Powered aerosol delivery system

Abstract

An aerosol delivery system (100), the aerosol delivery system comprising: a control body part (300), which includes a first slender tubular member (304) in which a power source (316) is disposed; and a cartridge body part (200), which includes a second tubular member (216) having a first end and a second end opposite to each other, wherein one of the first end and the second end is removably engaged with one end (302) of the control body part (300), and wherein the cartridge body part (200) further includes a first aerosol generating device (212), the first aerosol generating device being disposed in the second tubular member (216) and being configured to operably engage the power source once the control body part (300) and the cartridge body part (200) are engaged. A second aerosol generating device (400) is disposed between the first aerosol generating device (212) and the mouth-engaging end (220) of the aerosol delivery system, and the second aerosol generating device (400) is detachably engaged with the cartridge body portion (200) or accommodated in the second tubular member of the cartridge body portion. A related method is also provided.

Description

[0001] This application is a divisional application of a patent application with an application date of May 19, 2015, an international application number of PCT / US2015 / 031563, a Chinese application number of 201580039116.9, and a name of “Electric Aerosol Delivery System”. Technical Field

[0002] The present invention relates to aerosol delivery devices and systems, such as smoking articles; and more particularly to aerosol delivery devices and systems that utilize electrically generated heat to generate an aerosol (e.g., a smoking article commonly referred to as an electronic cigarette). The aerosol delivery devices and systems can be configured to heat an aerosol precursor that incorporates a material that may, but is not necessarily, be made or derived from tobacco or otherwise incorporates tobacco, and can be vaporized to form an inhalable aerosol for human consumption. Background Art

[0003] Many smoking devices have been proposed for many years as improvements or substitutes for smoking products that need to burn tobacco for use. It is believed that many of these devices are designed to provide the sensation associated with cigarettes, cigars or pipes, but do not deliver a large amount of incomplete combustion and pyrolysis products produced by tobacco burning. For this reason, many smoking products, flavor generators and medicated inhalers have been proposed, which utilize electric energy to evaporate or heat volatile substances, or attempt to provide the sensation of cigarettes, cigars or pipes without burning tobacco to a significant degree. Referring to, for example, various alternative smoking articles, aerosol delivery devices and heating sources described in the background technology, described in U.S. Patent No. 7,726,320 of Robinson et al., Griffith, Jr et al. U.S. Patent Application Publication No. 2013 / 0255702 and Sears et al. U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference. See also, for example, various types of smoking articles, aerosol delivery devices, and powered heat sources cited by brand name and commercial source in U.S. Patent Application Serial No. 14 / 170,838, filed February 3, 2014 by Bless et al., which is incorporated herein by reference.

[0004] It is desirable to provide an electrically powered aerosol delivery system that allows its user to inhale a highly flavored aerosol. It is also desirable to provide the aerosol under pleasant or comfortable conditions when inhaled into the user's mouth. Summary of the invention

[0005] The present invention relates to an aerosol delivery system. Such a system has the ability to generate an aerosol due to the heat generated by a power source, and can deliver an aerosol for inhalation into the user's mouth. Of particular interest is an aerosol delivery system that provides tobacco ingredients in the form of an aerosol, such as provided to a smoker by a device that is generally known or characterized as an electronic cigarette. As used herein, the term "aerosol" is intended to include steam, gas, aerosol and / or particulate matter in a form or type suitable for human inhalation, whether visible or not, and whether the form that may be considered is "smoke-like".

[0006] The above and other needs are met by multiple aspects of the present invention. In one aspect, the present invention provides an aerosol delivery system. This aerosol delivery system can include a control body part, wherein the control body part includes a first elongated tubular member with opposite ends and a power source arranged therein. The cartridge body part includes a second tubular member with opposite first and second ends. One end of the first end and the second end of the cartridge body part is removably engaged with one end of the opposite end of the control body part. The cartridge body part further includes a first aerosol generating device arranged in the second tubular member, which is configured to operably engage the power source once one end of the opposite end of the control body part is engaged with one end of the first end and the second end of the cartridge body part. Another of the first end and the second end of the cartridge body part is also configured as a mouth joint end. The cartridge body part also includes a second aerosol generating device in a second tubular member arranged between the first aerosol generating device and the mouth joint end. In some aspects, the second aerosol generating device may also include one or more aerosol generating elements, wherein one or more (at least one) aerosol generating elements may be selected from the group consisting of: particles, pellets, beads, discrete small units, carbon sheets, extruded carbon sheets, ceramic beads, marumarized tobacco sheets, extruded or compressed cylindrical or spherical elements, ground tobacco thin layers, fillers, flavors, visible aerosol-forming materials, adhesives, oval elements, irregularly shaped elements, fragments, flakes, elements comprising tobacco, elements comprising visible aerosol-forming materials, adsorbent objects, absorbent objects, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0007] Another aspect of the present invention provides a method for forming an aerosol delivery system. This method may include removably engaging one end of a first elongated tubular member with a first end of a second tubular member, wherein the first elongated tubular member is configured as a control body portion and a power source is disposed therein, and the second tube device is configured as a cartridge body portion and has a first aerosol generating device disposed therein. The first aerosol generating device is configured to operably engage the power source once one end of the control body portion and the first end of the cartridge body portion are engaged. The method may also include inserting a second aerosol generating device into the second tubular member of the cartridge body portion between the first aerosol generating device and the second end of the second tubular member, wherein the second end is opposite to the first end and is configured as a mouth engagement end. In some cases, inserting the second aerosol generating device into the second tubular member may also include inserting one or more aerosol generating elements that at least partially form the second aerosol generating device into the second tubular member, wherein one or more (at least one) aerosol generating elements are selected from the group consisting of: particles, pellets, beads, discrete small units, carbon sheets, extruded carbon sheets, ceramic beads, Malham tobacco sheets, extruded or compressed cylindrical or spherical elements, ground tobacco thin layers, fillers, flavors, visible aerosol-forming materials, adhesives, oval elements, irregularly shaped elements, fragments, flakes, elements comprising tobacco, elements comprising visible aerosol-forming materials, adsorbent objects, absorbent objects, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0008] Therefore, the present invention includes but is not limited to the following embodiments:

[0009] Embodiment 1: An aerosol delivery system, comprising: a control body part, including a first slender tubular member having opposite ends and a power source disposed therein; and a cartridge body part, including a second tubular member having opposite first and second ends, wherein one of the first and second ends is removably engaged with one of the opposite ends of the control body part, wherein the cartridge body part further comprises a first aerosol generating device, the first aerosol generating device being disposed in the second tubular member and being configured to operably engage the power source once the one of the opposite ends of the control body part is engaged with the one of the first and second ends of the cartridge body part, wherein the other of the first and second ends of the cartridge body part is optionally also configured as a mouth engaging end, and wherein the cartridge body part further comprises a second aerosol generating device disposed in the second tubular member and located between the first aerosol generating device and the mouth engaging end.

[0010] Embodiment 2: The aerosol delivery system of any preceding or subsequent embodiment, or a combination thereof, wherein the second aerosol generating device further comprises at least one aerosol generating element.

[0011] Embodiment 3: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, wherein the at least one aerosol generating element is selected from the group consisting of particles, pellets, beads, discrete small units, carbon sheets, extruded carbon sheets, ceramic beads, Malham tobacco sheets, extruded or compressed cylindrical or spherical elements, ground tobacco thin layers, fillers, flavors, visible aerosol-forming materials, adhesives, oval elements, irregularly shaped elements, fragments, flakes, elements comprising tobacco, elements comprising visible aerosol-forming materials, adsorbent objects, absorbent objects, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0012] Embodiment 4: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, further comprising a first separation element disposed within the first tubular member between the first aerosol generating device and the second aerosol generating device, the first separation element having one of thermal conductivity and air permeability.

[0013] Embodiment 5: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, wherein the first separation element extends along a longitudinal axis between opposite ends to define a thickness, the thickness of the first separation element being configured to separate the second aerosol generating device from the heating element of the first aerosol generating device.

[0014] Embodiment 6: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, further comprising a second separation element disposed within the second tubular member between the second aerosol generating device and the mouth-engaging end, the second separation element having one of thermal conductivity and air permeability.

[0015] Embodiment 7: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, wherein the second aerosol generating device comprises a cartridge having an elongated tubular body and opposing end members, each end member being one of a heat conductive and an air conductive member, the elongated tubular body being further configured to receive at least one aerosol generating element and cooperating with the opposing end members to contain the at least one aerosol generating element therein, the cartridge being configured to be received by the second tubular member.

[0016] Embodiment 8: The aerosol delivery system of any preceding or subsequent embodiment, or a combination thereof, wherein the first aerosol generating device comprises a liquid reservoir disposed within the second tubular member and configured to receive an aerosol precursor substance used by the first aerosol generating device to generate the first aerosol.

[0017] Embodiment 9: The aerosol delivery system of any preceding or subsequent embodiment, or a combination thereof, wherein the aerosol precursor substance is fragrance-free or acid-free.

[0018] Embodiment 10: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, wherein the aerosol precursor substance is one of glycerol, propylene glycol, water, saline, nicotine and a combination thereof.

[0019] Embodiment 11: The aerosol delivery system of any preceding or subsequent embodiment, or a combination thereof, wherein the first aerosol generating device comprises a heating element configured to provide heat to produce a first aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element is arranged to interact with the heat and the first aerosol drawn toward the mouth-engaging end in response to suction applied to the mouth-engaging end.

[0020] Embodiment 12: The aerosol delivery system of any preceding or subsequent embodiment, or a combination thereof, wherein the at least one aerosol generating element of the second aerosol generating device is configured to interact with one of the heat from the heating element of the first aerosol generating device and the first aerosol generated by the first aerosol generating device to generate a second aerosol.

[0021] Embodiment 13: The aerosol delivery system of any preceding or subsequent embodiment, or a combination thereof, wherein the first aerosol generated by the first aerosol generating device is configured to interact with the second aerosol generated by the second aerosol generating device in response to suction applied thereto to form a third aerosol that is drawn toward the mouth-engaging end.

[0022] Embodiment 14: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, wherein the at least one aerosol generating element of the second aerosol generating device is configured to interact with the first aerosol generated by the first aerosol generating device in response to suction applied thereto and impart an enhancing substance to the first aerosol to produce an enhanced aerosol that is drawn toward the mouth-engaging end.

[0023] Embodiment 15: The aerosol delivery system of any preceding or subsequent embodiment or a combination thereof, wherein the at least one aerosol generating element of the second aerosol generating device is configured to interact with and remove heat from the first aerosol generated by the first aerosol generating device in response to suction applied thereto to produce a cooled aerosol that is drawn toward the mouth-engaging end.

[0024] Embodiment 16: An aerosol delivery system, comprising: a control body part, which includes a first slender tubular member having opposite ends and a power source arranged therein; a cartridge body part, which includes a second tubular member having opposite first and second ends, the first end being engaged with one of the opposite ends of the control body part, the cartridge body part further comprising a first aerosol generating device, the first aerosol generating device being disposed in the second tubular member and being configured to operably engage the power source once one of the opposite ends of the control body part is engaged with the first end of the cartridge body part, the second end of the cartridge body part facing the mouth engaging end of the aerosol delivery system; and a second aerosol generating device, disposed between the first aerosol generating device and the mouth engaging end of the aerosol delivery system, the second aerosol generating device being removably engaged with the cartridge body part or accommodated in the second tubular member of the cartridge body part.

[0025] Embodiment 17: The aerosol delivery system of any preceding or subsequent embodiment, wherein the second aerosol-generating device further comprises a plurality of aerosol-generating elements in the form of beads or pellets comprising at least one aerosol-forming material.

[0026] Embodiment 18: The aerosol delivery system of any preceding or subsequent embodiment, wherein the aerosol-generating element further comprises one or more of particulate tobacco, tobacco extract, and nicotine, wherein the nicotine is in free base form, in salt form, as a complex, or as a solvate.

[0027] Embodiment 19: The aerosol delivery system of any preceding or subsequent embodiment, wherein the aerosol-generating element further comprises one or more fillers, binders, flavorants, and combinations thereof.

[0028] Embodiment 20: The aerosol delivery system of any preceding or subsequent embodiment, wherein the aerosol generating element is aerosolized.

[0029] Embodiment 21: An aerosol delivery system as described in any preceding or subsequent embodiment, wherein the second aerosol generating device is contained within the second tubular member of the cartridge body portion and comprises a plurality of aerosol generating elements in the form of beads or pellets, wherein the plurality of aerosol generating elements are held in place by a first air-permeable separation element disposed within the second tubular member between the first aerosol generating device and the second aerosol generating device and a second separation element disposed between the second aerosol generating device and the mouth-joining end.

[0030] Embodiment 22: The aerosol delivery system of any preceding or subsequent embodiment, wherein the second aerosol generating device is removably coupled to the cartridge body portion and comprises a plurality of aerosol generating elements in the form of beads or pellets, the plurality of aerosol generating elements being held in place by a first air-permeable separation element between the first aerosol generating device and the second aerosol generating device and a second separation element between the second aerosol generating device and the mouth-engaging end.

[0031] Embodiment 23: A method for forming an aerosol delivery system, comprising: removably engaging one end of a first slender tubular member with a first end of a second tubular member, wherein the first slender tubular member is configured as a control body portion and has a power source disposed therein, wherein the second tubular member is configured as a cartridge body portion and has a first aerosol generating device disposed therein, and wherein the first aerosol generating device is configured to operably engage the power source once the one end of the control body portion is engaged with the first end of the cartridge body portion; and inserting a second aerosol generating device into the second tubular member of the cartridge body portion between the first aerosol generating device and the second end of the second tubular member, wherein the second end is opposite to the first end and is configured as an oral engagement end.

[0032] Embodiment 24: The method of any preceding or subsequent embodiment, wherein the step of engaging the second aerosol generating device with the cartridge body portion comprises: inserting the second aerosol generating device into the second tubular member of the cartridge body portion between the first aerosol generating device and the second end of the second tubular member, the second end being opposite to the first end and configured as a mouth engaging end.

[0033] Embodiment 25: The method of any preceding or subsequent embodiment or a combination thereof, wherein inserting the second aerosol generating device into the second tubular member further comprises: inserting at least one aerosol generating element that at least partially forms the second aerosol generating device into the second tubular member, wherein the at least one aerosol generating element is selected from the group consisting of: particles, pellets, beads, discrete small units, carbon sheets, extruded carbon sheets, ceramic beads, Malham tobacco sheets, extruded or compressed cylindrical or spherical elements, ground tobacco thin layers, fillers, flavors, visible aerosol forming materials, adhesives, oval elements, irregularly shaped elements, fragments, flakes, elements comprising tobacco, elements comprising visible aerosol forming materials, adsorbent objects, absorbent objects, capsules, microcapsules, honeycomb monoliths, single porous structures and combinations thereof.

[0034] Embodiment 26: The method of any preceding or subsequent embodiment or a combination thereof, further comprising: inserting a first separation element into the second tubular member between the first aerosol generating device and the second aerosol generating device, the first separation element having one of thermal conductivity and air permeability.

[0035] Embodiment 27: The method of any preceding or subsequent embodiment or a combination thereof, further comprising: inserting a second separation element into the second tubular member between the second aerosol generating device and the mouth-engaging end of the cartridge body portion, the second separation element having one of thermal conductivity and air permeability.

[0036] Embodiment 28: The method of any preceding or subsequent embodiment or a combination thereof, wherein the second aerosol generating device comprises a cartridge having an elongated tubular body and opposing end members, wherein each of the end members has one of thermal conductivity and air permeability, wherein the elongated tubular body is further configured to receive at least one aerosol generating element and cooperate with the opposing end members to contain the at least one aerosol generating element therein, and wherein inserting the second aerosol generating device further comprises: inserting the cartridge into the second tubular member of the cartridge body portion.

[0037] Embodiment 29: A method for forming an aerosol delivery system, the method comprising: engaging one end of a first slender tubular member with a first end of a second tubular member, the first slender tubular member being configured as a control body portion and having a power source disposed therein, and the second tubular member being configured as a cartridge body portion and having a first aerosol generating device disposed therein, the first aerosol generating device being configured to operably engage the power source once the one end of the control body portion is engaged with the first end of the cartridge body portion, the second end of the cartridge body portion facing an oral engaging end of the aerosol delivery system; and engaging the second aerosol generating device with the cartridge body portion so that the second aerosol generating device is disposed between the first aerosol generating device and the oral engaging end of the aerosol delivery system.

[0038] Embodiment 30: The method of any preceding or subsequent embodiment, wherein the second aerosol generating device comprises a plurality of aerosol generating elements in the form of beads or pellets, and the plurality of aerosol generating elements are held in place by a first air-permeable separation element disposed within the second tubular member between the first aerosol generating device and the second aerosol generating device, and a second separation element disposed between the second aerosol generating device and the mouth-joining end.

[0039] Embodiment 31: The method of any preceding or subsequent embodiment, wherein the step of engaging a second aerosol generating device with the cartridge body portion comprises: removably engaging the second aerosol generating device with the cartridge body portion, the second aerosol generating device comprising a first end configured to be removably engaged with the cartridge body portion and a second end adapted to provide the mouth engaging end of the aerosol delivery system, and wherein the second aerosol generating device comprises a plurality of aerosol generating elements in the form of beads or pellets, the plurality of aerosol generating elements being held in place by a first air permeable separation element between the first aerosol generating device and the second aerosol generating device and a second separation element between the second aerosol generating device and the mouth engaging end.

[0040] Embodiment 32: The method of any preceding or subsequent embodiment, wherein the second aerosol-generating device comprises a plurality of aerosol-generating elements in the form of beads or pellets comprising at least one aerosol-forming material.

[0041] Embodiment 33: The method of any preceding or subsequent embodiment, wherein the aerosol-generating element further comprises one or more of particulate tobacco, tobacco extract, and nicotine, wherein the nicotine is in free base form, in salt form, as a complex, or as a solvate.

[0042] Embodiment 34: The method of any preceding or subsequent embodiment, wherein the aerosol-generating element further comprises one or more fillers, binders, flavorants, and combinations thereof.

[0043] Embodiment 35: The method of any preceding or subsequent embodiment, wherein the aerosol-generating element is aerosol-treated.

[0044] These and other features, aspects and advantages of the present invention will become apparent by reading the following detailed description and the accompanying drawings briefly described below. The present invention includes any combination of two, three, four or more of the above aspects and any combination of two, three, four or more of the features or elements set forth in the present invention, regardless of whether these features or elements are explicitly combined in the specific embodiment description herein. The present invention is intended to be interpreted as a whole, so that any separable features or elements of the present invention in any of its various aspects and embodiments should be considered to be intended to be combinable, unless the context clearly stipulates otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Having described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0046] Figure 1schematically illustrates an aerosol delivery device including a cartridge body and a control body according to an example aspect of the invention, the cartridge body being shown in an exploded configuration and the control body being shown in an assembled configuration;

[0047] Figure 2 Schematically shows an example of an embodiment of the present invention in a decomposed structure. Figure 1 The controlling entity;

[0048] Figure 3 Schematically illustrates an additional aerosol generating device including one or more aerosol generating elements according to one aspect of the present invention. Figure 1 The main body of the silo;

[0049] Figure 4 Schematically shows a method according to another aspect of the present invention Figure 3 An additional aerosol generating device configured as a cartridge including one or more aerosol generating elements;

[0050] Figure 5 schematically illustrates an exploded view of an alternative carbon-based silo body according to example aspects of the present invention;

[0051] Fig. 6A Schematically shows an example of an embodiment of the present invention. Figure 5 Assembly view of the carbon-based silo body;

[0052] Figure 6B Schematically showing an assembly view of a carbon-based cartridge body implementing an additional aerosol generating device including one or more aerosol generating elements according to one aspect of the present invention;

[0053] Figure 7 is a cross-sectional view of a second aerosol-generating device housed within the same outer body as the first aerosol-generating device according to an example aspect of the invention; and

[0054] Figure 8 is a cross-sectional view of a second aerosol-generating device removably attached to an outer body housing housing a first aerosol-generating device according to an example aspect of the invention. DETAILED DESCRIPTION

[0055] The present invention will now be more fully described hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the present invention will be thorough and complete and will fully convey the scope of the present invention to those skilled in the art. Indeed, the present invention may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; on the contrary, these embodiments are provided so that the present invention will satisfy applicable legal requirements. Unless the context clearly indicates otherwise, the singular forms "a", "an", "the" used in the specification and the appended claims include plural variations.

[0056] As described below, aspects of the present invention relate to aerosol delivery systems. The aerosol delivery system according to the present invention uses electrical energy to heat a material (preferably without burning the material to any significant extent) to form an inhalable substance; and the components of such a system are in the form of an article that is most preferably compact enough for such a system that is considered a handheld device. That is, the use of the components of the preferred aerosol delivery system does not result in the generation of smoke, that is, an aerosol produced mainly by the byproducts of the combustion or pyrolysis of tobacco, but the use of those preferred systems will result in the generation of steam (including steam within the aerosol, which can be considered as visible / invisible aerosol, which can be considered as smoke-like) due to the volatilization or evaporation of certain components incorporated therein. In a preferred aspect, the components of the aerosol delivery system can be characterized as electronic cigarettes, and those electronic cigarettes most preferably incorporate tobacco and / or components derived from tobacco, and thus deliver tobacco-derived components in the form of aerosol.

[0057] The aerosol-generating parts of certain preferred aerosol delivery systems can provide many of the sensations of smoking a cigarette, cigar, or pipe provided by lighting and burning tobacco (and thus inhaling tobacco smoke) (e.g., the inhalation and exhalation rituals, the type of taste or aroma, the sensory effects, the physical sensations, the ritual of use, the visual cues, such as those provided by a visible aerosol, etc.), without any substantial degree of combustion of any of its components. For example, a user of the aerosol-generating parts of the present invention can hold and use the parts, just as a smoker uses a traditional type of smoking article, draws on one end of the smoking part for inhaling the aerosol generated by the part, or takes or draws at selected time intervals, etc.

[0058] Aerosol delivery system of the present invention can also be characterized as suitable steam generation goods, aerosol generation goods or drug delivery goods.Therefore, this goods, system or equipment can be suitable for providing one or more materials (for example, spices, active pharmaceutical ingredients, peptides, protein fragments and / or protein coating) in inhalable form or state.For example, inhalable material can be the form of steam (that is, the material in gas phase at a temperature lower than its critical point).Alternately, inhalable material can be the form of aerosol (that is, fine solid particles or droplets in gas suspension).For simplicity, term "aerosol" used herein is intended to include steam, gas, aerosol and / or particulate matter in the form or type suitable for human inhalation, whether visible, and whether it is a form that may be considered as a smoky form.

[0059] The aerosol delivery system of the present invention most preferably comprises a power source (i.e., a power source), at least one control component (e.g., a device for actuating, controlling, regulating and / or stopping the supply of power for generating heat by, for example, controlling the current from the electric release unit to other components of the aerosol generating device), a heater or heat generating component (e.g., a resistive heating element and related components commonly referred to as providing an "atomizer"), and an aerosol precursor composition (e.g., a composition that is typically a liquid capable of generating an aerosol when sufficient heat is applied, such as ingredients commonly referred to as "smoke juice", "e-liquid" and "e-juice") and a mouth end region, mouth engagement end or terminal end for allowing suction on the aerosol delivery system for aerosol inhalation (e.g., through a defined air flow path of the aerosol generating device so that the generated aerosol can be inhaled therefrom during suction).

[0060] According to the further disclosure provided below, the more specific form, configuration and arrangement of the components in the aerosol delivery system of the present invention will be apparent. In addition, after considering commercially available electronic aerosol delivery devices (such as those representative products mentioned in the background of the present invention), the selection and arrangement of various aerosol delivery system components can be understood.

[0061] In some aspects, the use of the aerosol delivery device of the present invention can be subjected to many physical actions taken by individuals in using traditional types of smoking articles (e.g., cigarettes, cigars, or pipes used by lighting and inhaling tobacco. For example, a user of the aerosol delivery device of the present invention can hold the article like a traditional type of smoking article, draw on one end of the article to inhale the aerosol generated by the article, draw at selected time intervals or for selected durations, and the like.

[0062] Figure 1 One such example of an aerosol delivery system 100 is shown in FIG. Figure 1A partially exploded view of an aerosol delivery system 100 including a cartridge body 200 and a control body 300 (or referred to herein as a "cartridge body portion" and a "control body portion", respectively) is shown. The cartridge body 200 and the control body 300 may be permanently or removably aligned or removably engaged in a functional relationship. Various mechanisms may be used to connect the cartridge body 200 to the control body 300 to result in threaded engagement, press fit engagement, interference fit, magnetic engagement, and the like. In some embodiments, when the cartridge body 200 and the control body 300 are in an assembled configuration, the aerosol delivery system 100 may be generally rod-shaped, generally tubular in shape, or generally cylindrical in shape. As used herein, "tubular" is intended to represent a hollow, elongated body, but is not limited to a specific cross-sectional shape or a specific outer profile of the body. Those skilled in the art will also understand that in some cases and although not described in detail herein, the cartridge body 200 and the control body 300 forming the aerosol delivery system 100 may be configured as a single piece, non-detachable form, and may incorporate components, aspects, and features associated with the present invention and disclosed in the present invention.

[0063] In some cases, one or both of the cartridge body 200 and the control body 300 can be referred to as disposable (i.e., a single piece, non-detachable form previously disclosed) or reusable. For example, the reusable control body 300 can have a replaceable battery or a rechargeable battery, and can therefore be combined with any type of recharging technology, including connection to a typical AC outlet, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer such as via a universal serial bus (USB) cable. Typically, an aerosol delivery system of the type disclosed herein incorporates a battery or other power source to provide a current sufficient to provide various functions to the product, such as power supply of a heater or heating element, power supply of a control system, power supply of an indicator, etc. The power source can take various embodiments. Preferably, the power source is capable of delivering enough power to quickly heat the heating element to provide aerosol formation and power the product to use the desired duration. The power source is preferably designed to be conveniently assembled in the aerosol delivery device / system so that the aerosol delivery device / system can be easily manipulated; and in addition, the preferred power source has a sufficiently light weight so as not to impair the desired smoking experience. Furthermore, in some cases, cartridge body 200 may comprise a single-use cartridge (ie, disposable), such as disclosed in U.S. Patent Application Publication No. 2014 / 0060555 to Chang et al., the entire contents of which are incorporated herein by reference.

[0064] Figure 21 shows an exploded view of a control body 300 of an aerosol delivery system 100 according to another example. As shown, the control body 300 may include a coupling 302, an outer body 304, a seal 306, an adhesive 308 (e.g., 31 ), a flow sensor 310 (e.g., a suction sensor or a pressure switch), a control component 312, a spacer 314, a power source 316 (e.g., a rechargeable battery), a circuit board with an indicator 318 (e.g., a light emitting diode (LED)), a connector circuit 320, and an end cap 322. Examples of power sources are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the entire disclosure of which is incorporated herein by reference.

[0065] With respect to flow sensor 310, representative current regulating components and other current control components including various microcontrollers, sensors, and switches for use in aerosol delivery devices / systems are described, for example, in U.S. Pat. Nos. 4,735,217 to Gerth et al.; 4,947,874 to Brooks et al.; 5,372,148 to McCafferty et al.; 6,040,560 to Fleischhauer et al.; and 6,041,561 to Nguyen et al. No. 7,040,314 to the United States and No. 8,205,622 to Pan; U.S. Patent Publication No. 2009 / 0230117 to Fernando et al.; U.S. Patent Publication No. 2014 / 0060554 to Collett et al.; and U.S. Patent Publication No. 2014 / 0270727 to Ampolini et al., and U.S. Patent Application Serial No. 14 / 209,191 filed on March 13, 2014 by Henry et al., which are incorporated herein by reference.

[0066] In some cases, the indicator 318 may include one or more light emitting diodes. The indicator 318 may communicate with the control component 312 via the connector circuit 320, and may illuminate during, for example, a user's suction (as detected by the flow sensor 310) process on the cartridge body 200 connected to the coupler 302. The end cap 322 may be adapted to make the illumination provided by the indicator 318 visible thereunder. Therefore, the indicator 318 may illuminate during use of the aerosol delivery system 100 to simulate the ignition end of a smoking article. However, in other cases, the indicator 318 may be provided in different quantities, and may present different shapes, and may even be an opening in the outer body (e.g., for releasing a sound when such an indicator is present). Additional representative types of components that produce visual cues or indicators, such as light emitting diode (LED) components, and their configurations and uses, are described in U.S. Pat. No. 5,154,192 to Sprinkel et al.; U.S. Pat. No. 8,499,766 to Newton and U.S. Pat. No. 8,539,959 to Scatterday; and U.S. patent application serial number 14 / 173,266 filed on February 5, 2014 by Sears et al., which are incorporated herein by reference.

[0067] Other features, controls, or components that may be incorporated into the aerosol delivery devices and systems of the present invention are described in U.S. Pat. Nos. 5,967,148 to Harris et al.; 5,934,289 to Watkins et al.; 5,954,979 to Counts et al.; 6,040,560 to Fleischhauer et al.; 7,726,320 to Robinson et al.; 8,365,742 to Hon; 8,402,976 to Fernando et al. and 8,403,977 to Fernando et al. No. 689,804; U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al.; U.S. Patent Application Publication No. 2013 / 0298905 to Leven et al.; U.S. Patent Application Publication No. 2013 / 0180553 to Kim et al.; U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al.; and U.S. Patent Application Publication No. 2014 / 0261495 to Novak, III et al. and U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al.; the entire contents of which are incorporated herein by reference.

[0068] return Figure 1, the cartridge body 200 is shown in an exploded configuration. As shown, according to an exemplary embodiment of the present invention, the cartridge body 200 may include a base shipping plug 202, a base 204, a control component terminal 206, an electronic control component 208, a flow tube 210, an atomizer 212, a reservoir base 214, an outer body 216, a label 218, a mouthpiece 220, and a mouthpiece shipping plug 222. The base 204 may be coupled to a first end of the outer body 216, and the mouthpiece 220 may be coupled to an opposite second end of the outer body 216 to enclose the remaining components of the cartridge body 200 therein. The base 204 may be configured to removably engage a coupler 302 of a control body 300. In some cases, the base 204 may include an anti-rotation feature that substantially prevents relative rotation between the cartridge body and the control body, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak, III et al., the entire contents of which are incorporated herein by reference. Various representative coupling mechanisms for upstream and downstream components of electronic cigarettes have been described in the patent literature and have been used to produce commercially available electronic cigarettes. For example, representative types of coupling mechanisms and components for electronic cigarettes are described in Novak, III et al. U.S. Patent Application Publication No. 2014 / 0261495 and Bless et al. U.S. Patent Application Serial No. 14 / 170,838 filed on February 3, 2014; which are incorporated herein by reference.

[0069] The base shipping plug 202 can be configured to engage and protect the base 204 prior to use of the cartridge body 200. Similarly, the mouthpiece shipping plug 222 can be configured to engage and protect the mouthpiece 220 prior to use of the cartridge body 200. The control component terminals 206, the electronic control components 208, the flow tube 210, the atomizer 212, and the reservoir base 214 (engaging the aerosol precursor composition or substance) can be retained within the outer body 216. The label 218 can at least partially surround the outer body 216 and include information thereon, such as a product identifier.

[0070] The alignment of the components in one or both of the control body and the cartridge body of the aerosol delivery device / system can be varied. In a specific aspect, the aerosol precursor composition can be located near one end of the entire article (for example, in the cartridge body, it can be replaceable and disposable in some cases), and it can be configured to be relatively closer to the user's mouth, so as to maximize the aerosol delivery to the user. However, other configurations are not excluded. Usually, the heating element can be positioned close enough to the aerosol precursor composition so that the heat from the heating element can volatilize the aerosol precursor (and / or one or more spices, medicaments, etc., which can also be provided for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, the aerosol is formed, released or generated in a physical form suitable for the consumer to inhale. It should be noted that the aforementioned terms are interchangeable, so that the reference to release, release, release or release includes formation or generation, formation or generation, formation or generation, formation or generation, formation or generation. Specifically, inhalable material is released in the form of steam or aerosol or its mixture. Additionally, when considering commercially available electronic aerosol delivery devices, such as those representative products listed above in this disclosure, a variety of aerosol delivery device component options can be appreciated.

[0071] Atomizer (i.e., aerosol generating device) 212 can include a first heating terminal 234a and a second heating terminal 234b, a liquid transport element 238 and a heating element 240. In this regard, the reservoir and / or reservoir substrate 214 can be configured to hold an aerosol precursor composition. The aerosol precursor composition (also referred to as a gas phase precursor composition) can include various components in different aspects. These components can include, for example, any of polyols (e.g., glycerol, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, water, spices, and combinations thereof.

[0072] Aerosol precursor or gas phase precursor composition can change.Most preferably, aerosol precursor composition is composed of a composition or mixture of various ingredients or components.The selection of specific aerosol precursor components and the relative amount of those components used can be changed to control the overall chemical composition of the mainstream aerosol produced by the aerosol generating device.Of particular interest is an aerosol precursor composition that can be characterized as being generally liquid in nature.For example, a typical representative liquid aerosol precursor composition can have a liquid solution, a viscous gel, a mixture of miscible components or the form of a liquid incorporating a suspended or dispersed component.Under those conditions experienced during the aerosol generating device using the features of the present invention, a typical aerosol precursor composition can evaporate when exposed to heat; and therefore can produce steam and aerosol that can be inhaled.

[0073] For the aerosol delivery system characterized as an electronic cigarette, the aerosol precursor composition is most preferably mixed with tobacco or a component derived from tobacco. In one aspect, tobacco can be provided as a part or fragment of tobacco, such as finely ground, milled or powdered tobacco leaves. In another aspect, tobacco can be provided in the form of an extract, such as a spray-dried extract of a water-soluble component of many tobaccos. Alternatively, tobacco extracts can have a relatively high nicotine content extract in the form of extracts, and the extract is also incorporated into a small amount of other extracted components derived from tobacco. In another aspect, components derived from tobacco can be provided in a relatively pure form, such as some flavorings derived from tobacco. In one aspect, the component derived from tobacco and that can be used in a highly purified or substantially pure form is nicotine (such as pharmaceutical grade nicotine).

[0074] As mentioned above, highly purified tobacco-derived nicotine (e.g., purity greater than 98% or greater than 99% pharmaceutical grade nicotine) or its derivatives can be used in the present invention. Representative extracts containing nicotine can be provided using the technology described in U.S. Patent No. 5,159,942 of Brinkley et al., which is incorporated herein by reference. In certain embodiments, the product of the present invention may include nicotine in any form from any source, whether tobacco-derived or synthetically derived. The nicotine compound used in the product of the present invention may include nicotine in free base form, salt form, as a complex or as a solvate. See, for example, nicotine in the free base form discussed in U.S. Patent Publication No. 2004 / 0191322 of Hansson, which is incorporated herein by reference. At least a portion of the nicotine compound can be used in the form of a resin complex of nicotine, wherein nicotine is combined in an ion exchange resin such as a nicotine polysaccharide. See, for example, U.S. Patent No. 3,901,248 of Lichtneckert et al., which is incorporated herein by reference. At least a portion of the nicotine can be used in the form of a salt. The salt of nicotine can be provided using the composition and technology types described in Cox et al., U.S. Patent No. 2,033,909 and Perfetti, Beitrage Tabakforschung Int., 12, 43-54 (1983). In addition, the salt of nicotine can be obtained from sources such as Pfaltz and Bauer (Pfaltz and Bauer, Inc.) and K&K Laboratories, Division of ICN Biochemicals, Inc. Exemplary pharmaceutically acceptable nicotine salts include nicotine salts of tartrate (e.g., nicotine tartrate and nicotine tartrate), chlorides (e.g., nicotine hydrochloride and nicotine dihydrochloride), sulfates, perchlorates, ascorbates, fumarates, citrates, malates, lactates, aspartates, salicylates, tosylates, succinates, pyruvates, etc.; nicotine salt hydrates (e.g., nicotine zinc chloride monohydrate), etc. In certain embodiments, at least a portion of the nicotine compound is in the form of a salt formed with an organic acid moiety, including but not limited to levulinic acid, as discussed in U.S. Patent Publication No. 2011 / 0268809 to Brinkley et al., which is incorporated herein by reference.

[0075] Aerosol precursor compositions can also be mixed with so-called "aerosol forming materials". In some cases, under those conditions experienced during the normal use of the aerosol generating device that is a feature of the present invention, when exposed to heat and evaporated, these materials can have the ability to produce visible (or invisible) aerosols. Such aerosol forming materials include various polyols or polyols (such as glycerol, propylene glycol and mixtures thereof). Aspects of the present invention also incorporate aerosol precursor components that can be characterized as water, saline, moisture or aqueous liquids. During the conditional process of normal use of certain aerosol generating devices, the water mixed in those aerosol generating devices can evaporate to produce the components of the generated aerosol. Therefore, for the purposes of the present invention, the water present in the aerosol precursor composition can be considered as an aerosol forming material.

[0076] Can use a variety of optional flavorings or materials, it changes the organoleptic characteristics or the property of the mainstream aerosol of the suction generated by the aerosol delivery system of the present invention.For example, can use this optional flavoring in aerosol precursor composition or material to change the smell, fragrance and the organoleptic properties of aerosol.Some flavorings can be provided from sources other than tobacco.Exemplary flavorings can be natural or artificial in nature, and can be used as concentrates or flavor packaging.

[0077] Exemplary flavoring agents include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach and citrus flavors, including lime and lemon), maple, menthol, mint, mint leaves, spearmint, wintergreen, nutmeg, cloves, lavender, cardamom, ginger, honey, fennel, sage, cinnamon, sandalwood, jasmine, cascaria, cocoa, licorice and flavoring agents and flavoring packages traditionally used for the flavoring of cigarettes, cigars and pipes and features. Syrups, such as high fructose corn syrup, can also be used. Some flavoring agents can be incorporated into the aerosol forming material before preparing the final aerosol precursor mixture (e.g., some water-soluble flavoring agents can be incorporated into water, menthol can be incorporated into propylene glycol, and some complicated flavoring packages can be incorporated into propylene glycol). However, in some aspects of the present invention, the aerosol precursor composition does not contain any spices, flavoring features or additives.

[0078] Aerosol precursor compositions can also include components (such as organic acids, ammonium salts or organic amines) showing acidic or alkaline characteristics. For example, some organic acids (such as levulinic acid, succinic acid, lactic acid and pyruvic acid) can be included in the aerosol precursor preparations mixed with nicotine, preferably with an amount up to equimolar (based on total organic acid content) with nicotine. For example, aerosol precursors can include levulinic acid of about 0.1 to about 0.5 moles per 1 mole of nicotine, succinic acid of about 0.1 to about 0.5 moles per mole of nicotine, lactic acid of about 0.1 to about 0.5 moles per mole of nicotine, pyruvic acid of about 0.1 to about 0.5 moles per 1 mole of nicotine or its various arrangements and combinations thereof, until the total amount of the organic acid present is reached and the total amount of the nicotine present in the aerosol precursor is equimolar. However, in some aspects of the present invention, aerosol precursor compositions do not contain any acidic (or alkaline) characteristics or additives.

[0079] As a non-limiting example, a representative aerosol precursor composition or material may include glycerol, propylene glycol, water, saline and nicotine, and any or all of those components or mixtures. For example, in one case, a representative aerosol precursor composition may include (based on weight) about 70% to about 100% glycerol, typically about 80% to about 90% glycerol; about 5% to about 25% water, typically about 10% to about 20% water; and about 0.1% to about 5% nicotine, typically about 2% to about 3% nicotine. In a specific non-limiting example, a representative aerosol precursor composition may include about 84% glycerol, about 14% water and about 2% nicotine. A representative aerosol precursor composition may also include propylene glycol, optional flavorings or other additives based on different amounts of weight. In some cases, as needed or desired, an aerosol precursor composition may include any of up to about 100% by weight glycerol, water and saline.

[0080] Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Patent No. 7,217,320 to Robinson et al. and U.S. Patent Publication No. 2013 / 0008457 to Zheng et al.; U.S. Patent Publication No. 2013 / 0213417 to Chong et al. and U.S. Patent Publication No. 2014 / 0060554 to Collett et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include those that have been incorporated into RJ Reynolds Vapor Company's Products, BLU manufactured by Lorillard Technologies TMAerosol precursors of the products of ANTIQUE, the products of Mistic Ecigs, and the products of VYPE of CN Creative Ltd. Also advantageous are the so-called "tobacco juices" for electronic cigarettes that have been obtained from Johnson Creek Enterprises LLC.

[0081] The amount of the aerosol precursors incorporated into the aerosol delivery system makes the aerosol generating device provide acceptable sensations and desired performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol forming materials (such as glycerol and / or propylene glycol) are used to provide the generation of mainstream aerosol (visible or invisible), which is similar to the occurrence of tobacco smoke in many respects. The amount of the aerosol precursor composition in the aerosol generating device can depend on factors such as the number of puffs required for each aerosol generating device. Typically, the amount of the aerosol precursor composition incorporated into the aerosol delivery system, particularly the aerosol generating device, is less than about 2g, typically less than about 1.5g, typically less than about 1g, and typically less than about 0.5g.

[0082] The reservoir substrate 214 may include multiple layers of nonwoven fabric formed into the shape of a tube surrounding the interior of the outer body 216 of the cartridge body 200. Thus, for example, a liquid component may be adsorbed and held by the reservoir substrate 214. The reservoir substrate 214 is fluidly connected to the liquid transport element 238. The liquid transport element 238 may be configured to transport the liquid (i.e., the aerosol precursor composition) from the reservoir substrate 214 to the heating element 240 by capillary action. Representative types of substrates, reservoirs, or other components for supporting aerosol precursor compositions are described in U.S. Patent No. 8,528,569 to Newton; U.S. Patent Application Publication No. 2014 / 0261487 to Chapman et al. and U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al.; and U.S. Application Serial No. 14 / 170,838 filed by Bless et al. on February 3, 2014; which is incorporated herein by reference. Additionally, various wicking materials, as well as the construction and operation of those wicking materials within certain types of electronic cigarettes, are described in U.S. Patent Application Publication No. 2014 / 0209105 to Sears et al.; which is incorporated herein by reference.

[0083] As shown, the liquid transport element 238 can be in direct contact with the heating element 240. Figure 1As shown, the heating element 240 can include a wire defining a plurality of coils wound around the liquid transport element 238. In some cases, the heating element 240 can be formed by winding a wire around the liquid transport element 238, as described in U.S. Patent Application Publication No. 2014 / 0157583 to Ward et al., the entire contents of which are incorporated herein by reference. In addition, in some cases, the wire can define a variable coil spacing, as described in U.S. Patent Application Publication No. 2004 / 0270730 to DePiano et al., the entire contents of which are incorporated herein by reference. Various materials configured to generate heat when an electric current is applied thereto can be used to form the heating element 240. Example materials from which the coils can be formed include Kanthal (FeCrAl), Nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)2), graphite and graphite-based materials; and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0084] However, various other methods may be used to form the heating element 240, and various other aspects of the heating element may be used in the atomizer 212. For example, a stamped heating element may be used in the atomizer, as described in U.S. Patent Application Publication No. 2014 / 0270729 to DePiano et al., the entire contents of which are incorporated herein by reference. In addition to the above, additional representative heating elements and materials used therein are described in U.S. Patent Nos. 5,060,671 to Counts et al.; 5,093,894 to Deevi et al.; 5,224,498 to Deevi et al.; 5,228,460 to Sprinkel Jr. et al.; 5,322,075 to Deevi et al.; 5,353,813 to Deevi et al.; 5,464,671 to Deevi et al. No. 8,936 to Das; No. 5,498,850 to Das; No. 5,659,656 to Das; No. 5,498,855 to Deevi et al.; No. 5,530,225 to Hajaligol; No. 5,665,262 to Hajaligol; No. 5,573,692 to Das et al.; and No. 5,591,368 to Fleischhauer et al., the entire disclosures of which are incorporated herein by reference. In addition, chemical heating may be employed in other aspects. In certain aspects of the aerosol delivery device / system of the present invention, various heater components may also be used. In various cases, one or more microheaters or similar solid-state heating elements may be used. Exemplary microheaters that may be used are further described herein. Additional microheaters and atomizers suitable for incorporation in the microheater of the disclosed apparatus / system are described in U.S. Patent Application No. 2014 / 0060554 to Collett et al., the entire contents of which are incorporated herein by reference.

[0085] The first heating terminal 234a and the second heating terminal 234b (e.g., a positive terminal and a negative terminal) at opposite ends of the heating element 240 are configured to form an electrical connection (which may be a removable or detachable connection) with the control body 300 when the silo body 200 is connected thereto. In addition, when the control body 300 is coupled to the silo body 200, the electronic control component 208 may form an electrical connection with the control body 300 through the control component terminal 206. Thus, the control body 300 may employ the electronic control component 208 to determine whether the silo 200 is authentic and / or perform other functions. In addition, various examples of electronic control components and the functions performed thereby are described in U.S. Patent Application Publication No. 2004 / 0096781 to Sears et al., the entire contents of which are incorporated herein by reference.

[0086] During use, the user can draw on the mouthpiece or mouth-engaging end 220 of the cartridge body 200 of the aerosol delivery system 100. This can pull air through the opening in the control body 300 and / or cartridge body 200. For example, in one example, an opening can be defined between the coupler 302 and the outer body 304 of the control body 300, as described in U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al., the entire contents of which are incorporated herein by reference. However, in other aspects, the air flow can be received by other parts of the aerosol delivery device / system 100. As described above, in some aspects, the cartridge body 200 can include a flow tube 210. The flow tube 210 can be configured to direct the air flow received from the control body 300 to the heating element 240 of the atomizer 212.

[0087] A sensor in the aerosol delivery device / system 100 (e.g., a puff sensor or flow sensor in the control body 300) can sense the puff. More generally, when aerosol generation is desired (e.g., when inhaling during use), the sensor or detector can be implemented to control the supply of power to the heating element 240. Thus, for example, a mode or method is provided for turning off the power source to the heating element 240 when aerosol generation is not desired during use, and for turning on the power source during inhalation to initiate or trigger the generation of heat by means of the heating element 240. Other representative types of sensing or detection mechanisms, their structures and configurations, their components and their general methods of operation are described in U.S. Pat. No. 5,261,424 to Sprinkel, Jr.; U.S. Pat. No. 5,372,148 to McCafferty et al.; and PCT WO2010 / 003480 to Flick; which are incorporated herein by reference. When a puff is sensed, the control body 300 can direct current to the heating element 240 through a circuit including a first heating terminal 234a and a second heating terminal 234b. Thus, the heating element 240 can vaporize the aerosol precursor composition directed from the reservoir base 214 to the aerosolization region through the liquid transport element 238. Thus, the mouthpiece 220 can allow air and entrained vapor to pass (i.e., components of the aerosol precursor composition in an inhalable form, such as as an aerosol) from the cartridge body 200 to the consumer who draws on it. Various other details about the components that may be included in the cartridge body 200 are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to Novak, III et al., the entire contents of which are incorporated herein by reference.

[0088] The various components of the aerosol delivery device / system can be selected from those described in the art and commercially available. For example, refer to the storage and heater system for controllably delivering a variety of aerosolizable materials in an electronic smoking article disclosed in U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., the entire contents of which are incorporated herein by reference. Figure 1 The portions of the silo body 200 shown in FIG. 2 are optional. In this regard, as an example, in some cases, the silo body 200 may not necessarily include the flow tube 210, the control component terminal 206, and / or the electronic control component 208.

[0089] For example, in Figure 3 A particular aspect of the present invention is shown in . In this case, the cartridge body 200 may also incorporate a second aerosol generating device 400 (the atomizer 212 is considered to be a "first aerosol generating device") disposed in the outer body 216, longitudinally located between the atomizer 212 and the mouthpiece or mouthpiece engagement end 220 of the cartridge body 200. In some aspects, the second aerosol generating device 400 is typically porous or otherwise configured to allow air to pass therethrough. In some specific cases, the second aerosol generating device 400 may include one or more aerosol generating elements 425, which may include at least one or more pellets or beads or other suitable elements or combinations thereof. In some cases, at least one or more pellets or beads or other suitable elements or combinations thereof forming the aerosol generating element 425 may be coaxially surrounded by a generally tubular heat conductive member (not shown), as necessary, and / or surrounded or otherwise jacketed by an insulating member (e.g., a non-woven mat or glass filament or fiber layer) or other suitable material (not shown).

[0090] The overall structure of the second aerosol generating device 400 in the cartridge body 200 of the aerosol delivery device / system 100 can be considered to be substantially cylindrical in nature. Representative preferred beads or other articles can be produced by formulas that incorporate tobacco (e.g., granular tobacco), components of tobacco, and / or materials otherwise derived from tobacco (e.g., tobacco extracts, such as aqueous tobacco extracts or nicotine derived from tobacco, including pharmaceutical grade nicotine). Beads are most preferably incorporated with flavorings and visible or invisible aerosol-forming materials (e.g., glycerol or other materials that produce visible vapors similar to smoke). That is, the components of beads are preferably configured to be used as volatile flavorings, vapor-forming materials, moisture or other liquids and / or the base components of the aerosol-forming materials carried thereon. In some aspects, the aerosol generating element 425 may include or otherwise contain or be configured as, for example, eroded tobacco beads of different shapes and sizes; a monolith of bonded (e.g., sintered) beads; a porous monolith; a single porous structure; a honeycomb monolith; a monolithic porous material; extruded tobacco beads; beads of porous material containing tobacco extracts (e.g., calcium carbonate, ceramic, etc.); regenerated tobacco shreds; expanded tobacco; extruded rods (including hollow cylinders and slotted rods) of various materials containing tobacco flavors; shavings, particles, capsules and / or microcapsules of various materials containing tobacco flavors or other substances, whether in liquid or other form; and treatments or combinations thereof.

[0091] Generally, as used herein, the terms "pellets" and "beads" are intended to include beads, pellets or other discrete small units or pieces, which may include (in addition to those disclosed herein) such as carbon sheets, extruded carbon sheets cut into pellets, ceramic beads, marumarized tobacco sheets, etc., or combinations thereof. For example, particles, pellets or beads may be generally cylindrical or spherical extruded or compressed particles, pellets or beads, formed, cut or rotated into a desired size and shape, and then dried to maintain a desired configuration of ground tobacco leaves, fillers (e.g., granular calcium carbonate), spices, visible aerosol-forming materials and adhesives (e.g., carboxymethyl cellulose) Wet mixture or slurry composition. However, such "pellets" or "beads" may include any suitable element or combination of elements that meet the preferred aspects disclosed herein. For example, some or all beads or pellets can include thermosensitive spherical capsules so that when included in an aerosol generating element and exposed to heat, they rupture or decompose to cause the release of glycerol, propylene glycol, water, saline, tobacco flavors and / or nicotine or other substances or additives. In addition, beads can include ceramics or absorptive clays or silica or absorptive carbon to maintain and release aerosol formations. In addition, in some aspects, beads / pellets can include thermally conductive materials, such as thermally conductive graphite, thermally conductive ceramics, metals, tobacco, metals cast on foil or other suitable materials impregnated with suitable aerosol generating substances (such as glycerol and flavors), or suitable casting sheets to form required beads / pellets.

[0092] In one particular example, the beads / pellets (granules) can comprise, by weight, about 15% to about 60% finely ground tobacco particles (e.g., a mixture of Oriental tobacco, Burley tobacco, and Flue-cured tobacco, substantially all Oriental tobacco, substantially all Burley tobacco, or substantially all Flue-cured tobacco), about 15% to about 60% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 10% to about 50% glycerin (and optionally small amounts of flavoring agents), about 0.25% to about 15% binder (preferably carboxymethyl cellulose, guar gum, potassium, or ammonium alginate), and about 15% to about 50% water. In another example, the beads / particles (particles) may comprise about 30% finely ground tobacco particles (e.g., a mixture of oriental tobacco, burley tobacco and flue-cured tobacco, substantially all oriental tobacco, substantially all burley tobacco or substantially all flue-cured tobacco), about 30% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 15% glycerol (and optionally a small amount of spices), about 1% binder (preferably carboxymethyl cellulose, guar gum, potassium or ammonium alginate) and about 25% water. In such an example, the particles may be compressed to hold glycerol, and a porous matrix may be formed upon compression that promotes the migration of aerosol-generating components to promote effective aerosol formation. The manner in which the aerosol-forming material contacts the substrate material may vary. The aerosol-forming material may be applied to a forming material, may be incorporated into a processed material during the manufacture of these materials, or may be an endogenous material of the material. For example, an aerosol-forming material of glycerol may be dissolved or dispersed in an aqueous liquid or other suitable solvent or liquid carrier and sprayed onto the substrate material. See, for example, U.S. Patent Application Publication No. 2005 / 0066986 to Nestor et al. and U.S. Patent Application Publication No. 2012 / 0067360 to Conner et al.; which are incorporated herein by reference. Calcium carbonate or other inorganic fillers help create pores within the particles and can also serve to absorb heat, which in some cases can limit or prevent charring of the aerosol-generating components, as well as help and promote aerosol formation. See also, for example, U.S. Patent No. 5,105,831 to Banerjee et al., U.S. Patent Application Publication No. 2004 / 0173229 to Crooks et al., U.S. Patent Application Publication No. 2011 / 0271971 to Conner et al., and U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al.; which are incorporated herein by reference.

[0093] In one embodiment, the aerosol generating element 425 (e.g., an aerosol generating element in the form of beads or pellets) can be treated with smoke to impart a smoky flavor or aroma. For example, beads or pellets can be prepared and then subjected to smoke from a combustible source such as a wood source (e.g., selected from hickory, maple, oak, pecan, cherry, or legume). The beads or pellets can be treated with smoke for a sufficient time to impart the desired smoky flavor or aroma, and an exemplary time range is about 5 to about 45 minutes. The manner in which the beads or pellets are contacted with smoke can vary, and one example involves heating wood chips in a container until smoke is generated (e.g., heating the wood chips to a temperature of about 350-400°F), and treating the beads or pellets with smoke generated by the wood chips in a closed environment.

[0094] The composition of the aerosol precursor composition of the first aerosol generating device and the composition of the aerosol generating element of the second aerosol generating device are advantageously selected to complement each other to produce a desired sensory experience. In some embodiments, for example, the nicotine content of the aerosol precursor composition and the aerosol generating element is selected so that either or both of the aerosol precursor composition and the aerosol generating element may contain nicotine or a nicotine compound, or may be considered to be substantially or completely free of nicotine or a nicotine compound. In other words, all of the nicotine content may be within the aerosol generating element, or all of the nicotine content may be in the aerosol precursor composition, or both compositions may include some form of nicotine.

[0095] In some aspects, the aerosol generating element 425 includes beads or pellets cast or extruded from the above-mentioned various types of materials (i.e., graphite beads including tobacco extract and glycerin), which can be rolled, for example, between adjacent roller elements while "wet" or before drying, to flatten the shape of the corresponding beads / pellets. In some cases, the above-mentioned various types of materials can be extruded in the form of filamentary strands, wherein the strands can be gathered to form cylindrical rods or other materials of suitable shapes (i.e., in size relative to the beads / pellets used to form the aerosol generating section in other ways) to be applied to the second aerosol generating device 400. Then, when drying, the flat beads / pellets can be chopped or otherwise processed to form, for example, strands, flakes or other filler structures, which are flat or include planar segments that inhibit or prevent rolling. Any random structure produced by the pulverizing process may be sufficient. In this case, the flattened and shredded beads / particles may then be included in the aerosol-generating element 425, and their irregular or random configuration may promote, for example, a plurality of interstitial air spaces throughout the aerosol-generating element 425, where the interstitial air spaces may in turn promote heat transfer with various objects within the aerosol-generating element 425. That is, the heating of the air in the interstitial spaces within the second aerosol-generating device 400 may expose more of the aerosol-generating element 425 to the heat from the heating element 240, and thereby result in enhanced or otherwise improved heating of the aerosol-generating element 425. In other cases, heat and the first aerosol (i.e., a combination thereof) generated by the heating element 240 / atomizer 212 are directed through a porous matrix formed by the aerosol generating element 425, wherein the heated steam passes through and heats the porous aerosol-generating element 425 to promote, for example, elution of an enhancing substance (i.e., a flavor or other additive) from the aerosol generating element to the first aerosol (i.e., liquid, fluid or particle extraction; steam distillation; etc.), or otherwise promote the enhancing substance to be entrained, imparted, reacted or otherwise interacted with the first aerosol. The interaction between the enhancing substance and the first aerosol can, for example, change or alter the first aerosol, mix the enhancing substance with the first aerosol to form an enhanced aerosol or aerosol mixture, or promote a reaction that produces a different aerosol. In this case, the increased interstitial space within the aerosol generating element 425 can promote this interaction process through the second aerosol generating device 400.

[0096] In some respects, bead / pellet can be derived from tobacco material cast on foil / paper laminate.More specifically, tobacco material can comprise the slurry that for example comprises reconstituted tobacco, glycerine and adhesive material.This tobacco material is disclosed in for example U.S. Patent No. 5,101,839 of Jakob et al. and U.S. Patent Application No. 2010 / 0186757 of Crooks et al., which is incorporated herein by reference.In addition, slurry can be mixed with particulate inorganic material (i.e. calcium carbonate).Slurry is cast on the paper element of foil laminate, for example, in U.S. Patent No. 8,678,013 of Crooks et al. and U.S. Patent No. 7,647,932 of Cantrell et al., which is also incorporated herein by reference, then for example, by applying heat (i.e., by heated air, microwave drying etc.) dry assembled casting sheet product.Paper element can have for example specific porosity or texture, to promote for example close contact and interaction with slurry when directly contacting between slurry and foil. However, the exemplary aspects proposed herein do not exclude that tobacco material (that is, slurry) is directly cast on metal foil or other suitable thin film heat conductors. Once such laminated sheet is cast, dry casting sheet (that is, foil / paper / tobacco material) can be shredded, cut or otherwise separated into a plurality of casting sheet partial elements, wherein each such element preferably includes a part of paper element that closely interacts with tobacco material (that is, substrate), and the paper element then closely contacts with a part of the foil element of foil-paper laminate. A plurality of casting sheet partial elements can then be included in the aerosol generating element 425 forming the second aerosol generating device 400.

[0097] Those skilled in the art will appreciate that, in some cases, the casting sheet partial elements included in the aerosol generating element 425 can cooperate to promote improved heat transfer to tobacco materials, form a part of these casting sheet partial elements, or otherwise abut these elements. More specifically, in some cases, the heat transfer from the heating element 240 to the tobacco material included in the aerosol generating element 425 can be limited to any direct interface therebetween, wherein the heat conducting belt forms an additional mechanism for conducting heat from the heating element 240, for heating the external elements included in the aerosol generating element 425 and any aerosol generating element in contact therewith. In the aspect of including the casting sheet partial elements included in the aerosol generating element 425, the heat conducting portion of the foil element associated with the casting sheet partial element can form, for example, a plurality of additional heat conducting paths. That is, the casting sheet partial elements used as all or part of the aerosol generating element 425 can provide additional heat conducting elements dispersed in the entire aerosol generating element 425 in the second aerosol generating device 400, so as to enhance or otherwise improve the heat transfer to the aerosol generating element and between the aerosol generating element. In achieving such aspects, it may be further advantageous to comminute or process a base material achieved in, for example, a cast tobacco sheet base material that forms a base for incorporation into a cigarette type commercially sold under the trade name "Eclipse" by RJ Reynolds Tobacco Company, as disclosed in U.S. Pat. No. 5,469,871 to Barnes et al.

[0098] The pellets or other elements may have a smooth, regular outer shape (e.g., a sphere, a cylinder, an oval, etc.) and / or they may have an irregular outer shape (e.g., a fragment, a flake, etc.). The aerosol generating element 425 may have a generally cylindrical form within the second aerosol generating device 400, either discretely or cumulatively, and may in some cases include a collection of about 800 to about 1200 generally spherical beads, each bead having a diameter of about 0.05 mm to about 4 mm (e.g., in one example, a volume of about 1 mm). 3 ) has an average or nominal diameter of about 450 mg to about 750 mg (eg, in one example, 600 mg ± 25%).

[0099] In one method of preparation, substantially spherical beads or pellets of the aerosol generating element may be formed by first mixing the desired composition together, followed by extrusion of the composition to form an extrudate. The extrudate is then processed in a spheronizer (e.g., a spheronizer available from Caleva Process Solutions Ltd. or LCI Corporation) to produce spheroids of various sizes, which may be processed through a series of screens to provide the desired size range, such as the sizes described above.

[0100] The aerosol-generating elements may be selected to have a relatively uniform average diameter, or a range of sizes of aerosol-generating elements may be included in the second aerosol-generating device 400. Where different size ranges are used in the same device, the differently sized elements may be arranged in one or more gradients or layers within the second aerosol-generating device 400, or the differently sized elements may be randomly mixed within the aerosol-generating device 400. While not being bound by any particular theory of operation, the use of differently sized aerosol-generating elements in the same aerosol-generating device 400 may provide advantageous pressure drop variations within the device and / or provide advantageous sensory properties based on the different evaporation rates provided by the differently sized elements.

[0101] Preferably, sufficient beads are loaded into the second aerosol generating device 400 to provide at least about 95% maximum filling with beads and / or other suitable elements. Advantageously, large open pockets are avoided within the aerosol generating device 400 that may allow air passing through the aerosol generating device to substantially bypass interaction with the aerosol generating element 425.

[0102] In some cases, multiple forms of the aerosol-generating element 425 may be selected (e.g., aerosol-generating elements having different compositions), and each selected form of the aerosol-generating element is subsequently included in the second aerosol-generating device 400. In other cases, the selected forms of the aerosol-generating element may be combined prior to inclusion in the second aerosol-generating device 400 to produce an aerosol-generating element mixture, which is then subsequently included in the second aerosol-generating device 400.

[0103] The atomizer or the first aerosol generating device 212 and the second aerosol generating device 400 can be physically separated from each other and / or contain discrete units or sections within the cartridge body 200. In some cases, as shown in the figure, those sections can be positioned / set so that the downstream end of the atomizer or the first aerosol generating device 212 (toward the mouthpiece or mouth engagement end 220 of the cartridge body 200) is adjacent to the upstream end (i.e., back to the aerosol generating element 425) of the second aerosol generating segment 400. That is, the atomizer or the first aerosol generating device 212 and the second aerosol generating segment 400 can be axially aligned in a series end-to-end relationship, in some cases adjacent to or abutting each other. For example, in some cases, although physically separated and located downstream of the atomizer or the first aerosol generating device 212, it may be desirable that the aerosol generating element 425 of the second aerosol generating device 400 physically contacts the heating element 240 at the downstream end of the atomizer or the first aerosol generating device 212. Alternatively, the segments 212, 400 may be slightly spaced apart from one another so that their respective ends or parts 240, 425 do not have to physically contact one another (i.e., to prevent scorching). Those skilled in the art will appreciate that in some aspects, the second aerosol generating device 400 may include more than one segment or portion of the aerosol generating element 425.

[0104] In some cases, it acts as a spacer or screen (see e.g. Figure 3The additional segment, spacing element or separation element (also referred to herein as "first separation element") of the element 450 in the cartridge body 200 may be positioned substantially perpendicular to the longitudinal axis of the cartridge body 200, wherein the first separation element 450 may provide a physical separation of the two segments 212, 400 while maintaining a thermally conductive relationship between them in some cases. In some cases, the first separation element 450 may not conduct heat, and in other cases, the first separation element 450 may be non-conductive. That is, the first separation element 450 may, but need not be, thermally conductive and / or arranged to conduct heat from the heating element 240 of the atomizer / first aerosol generating device 212 to the second aerosol generating device 400, wherein the aerosol generating element 425 may respond to the heat and / or the accompanying first aerosol to form a second aerosol. In addition, in some cases, the first separation element 450 may be breathable or otherwise configured to allow airflow therethrough, so that the first aerosol generated by the atomizer / first aerosol generating device 400 can pass therethrough in a downstream direction. The first separation element 450 can therefore also be configured and / or arranged to retain the aerosol-generating element 425 within the second aerosol-generating device 400 and separate from the atomizer / first aerosol-generating device 212. In a further example, the first separation element 450 can be configured as a spacer (i.e., extending along the longitudinal direction of the cartridge body 200 so as to define a thickness) for separating the aerosol-generating element 425 from the heating element 240 of the atomizer / first aerosol-generating device 212, for example, to minimize or prevent the aerosol-generating element (i.e., bead) 425 from being scorched or burned by the heat from the heating element 240. In some cases, the first separation element 450 can also be configured as an insulator (i.e., non-conductive) to prevent the heating element 240 from short-circuiting in the event of contact between them.

[0105] Typically, the first separation element 450 is generally cylindrical or disc-shaped, and has an integral structure, and is breathable, to allow air to be drawn through. The first separation element 450 can be heat-conductive in nature, so that the heat generated by the heating element 240 can be easily transmitted to the second aerosol generating device 400. The length (thickness) of the first separation element 450 can vary, and typically extends from about less than 1mm until about 10mm. In some cases, the first separation element 450 is arranged longitudinally in the outer body 216 relative to the first separation element 450 and the interface of the aerosol generating element 425 is spaced apart at a distance of about 1mm from the heating element 240 and up to about 20mm (that is, 7mm in one example). Typically, the first separation element 450 is made of heat-resistant materials, such as porous ceramics, porous graphite materials, metal (that is, stainless steel, brass, copper, etc.) nets or wire meshes, high temperature resistant plastics, etc. In some cases, the first separation element 450 may include, for example, a longitudinally extending air passage formed during design / manufacturing, drilled through it or otherwise molded, extruded, printed (i.e., a 3D printed element using a 3D printer) or formed as a spacer element during its manufacturing process. If desired, the first separation element 450 may incorporate a catalytic material, such as a material incorporating an oxide and / or salt of cerium ions or copper ions or cerium ions and copper ions. See, for example, U.S. Patents Nos. 8,469,035 and 8,617,263 to Banerjee et al., and U.S. Patent Application Publication No. 2007 / 0215168 to Banerjee et al., which are incorporated herein by reference.

[0106] In the case where the aerosol generating element 425 can be surrounded by an insulating layer, a thermally conductive material layer (e.g., a layer or strip of metal foil) (not shown) can be provided therebetween. That is, the representative aerosol generating element 425 includes a plurality of particles and / or other suitable elements, which can be surrounded by a layer of metal foil strips along its length. A representative metal foil is, for example, an aluminum foil having a thickness of about 0.01 mm to about 0.05 mm. Preferably, the metal foil extends along the entire length of the outer coaxial surface of the aerosol generating element 425; and it may be preferred that the metal foil extends (i.e., at least partially overlaps) on the first separation element 450. The thermally conductive material can be provided by means other than using a metal foil. For example, the metal foil layer can be replaced by a metal mesh or a screen. Alternatively, the metal foil can be replaced by a thermally conductive fabric, such as a layer or sheet of graphite fiber or thermally conductive ceramic fiber. Alternatively, the thermally conductive material can be provided by applying a thermally conductive ink, such as an ink or coating coating incorporating metal particles, graphite fibers, thermally conductive ceramic material particles, etc.

[0107] Figure 7An example of another embodiment of a second aerosol generating device 400 located within an outer body or tubular member 216 (downstream of the first aerosol generating device 212, not shown) is provided. As shown, the aerosol generating element 425 is placed between the separation elements 450 and 475, which are used to hold the aerosol generating element 425 in place and allow airflow to pass through. As previously described, the separation elements 450 and 475 can be porous elements (e.g., a mesh or perforated metal plate) whose pore size is selected to hold the aerosol generating element 425 within the second aerosol generating device 400.

[0108] As shown, the second aerosol generating device 400 may also include a separate aerosol generating element housing 460 in the form of a tubular housing, for example, with an open end facing the mouthpiece 220, as shown, the mouthpiece 220 can engage the open end of the tubular housing, and can be fixed to the open end of the tubular housing by press-fit or other known means. The housing 460 may include an end 470 opposite to the mouthpiece 220, as shown, the end may be perforated to allow airflow to pass. The housing 460 may be configured by any suitable material including metal (e.g., stainless steel) or plastic. Separation elements 450 and 475 may be press-fitted or otherwise engaged with the housing 460, and if desired, the separation element 475 closest to the mouthpiece 220 may be fixed to the mouthpiece. In certain embodiments, separation elements 450 and 475 are incorporated into the housing 460 during the molding process of forming the housing. Figure 7 The design is particularly suitable for embodiments of the present invention where the second aerosol generating device 400 is permanently fixed to the rest of the cartridge body 200 rather than being separately removable or disposable.

[0109] Alternatively, in embodiments where the second aerosol generating device 400 is adapted to be removed from the cartridge body 200 as a separate unit, Figure 8 The design is advantageous. As shown in the figure, Figure 8 In the embodiment of the present invention, the second aerosol generating device 400 is formed as a separate unit having a separate housing 520, which is attached (e.g., by crimping or other means) to the first connector 540. The housing 520 and the first connector 540 together form a cavity for the aerosol generating element 425. Figure 7 In the embodiment of FIG. 4 , the aerosol generating element 425 is placed between the separation elements 450 and 475 , which are used to hold the aerosol generating element 425 in place and allow airflow to pass through. Figure 7 In the embodiment of the present invention, the separation elements 450 and 475 can be press-fitted or otherwise engaged with the surrounding portions of the first connector 540 or the housing body 520, respectively, and can be integrated into these surrounding portions during the molding process. The downstream separation element 475 is also optionally fixed to the mouthpiece 220.

[0110] The first connector 540 of the second aerosol generating device 400 is adapted to engage with a second connector 560, which is fixed (e.g., by press fit or other means) to the outer body or tubular member 216 (not shown) that houses the first aerosol generating device 212. The second connector 560 has an end facing the first connector 540, which enables a user to removably secure the second aerosol generating device 400 to the cartridge body 200, for example, by threaded engagement or other connection means. As shown, the second connector 560 is porous to allow airflow from the first aerosol generating device 212 to enter the second aerosol generating device 400. The second aerosol generating device 400 of the embodiment is similar to Figure 7 The mouthpiece 220 is cooperatively engaged with the mouthpiece 220 in a manner.

[0111] In some aspects, the spacer or screen (see e.g. Figure 3 Another spacing element or another dividing element (also referred to herein as a "second dividing element") of the element 475 in the cartridge body 200 can be positioned substantially perpendicular to the longitudinal axis of the cartridge body 200, wherein the second separating element 475 can provide a physical separation of the second aerosol generating device 400 from the mouthpiece or mouthpiece engaging end 220 of the cartridge body 200. That is, the second separating element 475 can, but is not necessarily, be thermally conductive and / or arranged to conduct heat from the second aerosol generating device 400 and through the mouthpiece or mouthpiece engaging end 220 of the cartridge body 200. However, the second separating element 475 can be air permeable or otherwise configured to allow airflow therethrough, so that the first aerosol generated by the atomizer / first aerosol generating device 212 and / or the second aerosol generated by the second aerosol generating device 400 can pass therethrough in a downstream direction and through the mouthpiece or mouthpiece engaging end 220. Thus, the second separating element 475 may also be configured and / or arranged to retain the aerosol-generating element 425 within the second aerosol-generating device 400 without losing any aerosol-generating element through the mouthpiece or mouth engaging end 220 of the cartridge body 200 .

[0112] In some aspects, in addition to the aerosol-generating element 425, in an alternative embodiment of implementing discrete first and second separation elements 450 and 475, the second aerosol-generating device 400 may include a cartridge 500 (see, e.g., Figure 4), the cartridge 500 has an elongated tubular body 525 and opposing end members 550, 575, wherein each of the end members 550, 575 can be thermally conductive and / or gas permeable in a manner similar to the first separation element 450 and the second separation element 475. Thus, the elongated tubular body 525 can be further configured to receive the aerosol generating element 425 and cooperate with the opposing end members 550, 575 to accommodate the aerosol generating element 425 therein. The assembled cartridge 500 can therefore be configured to be received as a unit by the outer body or tubular member 216 of the cartridge body 200 (forming the second aerosol generating device 400).

[0113] In use, the mouthpiece or mouth joint end 220 of the cartridge body 200 of the aerosol delivery system 100 is inserted into the user's mouth. Then, for example, the atomizer / first aerosol generating device 212 is actuated by the user sucking (e.g., suction) on the mouthpiece or mouth joint end 220 of the cartridge body 200. The heating element 240 and the liquid transport element 238 are configured to be in a heat exchange relationship. That is, the heat generated by the heating element 240 is used to heat the aerosol precursor composition carried by the liquid transport element 238 to produce the first aerosol. Then, the heat generated by the heating element 240 and the first aerosol are sucked into the second aerosol generating device 400 (i.e., through the aerosol generating element 425) toward the suction hole defined by the mouthpiece or mouth joint end 220. In some cases, the heat from the heating element 240 can interact with the aerosol generating element 425 to generate the second aerosol. The second aerosol can interact or mix with the first aerosol to form a third aerosol, and the third aerosol is an aerosol delivered to the user through the mouthpiece 220 in response to the user's suction thereof. In some cases, the interaction between heat and / or the first aerosol and the aerosol generating element 425 can cause the enhancing material to be given to the first aerosol so as to produce an enhanced aerosol. For example, the drug adsorbed on the aerosol generating element 425 can react with the first aerosol and / or heat, or desorb from the aerosol generating element 425 by the first aerosol and / or heat, and combine with the first aerosol to form an enhanced aerosol. In other cases, the aerosol generating element 425 can be configured so that the interaction of the first aerosol with it causes heat to be drawn away from the first aerosol (i.e., cooling the first aerosol). When properly implemented by the user, at least the first aerosol generated by the atomizer 212 and affected by the aerosol of the second aerosol generating device 400 is generated and inhaled into the user's mouth.

[0114] The components of the second aerosol generating device 400 and / or the aerosol generating element 425 therein can vary. In general, the second aerosol generating device 400 and / or the aerosol generating element 425 therein can be incorporated with components that can be vaporized, atomized, or entrained by the air drawn through the aerosol delivery system 100 during use. Most preferably, those components themselves or in cooperation with the first aerosol generated by the first aerosol generating device 212 provide sensory and sensory effects, such as fragrance, smell, mouthfeel, visible aerosol sensation, etc. Examples of components of the first aerosol generating device 212 and / or the second aerosol generating device 400 that are inhaled into the user's mouth during the inhalation process include water (e.g., as water vapor), visible or invisible aerosol-forming materials (e.g., glycerol), various volatile flavors (e.g., vanillin and menthol), volatile components of tobacco (e.g., nicotine), etc.

[0115] Preferred aerosol-forming materials produce aerosol (whether visible or not) when applying enough heat thereto, or produce aerosol by the effect of aerosol-forming conditions using the components of an aerosol delivery system. Preferred aerosol-forming materials produce visible aerosols that can be considered as "smoky". Relative to the chemical properties of the smoke produced by burning tobacco, preferred aerosol-forming materials are chemically simple. Preferred visible aerosol-forming materials are polyols, and exemplary preferred aerosol-forming materials include glycerol, propylene glycol, and mixtures thereof. If desired, aerosol-forming materials can be combined with other liquid materials such as water. For example, aerosol-forming material preparations can be incorporated with a mixture of glycerol and water, or a mixture of propylene glycol and water. See, for example, various aerosol-forming materials mentioned in U.S. Patent No. 8,678,013 of Crooks et al., which are incorporated herein by reference.

[0116] The aerosol-forming materials are carried or supported by the substrate material so as to maintain those aerosol materials within the desired area of ​​the smoking article. Exemplary substrate materials and exemplary formulations incorporating aerosol-forming materials are described in U.S. Pat. No. 4,793,365 to Sensabaugh et al.; U.S. Pat. No. 4,893,639 to White; U.S. Pat. No. 5,099,861 to Clearman et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; U.S. Pat. No. 5,105,836 to Gentry et al.; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,203,355 to Clearman et al.; Arzonico et al. No. 5,271,419 to Lekwauwa et al.; No. 5,327,917 to Lekwauwa et al.; No. 5,396,911 to Casey, III et al.; No. 5,533,530 to Young et al.; No. 5,588,446 to Clearman; No. 5,598,868 to Jakob et al.; and No. 5,715,844 to Young et al.; and U.S. Patent Application Publication No. 2005 / 0066986 to Nestor et al.; which are incorporated herein by reference. See also Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988). Exemplary substrate materials have been incorporated into cigarette types commercially sold by RJ Reynolds Tobacco Company under the trade names "Premier" and "Eclipse".

[0117] In some cases, reference Figure 1 The described aerosol delivery system can be used in a manner substantially similar to commercially available electronic cigarettes. As a result, when smoking, the preferred aerosol delivery system 100 of the type disclosed herein can produce a visible mainstream aerosol of volatile components mainly from the first aerosol generating device 212 and the second aerosol generating device 400, and the visible aerosol is similar in many respects to the mainstream tobacco smoke of a conventional cigarette that burns tobacco cut filler.

[0118] In another example, substantially the entire silo body 200 can be made of one or more carbon materials (see, for example, Figure 5), which can provide advantages over other cartridge body configurations disclosed herein in terms of biodegradability and wirelessness. In this regard, the heating element can include carbon foam, the reservoir can include carbonized fabric, and graphite can be used to form electrical connections to the battery and controller. Examples of carbon-based cartridge bodies are provided in U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al. or U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., the entire contents of which are incorporated herein by reference. In some cases, the combination of the second aerosol generating device disclosed herein can also be applied to such a carbon-based cartridge body. For example, Fig. 6A and 6B As shown, a portion 625 of the cartridge element 600 disposed toward the mouthpiece of the cartridge body (see, for example, Fig. 6A ) may be configured or otherwise changed (see e.g. Figure 6B ) to receive one or more aerosol-generating elements 425 of the type disclosed herein. In the alternative, a preassembled cartridge including such an aerosol-generating element 425 may be implemented, or the cartridge element 600 and / or the outer body housing the cartridge element 600 may be configured to receive a first separate element and a second separate element having an aerosol-generating element therebetween, as otherwise disclosed herein.

[0119] Benefiting from the teachings presented in the foregoing description and the associated drawings, those skilled in the art will appreciate many modifications and other aspects of the disclosure set forth herein. For example, it will be appreciated by those skilled in the art that embodiments not explicitly shown herein may be practiced within the scope of the present invention, and that the features described herein for different embodiments may be combined with each other and / or with currently known or future developed technologies while remaining within the scope of the claims set forth herein. Therefore, it should be understood that the present invention is not limited to the specific aspects disclosed, and equivalents, modifications and other aspects are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used only in a general and descriptive sense, and not for the purpose of limitation.

Claims

1. An aerosol delivery system comprising: a control body portion including a power source disposed therein; a cartridge body portion removably engageable with the control body portion, the cartridge body portion further comprising a first aerosol generating device disposed therein, and the first aerosol generating device operably engageable with the power source, the first aerosol generating device comprising a liquid aerosol precursor composition and having a heat generating component; as well as a second aerosol-generating device removably engageable with the cartridge body portion such that the first aerosol-generating device is upstream of the second aerosol-generating device; The second aerosol generating device is different from the first aerosol generating device and comprises a tubular housing, a mouthpiece engaged with an end of the tubular housing, a first separating element, a second separating element and at least one aerosol generating element between the first separating element and the second separating element, the first separating element being porous and press-fitted or otherwise engaged with the tubular housing at an end of the tubular housing opposite the mouthpiece, the second separating element being fixed to the mouthpiece, the first separating element, the second separating element and the at least one aerosol generating element being disposed within the tubular housing; wherein the first and second aerosol generating devices are arranged so that a fluid drawn into the system flows sequentially through the first aerosol generating device and the second aerosol generating device; as well as Wherein the first aerosol generating device comprises a heating element configured to provide heat to generate a first aerosol, and the at least one aerosol generating element is arranged to interact with the heat and the first aerosol drawn therethrough to generate a second aerosol. 2 . The aerosol delivery system of claim 1 , wherein the at least one aerosol-generating element is in the form of particles.

3. An aerosol delivery system according to claim 1, wherein the at least one aerosol-generating element is in the form of discrete small units. 4 . The aerosol delivery system of claim 1 , wherein the at least one aerosol-generating element is in the form of a pellet, a bead, or a carbon sheet.

5. The aerosol delivery system of claim 1, wherein the at least one aerosol-generating element comprises one or more of an extruded carbon sheet, a ceramic bead, a Malhaminated tobacco sheet, an extruded or compressed cylindrical or spherical element, and a ground tobacco lamina. 6 . The aerosol delivery system of claim 1 , wherein the at least one aerosol-generating element comprises one or more of a filler, a flavorant, a visible aerosol-forming material, and a binder.

7. The aerosol delivery system of claim 1, wherein the at least one aerosol-generating element is in the form of an oval-shaped element, an irregularly shaped element, a fragment, or a flake.

8. The aerosol delivery system of claim 1, wherein the at least one aerosol-generating element comprises one or more of an adsorptive object and an absorbent object.

9. The aerosol delivery system of claim 1, wherein the at least one aerosol-generating element comprises one or more of capsules, microcapsules, honeycomb monoliths, and single porous structures.

10. The aerosol delivery system of claim 1, wherein the first aerosol generating device comprises a liquid reservoir configured to receive an aerosol precursor substance for use by the first aerosol generating device to generate a first aerosol.

11. The aerosol delivery system of claim 10, wherein the aerosol precursor substance is fragrance-free or acid-free.

12. The aerosol delivery system of claim 10, wherein the aerosol precursor substance is one of glycerin, propylene glycol, water, saline, nicotine, and combinations thereof.

13. An aerosol delivery system according to claim 1, wherein the first aerosol generating device comprises a heating element configured to provide heat to generate a first aerosol, the delivery system being configured such that the heat and the first aerosol are drawn into engagement with and through the second aerosol generating device.

14. An aerosol delivery system according to claim 1, wherein the at least one aerosol-generating element of the second aerosol-generating device is configured to interact with one of the heat from the heating element of the first aerosol-generating device and the first aerosol generated by the first aerosol-generating device to produce a second aerosol. 15 . The aerosol delivery system of claim 1 , wherein the first aerosol generated by the first aerosol generating device is configured to interact with the second aerosol generated by the second aerosol generating device to form a third aerosol. 16 . The aerosol delivery system of claim 1 , wherein the at least one aerosol-generating element of the second aerosol-generating device is configured to interact with the first aerosol generated by the first aerosol-generating device and impart a enhancing substance to the first aerosol to produce an enhanced aerosol.

17. An aerosol delivery system according to claim 1, wherein the at least one aerosol-generating element of the second aerosol-generating device is configured to interact with and remove heat from the first aerosol generated by the first aerosol-generating device drawn therethrough to produce a cooled aerosol.

18. An aerosol delivery system according to any one of claims 1 to 17, wherein the aerosol-generating element further comprises nicotine, wherein the nicotine is in free base form, in salt form, as a complex or as a solvate.

19. An aerosol delivery system according to any one of claims 1 to 17, wherein the aerosol-generating element is aerosol treated.

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