Aerosol delivery device with indexing movement

Abstract

To provide a control body, an aerosol delivery device, and a method of operating the aerosol delivery device.SOLUTION: There are provided a control body 102, an aerosol delivery device 100, and a method of operating the aerosol delivery device. In various implementations, the aerosol delivery device comprises a control body having a housing 104, an electrical energy source 110 located within the housing, a heating member 112 operatively connected to the electrical energy source, an aerosol source member 500 that includes an inhalable substance medium, and an indexing mechanism 114 coupled to the heating member. The indexing mechanism is configured to move the heating member relative to the aerosol source member so as to sequentially heat one of two or more segments of the aerosol source member.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery articles and the use of the aerosol delivery articles to obtain tobacco components or other materials in an inhalable form. The articles may be made from, derived from, or otherwise incorporate tobacco for human consumption. More specifically, the present disclosure provides articles in which tobacco, tobacco-derived materials, or other materials are heated, preferably without significant combustion, to provide an inhalable substance in the form of a vapor or aerosol, in various embodiments. [Background technology]

[0002] Many smoking articles have been proposed for many years as an improvement or replacement for the smoking product based on tobacco combustion.Exemplary replacements include devices that use solid or liquid fuels to burn and transfer heat to tobacco, or devices that use chemical reactions to provide such heat source.Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0003] The main focus of the improvement or replacement of smoking article is typically to provide the sensation associated with smoking cigarettes, cigars or pipes without delivering a significant amount of incomplete combustion and pyrolysis products.For this purpose, many smoking products, flavor generators and medicinal inhalers have been proposed, which utilize electrical energy to vaporize or heat volatile materials, or to provide the sensation of smoking cigarettes, cigars or pipes without significantly burning tobacco.For example, see the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, and Griffith, Jr. et al., U.S. Patent Application Publication No. 2013 / 0255702 and Sears et al., U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade name and commercial source in U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade name and commercial source are described 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 U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,060,671 to Counts ...060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S No. 5,388,594 to Higgins et al., U.S. Pat. No. 5,666,977 to Adams et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi No. 7,726,320 to Robinson et al., U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Patent Application Publication Nos. 2009 / 0095311 to Hon, U.S. Patent Application Publication Nos. 2006 / 0196518, 2009 / 0126745 and 2009 / 0188490 to Hon, U.S. Patent Application Publication No. 2009 / 0188490 to Thorens et al., U.S. Patent Application Publication No. 2009 / 0196518, U.S. Patent Application Publication No. 2009 / 0126745, and U.S. Patent Application Publication No. 2009 / 0188490 to Thorens et al. No. 009 / 0272379, 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.

[0004] Representative products that mimic many of the attributes of a traditional cigarette, cigar or pipe include ACCORD® by Philip Morris Incorporated, ALPHA™, JOYE 510™ and M4™ by InnoVapor LLC, CIRRUS™ and FLING™ by White Cloud Cigarettes, BLU™ by Fontem Ventures BV, COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™ and SENSE™ by EPUFFER® International Inc., DUOPRO™, STORM™ and VAPORKING® by Electronic Cigarettes, Inc., EGAR™ by Egar Australia, eGo-C™ and eGo-T™ by Joyetech, ELUSION™ by Elusion UK Ltd, and Eonsmoke. EONSMOKE® by FIN Branding Group, LLC, FIN™ by FIN Branding Group, LLC, SMOKE® by Green Smoke Inc. USA, GREENARETTE™ by Greenarette LLC, HALLIGAN™, HENDU™, JET™, MAXXQ™, PINK™ and PITBULL™ by SMOKE STIK®, HEATBAR™ by Philip Morris International, Inc., HYDRO IMPERIAL™ and LXE™ by Crown7, LOGIC™ and THE CUBAN™ by LOGIC Technology, LUCI® by Luciano Smokes Inc., METRO® by Nicotek, LLC, NJOY® and ONEJOY™ by Sottera, Inc., NO.7™ by SS Choice LLC, PREMIUM ELECTRONIC by PremiumEstore LLC CIGARETTE(TM), Ruyan America, Inc.RAPP E-MYSTICK™ by Red Dragon Products, LLC, RED DRAGON™ by Red Dragon Products, LLC, RUYAN® by Ruyan Group (Holdings) Ltd., SF® by Smoker Friendly International, LLC, GREEN SMART SMOKER® by The Smart Smoking Electronic Cigarette Company Ltd., SMOKE ASSIST® by Coastline Products LLC, SMOKING EVERYWHERE® by Smoking Everywhere, Inc., V2CIGS™ by VMR Products LLC, VAPOR NINE™ by VaporNine LLC, VAPOR4LIFE® by Vapor 4 Life, Inc., VEPPO™ by E-CigaretteDirect, LLC, VUSE® by RJ Reynolds Vapor Company, Mistic Menthol products by Mistic Ecigs, and Vype products by CN Creative Ltd, Philip Morris and GLO™ by British American Tobacco. Still other electrically powered aerosol delivery devices, particularly those characterized as so-called e-cigarettes, are marketed under the trade names COOLER VISIONS™, DIRECT E-CIG™, DRAGONFLY™, EMIST™, EVERSMOKE™, GAMUCCI®, HYBRID FLAME™, KNIGHT STICKS™, ROYAL BLUES™, SMOKETIP®, and SOUTH BEACH SMOKE™. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 9,078,473 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] US Patent Application Publication No. 2013 / 0255702 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2015 / 0220232 [Patent Document 6] US Patent Application Publication No. 2015 / 0245659 [Patent Document 7] U.S. Patent No. 4,735,217 [Patent Document 8] U.S. Patent No. 4,922,901 [Patent Document 9] U.S. Patent No. 4,947,874 [Patent Document 10] U.S. Patent No. 4,947,875 [Patent Document 11] U.S. Patent No. 5,060,671 [Patent Document 12] U.S. Patent No. 5,249,586 [Patent Document 13] U.S. Patent No. 5,388,594 [Patent Document 14] U.S. Patent No. 5,666,977 [Patent Document 15] U.S. Patent No. 6,053,176 [Patent Document 16] U.S. Patent No. 6,164,287 [Patent Document 17] U.S. Patent No. 6,196,218 [Patent Document 18] U.S. Patent No. 6,810,883 [Patent Document 19] U.S. Patent No. 6,854,461 [Patent Document 20] U.S. Patent No. 7,832,410 [Patent Document 21] U.S. Patent No. 7,513,253 [Patent Document 22] U.S. Patent No. 7,896,006 [Patent Document 23] U.S. Patent No. 6,772,756 [Patent Document 24] US Patent Application Publication No. 2009 / 0095311 [Patent Document 25] US Patent Application Publication No. 2006 / 0196518 [Patent Document 26] US Patent Application Publication No. 2009 / 0126745 [Patent Document 27] US Patent Application Publication No. 2009 / 0188490 [Patent Document 28] US Patent Application Publication No. 2009 / 0272379 [Patent Document 29] US Patent Application Publication No. 2009 / 0260641 [Patent Document 30] US Patent Application Publication No. 2009 / 0260642 [Patent Document 31] US Patent Application Publication No. 2008 / 0149118 [Patent Document 32] US Patent Application Publication No. 2010 / 0024834 [Patent Document 33] US Patent Application Publication No. 2010 / 0307518 [Patent Document 34] International Publication No. 2010 / 091593 Summary of the Invention [Problem to be solved by the invention]

[0006] Articles that produce the taste and sensation of smoking by electrically heating tobacco have suffered from inconsistent release of flavors or other inhalable materials. Electrically heated smoking devices have often been further limited by the need for a relatively large and / or complex heat source. It is therefore desirable to provide a smoking article that can provide the smoking sensation of a cigarette, cigar, or pipe without substantial combustion, and that provides the smoking sensation of a cigarette, cigar, or pipe with improved efficiency performance characteristics. [Means for solving the problem]

[0007] The present disclosure relates to an aerosol delivery device, a control body for use with an aerosol source member, and a method of operating 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 a housing; an electrical energy source disposed within the housing; a heating member operably connected to the electrical energy source; an aerosol source member including an inhalable substance medium; and an indexing mechanism coupled to the heating member, wherein the indexing mechanism is configured to move the heating member relative to the aerosol source member to sequentially heat at least one of two or more segments of the aerosol source member.

[0009] Exemplary Embodiment 2: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the heating member is disposed proximate to the outer surface of the aerosol source member.

[0010] Exemplary Embodiment 3: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the heating member is disposed proximate to the inner surface of the aerosol source member.

[0011] Exemplary embodiment 4: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the indexing mechanism is actuated by a sensor configured to detect suction on the aerosol source member.

[0012] Exemplary Embodiment 5: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the indexing mechanism is actuated by a manual actuator.

[0013] Exemplary embodiment 6: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the manual actuator comprises a click-return actuator.

[0014] Exemplary embodiment 7: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the manual actuator is configured to move with the heating member.

[0015] Exemplary embodiment 8: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the aerosol source member is removably engageable with and replaceable by the control body.

[0016] Exemplary embodiment 9: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the inhalable substance medium of the aerosol source member comprises a solid or semi-solid inhalable substance medium.

[0017] Exemplary Embodiment 10: The aerosol delivery device of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the inhalable substance medium comprises an extruded substrate.

[0018] Exemplary embodiment 11: A control body for use with an aerosol source member containing an inhalable substance medium, the control body including a housing, an electrical energy source disposed within the housing, a heating member operably connected to the electrical energy source, and an indexing mechanism coupled to the heating member, the indexing mechanism configured to move the heating member relative to the aerosol source member to sequentially heat at least one of two or more segments of the aerosol source member.

[0019] Exemplary embodiment 12: The control body of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the indexing mechanism is actuated by a sensor configured to detect suction on the aerosol source member.

[0020] Exemplary Embodiment 13: The control body of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the indexing mechanism is actuated by a manual actuator.

[0021] Exemplary Embodiment 14: The control body of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the manual actuator includes a click return actuator.

[0022] Exemplary embodiment 15: The control body of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the manual actuator is configured to move with the heating member.

[0023] Exemplary embodiment 16: A method of operating an aerosol delivery device comprising a control body and an aerosol source member, the method comprising: energizing a heating member using an electrical energy source disposed in a housing of the control body; heating a first segment of the aerosol source member using the heating member; moving the heating member from a first position to a second position relative to the aerosol source member using an indexing mechanism; and heating a second segment of the aerosol source member using the heating member.

[0024] Exemplary Embodiment 17: The method of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein heating the first and second segments of the aerosol source member includes initially heating outer surfaces of the first and second segments of the aerosol source member.

[0025] Exemplary Embodiment 18: The method of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein heating the first and second segments of the aerosol source member includes initially heating inner surfaces of the first and second segments of the aerosol source member.

[0026] Exemplary embodiment 19: The method of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, further comprising activating the indexing mechanism using a sensor configured to detect suction on the aerosol source member.

[0027] Exemplary Embodiment 20: The method of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, further comprising using a manual actuator to actuate the indexing mechanism.

[0028] Exemplary Embodiment 21: The method of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein the manual actuator includes a click-return actuator.

[0029] Exemplary Embodiment 22: The method of any preceding exemplary embodiment or any combination of any preceding exemplary embodiment, wherein moving the heating member from a first position to a second position relative to the aerosol source member comprises moving a manual actuator from the first position to the second position.

[0030] These and other features, aspects and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying drawings, which are briefly described below.

[0031] To aid in understanding embodiments of the present disclosure, reference will now be made to the accompanying drawings, in which like reference numerals refer to like elements and which are not necessarily drawn to scale. The drawings are merely examples and are not to be construed as limiting the present disclosure. [Brief explanation of the drawings]

[0032] [Figure 1] 1A and 1B illustrate schematic diagrams of an aerosol delivery device including a heating member at a first heating position, according to exemplary embodiments of the present disclosure. [Figure 2] 2A and 2B are schematic diagrams of the aerosol delivery device of FIG. 1 showing the heating member in a second heating position according to an exemplary embodiment of the present disclosure; [Figure 3] 2A and 2B illustrate a schematic representation of the aerosol delivery device of FIG. 1 showing a series of increasing heat positions, according to an exemplary embodiment of the present disclosure. [Figure 4] 1A and 1B illustrate schematic diagrams of an aerosol delivery device including a heating member at a first heating position, according to exemplary embodiments of the present disclosure. [Figure 5] 5A and 5B are schematic diagrams of the aerosol delivery device of FIG. 4 showing the heating member in a second heating position according to exemplary embodiments of the present disclosure; [Figure 6] 5A and 5B illustrate a schematic representation of the aerosol delivery device of FIG. 4 showing a series of increasing heat positions, according to an exemplary embodiment of the present disclosure. [Figure 7] 1A and 1B illustrate schematic diagrams of an aerosol delivery device including a heating member at a first heating position, according to exemplary embodiments of the present disclosure. [Figure 8] 8A and 8B are schematic diagrams of the aerosol delivery device of FIG. 7 showing the heating member in a second heating position according to an exemplary embodiment of the present disclosure; [Figure 9] 8A and 8B schematically illustrate the aerosol delivery device of FIG. 7 showing a series of increasing heat positions, according to an exemplary embodiment of the present disclosure. [Figure 10] 1A and 1B illustrate schematic diagrams of an aerosol delivery device including a heating member at a first heating position, according to exemplary embodiments of the present disclosure. [Figure 11] 11A and 11B are schematic diagrams of the aerosol delivery device of FIG. 10 showing the heating member in a second heating position according to an exemplary embodiment of the present disclosure; [Figure 12] 11A and 11B are schematic diagrams of the aerosol delivery device of FIG. 10 showing a series of increasing heat positions according to an exemplary embodiment of the present disclosure; [Figure 13] 10 illustrates various operations in a method of operating an aerosol delivery device, according to exemplary embodiments of the present disclosure. [Figure 14] 1 illustrates a perspective view of a flexible heating member shown in a flat orientation according to an exemplary embodiment of the present disclosure. [Figure 15] 1 illustrates a perspective view of a flexible heating member shown in a formed orientation according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0033] The present disclosure is described more fully below. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that as used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0034] The present disclosure provides articles that use electrical energy to heat a material to form an inhalable substance (preferably without significantly burning the material), and the articles are small enough to be considered "handheld" devices. In certain embodiments, the articles may be specifically characterized as smoking articles. As used herein, this term is intended to mean an article that provides the taste and / or sensation (e.g., feel or mouthfeel) of smoking a cigarette, cigar, or pipe without actually burning any components of the article. The term smoking article does not necessarily indicate that the article produces smoke, in the sense of a combustion or pyrolysis by-product, during operation. Rather, smoking relates to the physical actions of an individual in using the article, e.g., holding the article in one's hand, drawing on one end of the article, and inhaling from the article. In further embodiments, the articles of the present invention may be characterized as vapor-producing articles, aerosolizing articles, or pharmaceutical delivery articles. Thus, the articles may be configured to provide one or more substances in an inhalable state. In other embodiments, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below the critical point of the inhalable substance). In other embodiments, the inhalable substance may be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). The physical form of the inhalable substance is not necessarily limited by the nature of the article of the present invention, but may depend on the nature of the medium and the inhalable substance itself, with respect to whether it exists in a vapor state or an aerosol state. In some embodiments, terms may be interchangeable. Thus, for simplicity, terms used to describe this disclosure will be understood to be interchangeable unless otherwise specified.

[0035] Although the systems are generally described herein with respect to embodiments relating to aerosol delivery devices, such as so-called "electronic cigarettes" or "tobacco heating products," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of items. For example, the descriptions provided herein may be used in conjunction with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustion heated tobacco products, and related packaging embodiments for any of the products disclosed herein. Accordingly, it should be understood that the descriptions of the features, components, features, and methods disclosed herein are described by way of example only with respect to embodiments relating to aerosol delivery devices, and may be embodied in and used in a variety of other products and methods.

[0036] The aerosol delivery device of the present disclosure may also be characterized as a vapor product or drug delivery article. Accordingly, such an article or device may be adapted to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below the critical point of the inhalable substance). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not they are visible and whether or not they are in a form that can be considered smoky.

[0037] When using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe used by lighting and inhaling tobacco), the aerosol delivery device of the present disclosure may undergo many physical actions by an individual during use. For example, a user of the aerosol delivery device of the present disclosure may hold the article as with a traditional type of smoking article, draw on one end of the article to inhale the aerosol produced by the article, take puffs at selected time intervals, etc.

[0038] The aerosol delivery device of the present disclosure generally includes a number of components disposed within an outer shell or body. The overall design of the outer shell or body can vary, and the type or configuration of the outer body can vary, which can define the overall dimensions and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, integral shell, or the elongated body can be formed from two or more separable parts. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and thereby resembling the shape of a traditional cigarette or cigar. However, in other embodiments, various other shapes and configurations can be used (e.g., rectangular or fob-shaped).

[0039] In one embodiment, all components of the aerosol delivery device are housed within a single outer body or shell. Alternatively, the aerosol delivery device can include two or more shells that are joined and separable. For example, the aerosol delivery device can have a control body at one end that includes a shell housing one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the device) and a removably attached shell at the other end that houses a disposable portion (e.g., a disposable flavor-containing cartridge). More specific formats, configurations, and arrangements of components within a single-shell type unit or a multi-part separable-shell type unit will become apparent in light of the further disclosure provided herein. Furthermore, the design and component arrangements of various aerosol delivery devices can be understood by considering commercially available electronic aerosol delivery devices.

[0040] In general, the aerosol delivery devices of the present disclosure may generally include some combination of an electrical energy source (i.e., a power source), a heating element or heat-generating component (e.g., an electrically conductive, resistive heating element or an induction heating element), an aerosol source element containing an inhalable substance medium positionable in proximity to or in direct contact with the heating element, an indexing mechanism, and at least one control element (e.g., a means for activating, controlling, regulating, and / or terminating electrical power for heat generation and indexing, such as by controlling the flow of electrical current from a power source to the components of the aerosol delivery device). When the heating element heats the inhalable substance medium, an inhalable substance is formed, released, or generated from the inhalable substance medium in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be interpreted to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be interchanged to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof, and such terms are also used interchangeably herein unless otherwise specified.

[0041] As described above, the aerosol delivery device may incorporate a source of electrical energy (e.g., a battery and / or other power source, e.g., a capacitor) to provide a flow of current sufficient to provide various functions for the aerosol delivery device, such as powering a heater, powering a control system, powering an indexing mechanism, powering an indicator, etc. The power source can assume a variety of embodiments. Preferably, the power source can provide sufficient power to rapidly heat the heating element to form an aerosol and power the aerosol delivery device throughout use for a 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. Furthermore, preferred power sources are lightweight enough so as not to detract from the desired smoking experience.

[0042] More specific forms, configurations, and arrangements of components within the aerosol delivery device of the present disclosure will become apparent in light of the further disclosure provided below. Furthermore, the selection of various aerosol delivery device components can be understood by considering commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device can be understood by considering commercially available electronic aerosol delivery devices. Examples of commercially available products, including components, methods of operation of commercially available products, materials contained therein, and / or attributes of other commercially available products that may be included in the device of the present disclosure, as well as manufacturers, designers, and / or assignees of components and related technology that may be used in the aerosol delivery device of the present disclosure, are described in U.S. Patent Application No. 15 / 222,615, filed July 28, 2016, to Watson et al., which is incorporated herein by reference in its entirety.

[0043] While devices according to the present disclosure may take on various embodiments, as described in detail below, consumer use of the devices will be similar in scope. In particular, the device may be provided as multiple components that are assembled by the consumer for use and then disassembled by the consumer. Specifically, the consumer may have a reusable control body that is substantially cylindrical, substantially rectangular, or another shape with an opening disposed in a portion of the control body housing. In some embodiments, the housing may also include one or more indicators of active use of the device. The consumer may further have one or more aerosol source members that engage or are received in the openings of the control body. To use the article, the consumer may insert the aerosol source member into the opening or otherwise combine the aerosol source member and the control body such that the device is operable as described herein. In some embodiments, the aerosol source member may be inserted into the control body as permitted by the overall structure of the components and / or other internal receiving features. Typically, at least a portion of the aerosol source member, at least large enough to be inserted into the consumer's mouth for smoking, remains outside the control body. This may be referred to as the mouth end of the aerosol source member.

[0044] During use, a consumer initiates heating of the heating element adjacent to the inhalable substance medium (or a specific portion of the inhalable substance medium), and heating of the medium releases the inhalable substance into a space within the housing and / or aerosol source member to generate the inhalable substance. When the consumer inhales into the mouth end of the aerosol source member, air is drawn into the aerosol source member through an opening in the control body and / or into the aerosol source member itself. As the inhaled material exits the mouth end of the aerosol source member and enters the consumer's mouth, a combination of the drawn-in air and the released inhalable substance is inhaled by the consumer. In some embodiments, to initiate heating, the consumer may manually activate a push button or similar component that causes the heating element to receive electrical energy from a battery or other power source. The electrical energy may be supplied for a predetermined length of time or may be manually controlled. Preferably, the flow of electrical energy is not substantially continuous between puffs using the device (although the energy flow may continue to maintain a baseline temperature higher than ambient temperature (e.g., a temperature that facilitates rapid heating to an operating heating temperature). In other embodiments, heating may be initiated by the consumer's puff action through the use of various sensors, as described elsewhere herein. Heating may cease or be reduced when a puff is discontinued. Once the consumer has taken a sufficient number of puffs to emit a sufficient amount of inhalable substance (e.g., an amount sufficient to represent a typical smoking experience), the aerosol source member may be detached from the control body and discarded.

[0045] In general, relative motion between the aerosol source member and the heating member can be achieved in a variety of ways. For example, in some embodiments, this can be achieved by moving the heating member relative to the aerosol source member; in other embodiments, this can be achieved by moving the aerosol source member relative to the heating member; and in still other embodiments, this can be achieved by moving both the aerosol source member and the heating member relative to each other. By way of example, in the embodiments described below, relative motion is achieved by moving the heating member relative to the aerosol source member. As described in detail below, in various embodiments, an indexing mechanism coupled to the heating member can be configured to create incremental relative motion between the heating member and the aerosol source member, such that the heating member can heat one or more segments of the aerosol source member corresponding to one or more positions of the heating member relative to the aerosol source member. In some embodiments, the indexing mechanism can operate “automatically,” in that the indexing mechanism can be activated by one or more puffs taken by the consumer. In other embodiments, the consumer may manually activate the indexing mechanism. In some embodiments, there may be a combination of automatic and manual activation. In either case, after the heating element heats the available segment of the aerosol source element, the aerosol source element can be removed from the control body and discarded. The above description of the use of the device can be applied to the various embodiments described through minor modifications that may be apparent to those skilled in the art in light of the further disclosure provided herein. However, the above description of use is not intended to limit the use of the device of the present invention, but is provided to comply with all necessary disclosure requirements of the present disclosure.

[0046] As noted above, at least a portion of the heated end of the aerosol source member may contain an inhalable substance medium, which may include tobacco-containing beads, shredded tobacco, tobacco chips, reconstituted tobacco material, or combinations thereof, and / or a mixture of finely ground tobacco, tobacco extract, spray-dried tobacco extract, or other tobacco form mixed with optional inorganic materials (such as calcium carbonate) and optional flavor and aerosol-forming materials to form a substantially solid or moldable (e.g., extruded) substrate. Gels and suspensions may also be utilized. Constructions and formulations of some representative types of solid and semi-solid inhalable substance vehicles are disclosed in U.S. Pat. No. 8,424,538 to Thomas et al., U.S. Pat. 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 to Nordskog et al., filed June 30, 2015, all of which are incorporated herein by reference.

[0047] In various embodiments, the aerosol source member or a portion thereof may be wrapped with an overwrap material, which may be formed from any material useful for providing additional structure and / or support to the aerosol source member. In various embodiments, the overwrap material may include a material that resists (or promotes) heat transfer, which may include paper or other fibrous materials, such as cellulosic materials. The overwrap material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the overwrap may be formed from multiple layers, such as an underlying bulk layer and an overlying layer, such as a typical wrapping paper in a cigarette. Such materials may include, for example, lightweight "rag fibers" such as flax, hemp, sisal, rice straw, and / or esparto. Additional description regarding the configuration of overwrapping materials that may be used with the present disclosure may be found 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 overwrapping material may have one or more of the following properties: it may be impermeable to aerosol migration, it may have the ability to withstand high temperatures of interest, it may promote radial heat transfer from the heater to the tobacco stick material, it may resist axial heat transfer along the tobacco stick, away from the heated segment, and / or it may have a relatively low thermal mass so as not to inhibit the rapid temperature rise of the heated segment. In one embodiment, the overwrapping material may be stainless steel foil, which in some embodiments may be about 0.001 inches thick.

[0048] In various embodiments, the mouth end of the aerosol source member can include a filter, which can be made from a cellulose acetate material or a polypropylene material. In various embodiments, the filter may enhance the structural integrity of the mouth end of the aerosol source member and / or provide optional filtration and / or resistance to suction. For example, articles according to the present disclosure can exhibit a pressure drop of about 50 to about 250 mm of water pressure drop at an airflow of 17.5 cc / sec. In further embodiments, the pressure drop can be about 60 mm to about 180 mm or about 70 mm to about 150 mm. Pressure drop values ​​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 at the mouth end of the aerosol source member can vary, such as about 2 mm to about 20 mm, about 5 mm to about 20 mm, or about 10 mm to about 15 mm. In some embodiments, the filter may be separate from the overwrap, and the filter may be held in place by the overwrap.

[0049] Additional exemplary types of overwrapping materials, wrapping material components, and treated wrapping materials that may be used for overwrapping in the present disclosure are described in U.S. Pat. No. 5,105,838 to White et al., U.S. Pat. No. 5,271,419 to Arzonico et al., U.S. Pat. No. 5,220,930 to Gentry, U.S. Pat. No. 6,908,874 to Woodhead et al., U.S. Pat. No. 6,929,013 to Ashcraft et al., U.S. Pat. No. 7,195,019 to Hancock et al., U.S. Pat. No. 7,276,120 to Holmes, U.S. Pat. No. 7,275,548 to Hancock et al., PCT Publication No. WO 01 / 08514 to Fournier et al., and PCT Publication No. WO 03 / 043450 to Hajaligol et al., which are incorporated herein by reference in their entireties. Representative winding materials 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 winding material can vary, frequently from about 5 CORESTA units to about 30,000 CORESTA units, often from about 10 CORESTA units to about 90 CORESTA units, and frequently from about 8 CORESTA units to about 80 CORESTA units.

[0050] To maximize delivery of aerosol and flavors that would otherwise be diluted by radial (i.e., outward) air penetration through the overwrap, one or more layers of non-porous tobacco paper may be used to encase the aerosol source member (with or without the presence of an overwrap). Examples of suitable non-porous tobacco paper are commercially available from Kimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2, and 780-63-5. Preferably, the overwrap is a material that is substantially impermeable to vapors formed during use of the article of the present invention. Optionally, the overwrap can include a resilient paperboard material, foil-backed paperboard, metal, polymeric material, or the like, which may be surrounded by a wrap of tobacco paper. The overwrap can include tipping paper that surrounds the components and, optionally, can be used to attach a filter material to the aerosol source member, as described elsewhere herein. In various embodiments, other components may be present between the inhalable substance medium and the mouth end of the aerosol source member, and the mouth end may include a filter. For example, in some embodiments, one or any combination of the following may be disposed between the inhalable substance medium and the mouth end: an air gap; a phase change material for cooling air; a flavor-releasing medium; ion-exchange fibers capable of selective chemical adsorption; aerogel particles as a filter medium; and other suitable materials.

[0051] As described above, in various embodiments, the aerosol source member may include an inhalable substance medium. The inhalable substance medium may be any material that, when heated, releases an inhalable substance, such as a flavor-containing substance. In the illustrated embodiment, the inhalable substance medium is a solid or semi-solid substrate containing an inhalable substance. The inhalable substance may specifically be a tobacco component or tobacco-derived material (i.e., a material that can be isolated directly from tobacco, naturally found in tobacco, or a synthetically prepared material). For example, the inhalable substance medium may include a tobacco extract or a fraction of a tobacco extract combined with an inert substrate. The inhalable substance medium may further include unburned tobacco or a composition containing unburned tobacco that releases an inhalable substance when heated to a temperature below combustion temperature. Less preferably, the inhalable substance medium may include tobacco condensate or a fraction of tobacco condensate (i.e., a condensed component of smoke produced by tobacco combustion that leaves flavor and possibly nicotine).

[0052] Tobacco materials useful in the present disclosure may vary and may include, for example, flue-cured, burley, Oriental or Maryland, dark, dark-flavored, and rustica tobaccos, as well as other rare or specialty tobaccos, or mixtures thereof. Tobacco materials may also include so-called "blend" forms and processed forms, such as processed tobacco stems (e.g., cut roll stems or cut puff stems), volume-expanded tobacco (e.g., puffed tobacco, advantageously in cut filler form, e.g., dry ice expanded tobacco (DIET)), and reconstituted tobacco (e.g., reconstituted tobacco produced using a paper-forming type process or a cast sheet type process). Various representative tobacco types, processed tobacco types, and tobacco blend types are described in U.S. Patent No. 4,836,224 to Lawson et al., U.S. Patent No. 4,924,888 to Perfetti et al., U.S. Patent No. 5,056,537 to Brown et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,220,930 to Gentry, U.S. Patent No. 5,360,023 to Blakley et al., U.S. Patent No. 5,360,023 to Sh, which are incorporated herein by reference. No. 6,701,936 to Afer et al., U.S. Patent No. 7,011,096 to Li et al., U.S. Patent No. 7,017,585 to Li et al., U.S. Patent No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004-0255965 to Perfetti et al., PCT International Publication No. WO 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, pp. 11-17 (1997). Additional exemplary tobacco compositions that may be useful in smoking devices, including those according to the present disclosure, are disclosed in U.S. Patent No. 7,726,320 to Robinson et al., the entire contents of which are incorporated herein by reference.

[0053] Additionally, the inhalable substance medium may comprise an inert substrate having an inhalable substance or a precursor thereof incorporated therein or otherwise deposited thereon. For example, a liquid containing the inhalable substance may be coated on, absorbed into, or adsorbed onto the inert substrate, such that upon application of heat, the inhalable substance is released in a form that can be drawn from the article of the present invention by application of positive or negative pressure. In some embodiments, the inhalable substance medium may comprise a mixture of flavorful, aromatic tobacco in cut filler form. In another embodiment, the inhalable substance medium may comprise reconstituted tobacco material, such as those described in U.S. Pat. Nos. 4,807,809 to Pryor et al., 4,889,143 to Pryor et al., and 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference.

[0054] In some embodiments, the inhalable substance medium may include tobacco, tobacco components and / or tobacco-derived materials that have been processed, manufactured, produced and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin, etc.) and / or at least one flavoring agent, as well as a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, thermal decomposition, combustion and / or charring of the aerosol delivery component by a heat source. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles designed to intentionally prevent the combustion of substantially all of the tobacco within the smoking article, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 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.

[0055] In some embodiments, other flame-retardant / flame-retardant materials and additives may be included in the inhalable medium, including organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others, such as nitrogen phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, may also be used. In each aspect of the flame-retardant, flame-retardant, and / or char-retardant materials used in the inhalable medium and / or other components (whether alone or in combination with each other and / or other materials), desirable properties are preferably provided without undesirable outgassing, chemical reactivity, or melting behavior. Additional flavors, flavorings, additives, and other possible enhancing ingredients are described in U.S. Patent Application Serial No. 15 / 707,461 to Phillips et al., incorporated herein by reference in its entirety.

[0056] In addition to the inhalable substance (e.g., generally, flavor, nicotine, or pharmaceutical), the inhalable substance medium may contain one or more aerosol-forming or vapor-forming materials, such as polyhydric alcohols (e.g., glycerin, propylene glycol, or mixtures thereof) and / or water. Representative types of aerosol-forming materials are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al. and U.S. Pat. No. 5,101,839 to Jakob et al., PCT International Publication No. 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), which are incorporated herein by reference. Preferred aerosol-forming materials produce a visible aerosol when sufficient heat is applied to the aerosol-forming material, and highly preferred aerosol-forming materials produce an aerosol that can be considered "smoke-like." Additional tobacco materials, such as tobacco aroma oil, tobacco essence, spray-dried tobacco extract, freeze-dried tobacco extract, or tobacco dust, may be combined with the vapor-forming or aerosol-forming material. It should also be understood that the inhalable substance itself may be in a form that, upon heating, releases the inhalable substance as a vapor, an aerosol, or a combination thereof. In other embodiments, the inhalable substance may not necessarily be released in the form of a vapor or aerosol, but the vapor-forming or aerosol-forming material that may be combined with the inhalable substance may form a vapor or aerosol upon heating and essentially function as a carrier for the inhalable substance itself. Thus, the inhalable substance may be characterized as being coated on a substrate, absorbed into a substrate, adsorbed onto the surface of a substrate, or a natural component of the substrate (i.e., the material that forms the substrate, e.g., tobacco or tobacco-derived materials). Similarly, aerosol-forming or vapor-forming materials may be similarly characterized.In certain embodiments, an inhalable substance medium may specifically include a substrate containing an inhalable substance and a separate aerosol-forming material contained within the substrate. Thus, during use, the substrate may be heated, and the aerosol-forming material may be volatilized into vapor form, entraining the inhalable substance along with the aerosol-forming material. In certain examples, an inhalable substance medium may include a solid substrate having a tobacco slurry and aerosol-forming and / or vapor-forming material coated on or absorbed or adsorbed into the solid substrate. The substrate component may be any material that does not burn or otherwise degrade at the temperatures described herein, achieved by the heating element to promote release of the inhalable substance. For example, paper materials, including tobacco paper (e.g., paper-like materials containing tobacco fiber and / or reconstituted tobacco), may be used. Thus, in various embodiments, an inhalable substance medium may be characterized as comprising an inhalable substance; alternatively, as comprising an inhalable substance and a separate aerosol- or vapor-forming agent; alternatively, as comprising an inhalable substance and a substrate; or alternatively, as comprising an inhalable substance medium, a separate aerosol- or vapor-forming agent, and a substrate. Thus, the substrate may contain an inhalable substance and one or both of an aerosol or vapor forming agent.

[0057] Optionally, the tobacco material or inhalable substance medium may further contain other ingredients, such as sugar, glycerin, vanilla, cocoa, licorice, and other flavorings, such as menthol. Exemplary plant-derived compositions that can be used are disclosed in U.S. Patent Application Publication No. 2012 / 0152265 to Dube et al. and U.S. Patent No. 9,107,453 to Dube et al. The selection of such additional ingredients may vary based on factors such as the sensory characteristics desired for the article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972).

[0058] The inhalable substance and / or the separate vapor-forming material may be provided on the substrate in various configurations. For example, both materials may be associated with the substrate such that the concentration of each material along the length of the substrate is substantially constant (e.g., if the substrate is divided into multiple longitudinal segments, the total concentration of the materials in each individual segment may 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 may be present in a defined pattern. For example, the pattern may be a gradient in which the concentration continuously increases or decreases along the length of the substrate. In this manner, the first puff with the article may provide a significantly greater or lesser amount of inhalable substance than the amount of inhalable substance in the last puff. The gradient may also be designed to provide a uniform production of inhalable substance throughout the entire puff. Furthermore, the pattern may be such that a large amount of inhalable substance is provided at a point along the length of the substrate (e.g., corresponding to the first puff with the article, the last puff, or some intermediate puff). In light of the present disclosure, any variety of such patterns may be envisioned, and such variations are similarly encompassed by the present disclosure. Such patterning may similarly be applied to additional ingredients (e.g., flavorings) described herein. For example, a large amount of flavoring may be provided on the substrate at a location substantially corresponding to the last puff or the last two or three puffs using the article. Such flavor release may notify the consumer that the last puff using the device is approaching or has been achieved. Various other configurations and components that may be included in the inhalable substance medium of the present disclosure are described in U.S. Patent No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0059] In some aspects of the present disclosure, the inhalable substance medium may be configured as an extruded material, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which is incorporated herein by reference in its entirety. In still other aspects, the inhalable substance medium may be configured as an extruded structure and / or substrate that includes or consists essentially of tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations do not include binder materials. In various embodiments, the binder material may be any binder material commonly used in tobacco formulations, including, for example, carboxymethylcellulose (CMC), gums (e.g., guar gum), xanthan, pullulan, and / or alginate. According to some aspects, the binder material included in the aerosol delivery component may be configured to substantially maintain the structural shape and / or integrity of the aerosol delivery component. Various exemplary binders, binder properties, binder uses, and binder amounts are described in U.S. Patent No. 4,924,887 to Raker et al., which is incorporated herein by reference in its entirety.

[0060] In some embodiments, the inhalable substance medium is further configured to substantially maintain its structure throughout the aerosol generation process. That is, the inhalable substance medium is configured to substantially maintain its shape throughout the aerosol generation process (i.e., the aerosol delivery component does not continuously deform under applied shear stress). In some embodiments, the inhalable substance medium components may contain liquid and / or some moisture content, but in some embodiments, the inhalable substance medium remains substantially solid throughout the aerosol generation process and is configured to substantially maintain its structural integrity throughout the aerosol generation process. Exemplary tobacco and / or tobacco-related materials suitable for 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.

[0061] In yet another embodiment, the inhalable substance medium may include an extruded structure and / or substrate formed from marumerized and / or non-marumerized tobacco. Marumerized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is incorporated herein by reference in its entirety. Marumerized tobacco comprises a blend of about 20 to about 50 percent (by weight) tobacco in powder form with glycerol (about 20 to about 30 percent by weight), calcium carbonate (generally about 10 to about 60 percent by weight, often about 40 to about 60 percent by weight), and a binder and / or flavoring agent as described herein.

[0062] In various embodiments, the substrate wall may be substantially formed from a material (e.g., cigarette paper) that can naturally contain the inhalable substance within the substrate wall, or may be formed from any additional material (e.g., paper) that can have the inhalable substance and / or vapor-forming or aerosol-forming agent entrained within the substrate wall. In addition to the inhalable substance and / or vapor-forming or aerosol-forming substance, the substrate wall may contain additional components. For example, a vapor barrier may be included on the outer surface of the inhalable substance medium wall. Preferably, the vapor barrier is disposed on the wall surface adjacent to (or in contact with) the heating element when the inhalable substance medium is heated. In certain 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 the vapor barrier, and the foil may have an insulating layer (e.g., a metal oxide layer) that contacts the heating element. The inhalable substance medium wall prevents vapor or aerosol release into the outer volume of the inhalable substance medium and facilitates vapor or aerosol release into the annular space defined by the inner surface of the inhalable substance medium wall. Any vapor barrier material may be used, such as metal foil.

[0063] In further embodiments, the inhalable substance medium may be formed from a material that softens or changes phase (particularly from solid to molten) at about the operating temperature of the article. For example, the inhalable substance medium may be a wax or gel, and the inhalable substance may be entrained within the inhalable substance medium. In such embodiments, it may be particularly useful to include a vapor barrier (or similar material) that provides support to the inhalable substance medium and substantially prevents the inhalable substance medium from contacting the heating element. Similarly, the inhalable substance medium may include a vapor barrier layer coated with the inhalable substance and / or aerosol-forming material. For example, one or more of such coating materials may be in a microencapsulated form that preferably releases its components at temperatures within one or more of the operating ranges described elsewhere herein. Microencapsulation techniques that may be useful in such embodiments are disclosed, for example, in U.S. Patent No. 4,464,434 to Davis.

[0064] In some embodiments (such as when a heating element is disposed within a hollow aerosol source element), tensioning the inhalable substance medium can be useful to provide specific performance features of the articles of the present invention. As described elsewhere herein, it can be beneficial for the inhalable substance medium to have a relatively thin thickness so that heat is transferred efficiently, particularly when a substrate exhibiting relatively low heat transfer, such as paper, is used. However, a substrate with a thin thickness may have relatively low strength in certain dimensions and relatively high strength in other dimensions. For example, thin paper under tension exhibits high strength compared to the strength of the same paper in compression. Tensioning can also facilitate direct contact of the heating element with the surface of the inhalable substance medium to be heated (including the substrate used or any vapor barrier that may be present).

[0065] In other embodiments (such as when a heating element is disposed around the exterior of a hollow aerosol source element), it may be desirable to support the interior of the aerosol source element to prevent it from collapsing due to the outward pressure of the heating element acting on the exterior of the aerosol source element. In some embodiments, for example, this may be achieved by filling the inner diameter of the aerosol source element with shredded tobacco or other material having a relatively low thermal mass and thermal conductivity. In other embodiments, for example, this may be achieved by relying on the stiffness of an overwrap material (e.g., metal foil) to provide additional strength to the thin substrate wall. In other embodiments, a laminate may be added to the inner surface of the substrate wall, for example, using permeable or perforated paper that allows vapor transport but provides additional stiffness to the tube wall.

[0066] As noted above, the end of the aerosol source member opposite the mouth end is sized and shaped for insertion into the control body. Thus, a receiving chamber can be formed within the control body in which the maximum outer diameter (or other dimension, depending on the particular cross-sectional shape of the embodiment) of the aerosol source member is preferably smaller than the inner diameter (or other dimension) of the open end of the receiving chamber within the control body. Ideally, the difference in their respective diameters is small enough so that the aerosol source member fits snugly within the receiving chamber and frictional forces prevent the aerosol source member from moving unforced.

[0067] As mentioned above, in some embodiments, the aerosol source member may include an overwrap. If an overwrap is present, the overall length of the overwrap may vary from substantially the same as the length of the inhalable substance medium to approximately twice the length of the inhalable substance medium. Thus, the inhalable substance medium may have a length that is up to about 50%, up to about 30%, or up to about 10% shorter than the length of the overwrap. Preferably, the inhalable substance medium may have a length that is at least 10%, at least 15%, or at least 20% shorter than the length of the overwrap. More specifically, the distance that the overwrap extends beyond the inhalable substance medium may be about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% of the length of the inhalable substance medium.

[0068] The overwrapping can also function to provide particular properties to the mouth end of the cartridge. For example, the structure and / or shape and / or dimensions of the overwrapping can function to provide the feel of a traditional cigarette in the user's mouth. Additionally, as mentioned above, the overwrapping may include a filter (e.g., cellulose acetate or polypropylene) positioned proximate the mouth end of the cartridge to enhance the structural integrity of the overwrapping and / or provide optional filtration capabilities and / or resistance to draw.

[0069] Schematic diagrams of exemplary embodiments of an aerosol delivery device 100 according to the present disclosure are shown in FIGS. 1-3. Generally, the aerosol delivery device 100 includes a control body 102 including a housing 104 configured to receive an aerosol source member 500. The housing may also include a push button 105 configured to activate a specific operation of the device 100, such as turning on the device and initiating heating of a heating member. In various embodiments, the aerosol source member 500 may include a heated end 502 configured to be inserted into the control body 102 and a mouth end 504 through which a user inhales to generate aerosol. Note that while the aerosol delivery device of FIGS. 1-3 is shown as having a substantially rectangular or fob-shaped control body 102 for ease of illustration, in other embodiments, the control body 102 may have any other shape, including an elongated shell or body that is substantially tubular in shape and, therefore, may resemble the shape of a traditional cigarette or cigar; thus, the components described below may be sized and configured to fit within the elongated body.

[0070] In various embodiments, the control body 102 may be referred to as reusable and the aerosol source members 500 may be referred to as disposable. In some embodiments, the entire device 100 may be characterized as disposable in that the control body 102 may be configured for only a limited number of uses with a limited number of aerosol source members 500 (e.g., until the battery power components no longer provide sufficient power for the item), after which the entire device 100, including the control body 102, may be discarded. In other embodiments, the control body 102 may have a replaceable battery such that the control body 102 may be reused through multiple battery changes and with many aerosol source members 500. Similarly, the device 100 may be rechargeable and therefore may be combined with any type of charging technology, including connection to a typical electrical outlet, connection to an automobile charger (i.e., cigarette lighter socket), connection to a wireless charger, such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard from the Wireless Power Consortium (WPC)), or connection to a radio frequency (RF)-based charger, and connection to a computer via a USB cable or the like.

[0071] In various embodiments, the housing 104 can be formed from any material suitable for forming and maintaining a suitable structure, such as a tubular or rectangular shape, and for retaining the aerosol source member within the housing 104. In some embodiments, the housing can be formed from a single wall or multiple walls and can be formed from one or more materials (natural or synthetic) that are heat-resistant so as to maintain its structural integrity (e.g., not deteriorate) at least at temperatures that are the heating temperatures provided by the electric heating member, as further described herein. In some embodiments, heat-resistant polymers can be used. In other embodiments, ceramic materials can be used. In further embodiments, insulating materials can be used to prevent unnecessary heat transfer from the aerosol source member. When formed from a single layer, the housing can preferably have a thickness of about 0.2 mm to about 5.0 mm, about 0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm to about 3.0 mm. Additional exemplary types of components and materials that may be used to provide the above-described functions or that may be used as substitutes for the above-described materials and components may be of the type described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., and U.S. Patent Application Publication No. 2011 / 0041861 to Sebastian et al., the entire disclosures of which are incorporated herein by reference.

[0072] Although not shown, the housing 104 may include one or more apertures therein to allow the ingress of ambient air to be directed toward the heated end 502 of the aerosol source member 500. Thus, when a consumer draws on the mouth end 504 of the aerosol source member 500, air is drawn into the receiving chamber, enters the aerosol source member 500 adjacent the heated end 502, is drawn through the inhalable substance medium, and may be inhaled by the consumer through the mouth end 504. In embodiments where an overwrap is present, the drawn air may carry the inhalable substance through an opening in the overwrap, through an optional filter, and out of the opening in the overwrap.

[0073] In various embodiments, the control body 102 may include an opening 106 defined in the housing 104, a flow sensor (not shown, e.g., a puff sensor or pressure switch), control components 108 (e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.), and an electrical energy source 110 (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor). Some examples of power sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the disclosures of which are incorporated herein by reference in their entireties. With respect to flow sensors, representative current regulation and other control components, including various microcontrollers, sensors, and switches, for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875, all of which are incorporated herein by reference in their entirety, 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 entirety. Reference is also made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., all of which are incorporated herein by reference in their entirety.

[0074] Additional components may be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that may be associated with the mouth end of the device that detects a user's lip movement associated with drawing and subsequently causes heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heating load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device that includes an identifier that detects non-uniformities in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes a viable power cycle defined by several different phases; and U.S. Pat. No. 5,934,289 to Watkins et al. discloses a photonic-optical device. No. 5,954,979 to Counts et al. discloses a means for varying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT Patent Application Publication No. WO 2010 / 003480 to Flick discloses a fluid flow sensing system to indicate a puff using an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0075] Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components that may be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, and U.S. Pat. No. 8,156,944 to Hon. and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Pat. App. Pub. No. 2006 / 0196518 to Hon, and U.S. Pat. App. Pub. No. 2006 / 0196518 to Hon. 09 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT Patent Application Publication No. WO 2010 / 091593 to Hon, and PCT Patent Application Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application No. 14 / 881,392 to Worm et al., filed October 13, 2015, discloses an aerosol delivery device and a capsule that can be included in a fob-shaped configuration for the aerosol delivery device, and is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0076] The aerosol delivery device 100 of the illustrated embodiment also includes a heating element 112 that receives power from an electrical energy source 110 and can be controlled by the control component 108. The heating element 112 can be any device suitable for providing sufficient heat to facilitate release of the inhalable substance for inhalation by the consumer. In certain embodiments, the electrical heating element can be a resistive heating element. Useful heating elements can have low mass, low density, moderate resistivity, and be thermally stable at the temperatures experienced during use. Useful heating elements heat and cool rapidly, thereby using energy efficiently. Rapid heating of the element also results in nearly instantaneous volatilization of the aerosol-forming substance. Rapid cooling prevents substantial volatilization (and therefore waste) of the aerosol-forming substance during periods when aerosol formation is not desired. Such heating elements also allow for relatively precise control of the temperature range experienced by the aerosol-forming substance, especially when time-based current control is used. Useful heating elements are also chemically non-reactive (and chemically non-catalytic) with the materials comprising the inhalable substance medium being heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. Exemplary, non-limiting materials that may comprise the heating element include carbon, graphite, carbon / graphite composites, metal and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. A variety of different materials can be blended to achieve desired properties of resistivity, mass, thermal conductivity, and surface properties.

[0077] As seen in FIGS. 1-3 , the electric heating element 112 of some embodiments includes a small segment heating element that may be in direct contact with the aerosol source element 500. Direct contact may be preferred given its ability to provide conductive heating more quickly and requiring less thermal resistance. In other embodiments, the heating element may have other shapes corresponding to the shape of the inhalable substance medium within the aerosol source element. Other examples of heater arrays that may be adapted for use in the present disclosure in accordance with the above description are described in U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al., U.S. Pat. No. 5,224,498 to Deevi et al., U.S. Pat. No. 5,224,498 to Sprinkel et al., which are incorporated herein by reference in their entireties. No. 5,228,460 to Jr. et al., U.S. Pat. No. 5,322,075 to Deevi et al., U.S. Pat. No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al., U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S. Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 to Hajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692 to Das et al., and U.S. Pat. No. 5,591,368 to Fleischhauer et al.

[0078] Considering various possible heater configurations, the heating element may be constructed from an alloy of nickel, chromium, and iron, such as nichrome, or iron, aluminum, and chromium (kathal), or other alloys known to be suitable for use as heating elements. In some embodiments, the heating element may be in the form of a metal foil, such as stainless steel foil, aluminum foil, copper foil, or the like, or may be provided in any other useful configuration, such as a significantly straight or coiled, or otherwise spirally wound, configuration. In certain examples, the inhalable substance medium may include a blend of finely ground tobacco, tobacco extract, spray-dried tobacco extract, or other tobacco form mixed with optional inorganic materials (such as calcium carbonate), optional flavors, and aerosol-forming materials to form a substantially solid or moldable (e.g., extruded) substrate, which may be in direct contact with the heating element. However, in other embodiments, the heating element may not be in contact with the inhalable substance medium, but rather may simply be in close proximity to the inhalable substance medium.

[0079] In some embodiments, heater temperature control may be provided by including a sensor such as a thermistor or thermocouple in proximity to the heating element / substrate interface and / or by monitoring the resistance of the heating element itself and utilizing the known relationship between temperature and resistivity of a particular heating element alloy to infer the temperature of the heating element.

[0080] In certain embodiments, a portion of the heating element may be integral with (e.g., embedded within) the inhalable substance medium. For example, the inhalable substance medium may be formed from materials such as those described above and may include one or more electrically conductive materials mixed therein. Due to the presence of the electrically conductive material in the inhalable substance medium, when power is applied to the inhalable substance medium from an electrical energy source, an electric current flows, which in turn generates heat from the electrically conductive material. Thus, the heating element may be described as integral with the inhalable substance medium. As a non-limiting example, graphite or other suitable electrically conductive material may be mixed with, embedded in, or otherwise directly present on or within the material forming the inhalable substance medium, making the heating element integral with the medium. Examples of suitable heating elements and related components are described in U.S. Pat. No. 9,078,473 to Worm et al., incorporated herein by reference.

[0081] As described above, the control body 102 may further include a control component 108. For example, the control component may include a control circuit (which may be connected to additional components, as further described herein) that may be connected to the electrical energy source 110 by conductive wires. In various embodiments, the control component may control when and how the heating member 112 receives electrical energy to heat the inhalable substance medium for release of the inhalable substance for inhalation by the consumer. Such control may relate to the actuation of a pressure-sensitive switch, or the like, described in further detail below. Note that the terms “connected” or “coupled” should not be interpreted as requiring a direct connection without intervening components. Rather, these terms may encompass a direct connection and / or a connection via one or more intervening components. Thus, in various embodiments, these terms may be understood to mean operably connected or operably coupled.

[0082] In various embodiments, the control component 108 can also be configured to precisely control the amount of heat provided to the inhalable substance medium. While the heat required to volatilize a sufficient volume of aerosol-forming substance to provide the desired dose of inhalable substance per puff may vary for each particular substance used, it may be particularly useful to heat the heating element to a temperature of at least 120°C, at least 130°C, or at least 140°C. In some embodiments, the heating temperature may be at least 150°C, at least 200°C, at least 300°C, or at least 350°C to volatilize an adequate amount of aerosol-forming substance and thus provide the desired dose of inhalable substance. However, it may be particularly desirable to avoid heating to temperatures substantially above about 550°C to avoid degradation and / or excessive premature volatilization of the aerosol-forming substance. In particular, heating should be at a temperature low enough and for a time short enough to avoid significant combustion (preferably any combustion) of the inhalable substance medium. The present disclosure may provide components of the present article in combinations and modes of use that, among other things, produce a desired amount of inhalable substance at relatively low temperatures. Thus, yield may refer to either or both of the generation of aerosol within the article and its delivery to the consumer. In certain embodiments, the heating temperature may be about 120°C to about 300°C, about 130°C to about 290°C, about 140°C to about 280°C, about 150°C to about 250°C, or about 160°C to about 200°C. As described in more detail below, the duration of heating may be controlled by several factors. As described further herein, the heating temperature and duration may depend on the desired volume of aerosol and ambient air desired to be drawn through the aerosol source member. However, the duration may vary depending on the heating rate of the heating element, since the article may be configured such that the heating element is energized only until the desired temperature is reached. Alternatively, the duration of heating may be tied to the duration of a puff by the consumer using the article. Generally, the temperature and duration of heating are controlled by one or more components housed in the control body, as described above.

[0083] It should be noted that in some cases, the heating element and / or segments exposed to the heating element may transfer heat to either or both previously heated segments or subsequent, not yet heated segments (i.e., "upstream and / or downstream"). Accordingly, some embodiments may include gaps or segment insulating barriers between segments within the aerosol source element.

[0084] The amount of inhalable material emitted by the aerosol source member can vary based on the properties of the inhalable material. Preferably, the aerosol source member is comprised of a sufficient amount of inhalable material, along with a sufficient amount of any aerosol-forming agent, to function at a sufficient temperature for a sufficient time to emit the desired amount over the course of use. The amount may be provided in a single inhalation from the aerosol source member, or may be divided up to be provided through several puffs from the article over 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 article may provide an amount of nicotine of about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg per puff with the aerosol source member. In other embodiments, the desired amount may be characterized in terms of the amount of wet total particulate matter delivered based on the duration and volume of the puff. For example, the aerosol source member may deliver at least 1.0 mg of wet total particulate matter per puff when smoked under standard FTC smoking conditions of a 2-second, 35 ml puff for a specified number of puffs (as described elsewhere herein). Such testing may be performed using any standard smoking machine. In other embodiments, the amount of total particulate matter (TPM) produced under the same conditions for each puff may be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, about 1.0 mg to about 5.0 mg, about 1.5 mg to about 4.0 mg, about 2.0 mg to about 4.0 mg, or about 2.0 mg to about 3.0 mg.

[0085] The aerosol delivery device 100 of the illustrated embodiment further includes an indexing mechanism 114. In various embodiments, the indexing mechanism 114 can be coupled to the heating member 112 and configured to generate incremental relative motion between the heating member 112 and the aerosol source member 500. In the illustrated embodiment, the indexing mechanism 114 is coupled to the heating member 112 such that the indexing mechanism 114 moves the heating member 112 through a series of incremental heating positions to incrementally heat a corresponding series of segments of the aerosol source member 500. In particular, in FIG. 1 , the heating member 112 is shown in a first position 116a configured to heat a first segment 508a of the aerosol source member 500. FIG. 2 schematically illustrates the aerosol delivery device 100 of FIG. 1 showing the heating member 112 in a second heating position 116b, according to an exemplary embodiment of the present disclosure. The second position 116b is configured to heat a second segment 508b of the aerosol source member. 3 is a schematic illustration of the aerosol delivery device 100 of FIG. 1 showing a series of increasing heat locations 116a-k, according to an exemplary embodiment of the present disclosure. Note that the size and spacing of the heat locations in FIGS. 1-3 are shown as such for clarity, but in various embodiments, the size and spacing of the heat locations may vary.

[0086] In the illustrated embodiment of FIGS. 1-3 , the heating member 112 includes a structure configured to surround a portion of the outer diameter of the aerosol source member 500. In various embodiments, such a structure may include, for example, a substantially ring-shaped, substantially tubular, or substantially cylindrical structure, may be formed from any suitable material as described above, and preferably exhibits the properties described above. In one embodiment, such a structure may include a flexible heating member configured to wrap around at least a portion, and in some embodiments, a majority (e.g., greater than 50%), and in some embodiments, substantially all, of the circumference of a segment of the aerosol source member 500. Examples of flexible heating members are shown in FIGS. 14 and 15 . In particular, FIG. 14 shows a perspective view of a flexible heating member 1000 shown in a flat orientation, according to an exemplary embodiment of the present disclosure. In the illustrated embodiment, the flexible heating member 1000 includes a flexible base component 1002, a flexible heating element component 1004, a pair of heater leads 1006, and one or more attachment mechanisms 1008. In the illustrated embodiment, the flexible base component 1002 may include, for example, a polyimide film, such as Kapton® developed by DuPont®.

[0087] In various embodiments, the flexible heating element 1004 may include, for example, an etched foil heating element or a heating element printed with ink on a flexible film. In either case, the flexible base component 1002 and the flexible heating element component 1004 are configured to wrap around a portion of the aerosol source member, such that actuation of the flexible heating member 1000 can occur via electrical connection of the heater leads 1006 to a source of electrical energy (e.g., a battery and / or other power source, e.g., a capacitor). In various embodiments, this connection can be made via a controller, such as the control component 108, to control the heating member. As mentioned above, the flexible heating member 1000 of the illustrated embodiment also includes one or more attachment mechanisms 1008 that can be configured to allow the flexible heating member 1000 to be attached to an indexing mechanism, such as, for example, a component of the indexing mechanism 114.

[0088] 15 shows a perspective view of a flexible heating member 1000 shown in a formed orientation according to an exemplary embodiment of the present disclosure. In the illustrated embodiment, the flexible heating member 1000 is configured to be formed substantially cylindrical (or partially cylindrical) so as to surround a portion of the outer diameter of the aerosol source member. It should be noted that in some embodiments, the leads 1006 of the flexible heating member 1000 can be positioned to function as a spring or to perform a spring-like function to facilitate a force between the heating member 1000 and the aerosol source member 500.

[0089] 1-3 , in the illustrated embodiment, the indexing mechanism 114 includes a small motor 118 (e.g., a microstepping motor) configured to rotate a lead screw 120. Furthermore, a carrier 122, to which the heating member 112 is attached, is threaded onto the lead screw 120. Rotation of the lead screw 120 by the stepper motor 118 can thus move the carrier 122, and thus the heating member 112, in a substantially linear fashion. In various embodiments, the characteristics (e.g., including dimensions and / or specifications and / or control features) of the control components, stepper motor, lead screw, and carrier can be designed to meet various performance objectives. For example, in the embodiment shown in FIGS. 1-3 , the indexing mechanism 114 is configured to move the heating member 112 through a series of discrete linear positions 116 relative to the aerosol source member 500. Because the aerosol source member 500 in the illustrated embodiment is stationary, these linear positions 116 correspond to a series of discrete segments 508 of the aerosol source member 500. Thus, control component 108, stepper motor 118, lead screw 120, carrier 122, and heating element 112 are configured such that heating element 112 can be controlled to sequentially heat each of the segments 508 of aerosol source element 500. With respect to the embodiment of FIGS. 1-3, this represents segments 508a-k. Note that for purposes of clarity, the illustrated embodiment shows a total of eleven distinct positions 116a-k of heating element 112, corresponding to eleven distinct segments 508a-k of aerosol source element 500. However, in various other embodiments, the heating element can have any number of distinct positions corresponding to any number of distinct segments of the aerosol source element, including an infinite number of distinct segments.Furthermore, although the embodiments shown in Figures 1-3 depict multiple, separate, heating element positions 116a-k and corresponding, separate heated segments 508a-k of the aerosol source element that are spaced apart from one another, in other embodiments, the separate positions and corresponding segments may have different spacings, including, but not limited to, spacings that result in the separate positions and corresponding segments being adjacent to and / or overlapping one another to any degree, as well as inconsistent spacings between them.

[0090] In some embodiments, operation of the heating element 112 may be initiated by a consumer's puff through the use of one or more various sensors, as described elsewhere herein, and / or may be initiated upon the cessation of a puff as sensed by one or more various sensors. Thus, in some embodiments, the number of heating element positions 116 may correspond to the number of puffs available from the aerosol source element 500. In some embodiments, a single aerosol source element may provide about 4 to about 12, about 5 to about 11, or about 6 to about 10 puffs, which approximates the number of puffs on a typical cigarette. In some embodiments, once the heating element 112 has passed through all of the available positions 116, the motor 118 may reverse direction, returning the carrier 122 and heating element 112 to the first or starting position of the heating element 112. In other embodiments, the heating element 112 may remain in its last or final position, or may be positioned at any other position or in between. Additionally, in some embodiments, the controller may provide an indication (e.g., via a sound and / or an indicator light) that the heating member 112 has passed through all of the available positions 116. Additionally, in some embodiments, the aerosol source member 500 may be ejected when the heating member has passed through all of the available positions 116.

[0091] For example, in some embodiments, the heating member 112 may have a tight friction fit with the outer diameter of the aerosol source member 500. During normal operation, as aerosol is released from the aerosol source member 500, the heating member 112 may move from the proximal end (closest to the mouth end 504) to the distal end (closest to the heated end 502) of the aerosol source member 500. Friction between the heating element and the aerosol source member 500 may act in a direction such that the frictional force is directed toward the control body 102 each time the heating element 112 moves from one segment to the next. In various embodiments, one or more stops or positioning features (not shown) located on the control unit 102 may prevent the aerosol source member 500 from moving in a direction toward the control body 102. When the heating member 112 reaches the end of its travel, it may be returned to its original starting position. In this case, the frictional force may act in a direction outward from the control body 102. Because the aerosol source member 500 is not prevented from moving in an outward direction from the control body 102 , it is dragged outward by the movement of the heating member 112 and is thus expelled from the control body 102 .

[0092] While operation of the aerosol delivery device may vary across various embodiments, in the exemplary embodiment of FIGS. 1-3 , general operation of the aerosol delivery device 100 may occur as follows, with one or more of the following steps occurring via control from the control component 108. In a first step, the heating element 112 located at the first heating position 116 (e.g., position 116a) may be turned on by pressing the push button 105. Furthermore, the heating element 112 may be preheated to a first temperature T1, which in some embodiments may be sufficiently low so that no aerosol is generated from the aerosol source element 500. In a second step, a user may inhale (e.g., as detected by a flow sensor) on the aerosol source element 500, and the heating element 112 may be heated to a second temperature T2 at which aerosol is generated from the aerosol source element 500. When the user stops puffing (e.g., as detected by a flow sensor), the heater temperature may return to the first temperature T1, and the indexing mechanism may automatically move to the next heating position 116 (e.g., position 116b, etc.). This process may continue until the heating member 112 moves to the last heating position 116 (e.g., position 116k, etc.). After this point, the aerosol source member 500 may be ejected from the housing 102.

[0093] In other embodiments, the indexing of the heating element may be manually controlled by the consumer, such that the heating element may be manually advanced by the consumer. For example, schematic diagrams of another exemplary embodiment of an aerosol delivery device 200 according to the present disclosure are shown in FIGS. 4-6. Generally, the aerosol delivery device 200 includes a control body 202 including a housing 204 configured to receive an aerosol source element 500. The housing may also include a push button 205 configured to activate a specific operation of the device 200, such as, for example, turning on the device and initiating heating of the heating element. In various embodiments, the aerosol source element 500 may include a heated end 502 configured to be inserted into the control body 202 and a mouth end 504 through which a user inhales to generate aerosol. It should be noted that while the aerosol delivery device of Figures 4-6 is shown as having a substantially rectangular or fob-shaped control body 202 for ease of illustration, in other embodiments, the control body 202 may have an elongated shell or body that is substantially tubular in shape and thus may resemble the shape of a traditional cigarette or cigar, and thus the components described below may be sized and configured to fit inside the elongated body.

[0094] In various embodiments, the control body 202 may be referred to as reusable and the aerosol source members 500 may be referred to as disposable. In some embodiments, the entire device 200 may be characterized as disposable in that the control body 202 may be configured for only a limited number of uses with a limited number of aerosol source members 500 (e.g., until the battery power component no longer provides sufficient power for the item), after which the entire device 200, including the control body 202, may be discarded. In other embodiments, the control body 202 may have a replaceable battery such that the control body 202 may be reused through multiple battery changes and with many aerosol source members 500. Similarly, the device 200 may be rechargeable and therefore may be combined with any type of charging technology, including connection to a typical electrical outlet, connection to an automobile charger (i.e., cigarette lighter socket), and connection to a computer via a USB cable, etc.

[0095] In various embodiments, the housing 204 may be formed from any material suitable for forming and maintaining an appropriate structure, such as a tubular or rectangular shape, and for retaining the aerosol source member within the housing. In some embodiments, the housing may be formed from a single wall or multiple walls and may be formed from one or more materials (natural or synthetic) that are heat-resistant so as to maintain the structural integrity of the housing (e.g., not deteriorate) at least at temperatures that are the heating temperatures provided by the electric heating member, as described above. In some embodiments, heat-resistant polymers may be used. In other embodiments, ceramic materials may be used. In further embodiments, thermal insulation may be used to prevent unnecessary heat transfer from the aerosol source member. In some embodiments, the size and shape of the housing may be similar to those described above with respect to FIGS. 1-3.

[0096] Although not shown, the housing 204 may include one or more apertures therein to allow the ingress of ambient air to be directed toward the heated end 502 of the aerosol source member 500. Thus, when a consumer draws on the mouth end 504 of the aerosol source member 500, air is drawn into the receiving chamber, enters the aerosol source member 500 adjacent the heated end 502, is drawn through the inhalable substance medium, and may be inhaled by the consumer through the mouth end 504. In embodiments where an overwrap is present, the drawn air may carry the inhalable substance through an opening in the overwrap, through an optional filter, and out of the opening in the overwrap.

[0097] In various embodiments, the control body 202 may include an opening 206 defined in the housing 204, a flow sensor (not shown, e.g., a puff sensor or pressure switch), control components 208 (e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.), and an electrical energy source 210 (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor). In some embodiments, the control body 202 may also include a flow sensor (not shown, e.g., a puff sensor or pressure switch). Examples of power sources and other components that may be part of the aerosol delivery device 200 are described above with respect to FIGS. 1-3.

[0098] The aerosol delivery device 200 of the illustrated embodiment also includes a heating element 212 that receives power from an electrical energy source 210 and can be controlled by a control component 208. The heating element 212 can be any device suitable for providing sufficient heat to facilitate release of the inhalable substance for inhalation by a consumer. In certain embodiments, the electrical heating element can be a resistive heating element. Useful heating elements can have low mass, low density, moderate resistivity, and be thermally stable at the temperatures experienced during use. Useful heating elements heat and cool rapidly, thereby using energy efficiently. Rapid heating of the element also results in nearly instantaneous volatilization of the aerosol-forming substance. Rapid cooling prevents substantial volatilization (and therefore waste) of the aerosol-forming substance during periods when aerosol formation is not desired. Such heating elements also allow for relatively precise control of the temperature range experienced by the aerosol-forming substance, especially when time-based current control is used. Useful heating elements are also chemically non-reactive with the materials comprising the inhalable substance medium being heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. Exemplary, non-limiting materials that may comprise the heating element include carbon, graphite, carbon / graphite composites, metal and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. Various different materials may be mixed to achieve desired properties of resistivity, mass, thermal conductivity, and surface properties.

[0099] As seen in FIGS. 4-6 , the electric heating element 212 in some embodiments includes a small segment heating element that may be in direct contact with the aerosol source member 500. While the configuration of the heating element may vary in various embodiments, in some exemplary embodiments, the heating element may be a wire-wound heating element, an etched foil heating element, or a heating element printed with ink on a temperature-resistant flexible film such as polyimide or silicone. Other deposition methods, including plasma deposition or chemical etching / vapor deposition, may also be used. In other embodiments, the heating element may be a resistive metal ribbon heater or an infrared (optical) heater. See also the description of the heating element 112 described above with respect to FIGS. 1-3 . Direct contact may be preferred given its ability to provide conductive heating, which requires more rapid and less resistance. However, in other embodiments, the heating element may not be in contact with the inhalable substance medium, but rather may simply be in close proximity to the inhalable substance medium. In some embodiments, the heating element may have other shapes corresponding to the shape of the inhalable substance medium within the aerosol source member. Examples of heater arrays and possible heater configurations are described above with respect to FIGS. 1-3 .

[0100] As described above, the control body 202 may further include a control component 208. For example, the control component may include a control circuit (which may be connected to additional components as further described herein) that may be connected by conductive wires to an electrical energy source 210. In various embodiments, the control component may control when and how the heating member 212 receives electrical energy to heat the inhalable substance medium for release of the inhalable substance for inhalation by the consumer. Such control may involve the actuation of a pressure-sensitive switch or the like, which is described in more detail below. The control component may also be configured to precisely control the amount of heat provided to the inhalable substance medium, as described in more detail above with respect to FIGS. 1-3.

[0101] The aerosol delivery device 200 of the illustrated embodiment further includes an indexing mechanism 214 including an actuator 250, which in some embodiments may be a thumb lever or the like. In various embodiments, the indexing mechanism may be coupled to the heating member 212 and configured to generate incremental relative motion between the heating member 212 and the aerosol source member 500. In the illustrated embodiment, the indexing mechanism 214 is coupled to the heating member 212 such that the indexing mechanism 214 moves the heating member 212 through a series of incremental heating positions to incrementally heat a corresponding series of segments of the aerosol source member. In the illustrated embodiment, the actuator 250 is a manual mechanical actuator configured to move with the heating member 212 and position the heating member 212 at a plurality of heating positions.

[0102] In particular, in FIG. 4 , the heating element 212 is shown in a first position 216a configured to heat a first segment 508a of the aerosol source element 500. FIG. 5 schematically illustrates the aerosol delivery device 200 of FIG. 4 showing the heating element 212 in a second heating position 216b, in accordance with an exemplary embodiment of the present disclosure. The second position 216b is configured to heat a second segment 508b of the aerosol source element. As shown, to move the heating element 212 from the first heating position 216a to the second heating position 216b, the actuator 250 moves from a first actuator position 252a to a second actuator position 252b. FIG. 6 schematically illustrates the aerosol delivery device 200 of FIG. 4 showing a series of increasing heating positions 216a-k, in accordance with an exemplary embodiment of the present disclosure. As mentioned above, it should be noted that the size and spacing of the heating locations in Figures 4-6 are shown as such for clarity, but in various embodiments, the size and spacing of the heating locations may vary.

[0103] In the illustrated embodiment, the heating member 212 includes a ring-like structure configured to surround a portion of the outer diameter of the aerosol source member 500. Such a structure may be formed from any suitable material, as described above, and preferably exhibits the properties described above. In the illustrated embodiment, the indexing mechanism 214 includes a carrier 222 to which the heating member 212 is attached and a guide mechanism 254 through which the actuator 250 is configured to move. In various embodiments, the guide mechanism 254 may include multiple linearly spaced stops, detents, or other features configured to capture the actuator 250 at a specific position and correspond to multiple actuator positions 252. In this manner, a consumer may linearly move the actuator 250 through the multiple actuator positions 252 to linearly advance the heating member 212 through the multiple heating positions. In various embodiments, the properties of the actuator and guide mechanism (including, for example, dimensions and / or specifications and / or features) may be designed to meet various performance goals. For example, in the embodiment shown in FIGS. 4-6 , indexing mechanism 214 is configured to move heating member 212 through a series of discrete linear positions 216. Because the aerosol source member 500 in the illustrated embodiment is stationary, these linear positions 216 correspond to a series of discrete segments 508 of the aerosol source member 500. Accordingly, control component 208, carrier 222, guide mechanism 254, and actuator 250 are configured to allow heating member 212 to sequentially heat segments of the aerosol source member. With reference to FIG. 6 , these segments are designated as segments 508 a-k. For purposes of clarity, the illustrated embodiment shows a total of eleven discrete positions 216 a-k of heating member 212, corresponding to eleven discrete heated segments 508 a-k of aerosol source member 500; however, it should be noted that in various other embodiments, the heating member may have any number of discrete positions corresponding to any number of discrete segments of the aerosol source member, including an infinite number of discrete segments.Additionally, while the embodiments shown in Figures 4-6 depict multiple discrete heating element locations and corresponding discrete heating segments that are spaced apart from one another, in other embodiments the discrete locations and corresponding discrete segments may have different spacings, including, but not limited to, spacings that result in the discrete locations and corresponding discrete segments being adjacent to one another and / or overlapping one another, as well as inconsistent spacings.

[0104] In various embodiments, operation of the heating element 212 can be initiated by the consumer via the actuator 250. For example, the consumer may advance the heating element 212 after a puff or when prompted to do so by the device 200. Thus, in some embodiments, the consumer may decide when to advance the actuator 250, and in other embodiments, the device 200 may provide an indication (e.g., via a sound and / or an indicator light) that the heating element 212 should be advanced. For example, in one embodiment, the user may advance the heating element 212 to the next position before taking a new puff on the aerosol source member 500. The heating element 212 is then preheated to a first temperature T1. Once the segment reaches T1 (or a predetermined time has elapsed), the device 200 uses a light or sound to indicate that the user may take a puff. In some embodiments, the number of heating element positions 216 may correspond to the number of puffs available from the aerosol source member 500. In some embodiments, a single aerosol source member may provide about 4 to about 12, about 5 to about 11, or about 6 to about 10 puffs, which approximate the number of puffs on a typical cigarette. In some embodiments, once the heating element 212 has passed through all of the available positions 216, the device may provide an indication (e.g., via a sound and / or an indicator light) that the heating element 212 has passed through all of the available positions. In this manner, the consumer may then return the actuator 250 to the initial actuator position 252a. In some embodiments, the aerosol source element 500 may be ejected when the actuator 250 is returned to the initial actuator position 252a. In various embodiments, the aerosol source element may be ejected in various ways, although in one embodiment, reference is made to the ejection methods described above with respect to FIGS. 1-3.

[0105] While operation of the aerosol delivery device may vary between embodiments, in the exemplary embodiment of FIGS. 4-6 , general operation of the aerosol delivery device 200 may occur as follows, with one or more of the following steps occurring via control from the control component 208. In a first step, the heating element 212 may be turned on by pressing the push button 205. In a second step, the user may click the actuator 250 downward, thereby moving the heating element 212 to one linear position 216 (e.g., from the null position to the first position 216a) and preheating the heating element 212 to a first temperature T1. In a third step, the user may inhale on the aerosol source element 500 (e.g., as detected by a flow sensor), and the heating element 212 may heat to a second temperature T2. When the user stops puffing (e.g., as detected by a flow sensor), the heater may be turned off. The user may then click the actuator 250 downward, which may move the heating member 212 to the next linear position 216 (e.g., position 216b, etc.) and preheat the heating member 212 to the first temperature T1. This process may continue until the heating member 212 moves to the last heating position 216 (e.g., position 216k, etc.). At this point, the actuator 250 may be returned to its initial position, and the aerosol source member 500 may be ejected from the housing 202.

[0106] Schematic diagrams of another exemplary embodiment of an aerosol delivery device 300 according to the present disclosure are shown in FIGS. 7-9. Generally, the aerosol delivery device 300 includes a control body 302 including a housing 304 configured to receive an aerosol source member 500. The housing may also include a push button 305 configured to activate a specific operation of the device 300, such as turning on the device and initiating heating of the heating member. In various embodiments, the aerosol source member 500 may include a heated end 502 configured to be inserted into the control body 302 and a mouth end 504 through which a user inhales to generate aerosol. Note that while the aerosol delivery device in FIGS. 7-9 is shown as having a substantially rectangular or fob-shaped control body 302 for ease of illustration, in other embodiments, the control body 302 may have an elongated shell or body that is substantially tubular in shape and, therefore, may resemble the shape of a traditional cigarette or cigar; therefore, the components described below may be sized and configured to fit within the elongated body.

[0107] In various embodiments, the control body 302 may be referred to as reusable and the aerosol source members 500 may be referred to as disposable. In some embodiments, the entire device 300 may be characterized as disposable in that the control body 302 may be configured for only a limited number of uses with a limited number of aerosol source members 500 (e.g., until the battery power components no longer provide sufficient power for the item), after which the entire device 300, including the control body 302, may be discarded. In other embodiments, the control body 302 may have a replaceable battery such that the control body 302 may be reused through multiple battery changes and with many aerosol source members 500. Similarly, the device 300 may be rechargeable and therefore may be combined with any type of charging technology, including connection to a typical electrical outlet, connection to an automobile charger (i.e., cigarette lighter socket), and connection to a computer via a USB cable, etc.

[0108] In various embodiments, the housing 304 may be formed from any material suitable for forming and maintaining an appropriate structure, such as a tubular or rectangular shape, and for retaining the aerosol source member within the housing 304. In some embodiments, the housing may be formed from a single wall or multiple walls and may be formed from one or more materials (natural or synthetic) that are heat-resistant so as to retain its structural integrity (e.g., not deteriorate) at least at certain temperatures, such as the heating temperatures provided by the electric heating member, as described above. In some embodiments, heat-resistant polymers may be used. In other embodiments, ceramic materials may be used. In further embodiments, thermal insulation may be used to prevent unnecessary heat transfer from the aerosol source member. The size and shape of the housing may be similar to those described above with respect to FIGS. 1-3.

[0109] Although not shown, the housing 304 may include one or more apertures therein to allow the ingress of ambient air to be directed toward the heated end 502 of the aerosol source member 500. Thus, when a consumer draws on the mouth end 504 of the aerosol source member 500, air is drawn into the receiving chamber, enters the aerosol source member 500 adjacent the heated end 502, is drawn through the inhalable substance medium, and may be inhaled by the consumer through the mouth end 504. In embodiments where an overwrap is present, the drawn air may carry the inhalable substance through an opening in the overwrap, through an optional filter, and out of the opening in the overwrap.

[0110] The control body 302 may include an opening 306 defined therein, a control component 308 (e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.), and an electrical energy source 310 (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor). In some embodiments, the control body 302 may also include a flow sensor (not shown, e.g., a puff sensor or pressure switch). Examples of power sources and other components that may be part of the aerosol delivery device 300 are described above with respect to FIGS. 1-3.

[0111] The aerosol delivery device 300 of the illustrated embodiment also includes a heating element 312 that receives power from an electrical energy source 310 and can be controlled by a control component 308. The heating element 312 can be any device suitable for providing sufficient heat to facilitate release of the inhalable substance for inhalation by the consumer. In certain embodiments, the electrical heating element can be a resistive heating element. Useful heating elements can have low mass, low density, moderate resistivity, and be thermally stable at the temperatures experienced during use. Useful heating elements heat and cool rapidly, thereby using energy efficiently. Rapid heating of the element also results in nearly instantaneous volatilization of the aerosol-forming substance. Rapid cooling prevents substantial volatilization (and therefore waste) of the aerosol-forming substance during periods when aerosol formation is not desired. Such heating elements also allow for relatively precise control of the temperature range experienced by the aerosol-forming substance, especially when time-based current control is used. Useful heating elements are also chemically non-reactive with the materials comprising the inhalable substance medium being heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. Exemplary, non-limiting materials that may comprise the heating element include carbon, graphite, carbon / graphite composites, metal and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. Various different materials may be mixed to achieve desired properties of resistivity, mass, thermal conductivity, and surface properties.

[0112] As seen in FIGS. 7-9 , the electric heating element 312 in some embodiments includes a small segment heating element that may be in direct contact with the aerosol source element. While the configuration of the heating element may vary in various embodiments, in some exemplary embodiments, the heating element may be a wire-wound heating element, an etched foil heating element, or a heating element printed with ink on a temperature-resistant flexible film such as polyimide or silicone. Other deposition methods, including plasma deposition or chemical etching / vapor deposition, may also be used. In other embodiments, the heating element may be a resistive metal ribbon heater or an infrared (optical) heater. See also the description of the heating element 112 described above with respect to FIGS. 1-3 . Direct contact may be preferred given its ability to provide conductive heating, which requires more rapid and less resistance. However, in other embodiments, the heating element may not be in contact with the inhalable substance medium, but rather may simply be in close proximity to the inhalable substance medium. In some embodiments, the heating element may have other shapes corresponding to the shape of the inhalable substance medium within the aerosol source element. Examples of heater arrays and possible heater configurations are described above with respect to FIGS. 1-3 .

[0113] As described above, the control body 302 may further include a control component 308. For example, the control component may include a control circuit (which may be connected to additional components as further described herein) that may be connected to an electrical energy source 310 by conductive wires. In various embodiments, the control component 308 may control when and how the heating member 312 receives electrical energy to heat the inhalable substance medium for release of the inhalable substance for inhalation by the consumer. Such control may involve the actuation of a pressure-sensitive switch or the like, which is described in further detail below. The control component may also be configured to precisely control the amount of heat provided to the inhalable substance medium, as described in further detail above with respect to FIGS. 1-3.

[0114] The aerosol delivery device 300 of the illustrated embodiment further includes an indexing mechanism 314 that includes an actuator 350, which in some embodiments can be a thumb lever or the like. In various embodiments, the indexing mechanism 314 can be coupled to the heating member 312 and configured to generate incremental relative motion between the heating member 312 and the aerosol source member 500. In the illustrated embodiment, the indexing mechanism 314 is coupled to the heating member 312 such that the indexing mechanism 314 remains relatively stationary but is configured to move the heating member 312 through a series of incremental heat positions to incrementally heat a corresponding series of segments of the aerosol source member 500. Thus, in the illustrated embodiment, the actuator 350 is a click-return actuator that advances the heating member one position each time the actuator 350 is actuated.

[0115] In particular, in FIG. 7 , the heating element 312 is shown in a first position 316a configured to heat the first segment 508a of the aerosol source element 500. FIG. 8 schematically illustrates the aerosol delivery device 300 of FIG. 7 showing the heating element 312 in a second heating position 316b, according to an exemplary embodiment of the present disclosure. The second position 316b is configured to heat the second segment 508b of the aerosol source element. As shown, to move the heating element 312 from the first heating position 316a to the second heating position 316b, the actuator 350 is pushed downward and returns to its original position. FIG. 9 schematically illustrates the aerosol delivery device 300 of FIG. 7 showing a series of increasing heating positions 316a-k, according to an exemplary embodiment of the present disclosure. As mentioned above, it should be noted that while the size and spacing of the heating positions in FIGS. 7-9 are shown as such for clarity, in various embodiments, the size and spacing of the heating positions may vary.

[0116] In various embodiments, various click-return mechanisms may be used to advance the heating element 312 through the multiple heating positions 316. Such mechanisms may include, but are not limited to, ratchet mechanisms, Geneva mechanisms, sector gear mechanisms, Whitworth mechanisms, ratchet mechanisms, bell cranks, slotted yokes, and cam follower mechanisms such as those used in small mechanical devices (e.g., ballpoint pens).

[0117] In the illustrated embodiment, the heating member 312 includes a ring-like structure configured to surround a portion of the outer diameter of the aerosol source member 500. Such a structure may be formed from any suitable material, as described above, and preferably exhibits the properties described above. In the illustrated embodiment, the indexing mechanism 314 includes a carrier 322 to which the heating member 312 is attached and a guide mechanism 354 configured to guide the carrier 322 and heating member 312 through the multiple positions. In this manner, a consumer may actuate the actuator 350, such as by pressing the actuator 350 downward, which linearly and sequentially advances the heating member 312 through the multiple heating member positions. In various embodiments, the properties (e.g., including dimensions and / or specifications and / or features) of the actuator and guide mechanism may be designed to meet various performance goals. For example, in the embodiment shown in FIGS. 7-9, the indexing mechanism 314 is configured to allow the heating member 312 to be moved through a series of discrete linear positions 316. Because the aerosol source member 500 in the illustrated embodiment is stationary, these linear positions 316 correspond to a series of discrete segments 508 of the aerosol source member 500. Accordingly, the carrier 322, guide mechanism 354, and actuator 350 are configured to allow the heating element 312 to sequentially heat segments of the aerosol source member. With reference to FIG. 9, these segments are designated as segments 508a-k. For purposes of clarity, the illustrated embodiment shows a total of eleven discrete heating element positions 316a-k corresponding to eleven discrete heating segments 508a-k of the aerosol source member 500; however, it should be noted that in various other embodiments, the heating element may have any number of discrete positions corresponding to any number of discrete segments of the aerosol source member, including an infinite number of discrete segments. Additionally, while the embodiments shown in Figures 7-9 depict multiple discrete heating element locations and corresponding discrete heating segments that are spaced apart from one another, in other embodiments the discrete locations and corresponding discrete segments may have different spacings, including, but not limited to, spacings that result in the discrete locations and corresponding discrete segments being adjacent to one another and / or overlapping one another, as well as inconsistent spacings.

[0118] In various embodiments, operation of the heating element 312 can be initiated by the consumer via the actuator 350. For example, the consumer may advance the heating element 312 after a puff or when prompted to do so by the device 300. Thus, in some embodiments, the consumer may decide when to advance the actuator, and in other embodiments, the device 300 may provide an indication (e.g., via a sound and / or an indicator light) that the heating element should be advanced. In some embodiments, the number of heating element positions 316 may correspond to the number of puffs available from the aerosol source element 500. In some embodiments, a single aerosol source element may provide about 4 to about 12 puffs, about 5 to about 11 puffs, or about 6 to about 10 puffs, which approximates the number of puffs on a typical cigarette. In some embodiments, once the heating element 312 has passed through all of the available positions 316, the device may provide an indication (e.g., via a sound and / or an indicator light) that the heating element has passed through all of the available positions. In this manner, the consumer may move the actuator 350 in a different direction (e.g., upward) to return the heating member 312 to its initial position. Additionally, in some embodiments, the aerosol source member 500 may be ejected when the actuator 350 is moved in a different direction.

[0119] While device operation may vary, in one exemplary embodiment, the general operation of the aerosol delivery device 300 of FIGS. 7-9 may occur as follows, with one or more of the following steps occurring via control from the control component 308. In a first step, the heating element 312 may be turned on by pressing the push button 305. In a second step, the user may click the actuator 350 downward, thereby moving the heating element 312 to one linear position 316 (e.g., from the null position to the first position 316a) and preheating the heating element 312 to the first temperature T1. Due to the nature of the click-return mechanism, the actuator 350 may return to its original position. In a third step, the user may inhale on the aerosol source element (e.g., as detected by a flow sensor), and the heating element 312 may heat to the second temperature T2. When the user stops puffing (e.g., as detected by a flow sensor), the heater may be turned off. The user may then click the actuator 350 downward, which may move the heating member 312 to the next linear position 316 (e.g., position 316b) and preheat the heating member 312 to the first temperature T1. Again, due to the nature of the click-return mechanism, the actuator 350 may return to its original position. This process may continue until the heating member 312 moves to the last heating position 316 (e.g., position 316k). At this point, the actuator 350 may be pushed in another direction, such as upward, to eject the aerosol source member 500 from the housing 302. In various embodiments, the aerosol source member may be ejected in various ways, but in one embodiment, reference is made to the ejection method described above with respect to FIGS. 1-3.

[0120] Schematic diagrams of another exemplary embodiment of an aerosol delivery device 400 according to the present disclosure are shown in FIGS. 10-12. Generally, the aerosol delivery device 400 includes a control body 402 including a housing 404 configured to receive an aerosol source member 500. The housing may also include a push button 405 configured to activate a specific operation of the device 400, such as turning on the device and initiating heating of a heating member. In various embodiments, the aerosol source member 500 may include a heated end 502 configured to be inserted into the control body 402 and a mouth end 504 through which a user inhales to generate aerosol. While the aerosol delivery device of FIGS. 10-12 is shown as having a substantially rectangular or fob-shaped control body 402 for ease of illustration, it should be noted that in other embodiments, the control body 402 may have an elongated shell or body that is substantially tubular in shape and, therefore, may resemble the shape of a traditional cigarette or cigar; thus, the components described below may be sized and configured to fit within the elongated body.

[0121] In various embodiments, the control body 402 may be referred to as reusable and the aerosol source members 500 may be referred to as disposable. In some embodiments, the entire device 400 may be characterized as disposable in that the control body 402 may be configured for only a limited number of uses with a limited number of aerosol source members 500 (e.g., until the battery power components no longer provide sufficient power for the item), after which the entire device 400, including the control body 402, may be discarded. In other embodiments, the control body 402 may have a replaceable battery such that the control body 402 may be reused through multiple battery changes and with many aerosol source members 500. Similarly, the device 400 may be rechargeable and therefore may be combined with any type of charging technology, including connection to a typical electrical outlet, to an automobile charger (i.e., cigarette lighter socket), to a computer via a USB cable or the like, or to a wireless charger, such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or to a radio frequency (RF)-based charger.

[0122] In various embodiments, the housing 404 may be formed from any material suitable for forming and maintaining an appropriate structure, such as a tubular or rectangular shape, and for retaining the aerosol source member within the housing 404. In some embodiments, the housing may be formed from a single wall or multiple walls and may be formed from one or more materials (natural or synthetic) that are heat resistant so as to maintain the structural integrity of the housing (e.g., not deteriorate) at least at certain temperatures, such as the heating temperatures provided by the electric heating member, as further described herein. In some embodiments, heat resistant polymers may be used. In other embodiments, ceramic materials may be used. In further embodiments, thermal insulation may be used to prevent unnecessary heat transfer from the aerosol source member. The size and shape of the housing may be similar to those described above with respect to FIGS. 1-3.

[0123] Although not shown, the housing 404 may include one or more apertures therein to allow the ingress of ambient air to be directed toward the heated end 502 of the aerosol source member 500. Thus, when a consumer draws on the mouth end 504 of the aerosol source member 500, air is drawn into the receiving chamber, enters the aerosol source member 500 adjacent the heated end 502, is drawn through the inhalable substance medium, and can be inhaled by the consumer through the mouth end 504. In embodiments where an overwrap is present, the drawn air may carry the inhalable substance through an opening in the overwrap, through an optional filter.

[0124] The control body 402 may include an opening 406 defined therein, a control component 408 (e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.), and an electrical energy source 410 (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor). In some embodiments, the control body 402 may also include a flow sensor (not shown, e.g., a puff sensor or pressure switch). Examples of power sources and other components that may be part of the aerosol delivery device 400 are described above with respect to FIGS. 1-3.

[0125] The aerosol delivery device 400 of the illustrated embodiment also includes a heating element 412 that receives power from an electrical energy source 410 and can be controlled by a control component 408. The heating element 412 can be any device suitable for providing sufficient heat to facilitate release of the inhalable substance for inhalation by the consumer. In certain embodiments, the electrical heating element can be a resistive heating element. Useful heating elements can have low mass, low density, moderate resistivity, and be thermally stable at the temperatures experienced during use. Useful heating elements heat and cool rapidly, thereby using energy efficiently. Rapid heating of the element also results in nearly instantaneous volatilization of the aerosol-forming substance. Rapid cooling prevents substantial volatilization (and therefore waste) of the aerosol-forming substance during periods when aerosol formation is not desired. Such heating elements also allow for relatively precise control of the temperature range experienced by the aerosol-forming substance, especially when time-based current control is used. Useful heating elements are also chemically non-reactive with the materials comprising the inhalable substance medium being heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. Exemplary, non-limiting materials that may comprise the heating element include carbon, graphite, carbon / graphite composites, metal and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. Various different materials may be mixed to achieve desired properties of resistivity, mass, thermal conductivity, and surface properties.

[0126] As seen in FIGS. 10-12 , the electric heating element 412 in some embodiments includes a small segment heating element that may be in direct contact with the aerosol source member 500. While the configuration of the heating element may vary in various embodiments, in some exemplary embodiments, the heating element may be a wire-wound heating element, an etched foil heating element, or a heating element printed with ink on a temperature-resistant flexible film such as polyimide or silicone. Other deposition methods, including plasma deposition or chemical etching / vapor deposition, may also be used. In other embodiments, the heating element may be a resistive metal ribbon heater or an infrared (optical) heater. See also the description of the heating element 112 above with respect to FIGS. 1-3 . Direct contact may be preferred given its ability to provide conductive heating, which requires more rapid and less resistance. However, in other embodiments, the heating element may not be in contact with the inhalable substance medium, but rather may simply be in close proximity to the inhalable substance medium. In other embodiments, the heating element may have other shapes corresponding to the shape of the inhalable substance medium within the aerosol source member. Examples of heater arrays and possible heater configurations are described above with respect to FIGS.

[0127] As described above, the control body 402 may further include a control component 408. For example, the control component may include a control circuit (which may be connected to additional components as further described herein) that may be connected by conductive wires to an electrical energy source 410. In various embodiments, the control component may control when and how the heating member 412 receives electrical energy to heat the inhalable substance medium for release of the inhalable substance for inhalation by the consumer. Such control may involve the actuation of a pressure-sensitive switch or the like, which is described in further detail below. The control component may also be configured to precisely control the amount of heat provided to the inhalable substance medium, as described in further detail above with respect to FIGS. 1-3.

[0128] The aerosol delivery device 400 of the illustrated embodiment further includes an indexing mechanism 414. In various embodiments, the indexing mechanism 414 can be coupled to the heating member 412 and configured to generate incremental relative motion between the heating member 412 and the aerosol source member 500. In the illustrated embodiment, the indexing mechanism 414 is coupled to the heating member 412 such that the indexing mechanism 414 moves the heating member 412 through a series of incremental heating positions to incrementally heat a corresponding series of segments of the aerosol source member 500. In particular, in FIG. 10 , the heating member 412 is shown in a first position 416 a configured to heat a first segment 508 a of the aerosol source member 500. FIG. 11 schematically illustrates the aerosol delivery device 400 of FIG. 10 showing the heating member 412 in a second heating position 416 b, in accordance with an exemplary embodiment of the present disclosure. The second location 416b is configured to heat the second segment 508b of the aerosol source member 500. Figure 12 schematically illustrates the aerosol delivery device 400 of Figure 10, showing a series of increasing heat locations 416a-k, according to an exemplary embodiment of the present disclosure. As mentioned above, it should be noted that the size and spacing of the heating locations in Figures 10-12 are shown as such for clarity, but in various embodiments, the size and spacing of the heating locations may vary.

[0129] In the illustrated embodiment, the aerosol source member 500 has an extruded tubular shape, and the heating member 412 comprises a disk-like structure configured to fit within a cavity 510 defined by the inner surface 512 of the aerosol source member 500. In other embodiments, the aerosol source member and the heating member may have other shapes. For example, in some embodiments, the aerosol source member may have any hollow shape. In some embodiments, the heating member may have any shape, including, for example, a shape complementary to the shape of the interior of the aerosol source member. In the illustrated embodiment, the indexing mechanism 414 includes a small motor 418 (e.g., a microstepping motor) configured to rotate a lead screw 420. A carrier 422, to which the heating member 412 is attached, may be threaded onto the lead screw 420. In this manner, rotation of the lead screw 420 by the stepper motor 418 may move the carrier 422, and therefore the heating member 412, in a substantially linear manner. In various embodiments, the characteristics (e.g., including dimensions and / or specifications and / or control functions) of the control components, stepper motor, lead screw, and carrier can be designed to meet various performance goals. For example, in the embodiment shown in FIGS. 10-12, the indexing mechanism 414 is configured to move the heating member 412 through a series of discrete linear positions 416. Because the aerosol source member 500 in the illustrated embodiment is stationary, these linear positions 416 correspond to a series of discrete segments 508 of the aerosol source member 500. Thus, the control components 408, stepper motor 418, lead screw 420, carrier 422, and heating member 412 are configured to allow the heating member 412 to sequentially heat segments of the aerosol source member. With reference to FIG. 12, these segments are shown as segments 508a-k. For purposes of clarity, the illustrated embodiment shows a total of eleven individual heating element positions 416a-k corresponding to eleven individual heating segments 508a-k of the aerosol source member 500, however, it should be noted that in various other embodiments, the heating element may have any number of individual positions corresponding to any number of individual segments of the aerosol source member, including an infinite number of individual segments.Additionally, while the embodiments shown in Figures 10-12 depict multiple discrete locations and corresponding discrete heating element segments that are spaced apart from one another, in other embodiments the discrete locations and corresponding discrete segments may have different spacings, including, but not limited to, spacings that result in the discrete locations and corresponding discrete segments being adjacent to one another and / or overlapping one another, as well as inconsistent spacings.

[0130] In various embodiments, operation of the heating element 412 may be initiated by a consumer's puff action through the use of one or more various sensors, as described elsewhere herein, and / or may be initiated upon the cessation of a puff as sensed by one or more various sensors. Thus, in some embodiments, the number of heating element positions 416 may correspond to the number of puffs available from the aerosol source element 500. In some embodiments, a single aerosol source element may provide about 4 to about 12, about 5 to about 11, or about 6 to about 10 puffs, which approximates the number of puffs on a typical cigarette. In some embodiments, once the heating element 412 has passed through all of the available positions 416, the motor 418 may reverse direction, returning the carrier 422 and heating element 412 to the first or starting position of the heating element 412. In other embodiments, the heating element 412 may remain in its last or final position, or may be positioned at any other position or in between. Additionally, in some embodiments, the controller may provide an indication (e.g., via a sound and / or an indicator light) that the heating element has passed through all of the available positions 416. In some embodiments, the aerosol source element 500 may be ejected when the heating element has passed through all of the available positions 416.

[0131] While device operation may vary, in one exemplary embodiment, the general operation of the aerosol delivery device 400 of FIGS. 10-12 may occur as follows, with one or more of the following steps occurring via control from the control component 408. In a first step, the heating element 412 located at a first heating position 416 (e.g., position 416a) may be turned on by pressing the push button 405. Furthermore, the heating element 412 may be preheated to a first temperature T1. In a second step, the user may inhale on the aerosol source element (e.g., as detected by a flow sensor), and the heating element 412 may heat to a second temperature T2. When the user stops puffing (e.g., as detected by a flow sensor), the heater temperature may return to the first temperature T1, and the indexing mechanism 414 may automatically move to the next heating position 416 (e.g., position 416b). This process may continue until the heating element 412 moves to the last heating position 416 (e.g., position 416k). After this point, the aerosol source member 500 can be ejected from the housing 402. In various embodiments, the aerosol source member can be ejected in various ways, but in one embodiment, reference is made to the ejection methods described above with respect to Figures 1-3.

[0132] It should be noted that instead of (or in addition to) any of the push buttons of the various embodiments described above, the aerosol delivery device may include a component that energizes the heating element (i.e., puff-activated heating) in response to other considerations, such as a consumer drawing on the article. Thus, the article may include a switch (i.e., a puff-activated switch) in the control component that is sensitive to either pressure or airflow changes when a consumer draws on the article. Other suitable current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch. An exemplary mechanism capable of providing such puff activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Illinois. With such a sensor, pressure changes when a consumer draws on the article can rapidly activate the heating element. Furthermore, a flow-sensing device, such as one that uses the principles of hot-wire anemometry, may be used to energize the heating element sufficiently quickly after sensing a change in airflow. Another pneumatically actuated switch that may be used is a pressure differential switch, such as Model No. MPL-502-V, Range A, manufactured by Micro Pneumatic Logic, Inc. of Fort Lauderdale, Florida. Another suitable pneumatically actuated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled to a comparator for detecting a predetermined threshold pressure. Yet another suitable pneumatically actuated mechanism is a vane deflected by airflow, the movement of which is detected by a motion-sensing means. Yet another suitable actuation mechanism is a piezoelectric switch. Also useful is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, Part No. AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc. of Freeport, Illinois. Another example of a demand-operated electrical switch that may be used in a heating circuit according to the present disclosure is described in U.S. Pat. No. 4,735,217 to Gerth et al., 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 with knowledge of this disclosure. The control body may include a pressure sensing tube or other passageway that provides a fluid connection between the puff-activated switch and the heated end of the aerosol source member so that pressure changes during inhalation can be easily identified by the switch.

[0133] In some embodiments, when a consumer draws on the mouth end of the aerosol source member, the current actuation means may rapidly generate heat such that the flow of current through the heating member is unrestricted or uninterrupted. Because of the rapid heating, it may be useful to include a current regulating component to (i) regulate the flow of current through the heating member to control the heating of the resistive element and the resulting temperature, and (ii) prevent overheating and degradation of the inhalable substance medium.

[0134] In some embodiments, the current regulation circuitry may be specifically time-based. Specifically, such circuitry may include means for ensuring that the flow of current through the heating element is uninterrupted for an initial period during inhalation, followed by a timer means for subsequently regulating the current flow until inhalation is complete. For example, subsequent regulation may include rapid on-off switching of the current flow (e.g., on the order of about every 1-50 milliseconds) to maintain the heating element within a desired temperature range. Furthermore, regulation may simply involve allowing the current flow to be uninterrupted until the desired temperature is achieved, and then completely turning off the current flow. The heating element may be reactivated by the consumer initiating another puff on the item (or by manually activating a push button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent regulation may involve modulating the current flow through the heating element to maintain the heating element within a desired temperature range. In some embodiments, to emit a desired dose of the inhalable substance, the heating element may 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. One exemplary time-based current regulation circuit may 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. An exemplary timer is available from NEC Electronics as C-1555C and from General Electric Intersil, Inc. as ICM7555, as well as so-called "555 timers" in various sizes and configurations. An exemplary comparator is available from National Semiconductor as 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. In some embodiments, the heater control scheme may include closed-loop temperature control of the heating element, in which case the temperature of the heating element may be sensed and provided to the controller.For example, heater temperature control may be provided by including a sensor such as a thermistor or thermocouple in proximity to the heating element / substrate interface, and / or by monitoring the resistance of the heating element itself and inferring the temperature of the heating element using the known relationship between temperature and resistivity of certain heating element alloys.

[0135] In light of the above, it can be seen that various mechanisms can be used to facilitate activation / deactivation of current to the heating element. For example, the aerosol delivery device can include a timer for regulating the flow of current within the article (such as during inhalation by the consumer). The article can further include a timer-responsive switch that enables and disables the flow of current to the heating element. Regulating the flow of current can also include the use of a capacitor and components for charging and discharging the capacitor at a prescribed rate (e.g., a rate approximating the rate at which the heating element heats and cools). The flow of current can be regulated so that the flow of current through the heating element is uninterrupted, particularly for the initial period during inhalation, but the flow of current can be turned off or cycled alternately on and off after the initial period until inhalation is completed. Such cycles can be controlled by a timer that can generate preset switching cycles, as described above. In some embodiments, the timer can generate a periodic digital waveform. The flow during the initial period can be further 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 enabling the timer. Such an embodiment may further include a component for generating a threshold voltage at the threshold input, and a component for generating a threshold voltage at the first input upon passage of an initial period of time.

[0136] In further embodiments, puff activation of the heating element may be tied to the operation of the heating element. For example, a current regulation component may enable the heating element to quickly achieve a desired temperature and then remain at that temperature for the duration of the consumer's puff. Furthermore, in some embodiments, puff-activated operation of the heating element may continue for the duration of the puff. When the puff stops, the heating element may be disabled and cease operation. Thus, in some embodiments, the distance the heating element travels during automatic indexing may be directly related to the duration of the puff. In this way, the consumer may control the amount of inhalable substance delivered by a single puff. A short puff may deliver only a small amount of inhalable substance, while a longer puff may deliver a greater amount of inhalable substance. Thus, a large initial puff may provide a large amount of inhalable substance, and subsequent, shorter puffs may provide a relatively smaller amount of inhalable substance. Exemplary smoke actuated devices that may be useful in accordance with the present disclosure are disclosed in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,874, all to Brooks et al., all of which are incorporated herein by reference in their entireties.

[0137] In various embodiments, the power source used to power the various electrical components of the aerosol delivery device may take on various forms. Preferably, the power source may fit inside the housing and provide sufficient energy to rapidly heat the heating element in the manner described above and power the article through use with multiple aerosol source elements. One example of a useful power source is the N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Company, Ltd. of Japan. Multiple such batteries, each providing 1.2 volts, may be connected in series. In other embodiments, a different power source, such as a rechargeable lithium manganese dioxide battery, may be used. While any of these power sources or a combination thereof may be used, rechargeable batteries may be preferred due to the cost and disposal considerations associated with disposable batteries. Furthermore, if disposable batteries are used, the device may be openable and closable to replace the batteries. In embodiments in which a rechargeable battery is used, the control segment may further include charging contacts (not shown) that interact with corresponding contacts on a conventional charging unit (not shown) that provides power from a standard 120 volt AC wall outlet or other source, such as an automobile's electrical system, or a separate portable power source. In some embodiments, multiple batteries may be used, which may be connected in series or in parallel.

[0138] In further embodiments, the power source may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the capacitor to discharge at a slower rate than if a battery were used to directly power the heating element. For example, a supercapacitor, i.e., an electric double layer capacitor (EDLC), may be used separately from or in combination with a battery. When used alone, the supercapacitor may be charged before each use of the device. Therefore, the present disclosure may also include a charger component that can be attached to the device between uses to replenish the supercapacitor. In certain embodiments of the present disclosure, a thin-film battery may be used.

[0139] As noted above, in various embodiments, the aerosol delivery device may include one or more indicators (not shown). In some embodiments, such indicators may be lights (e.g., light-emitting diodes) that can provide an indication of multiple aspects of the device's use. For example, a series of lights may correspond to the number of puffs on a given cartridge. Specifically, the lights may illuminate sequentially with each puff, such that when all lights are illuminated, the consumer is notified that the aerosol source member has been consumed. Alternatively, all lights may illuminate in response to the aerosol source member being inserted into the housing, and the lights may extinguish with each puff, such that when all lights are extinguished, the consumer is notified that the aerosol source member has been consumed. In yet other embodiments, there may be only a single indicator, the illumination of which may indicate that current is flowing to the heating member and that the device is actively heating. This may prevent a consumer from unintentionally leaving the item in active heating mode. In alternative embodiments, one or more of the indicators may be components of the aerosol source member. While the indicators are described above in connection with visual indicators of an on / off method, other operational indicators are also encompassed. For example, visual indicators may also include changes in light color or intensity to indicate the progression of the smoking experience. Tactile and audible indicators are also encompassed by the present disclosure. Furthermore, combinations of such indicators may be used in a single device.

[0140] While various materials have been described for use in the present device, such as heaters, batteries, capacitors, switching components, etc., the present disclosure should not be construed as limited to only the illustrated embodiments. Rather, one of ordinary skill in the art should recognize, based on this disclosure, similar components in the industry that may be interchangeable with any particular component of the present disclosure.For example, U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that may be associated with the mouth end of the device that detects a user's lip movement associated with inhalation and subsequently causes heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device that includes an identifier that detects non-uniformities in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes a defined, executable power cycle having multiple distinct phases; and U.S. Pat. No. 5,934,289 to Watkins et al. discloses a photonic-optronic component, C U.S. Pat. No. 5,954,979 to Bounts et al. discloses means for varying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Patent Application Publication No. 2009 / 0320863 to Fernando et al. discloses computer interface means for smoking devices to facilitate charging and enable computer control of the device; U.S. Patent Application Publication No. 2010 / 0163063 to Fernando et al. discloses an identification system for smoking devices; and WO 2010 / 003480 to Flick discloses a fluid flow sensing system to indicate a puff using an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components that may be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 7,896,006 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Patent Application Publication Nos. 2009 / 0095311, 2006 / 0196518, 2009 / 0126745 and 2009 / 0188490, U.S. Patent Application Publication No. 2009 / 0272379 to Thorens et al., U.S. Patent Application Publication No. Monsees et al. Nos. 2009 / 0260641 and 2009 / 0260642 to Oglesby et al., 2008 / 0149118 and 2010 / 0024834 to Oglesby et al., 2010 / 0307518 to Wang, and WO 2010 / 091593 to Hon. The various materials disclosed by the foregoing documents may be incorporated into the present device in various embodiments, and all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0141] It should be further noted that in various embodiments, the inhalable substance medium of the aerosol source member can be varied as desired to control various aspects of aerosol emission, volume, and flavor. For example, the inhalable substance can be uniformly dispersed on or within the inhalable substance medium, such that each heated segment emits substantially the same content of inhalable substance. Alternatively, the inhalable substance can be dispersed in a non-uniform configuration. For example, in one embodiment, the first segment of inhalable substance medium that contacts the heating element can be supercharged with inhalable substance. For example, a single segment of inhalable substance medium, corresponding to the size of the area heated by the heating element, can contain about 30% to about 90%, about 35% to about 75%, or about 40% to about 60% of the total amount of inhalable substance present in the inhalable substance medium. Similarly, a single segment, such as the final segment of inhalable substance medium heated by the heating element, can contain a flavor or other material that is different from the remainder of the inhalable substance medium. Such a final release of flavor or other material can serve as a signal to the consumer that the aerosol source member has been completely used. It can thus be seen that segmented heating can provide a controlled dosage of inhalable substance to each heated segment.

[0142] The present disclosure also provides, in various embodiments, methods of operating an aerosol delivery device. For example, FIG. 13 illustrates various operations in a method 600 of operating an aerosol delivery device including a control body and an aerosol source member. As indicated in block 602, the method may include energizing a heating element using an electrical energy source disposed in a housing of the control body. As indicated in block 604, the method may also include heating a segment of the aerosol source member using the heating element. As indicated in block 606, the method may further include moving the heating element relative to the aerosol source member by moving the heating element from a first position to a second position using an indexing mechanism. Furthermore, as indicated in block 608, the method may also include heating a subsequent segment of the aerosol source member using the heating element. As further illustrated in the figure, the process of creating incremental motion between the heating element and the aerosol source member may continue to heat multiple subsequent segments of the aerosol source member. As noted above, in some embodiments, the temperature of the heating element may remain at a heating temperature before heating subsequent segments, while in other embodiments, the temperature of the heating element may vary. For example, after heating one segment of the aerosol source member, the temperature of the heating member may be reduced, and then the heating member may be heated to the heating temperature before heating a subsequent segment of the aerosol source member.

[0143] Also as described above, in some embodiments, heating subsequent segments of the aerosol source member can include first heating the exterior surfaces of the first and second segments of the aerosol source member. In some embodiments, heating the first and second segments of the aerosol source member can include first heating the interior surfaces of the first and second segments of the aerosol source member. In some embodiments, the indexing mechanism can be activated using a sensor configured to detect suction on the aerosol source member. In some embodiments, the indexing mechanism can be activated using a manual actuator. In some embodiments, the manual actuator can be configured to move with the heating member, while in other embodiments, the manual actuator can include a click-return actuator. In addition to any benefits described elsewhere herein, in some embodiments, an advantage of incremental relative motion between the heating member and the aerosol source is that a wiping action between these two components can help keep the surface of the heating member relatively free of condensed material.

[0144] It should be noted that for any of the embodiments described or contemplated herein, the electrical heating element may include an induction heating element. In various embodiments, the induction heating element may include a resonant transmitter and / or a resonant receiver. Thus, operation of the aerosol delivery device may require directing an alternating current through the resonant transmitter to generate an oscillating magnetic field that induces eddy currents in the resonant receiver positioned proximate the inhalable substance medium of the aerosol source element. This alternating current causes the resonant receiver to generate heat, thereby generating an aerosol from the inhalable substance medium.

[0145] Thus, in some embodiments, the control component of the control body may include an inverter or inverter circuit configured to convert direct current supplied by the power source to alternating current supplied to the resonant oscillator. Thus, in some embodiments, the resonant oscillator (e.g., a coil member disposed proximate to the aerosol source member) and the aerosol source member may be moved relative to one another to sequentially heat one of two or more segments of the aerosol source member by induction heating. For example, in some embodiments, the resonant oscillator may be moved relative to a stationary aerosol source member. In other embodiments, the aerosol source member may be moved relative to a stationary resonant oscillator. In still other embodiments, both the resonant oscillator and the aerosol source member may be moved relative to one another.

[0146] In other embodiments, the resonant receiver (e.g., a receiving rod or prong disposed inside the hollow aerosol source member) and the aerosol source member may be moved relative to one another to sequentially heat one of two or more segments of the aerosol source member by inductive heating. For example, in some embodiments, the resonant receiver may be moved relative to a stationary aerosol source member. In other embodiments, the aerosol source member may be moved relative to a stationary resonant receiver. In still other embodiments, both the resonant receiver and the aerosol source member may be moved relative to one another.

[0147] In other embodiments, a shielding member, which may be configured to block electromagnetic energy and / or allow discrete regions of electromagnetic energy to pass therethrough, may be moved relative to the aerosol source member to sequentially heat one of two or more segments of the aerosol source member by inductive heating. For example, in some embodiments, the shielding member may be moved relative to a stationary aerosol source member. In other embodiments, the aerosol source member may be moved relative to a stationary shielding member. In still other embodiments, both the shielding member and the aerosol source member may be moved relative to one another.

[0148] Examples of various induction heating methods and configurations are described in U.S. Patent Application No. 15 / 799,365, filed October 31, 2017, entitled "Induction Heated Aerosol Delivery Device," which is incorporated herein by reference in its entirety. Additional examples of various induction-based control components and associated circuitry are described in U.S. Patent Application No. 15 / 352,153, filed November 15, 2016, entitled "Induction-Based Aerosol Delivery Device," and U.S. Patent Application Publication No. 2017 / 0202266 to Sur et al., each of which is incorporated herein by reference in its entirety.

[0149] It should be noted that while the aerosol source member and control body are generally provided together as a complete smoking article or medication delivery article, these components can also be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable medication delivery articles. In certain embodiments, such a disposable unit (which may be an aerosol source member as shown in the accompanying figures) may include a substantially tubular body having a heated end configured to engage the reusable smoking article or medication delivery article, an opposing mouth end configured to allow passage of an inhalable substance to a consumer, and a wall having outer and inner surfaces defining an interior space. Various embodiments of aerosol source members (or cartridges) are described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0150] The present disclosure may further be characterized as providing a separate control body for use with a reusable smoking article or a reusable medication delivery article, in addition to a disposable unit. In certain embodiments, the control body may generally be a housing having a receiving end (which may include a receiving chamber with an open end) for receiving the heated end of a separately provided aerosol source member. The control body may further include an electrical energy source that provides power to an electric heating element that may be a component of the control body or that may be included in an aerosol source member used with the control unit. In various embodiments, the control body may also include additional components, including a power source (such as a battery), components for activating the flow of current to the heating element, and components for regulating such current flow to maintain a desired temperature for a desired period of time and / or to cycle or stop the flow of current when the desired temperature is reached or the heating element has been heating for a desired length of time. In some embodiments, the control unit may further include one or more push buttons associated with one or both of the components for activating the flow of current to the heating element and a component for regulating such current flow. The control body may also include one or more indicators, such as a light to indicate that the heater is heating and / or a light to indicate the number of puffs remaining on an aerosol source member used with the control body.

[0151] Although the various figures described herein show the control body and aerosol source member in an operative relationship, it should be understood that the control body and aerosol source member may exist as separate devices, and therefore any description provided elsewhere herein regarding combined components should be understood as applying to the control body and aerosol source member as individual and separate components.

[0152] In another aspect, the present disclosure may be directed to a kit providing various components described herein. For example, the kit may include a control body having one or more aerosol source members. The kit may further include a control body having one or more charging components. The kit may further include a control body having one or more batteries. The kit may further include a control body having one or more aerosol source members and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol source members. The kit may further include multiple aerosol source members and one or more batteries and / or one or more charging components. In the above-described embodiments, the aerosol source member or control body may include a heating element included therein. The kit of the present invention may further include a case (or other packaging, transport, or storage component) for housing one or more of the additional kit components. The case may be a reusable hard or soft container. Furthermore, the case may simply be a box or other packaging structure.

[0153] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol delivery device comprising: a control body having a housing; a source of electrical energy disposed within the housing; a heating element operably connected to a source of electrical energy; an aerosol source member containing an inhalable substance medium; an indexing mechanism coupled to the heating element; Including, An aerosol delivery device, wherein the indexing mechanism is configured to move the heating member in a substantially linear manner to sequentially heat at least one of two or more segments of the aerosol source member.

2. 10. The aerosol delivery device of claim 1, wherein the heating member is disposed proximate to an outer surface of the aerosol source member.

3. 10. The aerosol delivery device of claim 1, wherein the heating member is disposed proximate to an inner surface of the aerosol source member.

4. 10. The aerosol delivery device of claim 1, wherein the indexing mechanism is actuated by a sensor configured to detect suction on the aerosol source member.

5. 10. The aerosol delivery device of claim 1, wherein the indexing mechanism is actuated by a manual actuator.

6. 6. The aerosol delivery device of claim 5, wherein the manual actuator comprises a click return actuator.

7. 6. The aerosol delivery device of claim 5, wherein the manual actuator is configured to move with the heating member.

8. 10. The aerosol delivery device of claim 1, wherein the aerosol source member removably engages with the control body and is replaceable.

9. 10. The aerosol delivery device of claim 1, wherein the inhalable substance medium of the aerosol source member comprises a solid or semi-solid inhalable substance medium.

10. 10. The aerosol delivery device of claim 9, wherein the inhalable substance vehicle comprises an extruded substrate.

11. 1. A control body for use with an aerosol source member containing an inhalable substance medium, the control body comprising: Housing and a source of electrical energy disposed within the housing; a heating element operably connected to a source of electrical energy; an indexing mechanism coupled to the heating element; Including, A control body configured with an indexing mechanism to move the heating member in a substantially linear manner to sequentially heat at least one of two or more segments of the aerosol source member.

12. The control body of claim 11 , wherein the indexing mechanism is actuated by a sensor configured to detect suction on the aerosol source member.

13. The control body of claim 11, wherein the indexing mechanism is actuated by a manual actuator.

14. The control body of claim 13 , wherein the manual actuator comprises a click return actuator.

15. The control body of claim 13, wherein the manual actuator is configured to move with the heating element.

16. 1. A method of operating an aerosol delivery device comprising a control body and an aerosol source member, comprising: energizing the heating element using an electrical energy source disposed in the housing of the control body; heating a first segment of the aerosol source member using a heating member; moving the heating element from a first position to a second position in a substantially linear manner using an indexing mechanism; heating a second segment of the aerosol source member using a heating member; A method comprising:

17. 17. The method of claim 16, wherein heating the first and second segments of the aerosol source member comprises first heating the exterior surfaces of the first and second segments of the aerosol source member.

18. 17. The method of claim 16, wherein heating the first and second segments of the aerosol source member comprises first heating an inner surface of the first and second segments of the aerosol source member.

19. 17. The method of claim 16, further comprising activating the indexing mechanism using a sensor configured to detect suction on the aerosol source member.

20. 17. The method of claim 16, further comprising using a manual actuator to actuate the indexing mechanism.

21. The method of claim 20, wherein the manual actuator comprises a click return actuator.

22. 21. The method of claim 20, wherein moving the heating member from a first position to a second position relative to the aerosol source member comprises moving a manual actuator from the first position to the second position.

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