Aerosol delivery device with segmented electric heater

Abstract

The present disclosure provides an aerosol delivery device. In various embodiments, an aerosol delivery device includes a control body having an outer housing; an electrical energy source located within the housing; a control component operably connected to the electrical energy source; a heating assembly operably connected to the control component; and an aerosol source member, the aerosol source member comprising an aerosol-generating component, the aerosol-generating component positioned proximate the heating assembly. The heating assembly includes a series of heating members, and each heating member is separate and distinct and is configured to heat a portion of the aerosol source member.

Description

[0001] This invention patent application is a divisional application of the invention patent application with international application number PCT / IB2019 / 057092, international application date August 22, 2019, application number 201980070216.6 entering the Chinese national phase, and name “Aerosol delivery device with segmented electric heater”. Technical Field

[0002] The present disclosure relates to aerosol delivery products and their use in producing tobacco components or other inhalable forms of materials. The products can be made of tobacco or derived from tobacco, or otherwise incorporated with tobacco for human consumption. More specifically, the present invention provides an aerosol delivery device in which tobacco, tobacco-derived materials or other materials are heated (preferably without significant combustion) to provide an inhalable substance, which, in various embodiments, is in the form of a vapor or aerosol. The present disclosure also relates to an aerosol delivery device comprising a reservoir and a vaporization assembly, which can utilize electricity to heat an aerosol precursor composition to generate an aerosol. Background Art

[0003] In recent years, many smoking articles have been proposed as improvements or alternatives to smoking products based on burning tobacco. Exemplary alternatives have included devices in which solid or liquid fuels are burned to transfer heat to the tobacco, or in which a chemical reaction is used to provide this heat source. Examples include the smoking article described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0004] The purpose of the improvement or alternative of smoking article is usually to provide the sensation related to cigarette, cigar or pipe smoking, without transmitting a large amount of incomplete combustion and pyrolysis products. For this reason, it has been proposed to adopt electric energy to evaporate or heat volatile materials or to attempt to provide the sensation of smoking cigarette, cigar or pipe without burning tobacco to a significant degree many cigarette products, flavor generators and medicated inhalers. For example, referring to the various alternative smoking articles, aerosol delivery devices and heat sources described in the background technology described in the U.S. Patent No. 7,726,320 and the U.S. Patent Application Publication No. 2013 / 0255702 of Griffith Jr. et al. and the U.S. Patent Application Publication No. 2014 / 0096781 of Sears et al., the above-mentioned documents are incorporated herein by reference in their entirety. For example, also referring to the various types of smoking articles, aerosol delivery devices and electric heat sources with reference to trademark names and commercial sources in the U.S. Patent Application Publication No. 2015 / 0220232 of Bless et al., the full text of which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically powered heat sources are listed by reference to trade names and commercial sources in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is also incorporated herein by reference in its entirety.Other representative cigarettes or smoking articles that have been described and, in some cases, are commercially available include those described in: U.S. Patent Nos. 4,735,217 to Gerth et al.; 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; 5,060,671 to Counts et al.; 5,249,586 to Morgan et al.; and 5,249,587 to Counts et al. No. 5,388,594 to Higgins et al.; No. 5,666,977 to Higgins et al.; No. 6,053,176 to Adams et al.; No. 6,164,287 to White; No. 6,196,218 to Voges; No. 6,810,883 to Fleter et al.; No. 6,854,461 to Nichols; No. 7 to Hon ,832,410; U.S. Patent No. 7,513,253 to Kobayashi; U.S. Patent No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Application Publication No. 2009 / 0095311 to Hon; U.S. Patent Application Publication Nos. 2006 / 0196518, 2009 / 0126745, and 2009 / 0188490 to Hon; U.S. Patent No. 2009 / 0188490 to Thorens et al. U.S. Patent Application Publication No. 2009 / 0272379 to Monsees et al.; U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al.; U.S. Patent Application Publication Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; and WO 2010 / 091593 to Hon, the entirety of each of which is incorporated herein by reference.

[0005] Representative products that have many attributes similar to traditional types of cigarettes, cigars, or pipes are marketed under the following brand names: ALPHA sold by InnoVapor LLC TM 、JOYE 510 TM and M4 TM CIRRUS, sold by White Cloud Cigarettes TM and FLING TM; BLU sold by Fontem Ventures TM ;Depend on International Co., Ltd. COHITA sold by International Inc. TM 、COLIBRI TM ELITECLASSIC TM 、MAGNUM TM PHANTOM TM and SENSE TM DUOPRO sold by Electronic Cigarettes, Inc. TM 、STORM TM and EGAR sold by Egar Australia TM ; eGo-C sold by Joyetech TM and eGo-T TM ; ELUSION sold by Elusion UK Ltd TM ; Sold by Eonsmoke LLC FINTM sold by FIN Branding Group, LLC; FINTM sold by Green Smoke Inc. USA GREENARETTE sold by Greenarette LLC TM ; by SMOKE ) Sold by HALLIGAN TM 、HENDU TM 、JET TM 、MAXXQ TM PINK TM and PITBULL TM HEATBAR sold by Philip Morris International, Inc. TM HYDRO IMPERIAL sold by Crown7 TM LOGIC sold by LOGIC Technology TM and THE CUBAN TM; sold by Luciano Smokes Inc. Sold by Nicotek, LLC Sold by Sottera, Inc. and ONEJOY TM ; NO.7 sold by SS Choice LLC TM PREMIUM ELECTRONICCIGARETTE sold by PremiumEstore LLC TM ; RAPP E-MYSTICK sold by Ruyan America, Inc. TM RED DRAGON sold by Red Dragon Products, LLC TM Sold by Ruyan Group (Holdings) Ltd. Sold by Smoker Friendly International, LLC GREEN SMART sold by The Smart Smoking Electronic Cigarette Company Ltd. Smoked Smoked Smoked Smoked Smoked Smoked Smoked Smoked Smoked Smoked Smoked SMOKING sold by Smoking Everywhere, Inc. V2CIGS sold by VMR Products LLC TM ; VAPOR NINE sold by VaporNine LLC TM ; sold by Vapor4Life, Inc. VEPPO sold by E-CigaretteDirect, LLC TM Provided by RJReynolds Vapor Mistic Menthol, sold by Mistic Ecigs; Vype products, sold by CN Creative Ltd.; and IQOS, sold by Philip Morris International. TM and GLO sold by British American Tobacco TM Other powered aerosol delivery devices, particularly those that have become known as so-called electronic cigarettes, have been marketed under the following trade names: COOLERVISIONS TM ;DIRECT E-CIG TM ;DRAGONFLY TM ;EMIST TM ;EVERSMOKE TM ; HYBRIDFLAME TM ;KNIGHT STICKS TM ROYAL BLUES TM ; and South Beach Smoke TM .

[0006] Articles that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, and / or liquids suffer from inconsistent performance characteristics. It would therefore be desirable to provide a smoking article that can provide the sensation of smoking a cigarette, cigar, or pipe, and do so with advantageous performance characteristics. Summary of the Invention

[0007] In various embodiments, the present disclosure provides an aerosol delivery device.The present disclosure includes, but is not limited to, the following exemplary embodiments.

[0008] Exemplary embodiment 1: An aerosol delivery device comprising: a control body having an outer shell; an electrical energy source located within the shell; a control component operably connected to the electrical energy source; a heating assembly operably connected to the control component; and an aerosol source component comprising an aerosol generating component configured to be positioned near the heating assembly, wherein the heating assembly comprises a series of heating components, and wherein each heating component is independent and different and is configured to heat a portion of the aerosol source component.

[0009] Exemplary embodiment 2: An aerosol delivery device as described in any of the foregoing exemplary embodiments or any combination of any of the foregoing exemplary embodiments, wherein the heating assembly includes a movable clamp and a fixed clamp, wherein the heating member is located on the movable clamp, and wherein the movable clamp is configured to move between an open position and a closed position, in which the movable clamp is spaced apart from the fixed clamp and the heating member is not in contact with the aerosol source member, and in the closed position, a series of heating members of the movable clamp are in contact with the aerosol source member.

[0010] Exemplary embodiment 3: The aerosol delivery device as described in any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, further comprising a receiving sleeve configured to receive the aerosol source member, and wherein, in the closed position, the receiving sleeve is located between the movable clamp and the fixed clamp.

[0011] Exemplary embodiment 4: An aerosol delivery device as described in any of the foregoing exemplary embodiments or any combination of any of the foregoing exemplary embodiments, wherein the series of heating members includes a series of heating pins that are configured to pass through the aerosol source member in a closed position and form an electrical connection with a series of corresponding connectors located on a fixed fixture.

[0012] Exemplary embodiment 5: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the heating pin has a substantially cylindrical shape.

[0013] Exemplary embodiment 6: An aerosol delivery device as described in any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the series of heating components includes a separate heating element that is configured to extend into the aerosol source component in the closed position.

[0014] Exemplary Embodiment 7: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the heating element has a substantially blade-like shape.

[0015] Exemplary embodiment 8: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the movable clamp is configured to be automatically movable.

[0016] Exemplary embodiment 9: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the movable clamp is configured to be manually movable.

[0017] Exemplary embodiment 10: An aerosol delivery device as described in any of the foregoing exemplary embodiments or any combination of any of the foregoing exemplary embodiments, wherein the series of heating members comprises a series of separate heating elements, wherein the heating assembly comprises two or more movable clamps, wherein one or more of the heating members are located on each movable clamp, and wherein the movable clamps are configured to move between an open position and a closed position, in which the movable clamps are spaced apart from each other and the heating members are not in contact with the aerosol source member, and in the closed position, the series of heating elements of the corresponding movable clamps are in contact with the aerosol source member.

[0018] Exemplary embodiment 11: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the heating assembly comprises three movable clamps, and wherein the heating element of each movable clamp has a staggered configuration relative to another movable clamp.

[0019] Exemplary Embodiment 12: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the heating element is configured to extend into the aerosol source member in the closed position.

[0020] Exemplary Embodiment 13: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the movable clamp is configured to be automatically movable.

[0021] Exemplary Embodiment 14: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the movable clamp is configured to be manually movable.

[0022] Exemplary Embodiment 15: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the heating assembly comprises a series of fixed heating elements positioned proximate the aerosol source member.

[0023] Exemplary Embodiment 16: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the aerosol source member comprises a removable cartridge and the aerosol-generating component comprises tobacco or a tobacco-derived material.

[0024] Exemplary embodiment 17: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the aerosol source member comprises a removable cartridge and the aerosol-generating component comprises a liquid aerosol precursor composition.

[0025] Exemplary Embodiment 18: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the cartridge defines a series of nebulizer chambers, and wherein a separate wick extends through each nebulizer chamber.

[0026] Exemplary Embodiment 19: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein each of the fixed heating elements is configured to be positioned adjacent a corresponding atomizer chamber.

[0027] Exemplary Embodiment 20: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiments, wherein the heating members are configured to be independently controllable.

[0028] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description and the accompanying drawings, which are briefly described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] To assist in understanding the various embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein like reference numerals refer to like elements and are not necessarily drawn to scale. The accompanying drawings are for illustration only and should not be construed as limiting the present disclosure.

[0030] Figure 1 shows a perspective schematic diagram of an aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0031] Figure 2 shows a front schematic view of an aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0032] Figure 3 shows a perspective view of certain components of a heating assembly of an aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0033] Figure 4 A perspective view showing certain components of a heating assembly of an aerosol delivery device and an aerosol source member of the aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0034] Figure 5 shows a perspective view of components of a heating assembly of an aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0035] Figure 6 shows top and perspective views of certain components of a heating assembly of an aerosol delivery device in an open position according to an exemplary embodiment of the present disclosure;

[0036] Figure 7shows a bottom view of certain components of a heating assembly of an aerosol source member shown in an open position and a closed position according to an exemplary embodiment of the present disclosure;

[0037] Figure 8 shows a perspective view of an aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0038] Figure 9 shows an exploded perspective view of an aerosol delivery device according to an exemplary embodiment of the present disclosure;

[0039] Figure 10 shows a perspective view of an aerosol source member according to an exemplary embodiment of the present disclosure;

[0040] Figure 11 shows an exploded perspective view of an aerosol source component according to an exemplary embodiment of the present disclosure; and

[0041] Figure 12 A perspective view of a cartridge of an aerosol source member according to an exemplary embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0042] The present disclosure will now be described more fully below. However, the present disclosure can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those skilled in the art. It must be noted that as used in this specification, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0043] The present disclosure provides a product that uses electric energy to heat material (preferably without burning the material to any significant extent) to form an inhalable substance, and such products are compact enough to be considered as a "handheld" device. In certain embodiments, such products can be specifically characterized as smoking products. As used herein, the term is intended to represent following products: it provides the taste and / or sensation (such as feel or mouthfeel) of a cigarette or cigar or pipe without any component of the actual burning product. The term smoking product does not necessarily represent that in operation, the product produces smoke from the meaning of the by-products of combustion or pyrolysis. On the contrary, smoking is related to the body movements of individuals when using the product, such as holding the product in their hands, inhaling on one end of the product, and inhaling from the product. In a further embodiment, the product of the present invention can be characterized as steam generation product, aerosolized product, or drug delivery product. Therefore, such products can be arranged to provide one or more substances in an inhalable state. In some embodiments, inhalable substance can be in the form of vapor (that is, a substance in a gas phase at a temperature below its critical point). In other embodiments, the inhalable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). The physical form of the inhalable substance is not necessarily limited by the properties of the article of the present invention, but may depend on the properties of the medium and whether the inhalable substance itself exists in a vapor state or an aerosol state. In some embodiments, the terms "vapor" and "aerosol" are interchangeable. Therefore, for simplicity, unless otherwise indicated, the terms "vapor" and "aerosol" used to describe the present disclosure should be understood to be interchangeable.

[0044] While the system is generally described herein in terms of embodiments associated with an aerosol delivery device, such as a so-called "electronic cigarette" or "tobacco heating product," it will be understood that the mechanisms, components, features, and methods may be implemented in many different forms and associated with a variety of different articles. For example, the description provided herein may be used in conjunction with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and related packaging for any of the products disclosed herein. Accordingly, it will be understood that the mechanisms, components, features, and methods disclosed herein are discussed merely by way of example in terms of embodiments associated with an aerosol delivery device and may be implemented and used in a variety of other products and methods.

[0045] Aerosol delivery device of the present disclosure can also be characterized as steam generation goods or medicament delivery goods.Therefore, this goods or device can be modified, thereby one or more substances (for example, flavoring and / or pharmaceutical active ingredient) are provided in a form or state that can be inhaled.For example, inhalable substance can be the form of steam (that is, the material in gas phase at a temperature lower than critical point).Alternatively, inhalable substance can be the form of aerosol (that is, fine solid particles or droplet suspension in gas).For the purpose of simplification, term " aerosol " used herein is intended to include steam, gas or aerosol of the form or type that is suitable for human body inhalation, no matter whether visible, also no matter whether can be considered as smoke-like form.

[0046] In use, the aerosol delivery device of the present disclosure can be subjected to many of the physical actions that an individual employs when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe for lighting and inhaling tobacco). For example, a user of the aerosol delivery device of the present disclosure can hold the article as they would hold a traditional type of smoking article, inhale on one end of the article to inhale the aerosol generated by the article, and inhale at selected time intervals, etc.

[0047] The aerosol delivery devices of the present disclosure generally include a plurality of components disposed within a housing or body. The overall design of the housing or outer body may vary, and the form or configuration of the outer body, which may define the overall size and shape of the aerosol delivery device, may vary. In some examples, an elongated body having a shape resembling a cigarette or cigar may be formed from a single shell; or the elongated body may be formed from two or more separable pieces. For example, the aerosol delivery device may include an elongated housing or body that may be generally tubular in shape and thereby resemble the shape of a conventional cigarette or cigar. Various other shapes and configurations (e.g., rectangular or keychain-shaped) may also be employed in other embodiments.

[0048] In one embodiment, all components of the aerosol delivery device are contained within an outer body or shell. Alternatively, the aerosol delivery device can include two or more shells that are connected and separable. For example, the aerosol delivery device can have a control body that includes a shell that houses one or more reusable components (e.g., a rechargeable battery and various electronic components for controlling the operation of the article), and the aerosol delivery device can be removably attached to a disposable portion (e.g., a disposable cartridge or aerosol source member containing an aerosol precursor material, a fragrance, etc.).

[0049] In general, the aerosol delivery devices of the present disclosure may generally include some combination of the following components: an electrical energy source (i.e., a power source); at least one control component (e.g., a device for actuating, controlling, regulating, and / or stopping electrical power, the electrical power being used to generate heat, such as by controlling the flow of current from the electrical energy source to the various components of the aerosol delivery device, such as a microprocessor, either alone or as part of a microcontroller); a heating member or heat-generating component (e.g., a conductive resistive heating member or an inductive heating member); and an aerosol source member comprising an aerosol-generating component, which may be positioned adjacent to or in direct contact with the heating member. When the heating member heats the aerosol-generating component, an inhalable substance is formed from, released from, or generated from the aerosol-generating component in a physical form suitable for inhalation by a consumer. It should be noted that the aforementioned terms are intended to be interchangeable, such that references to releasing, will release, will release, or after releasing include forming or generating, will form or will generate, will form or will generate, and after forming or generating. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof. It should be noted that the aforementioned terms are intended to be interchangeable, such that references to releasing, will release, will release, or after releasing include forming or generating, will form or will generate, will form or will generate, and after forming or generating. Specifically, the inhalable substance is released in the form of a vapor, or an aerosol, or a mixture of vapor and aerosol, wherein, unless otherwise indicated, these terms are also used interchangeably herein.

[0050] As described above, the aerosol delivery device may include an electrical energy source (e.g., a battery and / or other power source, such as a capacitor) to provide sufficient current to provide various functions to the aerosol delivery device, such as powering the heating member, powering the control system, powering the indicator, etc. The power source can take various embodiments. Preferably, the power source is capable of delivering sufficient power to quickly heat the heating member, thereby providing aerosol formation and powering the aerosol delivery device within the desired duration. The power source is preferably sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. In addition, the preferred power source is light enough so as not to detract from the desired smoking experience.

[0051] Based on the further disclosure provided herein, more specific forms, constructions and arrangements of components within a single-shell type unit or a multi-piece detachable shell type unit of the aerosol delivery device of the present disclosure will be apparent. In addition, the selection of various aerosol delivery device components can be understood in view of commercially available electronic aerosol delivery devices. Further, the arrangement of components within the aerosol delivery device can also be understood in view of commercially available electronic aerosol delivery devices. Examples of commercially available products that can be included in the devices of the present disclosure, their components, their operating methods, the materials included therein and / or their other properties, as well as manufacturers, designers and / or assignees of components and related technologies that can be employed in the aerosol delivery devices of the present disclosure are described in U.S. patent application serial number 15 / 222,615 filed by Watson et al. on July 28, 2016, the entirety of which is incorporated herein by reference.

[0052] Although the devices according to the present disclosure may take a variety of embodiments as discussed in detail below, the use of the devices by the consumer will be similar in scope. Specifically, the device may be provided as a plurality of components that are combined together by the consumer for use and then subsequently disassembled by the consumer. Specifically, the consumer may have a reusable control body that is substantially cylindrical, substantially rectangular, substantially cuboid, or another shape having an opening in a portion of the control body housing. In some embodiments, the housing may also include one or more indicators (e.g., one or more indicator lights, a mark displayed on an electronic display, tactile feedback, some combination thereof, etc.) that indicate that the device is actively in use. In some embodiments, one or more aerosol source components may fit or be accommodated in the opening of the control body. To use the article, the consumer may insert the aerosol source component into the opening, or otherwise combine the aerosol source component with the control body so that the device can operate as described herein. In some embodiments, the aerosol source component may be inserted into the control body as far as the overall structure of the component and / or other internal receiving features allow. In some examples, at least a portion of the aerosol source member, sized at least large enough to be inserted into a consumer's mouth for drawing a puff thereon, remains outside the control body. This may be referred to as the mouth end of the aerosol source member. In other examples, a portion of the aerosol delivery device itself may be sized at least large enough to be inserted into a consumer's mouth. This may be referred to as the mouth end of the aerosol delivery device.

[0053] During use, the consumer activates the heating of the heating element adjacent to the aerosol generating component (or a specific portion thereof) of the aerosol source member, and the heating of the component releases the inhalable substance in the space inside the housing and / or the aerosol source member, thereby producing the inhalable substance. When the consumer inhales at the mouth end of the aerosol source member or the mouth end of the aerosol delivery device, air is inhaled and / or drawn through the aerosol source member (e.g., through an opening in the aerosol delivery device and / or the aerosol source member itself). When the aspirated material leaves the mouth end of the aerosol source member or the mouth end of the aerosol delivery device and enters the consumer's mouth, the mixture of the aspirated air and the released inhalable substance is inhaled by the consumer. In some embodiments, to start heating, the consumer can manually actuate a button or similar component that causes the heating member to receive electrical energy from a battery or other power source. The electrical energy can be supplied for a predetermined length of time or can be manually controlled. Preferably, the flow of electrical energy is substantially non-existent between puffs on the device (although energy flow may continue to maintain a baseline temperature greater than ambient temperature, e.g., to facilitate rapid heating to an effective heating temperature). In other embodiments, heating may be initiated by the consumer's puffing action using various sensors, as described elsewhere herein. Once puffing ceases, heating may cease or decrease. When the consumer has taken a sufficient number of puffs to release a sufficient amount of inhalable material (e.g., an amount sufficient to equate to a typical smoking experience), the aerosol source component may be removed from the control body and discarded.

[0054] Figure 1 1 shows a perspective view of an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. Specifically, Figure 1 An aerosol delivery device 100 comprising a housing 102 and an aerosol source component 104 is depicted. Figure 2 A front view of the aerosol delivery device 100 is shown, wherein a portion of the housing 102 has been removed to expose some of its internal components. In particular, the aerosol delivery device 100 of the depicted embodiment also includes an electrical energy source 106 (e.g., a battery, which can be rechargeable, and / or a rechargeable supercapacitor), a control component 108 (e.g., a microprocessor, either alone or as part of a microcontroller, a printed circuit board (PCB) including a microprocessor and / or microcontroller, etc.), and a heating assembly 110. As will be discussed in more detail below, the heating assembly 110 of various embodiments includes a series of independent and distinct heating components, wherein each heating component is configured to heat a portion of the aerosol source component 104.

[0055] In various embodiments, one or both of the control component 108 and the electrical energy source 106 can be coupled to the housing 102. For the purposes of this application, when the phrase "coupled to" is used with respect to one component relative to another, the phrase can encompass embodiments in which one component is located within the other component and / or embodiments in which one component is separate but otherwise operably connected to the other component. For example, in the illustrated embodiment, both the control component 108 and the electrical energy source 106 are located within the housing 102; however, in other embodiments, one or both of the control component 108 and the electrical energy source 106 can be separate components. Further information regarding the control component 108 and the electrical energy source 106 is provided below.

[0056] In some embodiments, the housing 102 may further include one or more buttons configured to activate certain operations of the device 100, such as, for example, turning on the device and initiating heating of the heating assembly 110 (e.g., one or more heating members of the heating assembly). As will be discussed in more detail below, in various embodiments, the aerosol source assembly 104 may include a heating end and a mouth end, the heating end being configured to be inserted into the housing 102 and the user inhaling on the mouth end to generate the aerosol. It should be noted that although the heating end is referred to as the mouth end for ease of description, the aerosol source assembly 104 may be configured to generate an aerosol. Figure 1 The aerosol delivery device 100 is shown as having a generally rectangular or keychain-shaped housing 102, but in other embodiments, the housing 102 may have any other shape, including an elongated housing or body, which may be substantially tubular in shape and thus resemble the shape of a conventional cigarette or cigar, and accordingly, the components described below are sized and configured to fit within the elongated body.

[0057] In particular embodiments, one or both of the housing 102 and the aerosol source member 104 may be referred to as disposable or reusable. For example, the electrical energy source 106 may include a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, and the like, and thus be combined with any type of charging technology, including connection to a wall charger, connection to a car charger (e.g., a cigarette lighter socket), and connection to a computer such as via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a solar panel of photovoltaic cells (sometimes referred to as solar cells) or solar cells, or a wireless charger such as a charger using inductive wireless charging (e.g., including wireless charging according to the Qi wireless charging standard of the Wireless Power Consortium (WPC)), or a wireless radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the aerosol source member 104 may include a disposable device. A disposable component for controlling a body is disclosed in US Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0058] In some embodiments, the control component 108 may include a control circuit (which may be connected to additional components, as further described herein) that is connected to the electrical energy source 106 via conductive wires. In various embodiments, the control component 108 may control when and how the heating assembly 110 (e.g., one or more heating members of the heating assembly) receives electrical energy to heat the aerosol-generating components of the aerosol source component 104 for releasing the inhalable substance for inhalation by the consumer. Such control may involve actuation of a pressure-sensitive switch, etc., which will be described in more detail below. It should be noted that the terms "connect" or "couple" should not be understood to necessarily mean a direct connection without intermediate components. Rather, these terms may cover direct connection and / or connection via one or more intermediate components. Thus, in various embodiments, these terms may be understood to mean operably connected to or operably coupled to. In various embodiments, the control components of the present disclosure may include the control components and methods described in U.S. patent application Ser. No. 15 / 976,526, filed on May 10, 2018, entitled “Control Component for Segmented Heating in an Aerosol Delivery Device,” which is incorporated herein by reference in its entirety.

[0059] In some embodiments, the control component 108 may be configured to closely control the amount of heat provided to the aerosol-forming component. While the amount of heat required to volatilize the aerosol-forming substance in sufficient volume to provide the desired dose of inhalable substance may vary for each specific substance used, heating the heating assembly to at least 120°C, at least 130°C, or at least 140°C may be particularly advantageous. In some embodiments, to volatilize the appropriate amount of aerosol-forming substance and thereby provide the desired dose of inhalable substance, the heating temperature may be at least 150°C, at least 200°C, at least 300°C, or at least 350°C. However, it is particularly desirable to avoid heating to temperatures significantly exceeding approximately 550°C to avoid degradation and / or premature volatilization of the aerosol-forming substance. It should be noted that in some embodiments, the heating process may include different stages. For example, certain embodiments may include a preheating stage in which the heating assembly (e.g., each of the individual heating elements) may be heated to approximately 100°C. Then, upon activation of any individual heater (e.g., such as by a button), the temperature of that particular heater may be increased as described above. Specifically, the heating should be carried out at a sufficiently low temperature and for a sufficiently short time to avoid significant combustion (preferably any combustion) of the aerosol-generating components. The present disclosure may specifically provide components of the present article in combination and use mode that will produce a desired amount of inhalable substance at a relatively low temperature. Thus, generation can refer to one or both of the generation of an aerosol within the article and the delivery to the consumer outside the article. In a particular embodiment, the heating temperature may be from about 120°C to about 300°C, from about 130°C to about 290°C, from about 140°C to about 280°C, from about 150°C to about 250°C, or from about 160°C to about 200°C. The duration of heating can be controlled by many factors, as discussed in more detail below. As further described herein, the heating temperature and duration may depend on the desired volume of aerosol and ambient air that is desired to be inhaled through the aerosol source component. However, the duration may vary depending on the heating rate of the heating component, as the article may be configured so that the heating component is only energized to reach the desired temperature. Alternatively, the duration of heating may be linked to the duration of the consumer's puffing of the article. Typically, as described above, the temperature and time of heating will be controlled by one or more components contained in the control body.

[0060] The amount of inhalable material released by the aerosol source member can vary based on the properties of the aerosol generating components. Preferably, the aerosol source member is configured with a sufficient amount of aerosol generating components, is configured with a sufficient amount of any aerosol forming agent, and acts at a sufficient temperature for a sufficient time to release the desired amount during use. This amount can be provided from the aerosol source member in a single inhalation, or can be separated and provided by multiple suctions from the product in a relatively short period of time (e.g., less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes or less than 5 minutes). For example, the device can provide nicotine in an amount of about 0.01 mg to about 0.1 mg, about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg in each suction on the aerosol source member. In other embodiments, the desired amount can be characterized based on the amount of the wet total particulate matter delivered, relative to the duration of the suction and volume. For example, when smoking under the standard FTC smoking condition of 2 seconds, 35 milliliters, for a limited number of puffs (as described in other aspects herein), the aerosol source member can deliver at least 1.0 milligrams of wet total particulate matter in each puff. Any standard smoking machine can be used to carry out this type of test. In other embodiments, the amount of the total particulate matter (TPM) produced in each puff under the same conditions can be at least 1.5 milligrams, at least 1.7 milligrams, at least 2.0 milligrams, at least 2.5 milligrams, at least 3.0 milligrams, approximately 1.0 milligrams to approximately 5.0 milligrams, approximately 1.5 milligrams to approximately 4.0 milligrams, approximately 2.0 milligrams to approximately 4.0 milligrams or approximately 2.0 milligrams to approximately 3.0 milligrams, at least 3 milligrams to approximately 7 milligrams, approximately 4 milligrams to approximately 8 milligrams and approximately 5 milligrams to approximately 10 milligrams.

[0061] As noted, some embodiments of the aerosol delivery device 100 may include a button that may be linked to a control component for manually controlling the heating element. For example, in some embodiments, a consumer may use a button to energize the heating element 110. Similar functions associated with buttons may be achieved by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Therefore, the actuation of the heating element 110 may be controlled by a single button. Alternatively, multiple buttons may be provided to control various actions separately. In some embodiments, the one or more buttons present may be substantially flush with the outer shell of the housing 102.

[0062] As an alternative (or in addition) to any button, the aerosol delivery device 100 of the present disclosure may include a component that energizes the heating assembly 110 in response to a consumer inhaling on the article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) in the housing 102 that is sensitive to changes in pressure or airflow when the consumer inhales on the article (i.e., a puff-activated switch). Other suitable current actuation / deactuation mechanisms may include a temperature-activated on / off switch or a lip pressure-activated switch, or a touch sensor (e.g., a capacitive touch sensor) configured to sense contact between a user (e.g., a user's mouth or finger) and one or more surfaces of the aerosol delivery device 100. An exemplary mechanism that can provide such puff-activated capability includes the model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. Utilizing such a sensor, when a consumer inhales on the device, the heating element can be quickly activated by a change in pressure. Furthermore, flow sensing devices such as those using the hot wire anemometer principle can be used to quickly activate the heating assembly after sensing a change in air flow. Another suitable suction-activated switch is a pressure differential switch, such as the MPL-502-V model A from Micro Pneumatic Logic, Inc. of Fort Lauderdale, Florida. Another suitable suction-activated mechanism is a sensitive pressure sensor (e.g., equipped with an amplifier or gain stage), which is in turn coupled to a comparator to detect a predetermined threshold pressure. Yet another suitable suction-activated mechanism is a blade deflected by airflow, the movement of which is detected by a motion sensing device. Yet another suitable actuating mechanism is a piezoelectric switch. Also available is the Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, available from the MicroSwitch division of Honeywell Corporation of Freeport, Illinois, with suitable connections. Other examples of on-demand electrical switches that can be used in heating circuits according to the present disclosure are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, etc. will be apparent to those skilled in the art in light of this disclosure. In some embodiments, a pressure sensing tube or other passageway providing a fluid connection between the puff-activated switch and the aerosol source member 104 can be included in the housing 102 so that pressure changes during a puff are readily recognized by the switch.Other exemplary suction actuated devices that may be useful in accordance with the present disclosure are disclosed in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0063] In some embodiments, when a consumer inhales on the mouth end of the aerosol source component 104, the current actuation device may allow unrestricted or uninterrupted flow of current through the heating element to rapidly generate heat. Due to the rapid heating, it may be useful to include a current regulation component to (i) regulate the current flowing through the heating element to control the heating of the heating element and the temperature experienced thereby, and (ii) prevent overheating and degradation of the aerosol-generating component. In some embodiments, the current regulation circuit may be time-based. Specifically, such a circuit may include: a device for allowing uninterrupted current to flow through the heating element for an initial period of time during inhalation, and a timer device for subsequently regulating the current until the inhalation is complete. For example, the subsequent regulation may include rapidly switching the current on and off (e.g., on the order of approximately every 1 to 50 milliseconds) to maintain the heating element (or one or more heating elements of the heating element) within a desired temperature range. Further, the regulation may include simply allowing uninterrupted current to flow until the desired temperature is reached and then completely shutting off the current. The consumer can reactivate the heating assembly (or one or more heating members of the heating assembly) (or manually actuate a button, depending on the specific switch embodiment for activating the heater) by starting another puff on the article. Alternatively, subsequent regulation can include regulating the current through the heating assembly (or one or more heating members of the heating assembly) to maintain the heating assembly (or one or more heating members of the heating assembly) within a desired temperature range. In some embodiments, in order to release the desired dose of the inhalable substance, the heating assembly (or one or more heating members of the heating assembly) can be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds. An exemplary time-based current regulation circuit can include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art. Exemplary timers are the C-1555C available from NEC Electronics and the ICM7555 available from General Electric Intersil, Inc., as well as various other sizes and configurations of so-called "555 timers." An exemplary comparator is available from National Semiconductor as the LM311. Further description of such time-based current regulation circuits is provided in U.S. Patent No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0064] Based on the foregoing, it can be seen that various mechanisms can be employed to facilitate activation and deactivation of the current to the heating assembly (or one or more heating elements of the heating assembly). For example, the device may include a timer for regulating the current in the article (e.g., during a consumer's inhalation). The device may also include a timer-responsive switch that activates and deactivates the current to the heating element. Current regulation may also include the use of a capacitor and components that charge and discharge the capacitor at a defined rate (e.g., approximate the rate at which the heating element heats and cools). Specifically, the current may be regulated such that during an initial period of inhalation, there is uninterrupted current flowing through the heating element, but after this initial period, the current may be interrupted or alternately cycled until inhalation is complete. As described above, this cycling may be controlled by a timer that generates a preset switching cycle. In certain embodiments, the timer may generate a periodic digital waveform. The flow rate during the initial period may also be regulated by using a comparator that compares a first voltage at a first input with a threshold voltage at a threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby activating the timer. Such an embodiment may further include means for generating a threshold voltage at the threshold input and means for generating a threshold voltage at the first input when the initial time period has elapsed.

[0065] Further other components may be employed in the aerosol delivery devices of the present disclosure. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device to detect user lip movement associated with inhalation and subsequently triggering heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy into a heating load array in response to a pressure drop across the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device, the receptacle including an identification member that detects non-uniformity in infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle having multiple differential phases. ; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic-optoelectronic component; U.S. Patent No. 5,954,979 to Counts et al. discloses a means for varying the resistance to inhalation through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and allow computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT patent application publication WO2010 / 003480 to Flick discloses a fluid flow sensing system for indicating puffing in an aerosol generating system; all of the foregoing disclosures are incorporated herein by reference in their entirety. Another approach uses changes in electrical resistance to actuate the aerosol delivery device and / or its heating element. This approach utilizes a very thin metal probe, in the form of a ribbon or wire, mounted perpendicular to the airflow within the cartridge. The user-generated airflow exerts a mechanical force on the probe, causing it to flex to a certain degree. This geometric change, which causes a portion of the probe to bend / tension, results in a change in the probe's electrical resistance. This change in resistance is transmitted as a pulse / information to the PCB, serving as a trigger for activating the heating element 110.

[0066] Further examples of components related to electronic aerosol delivery articles and materials or components that can be used in the articles of the present disclosure are disclosed in U.S. Patent Nos. 4,735,217 to Gerth et al.; 5,249,586 to Morgan et al.; 5,666,977 to Higgins et al.; 6,053,176 to Adams et al.; 6,164,287 to White; 6,196,218 to Voges; 6,810,883 to Fleter et al.; 6,854,461 to Nichols; 7,832,410 to Hon; 7,513,253 to Kobayashi; 7,896,006 to Hamano; 6,196,218 to Shayan; and 6,196,227 to Osaka. ,772,756; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; U.S. Patent No. 8,794,231 to Thorens et al.; U.S. Patent No. 8,851,083 to Oglesby et al.; U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 9,220,302 to Depiano et al.; U.S. Patent No ...8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 8,920,302 to Depiano et al.; U.S. Patent No. 8,915,254 to Hon; U.S. Patent No. 8,915,254 to Oglesby et al.; U.S. Patent No. 8,915,254 to Monsees et al.; U.S. Patent No. 8,915,254 to Monsees et al.; U.S. Patent No. 8,915,

[0015] The present invention relates to a novel device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0016] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0017] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0018] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0019] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0019] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0020] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0021] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0022] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0023] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0024] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0025] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0026] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0027] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0028] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices. [0029 ...

[0067] As described above, the electrical energy source 106 for providing power to the various electrical components of the device 100 can adopt various embodiments. Preferably, the electrical energy source can deliver enough energy to quickly heat the heating assembly in the manner described above, and power the device by being used together with multiple aerosol source members 104, while still being conveniently assembled in the device 100. Examples of useful electrical energy sources include preferably rechargeable lithium-ion batteries (e.g., rechargeable lithium-manganese dioxide batteries). Specifically, lithium polymer batteries can be used because such batteries can provide increased safety. Other types of batteries can also be used, such as nickel-cadmium batteries, lithium metal batteries, lithium-sulfur batteries, lithium-air batteries, nanowire batteries, graphene batteries, foam batteries. In addition, the weight of the preferred electrical energy source is light enough, thereby not impairing the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed on October 21, 2015, the disclosures of which are each incorporated herein by reference in their entirety.

[0068] An example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery produced by Tadrian Battery GmbH in Germany. In another embodiment, a useful electrical energy source may be an N50-AAA nickel-cadmium battery produced by Sanyo Electric Company of Japan. In other embodiments, multiple such batteries, for example batteries each providing a voltage of 1.2 volts, may be connected in series. Other electrical energy sources such as rechargeable lithium-manganese dioxide batteries may also be used. Any of these batteries or a combination thereof may be used in the electrical energy source, but rechargeable batteries are preferred due to the cost and handling considerations associated with disposable batteries. In embodiments using rechargeable batteries, the aerosol delivery device 100 may also include charging contacts for interacting with corresponding contacts in a conventional charging unit (not shown) that draws power from a standard 120 volt AC wall outlet or other power source, such as a car electrical system or a portable power source. In other embodiments, the electrical energy source may also include a capacitor. Capacitors discharge faster than batteries and can be charged between puffs, allowing the battery to discharge into the capacitor at a lower rate than when directly powering the heating element. For example, supercapacitors, such as electric double layer capacitors (EDLCs), can be used separately from or in combination with batteries. When used alone, the supercapacitors can be charged before each use of the device 100. Therefore, the present disclosure may also include a charger component that can be attached to the device between uses to replenish the supercapacitors. Thin film batteries can be used in certain embodiments of the present disclosure.

[0069] As described above, in various embodiments, the aerosol delivery device 100 may include one or more indicators (not shown). In various embodiments, the one or more indicators may be located anywhere on the housing 102. In some embodiments, the indicator may be a light (e.g., a light emitting diode) that provides an indication of various aspects of the use of the article of the present invention. For example, a series of lights may correspond to the number of puffs of a given aerosol source component. Specifically, the lights may illuminate successively with each puff, so that when all lights are illuminated, the consumer is informed that the aerosol source component has been used up. Alternatively, when the aerosol source component is inserted into the housing, all lights may be illuminated, and with each puff, the lights may be turned off, so that when all lights are off, the consumer is informed that the aerosol source component has been used up. In other embodiments, a series of lights may correspond to a series of heating components, so that if one or more heating components are activated, the corresponding lights may be illuminated. In yet other embodiments, there may be only a single indicator, and its indicator may indicate that current is flowing to the heating component and that the device is actively heating. This ensures that consumers do not unknowingly leave the device unattended in active heating mode. In alternative embodiments, one or more indicators may be components of the aerosol source assembly. Although the indicators have been described above with respect to visual indicators in an on / off manner, other operational indicators are also contemplated. For example, a visual indicator may also include a change in light color or intensity to indicate the progression of a smoking experience. Tactile and audible indicators are similarly encompassed by the present disclosure. Furthermore, combinations of such indicators may also be used in a single device.

[0070] In various embodiments, the housing 102 may be formed of any material suitable for forming and maintaining an appropriate configuration, such as a tubular or rectangular shape, and for retaining the aerosol source component therein. In some embodiments, as further discussed herein, the housing may be formed of a single wall and may be formed of one or more materials (natural or synthetic) that are heat-resistant so as to maintain their structural integrity, e.g., not degrade, at least at the temperature of the heating temperature provided by the electric heating component. In some embodiments, a heat-resistant polymer may be used. In other embodiments, a ceramic material may be used. In yet other embodiments, an insulating material may be used to avoid unnecessarily drawing heat away from the aerosol source component. When the housing is formed of a single layer, its thickness may preferably be from about 0.2 mm to about 5.0 mm, from about 0.5 mm to about 4.0 mm, from about 0.5 mm to about 3.0 mm, or from about 1.0 mm to about 3.0 mm. Other exemplary types of components and materials that can be used to provide the above-described functions or as alternatives to the above-described materials and components can be those described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al.; No. 2010 / 00186757 to Crooks et al.; and No. 2011 / 0041861 to Sebastian et al.; the disclosures of which are incorporated herein by reference in their entirety.

[0071] Figure 3 An exemplary embodiment according to the present disclosure is shown. Figure 1 and 2FIG2 is a perspective view of certain components of a heating assembly 110 of an aerosol delivery device, and shows a perspective view of certain components of the heating assembly 110 according to an example embodiment of the present disclosure, wherein the aerosol source member 104 is located in a receiving sleeve 116. Specifically, the heating assembly 110 of the depicted embodiment includes a movable clamp 112, a fixed clamp 114 (flipped upside down in the drawing for clarity of illustration), and a receiving sleeve 116. Although other materials are possible, in the illustrated embodiment, the movable clamp 112, the fixed clamp 114, and / or the receiving sleeve 116 can be made of a metallic material (e.g., aluminum, stainless steel, metal alloys, etc.), a composite material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymer (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), and / or any combination thereof. As will be discussed in greater detail below, the movable clamp 112 of the depicted embodiment is configured to move between an open position, in which the movable clamp is spaced apart from the fixed clamp 114 and the receiving sleeve 116, and a closed position, in which the movable clamp is adjacent to the fixed clamp 114 with the receiving sleeve 116 positioned therebetween. In the depicted embodiment, the receiving sleeve 116 has a substantially cylindrical shape configured to receive at least the heating end of the aerosol source member 104; however, in other embodiments, the receiving sleeve may have any other shape, such as any shape that complements the shape of the heating end of the aerosol source member. In the illustrated embodiment, each of the movable clamp 112 and the fixed clamp 114 has an interior shape configured to substantially surround the receiving sleeve 116, and therefore, at least the heating end of the aerosol source member 104. Specifically, inner surface 118 of movable clamp 112 and inner surface 119 of fixed clamp 114 collectively form a shape complementary to that of receiving sleeve 116. In this manner, inner surfaces 118, 119 converge to surround receiving sleeve 116 when movable clamp 112 is in the closed position.

[0072] The movable clamp 112 of the depicted embodiment includes a series of heating pins 120 that extend outwardly from its inner surface 118. The movable clamp 112 of the depicted embodiment also includes a pair of locating pins 122 that extend outwardly from the inner surface 118 of the movable clamp 112. It should be noted that in some embodiments, no locating pins 122 are required, as the heating pins can also serve this function. In various embodiments, the series of heating pins 120 are configured to be electrically connected (in a closed position) to a series of corresponding connectors 124 that are located on the inner surface 119 of the fixed clamp 114. In addition, the receiving sleeve 116 includes two rows of opposing openings 126 that are aligned with the series of heating pins 120 and the series of connectors 124 during operation. In addition, a pair of end openings 128 are configured to align with the locating pins 122. When the movable clamp 112 is in the closed position, a series of heater pins 120 extend through corresponding openings 126 of the receiving sleeve 116 and make electrical contact with corresponding connectors 124 of the fixed clamp 120. The locating pins 122 of the depicted embodiment also extend through a pair of corresponding openings 128 of the receiving sleeve, but do not make electrical contact with the fixed clamp 114; however, in some embodiments, the locating pins 122 may also make electrical contact. In the depicted embodiment, there are seven heater pins 120, and therefore seven corresponding connectors 124 and seven corresponding openings 126; however, in other embodiments, any number of heater pins 120, connectors 124, and openings 126 may be used. In the depicted embodiment, the heater pins have a substantially cylindrical shape with rounded ends; however, in other embodiments, the heater pins 120 may have other shapes, and in other embodiments, the heater pins 120 need not have the same shape.

[0073] When electrically connected to a corresponding connector 124, the heater pins 120 of the depicted embodiment include a resistive heating element. The resistive heating element can be configured to generate heat when an electrical current is passed through it. Such heating elements typically comprise a metallic material or a conductive ceramic and are configured to generate heat due to the resistance associated with passing the electrical current through them. While in some embodiments, the material of the heater pins can be the same overall, the heater pins 120 of the depicted embodiment include a conductive material at each end (e.g., the end of the heater pin 120 that contacts the connector 124 and the end of the heater pin 120 that connects to the control component 108 and / or the electrical energy source 106) and a resistive material therebetween (e.g., the portion of the heater pin 120 that contacts the aerosol-generating component). Examples of resistive materials may include, but are not limited to, titanium, silver, nickel, nickel-chromium alloys, stainless steel, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. Examples of conductive materials may include, but are not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, and / or any combination thereof. Various conductive substrates useful in the present disclosure are described in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., which is incorporated herein by reference in its entirety. In some embodiments, the heater pins may include a resistive trace on their surface. In such embodiments, for example, the resistive trace may be added to the pins via a variety of techniques, including, for example, molding, printing, embedding, machining, extrusion casting, vapor deposition, and the like.

[0074] As noted, the receiving sleeve 116 of the depicted embodiment is configured to receive the heated end of the aerosol source member 104, which may include the aerosol generating component 130. In the open position (e.g., Figure 2 ), the movable clamp 112 is spaced apart from the fixed clamp 114, and the receiving sleeve 116 and the aerosol source member 104 are spaced apart, while in the closed position (e.g., in Figure 4), the movable clamp 112 is adjacent to the fixed clamp 114, and the receiving sleeve 116 and the aerosol source member 104 are configured therebetween. In various embodiments, actuation between the open position and the closed position (or vice versa) can be accomplished in a variety of ways, including, for example, manually, such as by the consumer pressing the clamps together, or automatically or semi-automatically, such as by using a hydraulic gas spring or other force-displacement mechanism that transmits force to the movable clamp 112. Another example may include a linear displacement motor or other actuator that is configured to shift the movable clamp 112 between the open position and the closed position. Other examples include piezoelectric actuators, ultrasonic ceramic actuators, rotating coil systems, screw systems, cam follower mechanisms, gear mechanisms, linkages, and / or any other system configured to generate directional motion and transmit that motion to the movable clamp 112. Regardless of which mechanism is used, this movement can be activated similarly to the above via a button and / or via the use of the device (for example, by powering the device, by inhaling on the aerosol source member, or by inserting the aerosol source member into the device). In addition to the above methods, another method for actuating the movable clamp 112 is to operate with the help of a small metal probe, such as a ribbon or wire, mounted perpendicular to the air flow inside the device 100. The air flow generated by the user exerts a mechanical force on the probe and folds or bends it to a certain extent. Due to the change in geometry that causes the probe to bend / tension, the resistance of the probe changes. This resistance change is sent to the control component 108 in the form of a pulse and / or signal and serves as a trigger element for activating the movable clamp 112.

[0075] In the closed position, each heater pin 120 completes an electrical circuit, thereby forming an independent and distinct heating circuit capable of heating a portion of the aerosol source component via the heater pin 120. However, in the open position, each circuit is incomplete, and the heater pins are unable to heat. In various embodiments, the control component 108 can independently control each heating circuit. In this way, in the closed position, each heater pin 120 can independently heat a portion of the aerosol source component, as controlled by the control component 108. Thus, in some applications, the heater pins 120 can sequentially heat various sections of the aerosol source component, while in other applications, the heater pins 120 can heat certain groups of sections of the aerosol source component. It will be understood that the present disclosure encompasses all of the different heating conditions provided by the use of independently controlled heater pins 120. As will be discussed in more detail below, in some embodiments, heater pin control can be performed by the user on the device (e.g., via buttons or a control panel). In addition, various indicators can also indicate which heaters have been used and which have not been used for consumables used in the device.

[0076] It should be noted that while in the depicted embodiment, there are a total of seven different heating pins 120 corresponding to seven different heating segments of the aerosol source component 104, in various other embodiments, the heating assembly 110 can have any number of different heating members corresponding to any number of discrete heating segments of the aerosol source component. Further, while in the depicted embodiment, a plurality of discrete heating member positions and corresponding discrete heating segments are shown as being spaced apart from one another, in other embodiments, the discrete positions and corresponding discrete segments can have different spacings, including but not limited to spacings that cause the discrete positions and corresponding discrete segments to abut and / or overlap one another, as well as non-uniform spacings.

[0077] In the depicted embodiment, the heater pin 120 is configured to pierce an aerosol-generating component 130 of an aerosol source member, which is contained in the aerosol source member 104 and received in the receiving sleeve 116, and to make electrical contact with the connector 124 of the securing fixture 114. Thus, the aerosol-generating component 130 of the depicted embodiment comprises a solid or semi-solid material (e.g., tobacco or tobacco-derived material, medicinal material, herbal material, etc.). However, in other embodiments, the aerosol-generating component may comprise a gel, liquid, or semi-liquid material.

[0078] As noted, in various embodiments, the aerosol-generating component may comprise a solid or semisolid material, which may be tobacco or tobacco-derived material. In some embodiments, such material may comprise tobacco-containing beads, tobacco shreds, tobacco rods, reconstituted tobacco materials (e.g., extruded or cast sheet substrates), and combinations thereof, and / or a mix of finely ground tobacco, tobacco extracts, spray-dried tobacco extracts, or mixed with optional inorganic materials (such as calcium carbonate), optional flavorings, and aerosol-forming materials to form other tobacco forms that are substantially solid, semisolid, or moldable (e.g., extrudable). Gels and suspensions may also be used. Some representative types of structures and formulations of solid and semisolid aerosol-generating components are disclosed in U.S. Patent No. 8,424,538 to Thomas et al.; U.S. Patent No. 8,464,726 to Sebastian et al.; U.S. Patent Application Publication No. 2015 / 0083150 to Conner et al.; U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al.; and U.S. Patent Application Publication No. 2017-0000188 filed on June 30, 2015 by Nordskog et al., all of which are incorporated herein by reference.

[0079] In various embodiments, the aerosol source member or a part thereof may be wrapped in an outer packaging material, which may be formed of any material that can be used to provide additional structure and / or support for the aerosol source member. In various embodiments, the outer packaging material may include a material that resists (or promotes) heat transfer, which may include paper or other fibrous materials such as cellulose materials. The outer packaging material may also include at least one filler material embedded or dispersed in the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. In addition, the filler material may be combined with an inorganic component. In various embodiments, the outer packaging may be formed by multiple layers, such as a loose layer below and a layer such as a typical wrapping paper in a cigarette above. Such materials may include, for example, lightweight "rag fibers", such as flax, sisal, straw and / or sedge. Further discussion related to the construction of the outer packaging material used in this disclosure is described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety. In additional embodiments, the outer wrapper may have one or more of the following properties: it may be impermeable to the transfer of aerosols, it may have the ability to withstand the high temperatures contemplated, it may promote radial transfer of heat from the heater to the cut tobacco material, it may resist heat transfer along the tobacco rod in an axial direction away from the heated section, and / or it may have a relatively low thermal mass so that it does not inhibit the rapid temperature increase of the heated section. In one embodiment, the outer wrapper may be stainless steel foil, which in some embodiments may be approximately 0.001 inches thick. In another embodiment, the outer wrapper may be aluminum foil.

[0080] In various embodiments, the mouth end of the aerosol source component may include a filter portion, which may be made of, for example, cellulose acetate, polypropylene, or polylactic acid. In various embodiments, the filter portion may increase the structural integrity of the mouth end of the aerosol source component, and / or provide filtering capacity if desired, and / or provide resistance to suction. For example, the product according to the present disclosure may exhibit a pressure drop of about 50 to about 250 mm of water pressure drop at an air flow rate of 17.5 cc / second. In another embodiment, the pressure drop may be about 60 mm of water column to about 180 mm of water column, or about 70 mm of water column to about 150 mm of water column. The pressure drop value can be measured using a Filtrona filter test station (CTS series) available from Filtrona Instruments and Automation Ltd or a quality test module (QTM) available from the Cerulean Division of Molins, PLC. The length of the filter portion at the mouth end of the aerosol source component can be different, for example, from about 2 mm to about 20 mm, from about 5 mm to about 20 mm, or from about 10 mm to about 15 mm. In some embodiments, the filter portion may include discrete segments. For example, some embodiments may include a segment that provides filtration, a segment that provides inhalation resistance, a hollow segment that provides space for aerosol cooling, a segment that provides increased structural integrity, other filter segments, and any one or any combination thereof. In some embodiments, the filter portion can be separated from the outer packaging, and the filter portion can be held in place by the outer packaging.

[0081] Additional example types of overwrap materials, packaging material components, and treated packaging materials that can be used in the overwrap of the present invention are described in U.S. Patent No. 5,105,838 to White et al.; U.S. Patent No. 5,271,419 to Arzonico et al.; U.S. Patent No. 5,220,930 to Gentry; U.S. Patent No. 6,908,874 to Woodhead et al.; U.S. Patent No. US 6,929,013 to Ashcraft et al.; U.S. Patent No. 7,195,019 to Hancock et al.; U.S. Patent No. 7,276,120 to Holmes; U.S. Patent No. 7,275,548 to Hancock et al.; PCT WO 01 / 08514 to Fournier et al.; and PCT WO 03 / 043450 to Hajaligol et al., all of which are incorporated herein by reference in their entirety. Representative wrappers are commercially available from Schweitzer-Maudit International as RJ Reynolds Tobacco Company Grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676, and 680. The porosity of the wrapper can vary and is typically between about 5 CORESTA units to about 30,000 CORESTA units, typically between about 10 CORESTA units to about 90 CORESTA units, and typically between about 8 CORESTA units to about 80 CORESTA units.

[0082] In order to maximize the delivery of aerosols and flavoring agents, one or more layers of non-porous cigarette paper can be used to enclose the aerosol source member (with or without an outer wrapper), otherwise the delivery of these aerosols and flavoring agents may be diluted by radial (i.e., external) air penetration through the outer wrapper. Examples of suitable non-porous cigarette papers are commercially available from Kimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2, and 780-63-5. Preferably, the outer wrapper is a material that is substantially impermeable to the vapors formed during use of the article of the present invention. If desired, the outer wrapper may comprise a resilient paperboard material, foil-lined paperboard, metal, polymeric material, or the like, and the material may be surrounded by the cigarette paper. As described elsewhere herein, the outer wrapper may comprise tipping paper surrounding the component and may optionally be used to attach a filter material to the aerosol source member. In various embodiments, other components may be present between the aerosol generating component and the mouth end of the aerosol source member, wherein the mouth end may comprise a filter portion. For example, in some embodiments, one or any combination of the following may be positioned between the aerosol-generating component and the mouth end: an air gap; a phase change material for cooling the air; a flavor-releasing medium; ion exchange fibers with selective chemical adsorption capabilities; aerogel particles as a filter medium; and other suitable materials.

[0083] Can be used for the tobacco material of present disclosure and can be different, and can comprise the tobacco of flue-cured tobacco, burley tobacco, Oriental (Oriental) tobacco, Maryland (Maryland) tobacco, dark tobacco, dark flue-cured tobacco and orchid (Rustica) cigarette and other rare or special tobacco, or its mixture.Tobacco material can also comprise so-called " mixing " form and processed form, such as the tobacco (such as puffed tobacco, such as the dry ice expanded tobacco (DIET) of preferably cut filler form) of the tobacco stem (such as cut roll or chip puffing) after processing, constant volume expansion, reconstituted tobacco (such as, the reconstituted tobacco using papermaking type or cast sheet type process to make). No. 4,836,224 to Lawson et al.; No. 4,924,888 to Perfetti et al.; No. 5,056,537 to Brown et al.; No. 5,159,942 to Brinkley et al.; No. 5,220,930 to Gentry; No. 5,360,023 to Blakley et al.; No. 6,701,936 to Shafer et al.; No. 7,011,096 to Li et al.; No. 7,017,585 to Li et al.; No. 7,025,066 to Lawson et al.; U.S. Patent Application Publication No. 2004 / 0255965 to Perfetti et al.; PCTWO to Bereman Various representative tobacco types, types of processed tobacco, and types of tobacco blends are described in U.S. Pat. No. 02 / 37990 and in the grant application to Bombick et al., Journal of Toxicology, 39, pp. 11-17 (1997); the entire text of the foregoing documents is incorporated herein by reference. Other exemplary tobacco compositions that can be used to comprise a smoking device according to the present disclosure are described in U.S. Pat. No. 7,726,320 to Robinson et al., the entire text of which is incorporated herein by reference.

[0084] Still further, the aerosol-generating component may comprise an inert substrate having an inhalable substance or a precursor thereof integrated therein or otherwise deposited thereon. For example, a liquid comprising the inhalable substance may be coated on the inert substrate or absorbed or adsorbed onto the inert substrate such that upon application of heat, the inhalable substance is released in a form that can be extracted from the article of the invention by application of positive or negative pressure. In some aspects, the aerosol-generating component may comprise a mixture of flavored aromatic tobacco in the form of cut filler. In another aspect, the aerosol-generating component may comprise a reconstituted tobacco material, such as described in U.S. Patent Nos. 4,807,809 to Pryor et al.; 4,889,143 to Pryor et al.; and 5,025,814 to Raker, the entireties of which are incorporated herein by reference.

[0085] In some embodiments, the aerosol-generating component may include tobacco, tobacco components, and / or tobacco-derived materials that have been treated, manufactured, produced, and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, such as propylene glycol, glycerin, etc.), and / or at least one flavoring, and a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent a heat source from igniting, pyrolyzing, burning, and / or charring an aerosol delivery component. Various ways and methods of incorporating tobacco into smoking articles, particularly smoking articles designed not to intentionally burn substantially all of the tobacco in those smoking articles, are proposed in U.S. Patent Nos. 4,947,874 to Brooks et al.; 7,647,932 to Cantrell et al.; 8,079,371 to Robinson et al.; 7,290,549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al.; the entire disclosures of which are incorporated herein by reference.

[0086] In some embodiments, flame retardant / combustion materials and additives may be included in the aerosol generating component and may include organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other materials may also be used, such as phosphonite nitrites, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ammonium ethanol borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide. In various aspects of the flame retardant, combustion, and / or anti-scorch materials used in the aerosol generating component and / or other components (whether used alone or in combination with each other and / or with other materials), it is most preferred that the desired performance be provided without undesirable outgassing, chemical reaction, or melt-type behavior. Further, other flavors, flavorings, additives, and other possible enhancing ingredients are described in U.S. Patent Application No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0087] In addition to the inhalable substance (e.g., flavoring, nicotine, or medication in general), the aerosol-forming component may also include one or more aerosol-forming or vapor-forming materials, such as polyols (e.g., glycerol, propylene glycol, or mixtures thereof) and / or water. Representative types of aerosol-forming materials are described in U.S. Pat. Nos. 4,793,365 to Sensabaugh, Jr. et al.; 5,101,839 to Jacob et al.; PCT WO 98 / 57556 to Biggs et al.; and in "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco" (1988), R.J. Reynolds Tobacco Company; the disclosures of which are incorporated herein by reference. Preferred aerosol-forming materials produce a visible aerosol when sufficient heat is applied thereto, and highly preferred aerosol-forming materials produce an aerosol that can be considered "smoke-like." In some embodiments, the present invention provides the invention claims a kind of inhalable substance, and the ... Thus, in use, substrate can be heated, and aerosol-forming material can be volatilized into vapor form together with inhalable substance. In a specific example, aerosol-generating components may include a solid substrate having tobacco pulp and smoke-forming material and / or vapor-forming material coated thereon or absorbed or adsorbed thereto. The substrate component can be any material that does not burn or degrade at a temperature at which the heating member reaches the release of inhalable substance as described herein. For example, a paper material including tobacco paper (for example, a paper-like material including tobacco fiber and / or reconstructed tobacco) can be used.Thus, in various embodiments, the aerosol-forming component can be characterized as comprising an inhalable substance, alternatively as comprising an inhalable substance and a separate aerosol-former or vapor-former, alternatively as comprising an inhalable substance and a substrate, or alternatively as comprising an aerosol-forming component, a separate aerosol-former or vapor-former, and a substrate. Thus, the substrate can comprise one or both of the inhalable substance and the aerosol-former or vapor-former.

[0088] If desired, tobacco material or aerosol generating component can also generally include other components, such as sugar, glycerine, vanilla, cocoa, liquorice and other flavoring materials such as menthol. In the U.S. Patent Application Publication No. 2012 / 0152265 of Dube et al. and the U.S. Patent No. 9,107,453 granting Dube et al., a composition of an exemplary plant origin that can be used is disclosed. Based on factors such as the required organoleptic properties of the product of the present invention, the selection of these other components is variable, and the disclosure is intended to cover any such other components that are apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. Referring to " Tobacco Flavoring Substances and Methods (tobacco flavoring substances and methods) " (1972) by Gutcho of Noyes Data Corp. and " Tobacco Flavoring for Smoking Products (tobacco flavoring for smoking products) " (1972) by Leffingwell et al.

[0089] The inhalable substance and / or the separate vapor-forming material can be disposed on the aerosol-generating component in a variety of different configurations. For example, both materials can be associated with the substrate such that the concentration of each material is substantially constant along the length of the substrate (e.g., when the substrate is divided into a plurality of longitudinal segments, the total concentration of the material in each separate segment can be substantially similar, e.g., varying by less than 10%, less than 5%, or less than 2% by weight). In other embodiments, one or both of the materials can be present in a defined pattern. For example, the pattern can be a gradient, wherein the concentration continuously increases or decreases along the length of the substrate. In this manner, the first puff on the article can provide a significantly greater or lesser amount of inhalable substance than the last puff. The gradient can also be designed to provide a uniform generation of inhalable substance over all puffs. Furthermore, the pattern can be such that a single point along the length of the substrate provides a large injection of inhalable substance (e.g., corresponding to the first puff, the last puff, or some intermediate puffs on the article). Any variety of such patterns is contemplated in accordance with the present disclosure, and such variations are also encompassed by the present disclosure. Such patterns are also applicable to other components described herein (e.g., fragrances). For example, a large burst of flavoring can be provided on the substrate in a location substantially corresponding to the last puff, or the last two or three puffs on the article. The release of such flavoring can signal to the consumer that the final puff on the device is approaching or has been reached. Various other configurations and components that may be included in the aerosol-generating components of the present disclosure are described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0090] In some aspects of the present disclosure, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., the aerosol generating component can be configured as an extruded material, the entire text of which is incorporated herein by reference. In another aspect, the aerosol generating component can be configured to include tobacco, tobacco-related materials, glycerol, water and / or adhesive materials or an extruded structure and / or substrate consisting essentially of these materials, although some formulations do not include adhesive materials. In various aspects, the adhesive material can be any adhesive material commonly used in tobacco formulations, including, for example, carboxymethyl cellulose (CMC), gums (e.g., guar gum), xanthan gum, pullulan and / or alginate. According to some aspects, the adhesive material included in the aerosol delivery component can be configured to substantially maintain the structural shape and / or integrity of the aerosol delivery component. Various representative adhesives, adhesive properties, uses of adhesives, and amounts of adhesives are described in U.S. Patent No. 4,924,887 to Raker et al., the entire text of which is incorporated herein by reference.

[0091] In some embodiments, the aerosol generating component can also be configured to substantially maintain its structure throughout the aerosol generation process. That is, the aerosol generating component is configured to substantially maintain its shape throughout the aerosol generation process (i.e., the aerosol delivery component does not continuously deform under the applied shear stress). Although in some embodiments, the aerosol generating component may include a liquid and / or some moisture, in some embodiments, the aerosol generating component is configured to remain substantially solid throughout the aerosol generation process and maintain its structural integrity throughout the aerosol generation process. Exemplary tobacco and / or tobacco-related materials suitable for use in substantially solid aerosol delivery components are described in U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al.; U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al.; U.S. Patent No. 6,204,287 to White; and U.S. Patent No. 5,060,676 to Hearn et al., each of which is incorporated herein by reference in its entirety.

[0092] In yet another aspect, the aerosol-generating component may comprise an extruded structure and / or substrate formed from marumarized tobacco and / or non-marumarized tobacco. Marumarized tobacco is known from, for example, U.S. Pat. No. 5,105,831 to Banerjee et al., the entirety of which is incorporated herein by reference. Marumarized tobacco comprises a tobacco blend in powder form of about 20% to about 50% by weight, glycerin (about 20% to about 30% by weight), calcium carbonate (generally about 10% to about 60% by weight, typically about 40% to about 60% by weight), and a binder and / or flavoring as described herein.

[0093] In various embodiments, the aerosol-generating component wall may be substantially formed from a material that can naturally include an inhalable substance therein (e.g., tobacco paper), or may be formed from any other material (e.g., paper) that can entrain an inhalable substance and / or a vapor-forming or aerosol-forming agent therein. In addition to the inhalable substance and / or vapor-forming or aerosol-forming substance, the substrate wall may also include other components. For example, a vapor barrier may be included on the outer surface of the aerosol-generating component wall. Preferably, when the aerosol-generating component is heated, the vapor barrier is positioned on the wall surface adjacent to (or in contact with) the heating element. In specific embodiments, the vapor barrier may be formed from an electrically insulating material or may include a layer of electrically insulating material that can contact the heating element. For example, a metal foil may be used as a vapor barrier, and the foil may have an insulating single layer, such as a metal oxide layer, in contact with the heating element to prevent the release of vapor or aerosol into the external volume of the aerosol-generating component and to facilitate the release of vapor or aerosol into the annular space defined by the inner surface of the wall of the aerosol-generating component. Any vapor barrier material, such as a metal foil, may be used.

[0094] In other embodiments, the aerosol-generating component may be formed from a material that softens or changes phase (particularly from a solid to a molten state) near the operating temperature of the article. For example, the aerosol-generating component may be a wax or a gel, and the inhalable substance may be entrained therein. In such embodiments, it may be particularly useful to include a vapor barrier (or similar material) that provides support for the aerosol-generating component and substantially prevents the aerosol-generating component from contacting the heating member. Similarly, the aerosol-generating component may include a vapor barrier layer coated with the inhalable substance and / or the aerosol-forming material. For example, one or more such coatings may be in the form of microcapsules that preferably release their components at temperatures within one or more operating ranges described elsewhere herein. Microencapsulation technology that may be useful in such embodiments is disclosed, for example, in U.S. Patent No. 4,464,434 to Davis.

[0095] In one embodiment, the aerosol generating component may include a tobacco component (such as, for example, reconstituted tobacco flakes or tobacco beads) or a non-tobacco component (such as herbs, paper, cellulose, etc.) and have one or more of the following: a binder component, a humectant component, a flavoring component, a moisturizing component, and a packaging material. In some embodiments, the binder component may include, for example, cellulose and / or guar gum. In some embodiments, the moisturizing component may include, for example, approximately 15-25% glycerol, approximately 14.5% sorbitol, and / or approximately 3-10% propylene glycol. In some embodiments, the flavoring component may include, for example, acetic acid, citric acid, acetylacetone, lactic acid, menthol, peppermint oil, carob pod / extract, cocoa products, licorice extract, invert sugar, and / or sucrose. In some embodiments, the moisturizing component includes, for example, approximately 15-25% water.

[0096] As described above, the end of the aerosol source member 104 opposite the mouth end is sized and shaped to be inserted into the receiving sleeve 116. In various embodiments, the outer diameter (or other dimension, depending on the specific cross-sectional shape of the embodiment) of the aerosol source member 104 is preferably sized to be slightly smaller than the inner diameter (or other dimension) of the receiving sleeve 116. Ideally, the difference between the diameters is small enough that the aerosol source member 104 fits tightly within the receiving sleeve 116 and friction prevents the aerosol source member from moving without applied force.

[0097] As described above, in some embodiments, the aerosol source member can include an overpack. When present, the overpack can have an overall length ranging from substantially the same as the length of the aerosol-generating component to approximately twice the length of the aerosol-generating component. Thus, the length of the aerosol-generating component can be up to about 50%, up to about 30%, or up to about 10% less than the length of the overpack. Preferably, the length of the aerosol-generating component can be at least 10%, at least 15%, or at least 20% less than the length of the overpack. More specifically, the distance that the overpack extends beyond the aerosol-generating component can be about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, or about 100% of the length of the aerosol-generating component.

[0098] The outer packaging can also serve to provide specific characteristics at the mouth end of the aerosol source member. For example, the configuration and / or shape and / or size of the outer packaging can serve to provide the feel of a conventional cigarette in the user's mouth. In addition, as noted, the outer packaging can include a filter (e.g., cellulose acetate or polypropylene) positioned near the mouth end of the cartridge to increase its structural integrity and / or provide filtering capacity, and / or provide suction resistance if desired.

[0099] Figure 1-4 The embodiments depicted in describe a heating assembly in which, in the closed position, a series of heating members (in these embodiments, a series of heating pins 120) extend through the aerosol source member 104. In other embodiments, the series of heating members need not extend through the aerosol source member, but may extend a certain depth into the aerosol source member. For example, Figure 5 1 shows a perspective view of components of a heating assembly of an aerosol delivery device according to another exemplary embodiment of the present disclosure. Specifically, Figure 5 A movable clamp 212 is depicted that can be used in conjunction with a housing, electrical energy source, control components, and aerosol delivery device similar to those described above. Although one or more of these components may be different (or omitted) in various embodiments, reference is made to the above description regarding these components.

[0100] Although other materials are possible, in the illustrated embodiment, the movable clamp 212 can be made of a metallic material (e.g., aluminum, stainless steel, metal alloys, etc.), a composite material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, boron nitride, etc.), a polymer (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), and / or any combination thereof. As will be discussed in more detail below, the movable clamp 212 of the depicted embodiment is configured to move between an open position, in which the movable clamp is spaced apart from the fixed clamp, and a closed position, in which the movable clamp 212 is adjacent to the fixed clamp. In many aspects, the movable clamp 212 is configured for use with a fixed clamp similar to the fixed clamp described with reference to FIG. Figure 1-4 The fixed clamp described, therefore, makes reference to the above description; however, as will be explained in more detail below, the movable clamp 212 of the depicted embodiment is configured for use with a fixed clamp that does not necessarily include an electrical connector.

[0101] The movable clamp 212 may be configured similarly to the reference Figure 1-4 The receiving sleeve of the aerosol source member is used in conjunction with the receiving sleeve described above, and reference is therefore made to the description above. As similarly described above, the receiving sleeve of some embodiments may have a substantially cylindrical shape configured to receive at least the heating end of the aerosol source member. In such embodiments, each of the movable clamp 212 and the fixed clamp may have an internal shape that is configured to substantially surround the receiving sleeve, and therefore surround at least the heating end of the aerosol source member. In particular, the inner surface 218 of the movable clamp 112 and the inner surface of the fixed clamp together form a shape that is complementary to the shape of the receiving sleeve. In this way, when the movable clamp 212 is in the closed position, the inner surfaces converge to surround the receiving sleeve.

[0102] The movable clamp 212 of the depicted embodiment includes a series of individual heating elements 220 extending outwardly from its inner surface 218. The movable clamp 212 of the depicted embodiment also includes a pair of locating pins 222 extending outwardly from the inner surface 218 of the movable clamp 212, although it should be noted that in some embodiments, no locating pins 222 are required. Figure 1-4In the described embodiments, a series of heating pins are configured to be electrically connected (in the closed position) to a series of corresponding connectors located on the fixed fixture to form a closed heating circuit; however, in the depicted embodiment, the series of heating elements 220 includes separate closed resistive heating circuits, each of which is configured to heat a portion of the aerosol source member. Thus, when the movable fixture 212 is in the closed position, the heating element 220 extends a certain depth in the aerosol source member. For example, in some embodiments, the heating element 220 extends through less than half of the aerosol source member. In other embodiments, the heating element 220 extends through approximately half of the aerosol source member. In other embodiments, the heating element 220 extends through more than half of the aerosol source member. It should be noted that in some embodiments, individual heating elements 220 within a series of heating elements 220 may extend to different depths in the aerosol source member.

[0103] The heating element 220 of the depicted embodiment comprises a resistive heating element and has a blade-like shape (e.g., a relatively thin and flat configuration with an angled top), although in other embodiments, the heating element 220 may have other shapes, such as, for example, a substantially cylindrical shape with the heating element positioned around its outer surface. A resistive heating element may be configured to generate heat when an electric current is directed through it. Such heating elements typically comprise a metallic material and are configured to generate heat due to the resistance associated with the passage of electric current. In the depicted embodiment, the heating element comprises a heating element wire and / or trace 220a (hereinafter referred to as a "heating trace") constructed of a resistive material. Examples of resistive materials may include, but are not limited to, titanium, silver, nickel, nickel-chromium alloys, stainless steel, tungsten, indium tin oxide, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, each heating trace 220a may be affixed to the body portion 220b using various techniques, including, for example, molding, printing, embedding, machining, extrusion casting, vapor deposition, and the like. In various embodiments, the main body portion 220b may be formed of a metal material (e.g., aluminum, stainless steel, metal alloy, etc.). It should be noted that in other embodiments, the main body 220b may be formed of another material, including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, boron nitride, metal oxides such as zinc oxide, zirconium oxide, copper oxide, etc.), a polymer material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof.

[0104] With reference to above Figure 1-4As with the embodiments described above, the receiving sleeve of the depicted embodiment is configured to receive the heated end of an aerosol source member, which may include an aerosol generating component. In the open position, the movable clamp 212 is spaced apart from the fixed clamp, and the receiving sleeve and the aerosol source member are spaced apart, while in the closed position, the movable clamp 212 is adjacent to the fixed clamp, with the receiving sleeve and the aerosol source member disposed therebetween. In various embodiments, actuation between the open position and the closed position (or vice versa) can be accomplished in a variety of ways, including, for example, manually (e.g., a consumer can press the clamps together), or automatically or semi-automatically, such as by using a hydraulic gas spring or other force-displacement mechanism that transmits force to the movable clamp 212. Another example may include a linear displacement motor or other actuator configured to linearly displace the movable clamp 212 between the open position and the closed position. Other examples include piezoelectric actuators, ultrasonic ceramic actuators, rotating coil systems, lead screw systems, and / or any other system configured to generate directional and / or rotational motion and transmit that motion to the movable clamp 212. Regardless of the mechanism employed, this motion can be activated similarly to that described above via a button and / or via use of the device (e.g., by powering the device, by inhaling on an aerosol source member, or inserting the aerosol source member into the device), and / or via a resistive probe.

[0105] Figure 6 shows top and perspective views of certain components of a heating assembly of an aerosol delivery device in an open position according to another exemplary embodiment of the present disclosure, and Figure 7 A bottom view of these components is shown, which are shown in an open position and a closed position. Specifically, Figure 6 and 7 A multi-piece movable clamp 312 is depicted that can be used in conjunction with a housing, electrical energy source, control components, and aerosol delivery device similar to those described above. Although one or more of these components may be different (or omitted) in various embodiments, reference is made to the above description regarding these components.

[0106] In various embodiments, the multi-piece movable clamp may include any number of segments, including, for example, as few as two segments, or as many as four or more segments. In the depicted embodiment, the multi-piece movable clamp 312 includes three separate segments: a first movable clamp segment 312-1, a second movable clamp segment 312-2, and a third movable clamp segment 312-3. Although other materials are possible, in the illustrated embodiment, the movable clamp segments 312-1, 312-2, 312-3 may be made of any of the following materials: a metallic material (e.g., aluminum, stainless steel, a metal alloy, etc.), a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymer (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof. As will be discussed in more detail below, the movable clamp sections 312-1, 312-2, 312-3 are configured to move together between an open position, in which the movable clamp sections 312-1, 312-2, 312-3 are spaced apart from one another, and a closed position, in which the movable clamp sections 312-1, 312-2, 312-3 are adjacent one another. In the depicted embodiment, no fixed clamp is required because the configuration of the movable clamp sections 312-1, 312-2, 312-3 in the closed position forms a substantially closed form around the aerosol source member (and possibly the receiving sleeve in some embodiments).

[0107] As similarly described above, some embodiments of the receiving sleeve may have a substantially cylindrical shape configured to receive at least the heated end of the aerosol source member. In such embodiments, the movable clamp segments 312-1, 312-2, 312-3 may have an internal shape configured to substantially surround the receiving sleeve, and therefore, at least the heated end of the aerosol source member. Specifically, the inner surfaces 318-1, 318-2, 318-3 of the movable clamp segments 312-1, 312-2, 312-3 together form a shape that complements the shape of the receiving sleeve. In this manner, when the movable clamp segments 312-1, 312-2, 312-3 are in the closed position, the inner surfaces converge to surround the receiving sleeve.

[0108] Each movable clamp section 312-1, 312-2, 312-3 of the depicted embodiment includes a series of heating elements 320-1, 320-2, 312-3 that extend outwardly from their respective inner surfaces 318-1, 318-2, 318-3. In other embodiments, it will be understood that more or fewer heating elements may be included on each movable clamp section. For example, in one embodiment, a single heating element may be included on each movable clamp section, such that there are three heating elements in total. Although other embodiments may differ (see Figure 6 ), but the series of heating elements 320-1, 320-2, 312-3 of the depicted embodiment have a staggered configuration such that the individual heating elements in the series of heating elements 20-1, 320-2, 312-3 are not aligned with one another and therefore overlap when the movable clamp sections 312-1, 312-2, 312-3 are in the closed position. In the depicted embodiment, each of the series of heating elements 320-1, 320-2, 312-3 comprises a separate closed resistive heating circuit configured to heat a section of the aerosol source member. Thus, when the movable clamp sections 312-1, 312-2, 312-3 are in the closed position, the heating elements 320-1, 320-2, 320-3 extend a certain depth into the aerosol source member. For example, in the depicted embodiment, the heating elements 320-1, 320-2, 320-3 extend through more than half of the aerosol source member. However, in other embodiments, the heating elements 320-1, 320-2, 320-3 may extend through approximately half of the aerosol source member, and in yet other embodiments, the heating elements 320-1, 320-2, 320-3 may extend through less than half of the aerosol source member.

[0109] The heating elements 320-1, 320-2, 320-3 of the depicted embodiment comprise resistive heating elements and have a blade-like shape, although in other embodiments, the heating elements 320-1, 320-2, 320-3 may have other shapes. The resistive heating elements may be configured to generate heat when an electrical current is directed through them. Such heating elements typically comprise a metallic material and are configured to generate heat due to the electrical resistance associated with passing an electrical current through them. Figure 7Each heating element 320-1, 320-2, 320-3 includes a heating element trace 320a-1, 320a-2, 320a-3 composed of a resistive material. Examples of resistive materials may include, but are not limited to, titanium, silver, nickel, nickel-chrome alloys, stainless steel, indium tin oxide, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, the heating traces 320a-1, 320a-2, and 320a-3 may be affixed to the body 320b-1, 320b-2, 320b-3 via printing, embedding, machining, extrusion casting, etc. In various embodiments, the heating traces may be affixed to the body 320b-1, 320b-2, 320b-3 composed of a metal material (e.g., aluminum, stainless steel, a metal alloy, etc.). It should be noted that in other embodiments, the body 220b may be made of another material, including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymer material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material and / or any combination thereof.

[0110] Although there may be no receiving sleeve in other embodiments, in the illustrated embodiment, a receiving sleeve (not shown) may be configured to receive the heated end of the aerosol source member. In the open position, the movable clamp sections 312-1, 312-2, 312-3 are spaced apart from each other, and the receiving sleeve and the aerosol source member are spaced apart from each other. In the closed position, the movable clamp sections 312-1, 312-2, 312-3 are adjacent to each other, with the receiving sleeve and the aerosol source member disposed therebetween. In various embodiments, actuation between the open position and the closed position (or vice versa) can be accomplished in a variety of ways, including, for example, manually (e.g., the consumer can press the clamps together), or automatically or semi-automatically, such as by using a hydraulic gas spring or other force-displacement mechanism that transmits force to the movable clamps 312-1, 312-2, 312-3. Another example may include a linear displacement motor or other actuator configured to displace the movable clamp sections 312-1, 312-2, 312-3 between an open position and a closed position. Other examples include piezoelectric actuators, ultrasonic ceramic actuators, rotating coil systems, lead screw systems, cam follower mechanisms, gear mechanisms, linkages, and / or any other system configured to generate directional and / or rotational motion and transmit that motion to the movable clamp sections 312-1, 312-2, 312-3. Regardless of the mechanism employed, this motion can be activated similarly to that described above via a button and / or via use of the device (e.g., by powering the device, by inhaling on an aerosol source member, or inserting the aerosol source member into the device), and / or via a resistive probe.

[0111] Figure 8 shows a perspective view of an aerosol delivery device 400 according to another exemplary embodiment of the present disclosure, and Figure 9 An exploded perspective view of an aerosol delivery device 400 is shown. Specifically, the aerosol delivery device 400 of the depicted embodiment includes a first housing portion 402, a second housing portion 404, a mouthpiece 406, an aerosol source member 408 (the aerosol source member includes an aerosol generating component, an outer packaging and a filter portion), a heating assembly 410 and an indicator 412. The aerosol delivery device 400 also includes an electrical energy source (not visible, such as a battery, which can be a rechargeable and / or rechargeable supercapacitor) and control components (not visible, such as a microprocessor alone or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.). As will be discussed in more detail below, the heating assembly 410 of various embodiments includes a series of independent and different heating members, wherein each heating member is configured to heat a portion of the aerosol source member 408.

[0112] In various embodiments, one or both of the control component and the electrical energy source can be coupled to the first housing portion 402 and / or the second housing portion 404. For the purposes of this application, when the phrase "coupled to" is used with respect to one component relative to another, the phrase encompasses embodiments in which one component is located within the other component and / or embodiments in which one component is separate but otherwise operably connected to the other component. For example, in the illustrated embodiment, both the control component and the electrical energy source are located within the first housing portion 402; however, in other embodiments, one or both of the control component and the electrical energy source can be located in different components. Further information regarding the control component and the electrical energy source is provided below.

[0113] In various embodiments, the first housing portion 402 and the second housing portion 404 can be mechanically coupled together in various ways. For example, in some embodiments, the first housing portion 402 and the second housing portion 404 can be coupled via a threaded connection. In other embodiments, the first housing portion 402 and the second housing portion 404 can be coupled via an interference fit or a friction fit. In other embodiments, the first housing portion 402 and the second housing portion 404 can be coupled via a magnetic connection. In other embodiments, the first housing portion 402 and the second housing portion 404 can be coupled via a snap-fit ​​connection. In other embodiments, the first housing portion 402 and the second housing portion 404 can be coupled via a bayonet-type connection comprising a male component (e.g., a pin) and a female component (e.g., an L-shaped slot). It should be noted that in some embodiments, the first housing portion 402 and the second housing portion 404 can comprise a single, integral housing portion.

[0114] Although other embodiments may differ, in the illustrated embodiment, the aerosol source member 408 is inserted into the second housing portion 404 by removing the mouthpiece 406 and inserting the aerosol source member 408, thereby positioning it near (e.g., above) the heating assembly 410. In the depicted embodiment, there is a single series of heating elements 420 extending from the heating assembly frame 422, such that they are configured to be positioned on one side of the aerosol source member 408; however, in other embodiments, there may be two or more series of heating elements 420 configured to be positioned on opposite sides of the aerosol source member 408. After the aerosol source member 408 is inserted, the mouthpiece 406 can then be reinserted into the second housing portion 404, such that the filter end of the aerosol source member 404 is closest to the mouthpiece 406. In this manner, one or both of the second housing portion 404 or the aerosol source member 408 can be keyed, or in other cases, can include stop features or locating features to facilitate their proper positioning. In various embodiments, the first housing portion 402, the second housing 404, and / or the mouthpiece 406 are detachable from one another, and thus any or all are replaceable.

[0115] In some embodiments, the first housing portion 402 and / or the second housing portion 404 may further include one or more buttons configured to activate certain operations of the device 400, such as, for example, turning on the device and initiating heating of the heating assembly 410 (e.g., one or more heating elements of the heating assembly). As will be discussed in greater detail below, in various embodiments, the aerosol source member 408 may include an aerosol-generating component configured to be positioned proximate to the heating assembly 410, and a filter configured to be positioned proximate to the mouthpiece 406. It should be noted that while the first housing portion 402, the second housing portion 404, and the aerosol source member 408 of the illustrated embodiment have a substantially elongated rectangular cuboid shape, in other embodiments, the first housing portion 402, the second housing portion 404, and / or the aerosol source member 408 may have any other shape, including, for example, the shape of a conventional cigarette or cigar.

[0116] In particular embodiments, the first housing portion 402, the second housing portion 404, and / or the aerosol source member 408 can be referred to as disposable or reusable. For example, the electrical energy source and / or the first housing portion 402 containing the electrical energy source can include replaceable or rechargeable batteries, solid-state batteries, thin-film solid-state batteries, rechargeable supercapacitors, and the like, and thus can be combined with any type of charging technology, including: connection to a wall charger, connection to a car charger (e.g., a cigarette lighter socket), and connection to a computer such as via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a solar panel of photovoltaic cells (sometimes referred to as solar cells) or solar cells, or wireless chargers such as chargers using inductive wireless charging (e.g., including wireless charging according to the Qi wireless charging standard of the Wireless Power Consortium (WPC)), or wireless radio frequency (RF)-based chargers. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the aerosol source member 408 and / or the second housing portion 404 containing the aerosol source member and / or the mouthpiece 406 may comprise a disposable device. Disposable components for controlling a body are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0117] In some embodiments, the control component may include a control circuit (which may be connected to additional components, as further described herein) that is connected to an electrical energy source via conductive wires. In various embodiments, the control component may control when and how the heating assembly 410 (e.g., one or more heating members of the heating assembly) receives electrical energy to heat the aerosol-generating component for releasing the inhalable substance for inhalation by the consumer. Such control (e.g., control of the heating phase, including preheating and final heating) may involve actuation of a pressure-sensitive switch, etc., which will be described in more detail below. It should be noted that the terms "connect" or "couple" should not be understood to necessarily mean a direct connection without intermediate components. Rather, these terms may cover direct connection and / or connection via one or more intermediate components. Thus, in various embodiments, these terms may be understood to mean operably connected to or operably coupled to. In various embodiments, the control components of the present disclosure may include the control components described in U.S. patent application Ser. No. 15 / 976,526, filed on May 10, 2018, entitled “Control Component for Segmented Heating in an Aerosol Delivery Device,” which is incorporated herein by reference in its entirety.

[0118] In various embodiments, the control component can be configured to closely control the amount of heat provided to the aerosol-generating component of the aerosol source member. While the amount of heat required to volatilize the aerosol-generating component in sufficient volume to provide the desired dose of inhalable substance may vary for each specific substance used, heating the heating member to at least 120°C, at least 130°C, or at least 140°C can be particularly advantageous. In certain embodiments, preheating can be performed at at least 50°C, at least 75°C, at least 100°C, or 125°C. In some embodiments, in order to volatilize the appropriate amount of aerosol-generating component and thereby provide the desired dose of inhalable substance, the heating temperature can be at least 150°C, at least 200°C, at least 220°C, at least 300°C, or at least 350°C. However, it is particularly desirable to avoid heating to temperatures significantly exceeding about 550°C to avoid degradation and / or premature volatilization of the aerosol-generating component. In particular, heating should be performed at a sufficiently low temperature and for a sufficiently short time to avoid significant combustion (preferably any combustion) of the aerosol-generating component. The present disclosure may specifically provide components of the present article in combination and use modes that will produce a desired amount of inhalable substance at a relatively low temperature. Thus, production can refer to one or both of the generation of an aerosol within the article and its delivery to the consumer outside the article. In specific embodiments, the heating temperature can be from about 120°C to about 300°C, from about 130°C to about 290°C, from about 140°C to about 280°C, from about 150°C to about 250°C, or from about 160°C to about 200°C. The duration of heating can be controlled by many factors, as discussed in more detail below. As further described herein, the heating temperature and duration can depend on the desired volume of aerosol and ambient air that is desired to be inhaled through the aerosol source component. However, the duration can vary depending on the heating rate of the heating component, as the article can be configured so that the heating component is only energized until the desired temperature is reached. Alternatively, the duration of heating can be linked to the duration of the consumer's puff on the article. Typically, as described above, the temperature and time of heating (as well as the heater's power-on cycle) will be controlled by one or more components contained in the control body.

[0119] The amount of the inhalable material released by the aerosol source member can change based on the property of the aerosol forming component. Preferably, the aerosol source member is configured with a sufficient amount of aerosol forming component, is configured with a sufficient amount of any aerosol forming agent, and works at a sufficient temperature for a sufficient time to release the desired amount in use. This amount can be provided from the aerosol source member in the form of a single inhalation, or can be separated and provided by multiple suctions from the article in a relatively short time (for example, less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes or less than 5 minutes). For example, the device can provide nicotine in an amount of about 0.01 milligram to about 0.1 milligram, about 0.05 milligram to about 1.0 milligram, about 0.08 milligram to about 0.5 milligram, about 0.1 milligram to about 0.3 milligram or about 0.15 milligram to about 0.25 milligram in each suction on the aerosol source member. In other embodiments, the desired amount can be characterized based on the amount of the wet total particulate matter delivered based on the suction duration and volume. In some embodiments, the aerosol source member can be used to deliver at least 1.0 milligrams of wet total particulate matter in each puff for a limited number of puffs (as described herein in other aspects). Any standard smoking machine can be used to carry out this type of test. In other embodiments, the amount of the total particulate matter (TPM) produced in each puff under the same conditions can be at least 1.5 milligrams, at least 1.7 milligrams, at least 2.0 milligrams, at least 2.5 milligrams, at least 3.0 milligrams, approximately 1.0 milligrams to approximately 5.0 milligrams, approximately 1.5 milligrams to approximately 4.0 milligrams, approximately 2.0 milligrams to approximately 4.0 milligrams, approximately 2.0 milligrams to approximately 3.0 milligrams, approximately 4.0 milligrams to approximately 6.0 milligrams, approximately 6.0 milligrams to approximately 8.0 milligrams or approximately 8.0 milligrams to approximately 10.0 milligrams.

[0120] As noted, the aerosol delivery device 400 of some embodiments may include a button that may be linked to a control component for manually controlling the heating element. For example, in some embodiments, a consumer may use a button to energize the heating element 410. Similar functions associated with buttons may be implemented by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Therefore, the actuation of the heating element 410 may be controlled by a single button. Alternatively, a plurality of buttons may be provided to control various actions respectively. In some embodiments, the one or more buttons present may be substantially flush with the outer shell of the first housing portion 402 and / or the second housing portion 404.

[0121] As an alternative (or in addition) to any button, the aerosol delivery device 400 of the present disclosure may include a component that energizes the heating assembly 410 in response to a consumer inhaling on the article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) in the first housing portion 402 and / or the second housing portion 404 and / or the mouthpiece 406 that is sensitive to changes in pressure or airflow when the consumer inhales on the article (i.e., a puff-activated switch). Other suitable current actuation / deactuation mechanisms may include a temperature-activated on / off switch or a lip pressure-activated switch, or a touch sensor (e.g., a capacitive touch sensor) configured to sense contact between a user (e.g., a user's mouth or finger) and one or more surfaces of the aerosol delivery device 400. An exemplary mechanism that can provide this suction actuation capability includes a 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. in Freeport, Illinois. Utilizing such a sensor, when a consumer inhales on the device, the heating mouthpiece 410 can be quickly activated by changes in pressure. In addition, flow sensing devices such as those using the hot wire anemometer principle can be used to cause the heating assembly to be energized quickly enough after sensing a change in air flow. Another available suction actuation switch is a pressure differential switch, such as the MPL-502-V model A from Micro Pneumatic Logic, Inc. in Fort Lauderdale, Florida. Another suitable suction actuation mechanism is a sensitive pressure sensor (e.g., equipped with an amplifier or gain stage), which is in turn coupled to a comparator to detect a predetermined threshold pressure. Another suitable suction actuation mechanism is a blade deflected by an airflow, the movement of which is detected by a motion sensing device. Another suitable actuation mechanism is a piezoelectric switch. Another useful switch is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, from the MicroSwitch division of Honeywell Inc., Freeport, Illinois. Other examples of on-demand electrical switches that can be used in heating circuits according to the present disclosure are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, etc. will be apparent to those skilled in the art in light of this disclosure.In some embodiments, a pressure sensing tube or other passageway providing a fluid connection between the suction-activated switch and the aerosol source member may be included in the first housing portion 402 and / or the second housing portion 404 so that changes in pressure during suction are readily recognized by the switch. Other exemplary suction-activated devices that may be useful according to the present disclosure are disclosed in U.S. Patents Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., 5,372,148 to McCafferty et al., 6,040,560 to Fleischhauer et al., 7,040,314 to Nguyen et al., and 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. Reference may also be made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0122] In some embodiments, when a consumer inhales on the mouthpiece 406, a current actuation mechanism may allow unrestricted or uninterrupted flow of current through the heating element 410 to rapidly generate heat. Due to the rapid heating, it may be useful to include a current regulation component to (i) regulate the current flowing through the heating element to control the heating of the resistive element and the temperature experienced thereby, and (ii) prevent overheating and degradation of the aerosol-forming component. In some embodiments, the current regulation circuit may be time-based. Specifically, such a circuit may include a mechanism for allowing uninterrupted current to flow through the heating element for an initial period during inhalation, and a timer mechanism for subsequently regulating the current until the inhalation is complete. For example, subsequent regulation may include rapidly switching the current on and off (e.g., on the order of approximately every 1 to 50 milliseconds) to maintain the heating element within a desired temperature range. Further, regulation may include simply allowing uninterrupted current to flow until the desired temperature is reached, and then completely shutting off the current. The consumer may reactivate the heating element by initiating another puff on the article (or manually actuating a button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent regulation can involve modulation of the current flowing through the heating member to keep the heating member within a desired temperature range. In some embodiments, in order to release the desired dose of the inhalable substance, the heating member can be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds. An exemplary time-based current regulation circuit can include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art. Exemplary timers are the C-1555C available from NEC Electronics and the ICM7555 available from General Electric Intersil, Inc., as well as various other sizes and configurations of so-called "555 timers." An exemplary comparator is available from National Semiconductor as the LM311. Further description of such a time-based current regulation circuit is provided in US Pat. No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0123] In some embodiments, the order in which the heaters are powered on can be controlled by a control unit, and corresponding data can be recorded so that if the user turns off the device (without replacing the aerosol source component), the user can later turn the device back on and continue consuming the remaining portion of the aerosol source component. For example, if the first two heaters have been powered on and the corresponding portions of the aerosol source component have been consumed by the consumer, the user can turn the device off, and when the user turns the device back on, the device will start with the third heater. Thus, in some embodiments, when the aerosol source component is removed from the device, the aerosol source component consumption status data can be reset. In some embodiments, individual heaters can be programmed to power on for multiple puffs (e.g., one to five puffs or more) before the next heater is powered on. In various embodiments, such programming may depend on the total number of heaters, the type and / or characteristics of the consumables (e.g., mass, size, glycerin level, etc.). Based on the foregoing, it can be seen that various mechanisms can be used to facilitate the activation / deactivation of the current to the heating components. For example, the device may include a timer for adjusting the current in the article (e.g., during the consumer's inhalation). The device may also include a timer-responsive switch that enables and disables current flow to the heating element. Current regulation may also include the use of a capacitor and a component that charges and discharges the capacitor at a defined rate (e.g., a rate that approximates the rate at which the heating element heats and cools). Specifically, the current may be regulated so that during an initial period of inhalation, current flows continuously through the heating element, but after this initial period, the current may be interrupted or alternately cycled until inhalation is complete. As described above, this cycling may be controlled by a timer that generates a preset switching cycle. In certain embodiments, the timer may generate a periodic digital waveform. The flow rate during the initial period may also be regulated using a comparator that compares a first voltage at a first input with a threshold voltage at a threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby activating the timer. Such embodiments may also include a component for generating a threshold voltage at the threshold input and a component for generating a threshold voltage at the first input after the initial period has elapsed.

[0124] Further other components may be employed in the aerosol delivery devices of the present disclosure. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device to detect user lip movement associated with inhalation and subsequently triggering heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy into a heating load array in response to a pressure drop across the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device, the receptacle including an identification member that detects non-uniformity in infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle having multiple differential phases. ; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic-optoelectronic component; U.S. Patent No. 5,954,979 to Counts et al. discloses a means for varying the resistance to inhalation through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and allow computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT patent application publication WO2010 / 003480 to Flick discloses a fluid flow sensing system for indicating puffing in an aerosol generating system; all of the foregoing disclosures are incorporated herein by reference in their entirety. Another approach uses changes in electrical resistance to actuate the aerosol delivery device and / or its heating element. This approach utilizes a very thin metal probe, in the form of a ribbon or wire, mounted perpendicular to the airflow within the cartridge. The user-generated airflow exerts a mechanical force on the probe, causing it to flex to a certain degree. This geometric change, which causes a portion of the probe to bend / tension, results in a change in the probe's electrical resistance. This change in resistance is transmitted as a pulse / information to the PCB, serving as a trigger for activating the heating element 410.

[0125] Further examples of components related to electronic aerosol delivery articles and materials or components that can be used in the articles of the present disclosure are disclosed in U.S. Patent Nos. 4,735,217 to Gerth et al.; 5,249,586 to Morgan et al.; 5,666,977 to Higgins et al.; 6,053,176 to Adams et al.; 6,164,287 to White; 6,196,218 to Voges; 6,810,883 to Fleter et al.; 6,854,461 to Nichols; 7,832,410 to Hon; 7,513,253 to Kobayashi; 7,896,006 to Hamano; 6,196,218 to Shayan; and 6,196,227 to Osaka. ,772,756; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; U.S. Patent No. 8,794,231 to Thorens et al.; U.S. Patent No. 8,851,083 to Oglesby et al.; U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 9,220,302 to Depiano et al.; U.S. Patent No ...8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 8,920,302 to Depiano et al.; U.S. Patent No. 8,915,254 to Hon; U.S. Patent No. 8,915,254 to Oglesby et al.; U.S. Patent No. 8,915,254 to Monsees et al.; U.S. Patent No. 8,915,254 to Monsees et al.; U.S. Patent No. 8,915,

[0015] The present invention relates to a novel device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0016] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0017] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0018] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0019] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0019] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0020] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0021] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0022] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0023] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0024] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0025] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0026] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0027] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0028] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices. [0029 ...

[0126] As described above, the electrical energy source used to power the various electrical components of device 400 can take various forms. Preferably, the electrical energy source is capable of delivering sufficient energy to rapidly heat the heating element in the manner described above and, when used in conjunction with the plurality of aerosol source elements 408, to power the device, while still being conveniently assembled within device 400. Examples of useful electrical energy sources include, preferably, rechargeable lithium-ion batteries (e.g., rechargeable lithium-manganese dioxide batteries). Specifically, lithium polymer batteries can be used, as they offer increased safety. Other types of batteries, such as nickel-cadmium batteries, can also be used. Furthermore, the preferred electrical energy source is lightweight enough so as not to detract from the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191, filed October 21, 2015, by Sur et al., the disclosures of each of which are incorporated herein by reference in their entirety.

[0127] An example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery produced by Tadrian Battery GmbH in Germany. In another embodiment, a useful electrical energy source may be an N50-AAA nickel-cadmium battery produced by Sanyo Electric Company of Japan. In other embodiments, multiple such batteries, for example, batteries each providing a voltage of 1.2 volts, may be connected in series. Other electrical energy sources such as rechargeable lithium-manganese dioxide batteries may also be used. Any of these batteries or a combination thereof may be used in the electrical energy source, but rechargeable batteries are preferred due to the cost and handling considerations associated with disposable batteries. In embodiments using rechargeable batteries, the aerosol delivery device 400 may also include charging contacts for interacting with corresponding contacts in a conventional charging unit (not shown) that draws power from a standard 120 volt AC wall outlet or other power source, such as a car electrical system or a portable power source. In other embodiments, the electrical energy source may also include a capacitor. Capacitors discharge faster than batteries and can be charged between puffs, allowing the battery to discharge into the capacitor at a lower rate than when directly powering the heating element. For example, supercapacitors, such as electric double layer capacitors (EDLCs), can be used separately from or in combination with batteries. When used alone, the supercapacitors can be charged before each use of the device 400. Therefore, the present disclosure may also include a charger component that can be attached to the device between uses to replenish the supercapacitors. Thin film batteries can be used in certain embodiments of the present disclosure.

[0128] As described above, in various embodiments, the aerosol delivery device 400 may include one or more indicators, such as indicator 412, which is located near the distal end of the first housing portion 402 in the depicted embodiment. In various embodiments, the one or more indicators may be located anywhere on the first housing portion 402 and / or the second housing portion 404 and / or the mouthpiece 406. In some embodiments, the indicator may include a light (e.g., a single or multi-color light emitting diode (LED)) that provides an indication of multiple aspects of device use. For example, in some embodiments, a series of lights may correspond to the number of puffs of a given aerosol source component. Specifically, the lights may illuminate successively with each puff, such that when all lights are illuminated, the consumer is informed that the aerosol source component has been used up. Alternatively, when the aerosol source component is inserted into the housing, all lights may be illuminated, and with each puff, the lights may be turned off, such that when all lights are off, the consumer is informed that the aerosol source component has been used up. In other embodiments, for example, each light may correspond to a respective heating element, and once the respective heating element has reached a puff threshold (e.g., one to five puffs or more), the light may be turned off, thereby indicating that that portion of the aerosol source component has been used up. In yet other embodiments, there may be only a single indicator, and its indicator may indicate that current is flowing to the heating component and that the device is actively heating. This ensures that the consumer does not unknowingly leave the device unattended in active heating mode. In alternative embodiments, one or more indicators may be components of the aerosol source component. Although the indicators are described above in an on / off manner with respect to visual indicators, other operational indicators are also included. For example, a visual indicator may also include a change in the color or intensity of the light to show the progress of the smoking experience. Tactile indicators and auditory indicators are similarly encompassed by the present disclosure. Moreover, a combination of such indicators may also be used in a single device.

[0129] In various embodiments, the first housing portion 402 and / or the second housing portion 404 and / or the mouthpiece 406 may be formed of any material suitable for forming and maintaining an appropriate configuration, such as a tubular or rectangular shape, and for retaining the aerosol source component therein. In some embodiments, as further discussed herein, the housing may be formed of a single wall and may be formed of one or more materials (natural or synthetic) that are heat-resistant so as to maintain their structural integrity, e.g., not degrade, at least at the temperature of the heating temperature provided by the electric heating component. In some embodiments, a heat-resistant polymer may be used. In other embodiments, a ceramic material may be used. In yet other embodiments, an insulating material may be used to avoid unnecessarily drawing heat away from the aerosol source component. When the housing is formed of a single layer, its thickness may preferably be from about 0.1 mm to about 2 mm, from about 0.2 mm to about 5.0 mm, from about 0.5 mm to about 4.0 mm, from about 0.5 mm to about 3.0 mm, or from about 1.0 mm to about 3.0 mm. Other exemplary types of components and materials that can be used to provide the above-described functions or as alternatives to the above-described materials and components can be those described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al.; No. 2010 / 00186757 to Crooks et al.; and No. 2011 / 0041861 to Sebastian et al.; the disclosures of which are incorporated herein by reference in their entirety.

[0130] like Figure 9As shown, the depicted embodiment includes a heating assembly 410 that includes a series of individual resistive heating elements 420 extending from a heating assembly frame 422. In various embodiments, the control assembly is configured to control each heating element 420 independently and / or in any combination, wherein activation of the heating element 420 is initiated using any of the methods described above. In the depicted embodiment, each heating element 420 is configured to heat a section of the aerosol source component 408. The heating elements 420 of the depicted embodiment include resistive heating elements and have a substantially flat rectangular shape, although in other embodiments, the heating elements 420 may have other shapes. The resistive heating elements may be configured to generate heat when an electric current is directed through them. Such heating elements typically include a metallic material or a conductive ceramic material and are configured to generate heat due to the resistance associated with the passage of electric current. In the depicted embodiment, each of the heating elements includes a heating element wire and / or trace 420a (hereinafter referred to as a "heating trace") constructed of a resistive material. Examples of resistive materials may include, but are not limited to, titanium, silver, nickel, nickel-chrome, stainless steel, tungsten, indium tin oxide, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, each heating trace 420a may be affixed to a body portion 420b, which, in the illustrated embodiment, may be an extension of or a portion of the heating assembly frame 422. In various embodiments, each heating trace 420a may be formed by printing, embedding, machining, extrusion casting, and other particle deposition techniques such as chemical vapor deposition (CVD), physical vapor deposition (PVD), and the like. In various embodiments, the heating assembly frame 422 and / or the main body portion 420b may be constructed from a metal material (e.g., aluminum, stainless steel, a metal alloy, etc.); however, in other embodiments, the heating assembly frame 422 and / or the main body portion 420b may be constructed from another material, including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, boron nitride, etc.), a polymer material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof.

[0131] Figure 10 An exemplary embodiment according to the present disclosure is shown. Figure 94. A perspective view of an aerosol source member 408 of the aerosol delivery device 400 is shown. In the depicted embodiment, the aerosol source member 408 includes an aerosol-generating component 430, an outer packaging material 432, and a filter portion 434. As will be discussed in more detail below, when the aerosol source member 408 of the depicted embodiment is installed in the second housing portion 404 of the aerosol delivery device 400, the filter portion 434 can be positioned adjacent the mouthpiece 406. In some embodiments, the aerosol source member 408 can be insertable and removable from the second housing portion 404, such as, for example, by removing the mouthpiece 406. In other embodiments, the second housing portion 404 and the aerosol source member 408 can be insertable and removable from the first housing portion 402.

[0132] As noted, the aerosol-generating component 430 of the depicted embodiment can include a solid or semi-solid material, which can be tobacco or tobacco-derived material or non-tobacco material. In various embodiments, such materials can include tobacco-containing beads, tobacco shreds, tobacco rods, reconstituted tobacco materials, or combinations thereof, and / or a mix of finely ground tobacco, tobacco extracts, spray-dried tobacco extracts, extruded tobacco, tobacco flakes, or mixed with optional inorganic materials (such as calcium carbonate), optional flavorings and / or adhesives, and aerosol-forming materials such as, for example, glycerol to form other tobacco forms that are substantially solid or formable (e.g., extrudable) substrates. Gels and suspensions can also be used. Some representative types of structures and formulations of solid and semisolid aerosol-generating components are disclosed in U.S. Patent No. 8,424,538 to Thomas et al.; U.S. Patent No. 8,464,726 to Sebastian et al.; U.S. Patent Application Publication No. 2015 / 0083150 to Conner et al.; U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al.; and U.S. Patent Application Publication No. 2017-0000188 filed on June 30, 2015 by Nordskog et al., all of which are incorporated herein by reference in their entirety.

[0133] As mentioned above, in various embodiments, the aerosol generating component may include a kind of aerosol generating component. The aerosol generating component can be any material that releases an inhalable substance, such as a substance containing a flavoring agent when heated. In the embodiment shown in the accompanying drawings, the aerosol generating component is a solid or semi-solid substrate comprising an inhalable substance. The inhalable substance can specifically be a tobacco component or a material derived from tobacco (that is, a material naturally present in tobacco, which can be directly separated from tobacco or can be artificially prepared) or a non-tobacco material. For example, the aerosol generating component may include a tobacco extract or a fraction thereof combined with an inert substrate. The aerosol generating component may also include unburned tobacco or a composition containing unburned tobacco, which, when heated to a temperature below its combustion temperature, releases an inhalable substance. Although it is less preferred, the aerosol generating component may include tobacco condensate or a fraction thereof (that is, a condensation component of the smoke produced by burning tobacco, thereby leaving flavoring agents, and possibly leaving nicotine).

[0134] In various embodiments, heating of the aerosol-generating component 430 can result in aerosolization of an aerosol precursor composition associated with the aerosol-generating component 430. In various embodiments, the filter portion 434 of the aerosol source assembly 408 is configured to receive the generated aerosol passing through the filter portion in response to inhalation applied by a user to the mouthpiece 406 of the aerosol delivery device 400. Preferably, the elements of the aerosol-generating component 430 do not undergo any significant degree of thermal decomposition (e.g., charring, burning, or burning), and the aerosol component is entrained in air that is inhaled through the aerosol delivery device 400, including the filter portion (if present), and into the mouth of the user.

[0135] In one embodiment, the aerosol-forming component may include a mixture of flavored, aromatic tobacco in the form of shredded filler. In another embodiment, the aerosol-forming component may include a reconstituted tobacco material, such as described in U.S. Patent Nos. 4,807,809 to Pryor et al.; 4,889,143 to Pryor et al.; and 5,025,814 to Raker, the entireties of which are incorporated herein by reference. Additionally, the reconstituted tobacco material may include reconstituted tobacco paper for cigarettes as described in R.J. Reynolds Tobacco Company's (1988) monograph, "Chemical and Biological Studies of a Novel Cigarette Prototype for Heating as an Alternative to Burning Tobacco," the entirety of which is incorporated herein by reference. For example, the reconstituted tobacco material may include a sheet material containing tobacco and / or tobacco-related materials. Thus, in some embodiments, the aerosol-forming component may be formed from a roll of reconstituted tobacco material. In another embodiment, the substrate material may be formed from shredded, striped, and / or the like reconstituted tobacco material. In another embodiment, the tobacco sheet may include a rolled sheet of reconstituted tobacco material. In some embodiments, the base material may include overlapping layers (e.g., a gathered web) that may or may not include a thermally conductive component. Examples of aerosol-forming components including a series of overlapping layers (e.g., a gathered web) of an initial substrate sheet formed from a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components are described in U.S. Patent Application Publication No. 15 / 905,320, filed on February 26, 2018, entitled “Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device,” which is incorporated herein by reference in its entirety.

[0136] In some embodiments, the aerosol-generating component 430 may include a plurality of microcapsules, beads, particles, and / or the like comprising a tobacco-related material. For example, a representative microcapsule may be generally spherical and may have an outer covering or shell containing a liquid central region comprising a tobacco-derived extract and / or the like. In some embodiments, one or more of the substrate materials may include a plurality of microcapsules, each of which is formed into a hollow cylindrical shape. In some embodiments, one or more of the substrate materials may include a binder material configured to maintain the structural shape and / or integrity of the plurality of microcapsules formed into a hollow cylindrical shape.

[0137] Can be used for the tobacco material of present disclosure and can be different, and can comprise the tobacco of flue-cured tobacco, burley tobacco, Oriental (Oriental) tobacco, Maryland (Maryland) tobacco, dark tobacco, dark flue-cured tobacco and orchid (Rustica) cigarette and other rare or special tobacco, or its mixture.Tobacco material can also comprise so-called " mixing " form and processed form, such as the tobacco (such as puffed tobacco, such as the dry ice expanded tobacco (DIET) of preferably cut filler form) of the tobacco stem (such as cut roll or chip puffing) after processing, constant volume expansion, reconstituted tobacco (such as, the reconstituted tobacco using papermaking type or cast sheet type process to make). No. 4,836,224 to Lawson et al.; No. 4,924,888 to Perfetti et al.; No. 5,056,537 to Brown et al.; No. 5,159,942 to Brinkley et al.; No. 5,220,930 to Gentry; No. 5,360,023 to Blakley et al.; No. 6,701,936 to Shafer et al.; No. 7,011,096 to Li et al.; No. 7,017,585 to Li et al.; No. 7,025,066 to Lawson et al.; U.S. Patent Application Publication No. 2004 / 0255965 to Perfetti et al.; PCTWO to Bereman Various representative tobacco types, types of processed tobacco, and types of tobacco blends are described in U.S. Pat. No. 02 / 37990 and in the grant application to Bombick et al., Journal of Toxicology, 39, pp. 11-17 (1997); the foregoing documents are incorporated herein by reference. Other exemplary tobacco compositions that can be used to comprise a smoking device according to the present disclosure are described in U.S. Pat. No. 7,726,320 to Robinson et al., the entirety of which is incorporated herein by reference.

[0138] Still further, the aerosol-generating component may comprise an inert substrate having an inhalable substance or a precursor thereof integrated therein or otherwise deposited thereon. For example, a liquid comprising the inhalable substance may be coated on the inert substrate or absorbed or adsorbed onto the inert substrate such that upon application of heat, the inhalable substance is released in a form that can be extracted from the article of the invention by application of positive or negative pressure. In some aspects, the aerosol-generating component may comprise a mixture of flavored aromatic tobacco in the form of cut filler. In another aspect, the aerosol-generating component may comprise a reconstituted tobacco material, such as described in U.S. Patent Nos. 4,807,809 to Pryor et al.; 4,889,143 to Pryor et al.; and 5,025,814 to Raker, the entireties of which are incorporated herein by reference.

[0139] In some embodiments, the aerosol generating component may include tobacco, tobacco components, tobacco-derived materials and / or non-tobacco materials that have been treated, manufactured, produced and / or processed to combine with an aerosol precursor composition (e.g., a humectant such as propylene glycol, glycerin, etc.) and / or at least one flavoring, and a flame retardant (e.g., diammonium phosphate and / or another salt) that is configured to help prevent a heat source from igniting, pyrolyzing, burning and / or charring the aerosol delivery component. Various ways and methods of incorporating tobacco into smoking articles, particularly smoking articles designed not to intentionally burn substantially all of the tobacco in those smoking articles, are proposed in U.S. Patent Nos. 4,947,874 to Brooks et al.; 7,647,932 to Cantrell et al.; 8,079,371 to Robinson et al.; 7,290,549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al.; the entire disclosures of the foregoing documents are incorporated herein by reference.

[0140] In some embodiments, flame retardant / combustion materials and additives may be included in the aerosol generating component and may include organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol and polyols. Others such as phosphonites, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ammonium ethanol borate, ammonium sulfamate, halogenated organic compounds, thiourea and antimony oxide may also be used. In various aspects of the flame retardant, combustion and / or anti-scorch materials used in the aerosol generating component and / or other components (whether used alone or in combination with each other and / or with other materials), it is most preferred that the desired performance is provided without undesirable degassing, chemical reaction or melting type behavior. Further, other fragrances, flavorings, additives and other possible enhancing ingredients are described in U.S. Patent Application No. 15 / 707,461 to Phillips et al., the entire text of which is incorporated herein by reference.

[0141] In addition to the inhalable substance (e.g., flavoring, nicotine, or medication in general), the aerosol-forming component may also include one or more aerosol-forming or vapor-forming materials, such as polyols (e.g., glycerol, propylene glycol, or mixtures thereof) and / or water. Representative types of aerosol-forming materials are described in U.S. Pat. Nos. 4,793,365 to Sensabaugh, Jr. et al.; 5,101,839 to Jacob et al.; PCT WO 98 / 57556 to Biggs et al.; and in "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco" (1988), R.J. Reynolds Tobacco Company; the disclosures of which are incorporated herein by reference. Preferred aerosol-forming materials produce a visible aerosol when sufficient heat is applied thereto, and highly preferred aerosol-forming materials produce an aerosol that can be considered "smoke-like." In some embodiments, the present invention provides the invention claims a kind of inhalable substance, and the ... Thus, in use, substrate can be heated, and aerosol-forming material can be volatilized into vapor form together with inhalable substance. In a specific example, aerosol-generating components may include a solid substrate having tobacco pulp and smoke-forming material and / or vapor-forming material coated thereon or absorbed or adsorbed thereto. The substrate component can be any material that does not burn or degrade at a temperature at which the heating member reaches the release of inhalable substance as described herein. For example, a paper material including tobacco paper (for example, a paper-like material including tobacco fiber and / or reconstructed tobacco) can be used.Thus, in various embodiments, the aerosol-forming component can be characterized as comprising an inhalable substance, alternatively as comprising an inhalable substance and a separate aerosol-former or vapor-former, alternatively as comprising an inhalable substance and a substrate, or alternatively as comprising an aerosol-forming component, a separate aerosol-former or vapor-former, and a substrate. Thus, the substrate can comprise one or both of the inhalable substance and the aerosol-former or vapor-former.

[0142] If desired, tobacco material or aerosol generating component can also generally include other components, such as sugar, glycerine, vanilla, cocoa, liquorice and other flavoring materials such as menthol. In the U.S. Patent Application Publication No. 2012 / 0152265 of Dube et al. and the U.S. Patent No. 9,107,453 granting Dube et al., a composition of an exemplary plant origin that can be used is disclosed. Based on factors such as the required organoleptic properties of the product of the present invention, the selection of these other components is variable, and the disclosure is intended to cover any such other components that are apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. Referring to " Tobacco Flavoring Substances and Methods (tobacco flavoring substances and methods) " (1972) by Gutcho of Noyes Data Corp. and " Tobacco Flavoring for Smoking Products (tobacco flavoring for smoking products) " (1972) by Leffingwell et al.

[0143] The inhalable substance and / or the separate vapor-forming material can be disposed on the aerosol-generating component in a variety of different configurations. For example, both materials can be associated with the aerosol-generating component such that the concentration of each material is substantially constant along the length of the aerosol-generating component (e.g., when the substrate is divided into a plurality of longitudinal segments, the total concentration of the material in each separate segment can be substantially similar, e.g., varying by less than 10%, less than 5%, or less than 2% by weight). In other embodiments, one or both of the materials can be present in a defined pattern. For example, the pattern can be a gradient, wherein the concentration continuously increases or decreases along the length of the substrate. In this manner, the first puff on the article can provide a significantly greater or lesser amount of inhalable substance than the last puff. The gradient can also be designed to provide a uniform generation of inhalable substance over all puffs. Furthermore, the pattern can be such that a single point along the length of the substrate provides a large injection of inhalable substance (e.g., corresponding to the first puff, the last puff, or some intermediate puffs on the article). Any variety of such patterns are contemplated in accordance with the present disclosure, and such variations are also encompassed by the present disclosure. Such patterns can also be applied to other components described herein (e.g., flavoring). For example, a large shot of flavoring can be provided on the substrate in a position substantially corresponding to the last puff, or the last two or three puffs on the article. The release of such flavoring can signal to the consumer that the final puff on the device is approaching or has been reached. Various other configurations and components that can be included in the aerosol-generating components of the present disclosure are described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0144] In some aspects of the present disclosure, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., the aerosol generating component can be configured as an extruded material, the entire text of which is incorporated herein by reference. In another aspect, the aerosol generating component can be configured to include tobacco, tobacco-related materials, glycerol, water and / or adhesive materials or an extruded structure and / or substrate consisting essentially of these materials, although some formulations do not include adhesive materials. In various aspects, the adhesive material can be any adhesive material commonly used in tobacco formulations, including, for example, carboxymethyl cellulose (CMC), gums (e.g., guar gum), xanthan gum, pullulan and / or alginate. According to some aspects, the adhesive material included in the aerosol delivery component can be configured to substantially maintain the structural shape and / or integrity of the aerosol delivery component. Various representative adhesives, adhesive properties, uses of adhesives, and amounts of adhesives are described in U.S. Patent No. 4,924,887 to Raker et al., the entire text of which is incorporated herein by reference.

[0145] In some embodiments, the aerosol generating component can also be configured to substantially maintain its structure throughout the aerosol generation process. That is, the aerosol generating component is configured to substantially maintain its shape throughout the aerosol generation process (i.e., the aerosol delivery component is discontinuously deformed under the applied shear stress). Although in some embodiments, the aerosol generating component may include a liquid and / or some moisture, in some embodiments, the aerosol generating component is configured to remain substantially solid throughout the aerosol generation process and maintain its structural integrity throughout the aerosol generation process. Exemplary tobacco and / or tobacco-related materials suitable for use in substantially solid aerosol delivery components are described in U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al.; U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al.; U.S. Patent No. 6,204,287 to White; and U.S. Patent No. 5,060,676 to Hearn et al., each of which is incorporated herein by reference in its entirety.

[0146] In yet another aspect, the aerosol-generating component may comprise an extruded structure and / or substrate formed from marumarized tobacco and / or non-marumarized tobacco. Marumarized tobacco is known from, for example, U.S. Pat. No. 5,105,831 to Banerjee et al., the entirety of which is incorporated herein by reference. Marumarized tobacco comprises a tobacco blend in powder form of about 20% to about 50% by weight, glycerin (about 20% to about 30% by weight), calcium carbonate (generally about 10% to about 60% by weight, typically about 40% to about 60% by weight), and a binder and / or flavoring as described herein.

[0147] In various embodiments, the aerosol-generating component wall may be substantially formed from a material that can naturally include an inhalable substance therein (e.g., tobacco paper), or may be formed from any other material (e.g., paper) that can entrain an inhalable substance and / or a vapor-forming or aerosol-forming agent therein. In addition to the inhalable substance and / or vapor-forming or aerosol-forming substance, the substrate wall may also include other components. For example, a vapor barrier may be included on the outer surface of the aerosol-generating component wall. Preferably, when the aerosol-generating component is heated, the vapor barrier is positioned on the wall surface adjacent to (or in contact with) the heating element. In specific embodiments, the vapor barrier may be formed from an electrically insulating material or may include a layer of electrically insulating material that can contact the heating element. For example, a metal foil may be used as a vapor barrier, and the foil may have an insulating single layer, such as a metal oxide layer, in contact with the heating element to prevent the release of vapor or aerosol into the external volume of the aerosol-generating component and to facilitate the release of vapor or aerosol into the annular space defined by the inner surface of the aerosol-generating component wall. Any vapor barrier material, such as metal foil, may be used.

[0148] In other embodiments, the aerosol-generating component may be formed from a material that softens or changes phase (particularly from a solid to a molten state) near the operating temperature of the article. For example, the aerosol-generating component may be a wax or a gel, and the inhalable substance may be entrained therein. In such embodiments, it may be particularly useful to include a vapor barrier (or similar material) that provides support for the aerosol-generating component and substantially prevents the aerosol-generating component from contacting the heating member. Similarly, the aerosol-generating component may include a vapor barrier layer coated with the inhalable substance and / or aerosol-forming material. For example, one or more such coatings may be in the form of microcapsules that preferably release their components at temperatures within one or more operating ranges described elsewhere herein. Microencapsulation technology that may be useful in such embodiments is disclosed, for example, in U.S. Patent No. 4,464,434 to Davis.

[0149] In one embodiment, the aerosol generating component may include a tobacco component (such as, for example, reconstituted tobacco flakes or tobacco beads) or a non-tobacco component (such as herbs, paper, cellulose, etc.) and have one or more of the following: a binder component, a humectant component, a flavoring component, a moisturizing component, and a packaging material. In some embodiments, the binder component may include, for example, cellulose and / or guar gum. In some embodiments, the moisturizing component may include, for example, approximately 15-25% glycerol, approximately 14.5% sorbitol, and / or approximately 3-10% propylene glycol. In some embodiments, the flavoring component may include, for example, acetic acid, citric acid, acetylacetone, lactic acid, menthol, peppermint oil, carob pod / extract, cocoa products, licorice extract, invert sugar, and / or sucrose. In some embodiments, the moisturizing component includes, for example, approximately 15-25% water.

[0150] In the depicted embodiment, the aerosol-generating component 430, or a portion thereof, is encased in an outer packaging material 432. In the depicted embodiment, the outer packaging material comprises an aluminum laminate; however, in other embodiments, the outer packaging material may be different. In some embodiments, the outer packaging material may be formed from a thermally conductive material and / or any material used to provide additional structure and / or support for the aerosol source component. In various embodiments, the outer packaging material may comprise a material that resists (or promotes) heat transfer, which may comprise paper or other fibrous materials such as cellulose materials. The outer packaging material may also comprise at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may be in the form of water-insoluble particles. In addition, the filler material may be combined with an inorganic component. In various embodiments, the outer packaging may be formed from multiple layers, such as a loose layer at the bottom and a layer such as the typical wrapping paper in cigarettes at the top. Such materials may comprise, for example, lightweight "rag fibers" such as flax, sisal, straw, and / or esparto grass. The further discussion relevant to the construction of the outer packaging material used in the present disclosure is described in the U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety. In additional embodiments, the outer packaging material may have one or more of the following properties: it may be impermeable to the transmission of aerosols, it may have the ability to withstand the high temperature considered, it may promote the radial transmission of heat from the heater to the cut tobacco material, it may resist the heat transmission away from the heated section in the axial direction along the tobacco rod, and / or it may have a relatively low thermal mass so that it does not suppress the rapid temperature rise of the heated section. In one embodiment, the outer packaging material may be a stainless steel foil, which may be approximately 0.001 inches thick in some embodiments.

[0151] As noted, in the depicted embodiment, the aerosol source component 408 includes a filter portion 434. In various embodiments, the filter portion can be made of various materials, including, for example, cellulose acetate material, polylactic acid resin material, and / or polypropylene material. In various embodiments, the filter portion can increase the structural integrity of the aerosol source component, and / or provide filtering capacity if desired, and / or provide resistance to suction. For example, the article according to the present disclosure can exhibit a pressure drop of about 50 to about 250 mm of water column pressure drop at an air flow rate of 17.5 cc / second. In other embodiments, the pressure drop can be about 60 mm to about 180 mm, or about 70 mm to about 150 mm. The pressure drop value can be measured using a Filtrona filter test station (CTS series) available from Filtrona Instruments and Automation Ltd or a quality test module (QTM) available from the Cerulean Division of Molins, PLC. The length of the filter portion at the mouth end of the aerosol source component can vary, for example, from about 2 mm to about 20 mm, from about 5 mm to about 20 mm, or from about 10 mm to about 15 mm. In some embodiments, the filter portion can be separated from the outer packaging, and in other embodiments, the filter portion can be held in place by the outer packaging.

[0152] Additional example types of overwrap materials, packaging material components, and treated packaging materials that can be used in the overwrap of the present invention are described in U.S. Patent No. 5,105,838 to White et al.; U.S. Patent No. 5,271,419 to Arzonico et al.; U.S. Patent No. 5,220,930 to Gentry; U.S. Patent No. 6,908,874 to Woodhead et al.; U.S. Patent No. US 6,929,013 to Ashcraft et al.; U.S. Patent No. 7,195,019 to Hancock et al.; U.S. Patent No. 7,276,120 to Holmes; U.S. Patent No. 7,275,548 to Hancock et al.; PCT WO 01 / 08514 to Fournier et al.; and PCT WO 03 / 043450 to Hajaligol et al., all of which are incorporated herein by reference in their entirety. Representative wrappers are commercially available from Schweitzer-Maudit International as RJ Reynolds Tobacco Company Grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676, and 680. The porosity of the wrapper can vary and is typically between about 5 CORESTA units to about 30,000 CORESTA units, typically between about 10 CORESTA units to about 90 CORESTA units, and typically between about 8 CORESTA units to about 80 CORESTA units.

[0153] In order to maximize the delivery of aerosols and flavoring agents, one or more layers of non-porous cigarette paper can be used to enclose the aerosol source member (with or without an outer wrapper), otherwise the delivery of these aerosols and flavoring agents may be diluted by radial (i.e., external) air penetration through the outer wrapper. Examples of suitable non-porous cigarette papers are commercially available from Kimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2, and 780-63-5. Preferably, the outer wrapper is a material that is substantially impermeable to the vapors formed during use of the article of the present invention. If desired, the outer wrapper may comprise a resilient paperboard material, foil-lined paperboard, metal, polymeric material, or the like, and the material may be surrounded by the cigarette paper. As described elsewhere herein, the outer wrapper may comprise tipping paper surrounding the component and may optionally be used to attach a filter material to the aerosol source member. In various embodiments, other components may be present between the aerosol generating component and the mouth end of the aerosol source member, wherein the mouth end may comprise a filter. For example, in some embodiments, one or any combination of the following may be positioned between the aerosol-generating component and the mouth end: an air gap; a phase change material for cooling the air; a flavor-releasing medium; ion exchange fibers with selective chemical adsorption capabilities; aerogel particles as a filter medium; and other suitable materials.

[0154] When an outer packaging material is present, its total length may range from substantially the same as the length of the aerosol-generating component to about twice the length of the aerosol-generating component. Thus, the length of the aerosol-generating component may be up to about 50%, up to about 30%, or up to about 10% less than the length of the outer packaging. Preferably, the length of the aerosol-generating component may be at least 10%, at least 15%, or at least 20% less than the length of the outer packaging. More specifically, the distance that the outer packaging extends beyond the aerosol-generating component may be about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, or about 100% of the length of the aerosol-generating component.

[0155] Figure 11A perspective exploded view of an aerosol source assembly 500 according to an exemplary embodiment of the present disclosure is shown. Specifically, the aerosol delivery device 500 of the depicted embodiment includes a first housing portion 502, a second housing portion 504, a mouthpiece 506, an aerosol source assembly 508 (the aerosol source assembly is in the form of a cartridge including a liquid or semi-liquid aerosol generating component), a heating assembly 510, and an indicator 512. The aerosol delivery device 500 also includes an electrical energy source (not visible, such as a battery, which can be a rechargeable and / or rechargeable supercapacitor) and control components (not visible, such as a microprocessor alone or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.). As will be discussed in more detail below, the heating assembly 510 of various embodiments includes a series of independent and different heating components, wherein each heating component is configured to heat a portion of the aerosol source assembly 508.

[0156] In various embodiments, one or both of the control component and the electrical energy source can be coupled to the first housing portion 502. For the purposes of this application, when the phrase "coupled with" is used with respect to one component relative to another, the phrase encompasses embodiments in which one component is located within the other component and / or embodiments in which one component is separate but otherwise operably connected to the other component. For example, in the illustrated embodiment, both the control component and the electrical energy source are located within the first housing portion 502; however, in other embodiments, one or both of the control component and the electrical energy source can be located in different components. Further information regarding the control component and the electrical energy source is provided below.

[0157] In various embodiments, the first housing portion 502 and the second housing portion 504 can be mechanically coupled together in various ways. For example, in some embodiments, the first housing portion 502 and the second housing portion 504 can be coupled via a threaded connection. In other embodiments, the first housing portion 502 and the second housing portion 504 can be coupled via an interference fit or a friction fit. In other embodiments, the first housing portion 502 and the second housing portion 504 can be coupled via a magnetic connection. In other embodiments, the first housing portion 502 and the second housing portion 504 can be coupled via a snap-fit ​​connection. In other embodiments, the first housing portion 502 and the second housing portion 504 can be coupled via a bayonet-type connection comprising a male component (e.g., a pin) and a female component (e.g., an L-shaped slot). It should be noted that in some embodiments, the first housing portion 502 and the second housing portion 504 can comprise a single, unitary housing portion.

[0158] Although other embodiments may differ, in the illustrated embodiment, the aerosol source member 508 is inserted 508 into the second housing portion 504 by removing the mouthpiece 506 and inserting the aerosol source member 508, thereby positioning it adjacent to the heating assembly 510. In various embodiments, one or both of the second housing portion 504 or the aerosol source member 508 may be keyed or may include one or more stops or locating features to assist in the proper placement of the aerosol source member 508. In the depicted embodiment, there is a single series of heating elements 522 extending from the heating assembly frame 520, such that they are configured to be positioned on one side of the aerosol source member 508; however, in other embodiments, there may be two or more series of heating elements 520 configured to be positioned on opposite sides of the aerosol source member 508. After the aerosol source member 508 is inserted, the mouthpiece may then be reinserted into the second housing portion 504. In various embodiments, the mouthpiece can be attached to the second attachment portion in various ways, including, for example, via a press-fit attachment, a threaded attachment, a hinged attachment, a magnetic attachment, etc. In various embodiments, the first housing portion 502, the second housing 504, and / or the mouthpiece 506 are detachable from one another, and thus any or all are replaceable.

[0159] In some embodiments, the first housing portion 502 and / or the second housing portion 504 may further include one or more buttons configured to activate certain operations of the device 500, such as, for example, turning on the device and initiating heating of the heating assembly 510 (e.g., one or more heating elements of the heating assembly). As will be discussed in more detail below, in various embodiments, the aerosol source member 508 may include an aerosol-generating component configured to be positioned proximate to the heating assembly 510. It should be noted that while the first housing portion 502, the second housing portion 504, and the aerosol source member 508 of the illustrated embodiment have a substantially elongated rectangular cuboid shape, in other embodiments, the first housing portion 502, the second housing portion 504, and / or the aerosol source member 508 may have any other shape, including, for example, the shape of a conventional cigarette or cigar.

[0160] In particular embodiments, the first housing portion 502, the second housing portion 504, and / or the aerosol source member 508 can be referred to as disposable or reusable. For example, the electrical energy source and / or the first housing portion 502 containing the electrical energy source can include replaceable or rechargeable batteries, solid-state batteries, thin-film solid-state batteries, rechargeable supercapacitors, and the like, and thus can be combined with any type of charging technology, including: connection to a wall charger, connection to a car charger (e.g., a cigarette lighter socket), and connection to a computer such as via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a solar panel of photovoltaic cells (sometimes referred to as solar cells) or solar cells, or wireless chargers such as chargers using inductive wireless charging (e.g., including wireless charging according to the Qi wireless charging standard of the Wireless Power Consortium (WPC)), or wireless radio frequency (RF)-based chargers. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the aerosol source member 508 and / or the second housing portion 504 containing the aerosol source member 508 and / or the mouthpiece 506 may comprise a disposable device. Disposable components for controlling a body are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0161] In some embodiments, the control component may include a control circuit (which may be connected to additional components, as further described herein) that is connected to an electrical energy source via conductive wires. In various embodiments, the control component may control when and how the heating assembly 510 (e.g., one or more heating members) receives electrical energy to heat the aerosol-generating components for releasing the inhalable substance for inhalation by the consumer. Such control may involve actuation of a pressure-sensitive switch, etc., which will be described in more detail below. It should be noted that the terms "connect" or "couple" should not be understood to necessarily mean a direct connection without intermediate components. Rather, these terms may cover direct connection and / or connection via one or more intermediate components. Thus, in various embodiments, these terms may be understood to mean operably connected to or operably coupled to. In various embodiments, the control components of the present disclosure may include the control components described in U.S. patent application Ser. No. 15 / 976,526, filed on May 10, 2018, entitled “Control Component for Segmented Heating in an Aerosol Delivery Device,” which is incorporated herein by reference in its entirety.

[0162] In various embodiments, the control component can be configured to closely control the amount of heat provided to the aerosol-generating component of the aerosol source component. While the amount of heat required to volatilize the aerosol-generating component in sufficient volume to provide the desired dose of inhalable substance may vary for each specific substance used, heating the heating component to at least 120°C, at least 130°C, or at least 140°C can be particularly advantageous. In some embodiments, in order to volatilize the appropriate amount of aerosol-generating component and thereby provide the desired dose of inhalable substance, the heating temperature can be at least 150°C, at least 200°C, at least 300°C, or at least 350°C. However, it is particularly desirable to avoid heating to temperatures significantly exceeding about 550°C to avoid degradation and / or premature volatilization of the aerosol-generating component. The present disclosure can specifically provide components of the present article in combination and use mode that will produce a desired amount of inhalable substance at relatively low temperatures. Thus, production can refer to one or both of the generation of aerosol within the article and the delivery of the aerosol to the consumer. In particular embodiments, the heating temperature can be from about 120°C to about 300°C, from about 130°C to about 290°C, from about 140°C to about 280°C, from about 150°C to about 250°C, or from about 160°C to about 200°C. The duration of heating can be controlled by a number of factors, as discussed in more detail below. As further described herein, the heating temperature and duration can depend on the desired volume of aerosol and ambient air that is desired to be inhaled through the aerosol source member. However, the duration can vary depending on the heating rate of the heating member, as the article can be configured so that the heating member is only energized until the desired temperature is reached. Alternatively, the duration of heating can be linked to the duration of the consumer's puff on the article. Typically, as described above, the temperature and duration of heating will be controlled by one or more components contained in the control body.

[0163] The amount of the inhalable material released by the aerosol source member can change based on the property of the aerosol forming component. Preferably, the aerosol source member is configured with a sufficient amount of aerosol forming component, is configured with a sufficient amount of any aerosol forming agent, and works at a sufficient temperature for a sufficient time to release the desired amount in use. This amount can be provided from the aerosol source member in the form of a single inhalation, or can be separated and provided by multiple suctions from the article in a relatively short time (for example, less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes or less than 5 minutes). For example, the device can provide nicotine in the amount of about 0.01 milligram to about 0.10 milligram, about 0.05 milligram to about 1.0 milligram, about 0.08 milligram to about 0.5 milligram, about 0.1 milligram to about 0.3 milligram or about 0.15 milligram to about 0.25 milligram in each suction on the aerosol source member. In other embodiments, the desired amount can be characterized based on the amount of the wet total particulate matter delivered based on the suction duration and volume. For example, when smoking under the standard FTC smoking condition of 2 seconds and 35 milliliters, for a limited number of puffs (as described in other aspects herein), the aerosol source member can deliver at least 1.0 milligrams of wet total particulate matter in each puff. Any standard smoking machine can be used to carry out this type of test. In other embodiments, the amount of the total particulate matter (TPM) produced in each puff under the same conditions can be at least 1.5 milligrams, at least 1.7 milligrams, at least 2.0 milligrams, at least 2.5 milligrams, at least 3.0 milligrams, about 1.0 milligrams to about 5.0 milligrams, about 1.5 milligrams to about 4.0 milligrams, about 2.0 milligrams to about 4.0 milligrams, about 2.0 milligrams to about 3.0 milligrams, about 4.0 milligrams to about 6.0 milligrams, about 6.0 milligrams to about 8.0 milligrams or about 8.0 milligrams to about 10.0 milligrams.

[0164] As noted, the aerosol delivery device 500 of some embodiments may include a button that may be linked to a control component for manually controlling the heating element. For example, in some embodiments, a consumer may use a button to energize the heating element 510. Similar functions associated with buttons may be implemented by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Therefore, the actuation of the heating element 510 may be controlled by a single button. Alternatively, a plurality of buttons may be provided to control various actions respectively. In some embodiments, the one or more buttons present may be substantially flush with the outer shell of the first housing portion 502 and / or the second housing portion 504.

[0165] As an alternative (or in addition) to any button, the aerosol delivery device 500 of the present disclosure may include a component that energizes the heating assembly 510 in response to a consumer inhaling on the article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) in the first housing portion 502 and / or the second housing portion 504 and / or the mouthpiece 506 that is sensitive to changes in pressure or airflow when the consumer inhales on the article (i.e., a puff-activated switch). Other suitable current actuation / deactuation mechanisms may include a temperature-activated on / off switch or a lip pressure-activated switch, or a touch sensor (e.g., a capacitive touch sensor) configured to sense contact between a user (e.g., a user's mouth or finger) and one or more surfaces of the aerosol delivery device 500. An exemplary mechanism that can provide this suction actuation capability includes a 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. in Freeport, Illinois. Utilizing such a sensor, when a consumer inhales on the device, the heating mouthpiece 510 can be quickly activated by changes in pressure. In addition, flow sensing devices such as those using the hot wire anemometer principle can be used to cause the heating assembly to be energized quickly enough after sensing a change in air flow. Another available suction actuation switch is a pressure differential switch, such as the MPL-502-V model A from Micro Pneumatic Logic, Inc. in Fort Lauderdale, Florida. Another suitable suction actuation mechanism is a sensitive pressure sensor (e.g., equipped with an amplifier or gain stage), which is in turn coupled to a comparator to detect a predetermined threshold pressure. Another suitable suction actuation mechanism is a blade deflected by an airflow, the movement of which is detected by a motion sensing device. Another suitable actuation mechanism is a piezoelectric switch. Another useful switch is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, from the MicroSwitch division of Honeywell Inc., Freeport, Illinois. Other examples of on-demand electrical switches that can be used in heating circuits according to the present disclosure are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, etc. will be apparent to those skilled in the art in light of this disclosure.In some embodiments, a pressure sensing tube or other channel providing a fluid connection between the suction-activated switch and the aerosol source member may be included in the first housing portion 502 and / or the second housing portion 504 so that pressure changes during suction are easily identified by the switch. Other exemplary suction-activated devices that may be useful in accordance with the present disclosure are disclosed in U.S. Patents Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., 5,372,148 to McCafferty et al., 6,040,560 to Fleischhauer et al., 7,040,314 to Nguyen et al., and 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. Reference may also be made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0166] In some embodiments, when a consumer inhales on the mouthpiece 506, a current actuation mechanism may allow unrestricted or uninterrupted flow of current through the heating element 510 to rapidly generate heat. Due to the rapid heating, it may be useful to include a current regulation component to (i) regulate the current flowing through the heating element to control the heating of the resistive element and the temperature experienced thereby, and (ii) prevent overheating and degradation of the aerosol-forming component. In some embodiments, the current regulation circuit may be time-based. Specifically, such a circuit may include a mechanism for allowing uninterrupted current to flow through the heating element for an initial period during inhalation, and a timer mechanism for subsequently regulating the current until the inhalation is complete. For example, subsequent regulation may include rapidly switching the current on and off (e.g., on the order of approximately every 1 to 50 milliseconds) to maintain the heating element within a desired temperature range. Further, regulation may include simply allowing uninterrupted current to flow until the desired temperature is reached, and then completely shutting off the current. The consumer may reactivate the heating element by initiating another puff on the article (or manually actuating a button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent regulation can involve modulation of the current flowing through the heating member to keep the heating member within a desired temperature range. In some embodiments, in order to release the desired dose of the inhalable substance, the heating member can be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds. An exemplary time-based current regulation circuit can include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and are obvious to those skilled in the art. An exemplary timer is the C-1555C available from NEC Electronics and the ICM7555 available from General Electric Intersil, Inc., as well as various other sizes and configurations of so-called "555 timers." An exemplary comparator is available from National Semiconductor, model LM311. Further description of such a time-based current regulation circuit is provided in US Pat. No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0167] Based on the foregoing, it can be seen that various mechanisms can be employed to facilitate activation and deactivation of the current to the heating element. For example, the device may include a timer for regulating the current in the article (e.g., during a consumer's inhalation). The device may also include a timer-responsive switch that activates and deactivates the current to the heating element. Current regulation may also include the use of a capacitor and components that charge and discharge the capacitor at a defined rate (e.g., approximate the rate at which the heating element heats and cools). Specifically, the current may be regulated such that during an initial period of inhalation, the current flows continuously through the heating element, but after this initial period, the current may be interrupted or alternately cycled until inhalation is complete. As described above, this cycling may be controlled by a timer that generates a preset switching cycle. In certain embodiments, the timer may generate a periodic digital waveform. The flow rate during the initial period may also be regulated by using a comparator that compares a first voltage at a first input with a threshold voltage at a threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby activating the timer. Such an embodiment may further include means for generating a threshold voltage at the threshold input and means for generating a threshold voltage at the first input when the initial time period has elapsed.

[0168] Further other components may be employed in the aerosol delivery devices of the present disclosure. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device to detect user lip movement associated with inhalation and subsequently triggering heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy into a heating load array in response to a pressure drop across the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device, the receptacle including an identification member that detects non-uniformity in infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle having multiple differential phases. ; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic-optoelectronic component; U.S. Patent No. 5,954,979 to Counts et al. discloses a means for varying the resistance to inhalation through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and allow computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT patent application publication WO2010 / 003480 to Flick discloses a fluid flow sensing system for indicating puffing in an aerosol generating system; all of the foregoing disclosures are incorporated herein by reference in their entirety. Another approach uses changes in electrical resistance to actuate the aerosol delivery device and / or its heating element. This approach utilizes a very thin metal probe, in the form of a ribbon or wire, mounted perpendicular to the airflow within the cartridge. The user-generated airflow exerts a mechanical force on the probe, causing it to flex to a certain degree. This geometric change, which causes a portion of the probe to bend / tension, results in a change in the probe's electrical resistance. This change in resistance is transmitted as a pulse / information to the PCB, serving as a trigger for activating the heating element 510.

[0169] Further examples of components related to electronic aerosol delivery articles and materials or components that can be used in the articles of the present disclosure are disclosed in U.S. Patent Nos. 4,735,217 to Gerth et al.; 5,249,586 to Morgan et al.; 5,666,977 to Higgins et al.; 6,053,176 to Adams et al.; 6,164,287 to White; 6,196,218 to Voges; 6,810,883 to Fleter et al.; 6,854,461 to Nichols; 7,832,410 to Hon; 7,513,253 to Kobayashi; 7,896,006 to Hamano; 6,196,218 to Shayan; and 6,196,227 to Osaka. ,772,756; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; U.S. Patent No. 8,794,231 to Thorens et al.; U.S. Patent No. 8,851,083 to Oglesby et al.; U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 9,220,302 to Depiano et al.; U.S. Patent No ...8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 8,920,302 to Depiano et al.; U.S. Patent No. 8,915,254 to Hon; U.S. Patent No. 8,915,254 to Oglesby et al.; U.S. Patent No. 8,915,254 to Monsees et al.; U.S. Patent No. 8,915,254 to Monsees et al.; U.S. Patent No. 8,915,

[0015] The present invention relates to a novel device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0016] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0017] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0018] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0019] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0019] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0020] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0021] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0022] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0023] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0024] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0025] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0026] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0027] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices.

[0028] The present invention relates to a device comprising a capsule and a keychain-shaped structure for aerosol delivery devices. [0029 ...

[0170] As described above, the electrical energy source used to power the various electrical components of device 500 can take various forms. Preferably, the electrical energy source is capable of delivering sufficient energy to rapidly heat the heating element in the manner described above and, when used in conjunction with the plurality of aerosol source elements 508, to power the device, while still being conveniently assembled within device 500. Examples of useful electrical energy sources include, preferably, rechargeable lithium-ion batteries (e.g., rechargeable lithium-manganese dioxide batteries). Specifically, lithium polymer batteries can be used, as such batteries offer increased safety. Other types of batteries, such as nickel-cadmium batteries, can also be used. Furthermore, the preferred electrical energy source is lightweight enough so as not to detract from the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191, filed October 21, 2015, by Sur et al., the disclosures of which are each incorporated herein by reference in their entirety.

[0171] An example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery produced by Tadrian Battery GmbH in Germany. In another embodiment, a useful electrical energy source may be an N50-AAA nickel-cadmium battery produced by Sanyo Electric Company of Japan. In other embodiments, multiple such batteries, for example batteries each providing a voltage of 1.2 volts, may be connected in series. Other electrical energy sources such as rechargeable lithium-manganese dioxide batteries may also be used. Any of these batteries or a combination thereof may be used in the electrical energy source, but rechargeable batteries are preferred due to the cost and handling considerations associated with disposable batteries. In embodiments using rechargeable batteries, the aerosol delivery device 500 may also include charging contacts for interacting with corresponding contacts in a conventional charging unit (not shown) that draws power from a standard 120 volt AC wall outlet or other power source, such as a car electrical system or a portable power source. In other embodiments, the electrical energy source may also include a capacitor. Capacitors discharge faster than batteries and can be charged between puffs, allowing the battery to discharge into the capacitor at a lower rate than when directly powering the heating element. For example, supercapacitors, such as electric double layer capacitors (EDLCs), can be used separately from or in combination with batteries. When used alone, the supercapacitors can be charged before each use of the device 500. Therefore, the present disclosure may also include a charger component that can be attached to the device between uses to replenish the supercapacitors. Thin film batteries can be used in certain embodiments of the present disclosure.

[0172] As described above, in various embodiments, the aerosol delivery device 500 may include one or more indicators, such as indicator 512, which is located near the distal end of the first housing portion 502 in the depicted embodiment. In various embodiments, the one or more indicators may be located anywhere on the first housing portion 502 and / or the second housing portion 504 and / or the mouthpiece 506. In some embodiments, the indicator may include a light (e.g., a single or multi-color light emitting diode (LED)) that provides an indication of multiple aspects of the use of the device. For example, in some embodiments, a series of lights may correspond to the number of puffs of a given aerosol source component. Specifically, the lights may illuminate successively with each puff, such that when all lights are illuminated, the consumer is informed that the aerosol source component has been used up. Alternatively, when the aerosol source component is inserted into the housing, all lights may be illuminated, and with each puff, the lights may be turned off, such that when all lights are off, the consumer is informed that the aerosol source component has been used up. In yet other embodiments, there may be only a single indicator, and its indicator may indicate that current is flowing to the heating element and that the device is actively heating. This ensures that the consumer does not unknowingly leave the device unattended in the active heating mode. In alternative embodiments, one or more indicators may be components of the aerosol source element. Although the indicators are described above in an on / off manner with respect to visual indicators, other operational indicators are also included. For example, a visual indicator may also include a change in the color or intensity of light to show the progression of the smoking experience. Tactile indicators and audible indicators are similarly encompassed by the present disclosure. Moreover, a combination of such indicators may also be used in a single device.

[0173] In various embodiments, the first housing portion 502 and / or the second housing portion 504 and / or the mouthpiece 506 may be formed of any material suitable for forming and maintaining an appropriate configuration, such as a tubular or rectangular shape, and for retaining the aerosol source component therein. In some embodiments, as further discussed herein, the housing may be formed of a single wall and may be formed of one or more materials (natural or synthetic) that are heat-resistant so as to maintain their structural integrity, e.g., not degrade, at least at the temperature of the heating temperature provided by the electric heating component. In some embodiments, a heat-resistant polymer may be used. In other embodiments, a ceramic material may be used. In yet other embodiments, an insulating material may be used to avoid unnecessarily drawing heat away from the aerosol source component. When the housing is formed of a single layer, its thickness may preferably be from about 0.2 mm to about 5.0 mm, from about 0.5 mm to about 4.0 mm, from about 0.5 mm to about 3.0 mm, or from about 1.0 mm to about 3.0 mm. Other exemplary types of components and materials that can be used to provide the above-described functions or as alternatives to the above-described materials and components can be those described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al.; No. 2010 / 00186757 to Crooks et al.; and No. 2011 / 0041861 to Sebastian et al.; the disclosures of which are incorporated herein by reference in their entirety.

[0174] like Figure 11As shown, the depicted embodiment includes a heating assembly 510 comprising a series of individual resistive heating elements 522 extending from a heating assembly frame 520. In the depicted embodiment, there are six individual heating elements 520; however, in other embodiments, there may be any number of heating elements, including, for example, as few as one or more than six, such as, for example, sixteen heating elements. In various embodiments, the control assembly is configured to control the individual heating elements 520 independently and / or in any combination, wherein activation of the heating elements 520 is initiated using any of the methods described above. In the depicted embodiment, each heating element 520 is configured to heat a section of the aerosol source component 508. The heating elements 520 of the depicted embodiment comprise resistive heating elements and have a substantially flat rectangular shape, although in other embodiments, the heating elements 520 may have other shapes. Resistive heating elements may be configured to generate heat when an electrical current is directed through them. Such heating elements typically comprise a metallic material and are configured to generate heat due to the electrical resistance associated with the passage of the electrical current. In the depicted embodiment, each of the heating elements includes a heating element wire and / or trace 520a (hereinafter referred to as a "heating trace") constructed of a resistive material. Examples of resistive materials include, but are not limited to, titanium, silver, nickel, nickel-chrome, stainless steel, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, each heating trace 520a can be secured to a body portion 520b, which, in the illustrated embodiment, can be an extension of or a portion of a heating assembly frame 522. In various embodiments, each heating trace 520a can be formed on a corresponding body portion 520b via printing, embedding, machining, extrusion casting, or the like. In various embodiments, the heating assembly frame 522 and / or the main body portion 520b may be constructed from a metal material (e.g., aluminum, stainless steel, a metal alloy, etc.); however, in other embodiments, the heating assembly frame 522 and / or the main body portion 520b may be constructed from another material, including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymer material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof.

[0175] Figure 12A perspective view of an aerosol source assembly 508 in the form of a storage cartridge according to an exemplary embodiment of the present disclosure is shown. In various embodiments, the aerosol source assembly 508 includes a reservoir housing 540, a reservoir 542, and a series of atomizer chambers 544, each of which includes a liquid delivery element 546. As will be discussed in more detail below, the series of atomizer chambers 544 are configured to be substantially aligned with the series of heating elements 520 of the heating assembly 510. In various embodiments, the reservoir housing 540 may be constructed of one or more of a variety of materials, including, for example, metal materials, ceramic materials, glass materials, and / or plastic materials, such as, for example, acrylic materials (e.g., polymethyl methacrylate). In some embodiments, the reservoir housing 540 may include a translucent or transparent material so that a user can view the amount of aerosol generating component remaining therein. In the embodiment shown, the reservoir housing 540 is constructed of polypropylene or Tritan. TM However, in other embodiments, other materials are possible.

[0176] In various embodiments, the reservoir 542 can hold an aerosol-forming component, which can be in the form of a liquid or semi-liquid aerosol precursor composition. The components and compositions of some representative types of aerosol precursors are also described and characterized in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent No. 8,881,737 to Collett et al., U.S. Patent No. 9,254,002 to Chong et al.; and U.S. Patent Publication No. 2013 / 0008457 to Zheng et al.; U.S. Patent Publication No. 2015 / 0030823 to Lipowicz et al.; and U.S. Patent Publication No. 2015 / 0020830 to Koller; and WO 2014 / 182736 to Bowen et al., the entire contents of which are incorporated herein by reference. Other aerosol precursors that may be used include those included in the following products: RJ Reynolds Vapor Co. products; BLUTM products from Fontem Ventures BV; MISTIC MENTHOL products from MisticEcigs; MARK TEN products from Nu Mark LLC; JUUL products from Juul Labs; and VYPE products from British American Tobacco. Also expected are so-called "tobacco juices" for electronic cigarettes, which are already available from John Creek Ltd. Additional exemplary aerosol precursor compositions are sold under the following trade names: BLACK NOTE, COSMIC FOG, MILKMAN E-LIQUID, FIVE PAWNS, VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONESMAINLINE RESERVE, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THE JUICE MAN. Embodiments of effervescent materials can be used with aerosol precursor compositions and are described, by way of example, in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which is incorporated herein by reference in its entirety. Further, the use of effervescent materials is described, for example, in U.S. Pat. No. 4,639,368 to Niazi et al.; U.S. Pat. No. 5,178,878 to Wehling et al.; U.S. Pat. No. 6,974,590 to Pather et al.; U.S. Pat. No. 7,381,667 to Bergquist et al.; U.S. Pat. No. 8,424,541 to Crawford et al.; U.S. Pat. No. 8,627,828 to Strickland et al.; and U.S. Pat. No. 9,307,787 to Sun et al., and U.S. Patent Publication No. 2010 / 0018539 to Brinkley et al.; and PCT WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference in their entirety.Additional descriptions of embodiments of aerosol precursor compositions, including descriptions of tobacco or tobacco-derived components thereof, are provided in U.S. patent application serial numbers 15 / 216,582 and 15 / 216,590, both filed by Davis et al. on July 21, 2016, which are incorporated herein by reference in their entirety.

[0177] The reservoir housing 540 may include an aerosol passage 548 extending from one end of the reservoir housing 540 to the other end of the reservoir housing 540. Specifically, in some embodiments, when the aerosol source member 508 is inserted into the second housing portion 504, the aerosol passage 548 extends from the distal end of the reservoir housing 540 to the end of the aerosol housing 540 proximal to the mouthpiece 506. In various embodiments, the aerosol passage 548 may include a groove or slot in the reservoir housing 540 that spans across each of the nebulizer chambers 544. In this manner, when a user inhales on the aerosol delivery device 500, the inhaled air passes through the nebulizer passage 544 and may entrain any aerosol generated in one or more of the nebulizer chambers 544.

[0178] In the depicted embodiment, the aerosol source component 508 includes six atomizing chambers 544 (and therefore six liquid delivery elements 546). In various embodiments, the liquid delivery element 546 may include a porous monomer. For example, in the depicted embodiment, the liquid delivery element 546 may include a ceramic material so that the aerosol precursor composition delivered to the liquid delivery element 546 can be absorbed therein to perform aerosolization. In other embodiments, the liquid delivery element may include other materials, including, for example, cotton, silicon dioxide, cellulose and other fibrous materials. Although in various embodiments, the size and shape of the atomizer chamber can vary, in the depicted embodiment, the atomizer chamber 544 has a substantially semi-cylindrical shape, wherein each corresponding liquid delivery element 546 extends from one end of the atomizer chamber 544 to the other end in a direction substantially vertical and slightly lower than the aerosol passage 548. In particular, an end of each liquid transport element 546 extends through the reservoir housing 540 so that the liquid transport element 546 is in fluid contact with the aerosol precursor composition contained in the reservoir 542, causing the aerosol precursor composition to flow (e.g., via capillary action) into the liquid transport element 546.

[0179] The electrical connection between the control component and the heating assembly 510 allows the control component to direct electrical current to the heating assembly 510, such as upon user actuation (e.g., via a button) and / or upon detection of a puff on the aerosol delivery device. As described above, the aerosol delivery device 500 of the depicted embodiment includes a mouthpiece 506. When the user inhales on the mouthpiece 506, air 550 can be directed from the surrounding environment through one or more air inlets in the device 500 and into the distal end of the aerosol passageway 548. In some embodiments, air 550 can enter the device 500 through one or more openings in the first housing portion 502 and / or the second housing portion 504. In some embodiments, air 550 can additionally or alternatively enter the device 500 through an opening between the first housing portion 502 and the second housing portion 504. Other possible inlet openings are described in U.S. Patent No. 9,220,302 to DePiano et al., which is incorporated herein by reference in its entirety.

[0180] In some embodiments, a sensor (e.g., a flow sensor) in the aerosol delivery device 500 can sense the puff. When a puff is sensed, the control component can direct current to one or more of the heating elements 520. As a result, the one or more heating elements 520 can vaporize the aerosol precursor composition contained in the one or more liquid delivery elements 546 near the activated heating element 520. When air 550 enters the atomizer chamber 544, the air travels through (and / or around) the liquid delivery element 546. At this point, if the corresponding heating element 520 is active, the air 550 mixes with the vaporized aerosol precursor composition and becomes an aerosol 552.

[0181] Air drawn into the aerosol passage 548 can be drawn through each atomizer chamber 544, such that air 550 passes through opposite ends of the aerosol passage 548 and exits through the mouthpiece 506 of the device 500. As shown, for example, if only the third heating element 520 is activated, the inhaled air 550 will mix with the aerosol formed in the third atomizer chamber 544. Thus, for example, if multiple heating elements 520 are activated, the air 550 will pick up aerosol from multiple atomizer chambers 544.

[0182] In some embodiments, at least a portion of the reservoir 542 can include multiple layers of nonwoven fibers. Thus, a liquid component can be adsorbed and retained in the reservoir 542, for example. In various embodiments, the reservoir 542 is fluidly connected to a series of atomizer chambers 544. Thus, each liquid transport element 546 can be configured to transport liquid from the reservoir 542 adjacent to a corresponding heating element 520 in the plurality of heating elements 520 by capillary action or other liquid transport mechanisms.

[0183] In the depicted embodiment, the reservoir 542 comprises a single reservoir compartment, wherein all liquid delivery elements 546 are in contact with the same liquid composition; however, in other embodiments, there may be two or more separate reservoir compartments, each of which may encompass one or more atomizer chambers. For example, in some embodiments, the reservoir 542 may comprise two or more separate reservoir compartments that are sealed and independent of each other. In this way, for example, some atomizer chambers can be separated from each other so that some liquid delivery elements 546 do not come into contact with the same liquid composition. For example, in some embodiments having six atomizer chambers, there may be two, three, four, five, or six separate reservoir compartments, each of which may contain a different liquid composition. As an example, one or more separate reservoir compartments may contain different aerosol precursor compositions and / or different fragrances, allowing the user to select between one or more aerosol precursor compositions and / or fragrances as desired. In other embodiments, the separate sub-reservoirs containing different substances may be heated to assist or increase the vapor produced by the device. For example, one sub-reservoir may contain a nicotine-containing liquid, while another sub-reservoir may contain a flavoring (e.g., selected from a plurality of sub-reservoirs containing flavorings), the nicotine-containing liquid and the flavoring being added to the vapor produced by the device. In another example, the two sub-reservoirs may be heated simultaneously to form a binary reaction in the generated vapor. For example, a sub-reservoir containing an acidic liquid (e.g., lactic acid) may be heated and combined with a sub-reservoir containing a nicotine liquid to form a nicotine salt in the vapor. Because the number of possible separate heating elements and / or reservoir compartments can vary, in some embodiments, a user can select from an almost unlimited number of combinations of aerosol precursor compositions and / or aerosol precursor composition flavorings.

[0184] As used herein, mentioned " spices " refer to compounds or components that can be aerosolized and delivered to users and give sensory experience in terms of taste and / or aroma. Exemplary spices include but are not limited to vanillin, ethyl vanillin, cheese, tea, coffee, fruit (for example, apple, cherry, strawberry, peach and citrus flavor, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, cloves, lavender, cardamom, ginger, honey, fennel, sage, rosemary, hibiscus, rose hip, mate, wintergreen tea, honey tree tea, rooibos tea, Paraguayan tea, bacopa, ginkgo leaves, withania somnifera, cinnamon, sandalwood, jasmine, West Indian bittersweet tree, cocoa beans, licorice; and traditionally used as the flavoring type and characteristic condiments and seasoning packets of cigarettes, cigars and pipe tobacco. Syrups such as high fructose corn syrup can also be used. Suitable exemplary plant-derived compositions are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265 of Dube et al., the disclosure of which is incorporated herein by reference in its entirety. Based on factors such as the organoleptic properties required for smoking articles, the selection of these other components is variable, and the disclosure is intended to encompass any such other components that are apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, " Tobacco Flavoring Substances and Methods (tobacco flavoring substances and methods) " (1972) by Gutcho of Noyes Data Corp. (Noyes Data Corp.) and " Tobacco Flavoring for Smoking Products (tobacco flavoring for smoking products) " (1972) by Leffingwell et al., the disclosure of which is incorporated herein by reference in its entirety. It should be noted that reference to spices should not be limited to any single spice as described above, and in fact can represent a combination of one or more spices.

[0185] For example, some possible components that may be included in an aerosol source member cartridge are provided in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., which is incorporated herein by reference in its entirety. Additional components that may be included in an aerosol source member cartridge and details related thereto are provided, for example, in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., filed May 23, 2014, which is incorporated herein by reference in its entirety. Various other components that may be applied to an aerosol delivery device according to the present disclosure may be selected from components described in the prior art and commercially available components. For example, reference is made to a storage portion and heater for controlled delivery of a plurality of aerosolizable materials in an electronic smoking article disclosed in U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0186] With respect to any of the above embodiments, the overall functionality of the device may vary based on the requirements of a particular application. In one embodiment, for example, once the aerosol source member is inserted into the device and the heating assembly is in the heating (e.g., closed) position, the device may be first actuated using a switch and / or button as described above. Preheating may be the next operation and may be performed for approximately 20-30 seconds. During the preheating period, a specific current / voltage passed through the heating assembly (e.g., a heating element) may cause the temperature of the heating element to reach approximately 100-120°C. A temperature sensor (e.g., a resistance temperature detector) may be included to control the preheating temperature so that it does not exceed the desired preheating temperature.

[0187] After preheating is complete, the individual heating elements can be activated. In some embodiments, these heating elements can be triggered by the user by drawing air into the device. In some embodiments, the temperature of the heating elements can reach a peak of 250-350°C during each inhalation. Some embodiments may include a pressure sensor to measure pressure changes in the device to activate one or more heating elements with each inhalation of air. The device can also be configured so that one or more stimuli can be used to switch / control power between / among the elements via a control component. For example, in some embodiments, the stimulus can involve the number of puffs and / or other parameters, such as, for example, temperature changes in the heating elements.

[0188] In some embodiments, the heating element may be energized after a preheating period triggered by the first inhalation on the device. The heating element may be energized again for the second and third inhalations on the device. The number of times each heating element is energized may be adjusted based on the total number of heating elements, the resistance and size of the heating elements, and the electrical power of the heating elements. After a portion of the aerosol-generating component associated with the heating element has been consumed, another heating element, such as, for example, the next heating element, may be activated. In some embodiments, the device may be configured such that the power to subsequent heating elements may be controlled each time the user turns on the device. In some embodiments, the heating cycle may be reset to zero and may restart after the last heating element in a series of heating elements is energized and / or when the user removes or inserts the aerosol source component into the device. Other functional features that may be applicable to the aerosol delivery device of the present invention are described in U.S. patent application Ser. No. 15 / 976,526, filed on May 10, 2018, entitled “Control Component for Segmented Heating in an Aerosol Delivery Device,” which is incorporated herein by reference in its entirety.

[0189] It should be noted that for any of the aerosol delivery devices described above, the device can be configured to accommodate an aerosol source component having a solid or semi-solid aerosol-generating component (e.g., similar to aerosol source component 408) or an aerosol source component having a liquid or semi-liquid aerosol-generating component (e.g., similar to aerosol source component 508). In this manner, the control components of the particular device can be configured to adjust or control various parameters (e.g., heating temperature, heating time, etc.) to accommodate the particular aerosol-generating component used with the device.

[0190] Although the various figures described herein illustrate the housing or housing portion and the aerosol source member in a working relationship, it should be understood that the housing or housing portion and the aerosol source member may exist as separate devices. Therefore, any discussion of combined components provided elsewhere herein should also be understood to apply to the control body and aerosol source member as separate and distinct components.

[0191] In another aspect, the present disclosure may relate to a kit providing a variety of components as described herein. For example, the kit may include a housing or one or more housing portions having one or more aerosol source components. The kit may also include a housing or one or more housing portions having one or more charging components. The kit may also include a housing or one or more housing portions having one or more batteries. The kit may also include a housing or one or more housing portions having one or more aerosol source components and one or more charging components and / or one or more batteries. In another embodiment, the kit may include multiple aerosol source components. The kit may also include multiple aerosol source components and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol source components or the housing or housing portion may be provided with a heating assembly included therein. The kit of the present invention may also include a housing (or other packaging, carrying or storage component) that houses one or more additional kit components. The housing may be a reusable hard or soft container. Further, the housing may simply be a box or other packaging structure.

[0192] Many modifications and other embodiments of the present disclosure will occur to those skilled in the art to which the present disclosure pertains, having the benefit of the teachings presented in the foregoing description and the associated drawings. It should be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed, and that various modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense and not for purposes of limitation.

Claims

1. An aerosol delivery device comprising: A control body, wherein the control body has an outer shell; an electrical energy source, the electrical energy source being located within the housing; a control component operatively connected to the electrical energy source; a heating assembly operatively connected to the control component; as well as an aerosol source member comprising an aerosol generating component configured to be positioned proximate to the heating assembly, wherein the aerosol source means comprises a storage cartridge and the aerosol-generating component comprises a liquid aerosol precursor composition, wherein the heating assembly comprises a series of heating means, and wherein the storage cartridge defines a series of atomizer chambers.

2. The aerosol delivery device according to claim 1, characterized in that The series of atomizer chambers are configured to be substantially aligned with the series of heating members.

3. The aerosol delivery device according to claim 1, characterized in that A separate liquid delivery element extends through each atomizer chamber.

4. The aerosol delivery device according to claim 3, characterized in that Each of the heating members is configured to be positioned adjacent a corresponding atomizer chamber.

5. The aerosol delivery device according to claim 3, characterized in that The liquid transport element comprises a porous monomer.

6. The aerosol delivery device according to claim 3, characterized in that The liquid transport element comprises a fibrous material.

7. The aerosol delivery device according to claim 3, characterized in that The liquid delivery element extends through the atomizer chamber such that the liquid delivery element is in fluid contact with the aerosol precursor composition in the cartridge.

8. The aerosol delivery device of claim 1, wherein: The heating components are configured to be independently controllable.

9. The aerosol delivery device according to claim 1, characterized in that The storage cartridge includes an aerosol passage.

10. The aerosol delivery device of claim 9, wherein: The aerosol passage extends from one end of the storage cartridge to the other end of the storage cartridge.

11. The aerosol delivery device of claim 9, wherein: The aerosol passage comprises a groove or slot in the reservoir cartridge that spans each of the atomizer chambers.

12. The aerosol delivery device of claim 1, wherein: The atomizer chamber has a substantially semi-cylindrical shape.

13. The aerosol delivery device of claim 1, wherein: The storage cartridge includes at least one storage compartment.

14. The aerosol delivery device of claim 13, wherein: The at least one reservoir compartment comprises a single reservoir compartment.

15. The aerosol delivery device of claim 13, wherein: The at least one reservoir compartment includes two or more separate reservoir compartments that are sealed and independent from each other.

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