Aerosol delivery device with improved mouthpiece

Abstract

An aerosol delivery device for use with a removable and replaceable cartridge is disclosed, the device including an improved mouthpiece, such as a removable or customizable mouthpiece. The device includes a holder defining a receiving chamber and a first aerosol passageway configured to receive a removable cartridge including an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat, and a mouthpiece with a first end and a longitudinally opposed second end defining a second aerosol passageway, the first end configured to engage with a user's mouth and the second end connectable to a proximal end of the holder. The mouthpiece may be removed for cleaning and then reattached for continued use, or in some cases, a different mouthpiece may be attached to customize the user's experience.

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery devices and systems such as smoking articles, and more particularly applies to aerosol delivery devices and systems that utilize a heat source, such as a combustible carbon-based ignition source, for the generation of an aerosol (e.g., smoking articles intended to obtain components of tobacco, tobacco extracts, nicotine, synthetic nicotine, non-nicotine flavors, and other materials in inhalable form, commonly referred to as non-combustion heating systems or e-cigarettes). Components of such articles may be manufactured or derived from tobacco, or the articles may otherwise be characterized as incorporating tobacco for human consumption, and may be capable of vaporizing components of tobacco and / or other tobacco-related materials to form an inhalable aerosol for human consumption. [Background technology]

[0002] Many smoking articles have been proposed over the years as improvements or replacements for smoking articles based on tobacco combustion. Exemplary alternatives include devices that burn solid or liquid fuels to transfer heat to the tobacco or use chemical reactions to provide such a 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 in its entirety.

[0003] The focus of improvements or replacements for smoking articles has typically been to provide the sensations associated with cigarette, cigar, or pipe smoking without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, many smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensations of cigarette, cigar, or pipe smoking without significantly burning tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art of U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al., and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., all of 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 listed in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is 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 ... No. 5,388,594; U.S. Patent No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; U.S. Patent No. 6,164,287 to White; U.S. Patent No. 6,196,218 to Voges; U.S. Patent No. 6,810,883 to Felter et al.; U.S. Patent No. 6,854,461 to Nichols; U.S. Patent No. 7,832,476 to Hon; U.S. Patent No. 7,832,476 to Kobayashi; No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Application Publication No. 2009 / 0095311 to Hon; U.S. Patent Application Publication Nos. 2006 / 0196518, 2009 / 0126745, and 2009 / 0188490 to Hon; U.S. Patent Application Publication Nos. 2009 / 0188490 to Thorens et al. U.S. Patent Application Publication No. 2009 / 0272379 to Monsees et al.; U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Oglesby 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] Various methods and methods have been proposed for assembling smoking articles having a plurality of serially arranged segmented components. For example, various types of assembly techniques and methods are described in U.S. Patent No. 5,469,871 to Barnes et al. and U.S. Patent No. 7,647,932 to Crooks et al.; U.S. Patent Application Publication No. 2010 / 0186757 to Crooks et al.; U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., and U.S. Patent Application Publication No. 2012 / 00673620 to Conner et al., each of which is incorporated herein by reference in its entirety.

[0005] Certain types of cigarettes that use carbonaceous fuel elements are marketed by RJ Reynolds Tobacco Company under the trade names "Premier," "Eclipse," and "Revo." See, for example, the types of cigarettes described in "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco," RJ Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, pp. 1-58 (2000). Similar cigarettes are also sold in Japan by Japan Tobacco Inc. under the trade name "Steam Hot One."

[0006] In some cases, some smoking articles, particularly those using conventional paper wrappers, are also prone to scorching of the wrapper material covering the ignitable fuel source due to the high temperatures achieved by the fuel source in close proximity to the wrapper material. This can reduce the enjoyment of the smoking experience for some consumers and can mask or undesirably alter the flavor delivered to the consumer by the aerosol-delivery component of the smoking article. In a further example, conventional types of smoking articles can produce relatively significant levels of gases, such as carbon monoxide and / or carbon dioxide, during use (e.g., as products of carbon combustion). In yet another example, conventional types of smoking articles can suffer from poor performance with respect to aerosolizing aerosol-forming components.

[0007] It would thus be desirable to provide a smoking article that addresses one or more of the technical problems sometimes associated with conventional types of smoking articles, and in particular, it would be desirable to provide a smoking article that is easy to use and provides reusable and / or replaceable components. [Prior art documents] [Patent documents]

[0008] [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] U.S. 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. 7,832,476 [Patent Document 21] U.S. Patent No. 7,513,253 [Patent Document 22] U.S. Patent No. 7,726,320 [Patent Document 23] U.S. Patent No. 7,896,006 [Patent Document 24] U.S. Patent No. 6,772,756 [Patent Document 25] US Patent Application Publication No. 2009 / 0095311 [Patent Document 26] US Patent Application Publication No. 2006 / 0196518 [Patent Document 27] US Patent Application Publication No. 2009 / 0126745 [Patent Document 28] US Patent Application Publication No. 2009 / 0188490 [Patent Document 29] US Patent Application Publication No. 2009 / 0272379 [Patent Document 30] US Patent Application Publication No. 2009 / 0260641 [Patent Document 31] US Patent Application Publication No. 2009 / 0260642 [Patent Document 32] US Patent Application Publication No. 2008 / 0149118 [Patent Document 33] US Patent Application Publication No. 2010 / 0024834 [Patent Document 34] US Patent Application Publication No. 2010 / 0307518 [Patent Document 35] International Publication No. 2010 / 091593 [Patent Document 36] U.S. Patent No. 5,469,871 [Patent Document 37] U.S. Patent No. 7,647,932 [Patent Document 38] US Patent Application Publication No. 2010 / 0186757 [Patent Document 39] US Patent Application Publication No. 2012 / 0042885 [Patent Document 40] US Patent Application Publication No. 2012 / 00673620 [Non-patent literature]

[0009] [Non-Patent Document 1] Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJReynolds Tobacco Company Monograph(1988) [Non-patent document 2] Inhalation Toxicology, 12:5, pp. 1-58 (2000) Summary of the Invention

[0010] In various embodiments, the present disclosure relates to an aerosol delivery device for use with a removable and replaceable cartridge (i.e., a consumable item), the device including a removable mouthpiece. The mouthpiece may be removable for cleaning and reuse, or may be replaceable for customization purposes. The present disclosure includes, but is not limited to, the following exemplary embodiments. [Means for solving the problem]

[0011] Embodiment 1: An aerosol delivery device comprising: a holder including a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; a removable mouthpiece including a first end and a longitudinally opposed second end, with a second aerosol passageway extending longitudinally between the first end and the second end, the removable mouthpiece having the first end configured to engage a user's mouth and the second end connectable to a proximal end of the holder; and a collar disposed between the holder and the mouthpiece, the collar including the first end configured to sealingly engage with the proximal end of the holder and the second end configured to sealingly engage with the second end of the mouthpiece, and a first channel extending therethrough configured to fluidly couple the first and second aerosol passageways. The collar may include a second channel extending therethrough. The second channel is configured to access a charging port. In some embodiments, the removable cartridge comprises an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat.

[0012] Embodiment 2: The aerosol delivery device of embodiment 1, wherein the collar further comprises: a base portion defining an opening in fluid communication with the first channel, the base portion having a first sealing mechanism disposed around its outer surface and sized and shaped to engage with an opening in the proximal end of the holder; and a body portion defining an opening in fluid communication with the first channel, the body portion having a second sealing mechanism disposed around its outer surface and sized and shaped to engage with a recess disposed in the second end of the mouthpiece.

[0013] Embodiment 3: The aerosol delivery device of either embodiment 1 or 2, or any combination thereof, wherein the base portion is disposed within the proximal end of the holder. In some cases, the base portion is disposed entirely within the holder so that it is not visible when the device is assembled.

[0014] Embodiment 4: The aerosol delivery device of any one of embodiments 1 to 3, or any combination thereof, wherein the base portion is coupled to the holder via at least one fastener.

[0015] Embodiment 5: The aerosol delivery device of any one of embodiments 1 to 4, or any combination thereof, further comprising an inner housing configured to secure one or more components therein, wherein the base portion is secured to the inner housing via at least one fastener.

[0016] Embodiment 6: The aerosol delivery device of any of embodiments 1 to 5, or any combination thereof, wherein the body portion is disposed within a recess in the mouthpiece. In some cases, the body portion is disposed entirely within the mouthpiece so that it is not visible when the device is assembled.

[0017] Embodiment 7: The aerosol delivery device of any one of embodiments 1 to 6, or any combination thereof, wherein the first sealing mechanism comprises an O-ring disposed within a groove defined by the exterior surface of the base portion.

[0018] Embodiment 8: The aerosol delivery device of any of embodiments 1 to 7, or any combination thereof, wherein the second sealing mechanism comprises at least one O-ring disposed within one or more grooves defined by the exterior surface of the body portion.

[0019] Embodiment 9: The aerosol delivery device of any one of embodiments 1 to 8, or any combination thereof, further comprising an actuator assembly coupled to the holder and configured to eject the removable cartridge therefrom.

[0020] Embodiment 10: The aerosol delivery device of any one of embodiments 1 to 9, or any combination thereof, further comprising a power source disposed within the body.

[0021] Embodiment 11: An aerosol delivery device of any one of embodiments 1 to 10, or any combination thereof, further comprising an inner housing disposed within the body of the holder, and a printed circuit board in electrical communication with the power source and comprising a controller, wherein the inner housing is configured to receive the power source and the printed circuit board.

[0022] Embodiment 12: An aerosol delivery device of any one of embodiments 1 to 11, or any combination thereof, wherein the printed circuit board further comprises a charging port, and the printed circuit board is oriented within the inner housing so that the charging port is located at the proximal end of the holder.

[0023] Embodiment 13: The aerosol delivery device of any one of embodiments 1 to 12, or any combination thereof, wherein the collar further defines a second channel extending therethrough, the second channel configured to at least partially accommodate or receive the charging port such that the charging port is accessible after removal of the mouthpiece.

[0024] Embodiment 14: The aerosol delivery device of any of embodiments 1 to 13, or any combination thereof, wherein the collar further comprises: a base portion defining an opening in fluid communication with the first channel, the base portion being sized and shaped to engage with the opening at the proximal end of the holder; and a body portion defining an opening in fluid communication with the first channel, the body portion having a sealing mechanism disposed around its outer surface and sized and shaped to engage with a recess disposed in the second end of the mouthpiece.

[0025] Embodiment 15: An aerosol delivery device of any of embodiments 1 to 14, or any combination thereof, wherein the base portion is configured to engage with the opening at the proximal end of the holder via at least one of complementary threaded surfaces for threaded engagement, press-fit engagement, snap-fit ​​engagement, or magnetic engagement.

[0026] Embodiment 16: The aerosol delivery device of any one of embodiments 1 to 15, or any combination thereof, wherein the sealing mechanism comprises at least one O-ring disposed within one or more grooves defined by the exterior surface of the body portion.

[0027] Embodiment 17: The aerosol delivery device of any of embodiments 1 to 16, or any combination thereof, further comprising an inner housing disposed within the body of the holder and configured to secure one or more components therein, the inner housing further defining at least a portion of a first aerosol passage, and the base portion of the collar including a stem extending distally therefrom and configured to engage with at least a portion of the first aerosol passage in the inner housing.

[0028] Embodiment 18: An aerosol delivery device comprising: a holder comprising a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; and a removable mouthpiece comprising a hollow body including a first end and a longitudinally opposite second end, a stem disposed within the hollow body and extending from the first end to the second end, the stem defining the second aerosol passageway extending therethrough, the first end configured to engage with a user's mouth and the second end configured to engage with the proximal end of the holder. In some embodiments, the removable cartridge comprises an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. In some embodiments, a central axis of the stem is offset from a central axis of the mouthpiece.

[0029] Embodiment 19: The aerosol delivery device of embodiment 18, wherein the second longitudinally opposite end is configured to engage with the opening at the proximal end of the holder via at least one of complementary threaded surfaces for threaded engagement, press-fit engagement, snap-fit ​​engagement, or magnetic engagement.

[0030] Embodiment 20: The aerosol delivery device of either embodiment 18 or 19, or any combination thereof, wherein the stem is in sealing engagement with the first aerosol passage in the holder.

[0031] Embodiment 21: The aerosol delivery device of any of embodiments 18 to 20, or any combination thereof, wherein the stem includes a sealing mechanism disposed around its outer surface.

[0032] Embodiment 22: The aerosol delivery device of any of embodiments 18 to 21, or any combination thereof, wherein the sealing mechanism comprises an O-ring disposed in a groove defined by the outer surface of the stem.

[0033] Embodiment 23: An aerosol delivery device of any of embodiments 18 to 22, or any combination thereof, further comprising an inner housing disposed within the body of the holder and defining at least a portion of a first aerosol passage, the stem being partially disposed within the inner housing and in fluid communication with at least a portion of the first aerosol passage within the inner housing.

[0034] Embodiment 24: An aerosol delivery device of any of embodiments 18 to 23, or any combination thereof, further comprising an inner housing disposed within the body of the holder and having a retaining structure disposed at its proximal end, wherein a second longitudinally opposite end of the mouthpiece forms a mating retaining structure configured to engage with the retaining structure on the inner housing.

[0035] Embodiment 25: The aerosol delivery device of any of embodiments 18 to 24, or any combination thereof, wherein the mouthpiece further comprises an insert removably positioned within a recess formed in the first end of the mouthpiece.

[0036] Embodiment 26: The aerosol delivery device of any of embodiments 18 to 25, or any combination thereof, wherein the insert is configured to reduce the aerosol outlet in the mouthpiece.

[0037] Embodiment 27: An aerosol delivery device comprising: a holder having a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passage extending through at least a portion of the body; a mouthpiece including a first end and a longitudinally opposite second end, with a second aerosol passage extending longitudinally between the first and second ends, the first end configured to engage with a user's mouth and the second end configured to engage with the proximal end of the holder; and a removable flow restrictor having an outer surface configured to be removably secured within the holder and an inner surface defining a third aerosol passage.

[0038] Embodiment 28: The aerosol delivery device of embodiment 27, wherein the flow restrictor is configured to be at least partially disposed within the first aerosol passageway, the second aerosol passageway, or both.

[0039] Embodiment 29: The aerosol delivery device of either embodiment 27 or 28, or any combination thereof, wherein the removable flow restrictor is configured to sealingly engage with the first aerosol passage, the second aerosol passage, or both.

[0040] Embodiment 30: An aerosol delivery device of any of embodiments 27 to 29, or any combination thereof, wherein the flow restrictor comprises a body portion and a lip portion disposed at a proximal end thereof, the lip portion being configured to engage with the proximal end of the body.

[0041] Embodiment 31: The aerosol delivery device of any of embodiments 27 to 30, or any combination thereof, wherein the body portion is disposed within the first aerosol passageway.

[0042] Embodiment 32: The aerosol delivery device of any of embodiments 27 to 31, or any combination thereof, wherein the lip portion is disposed within the second aerosol passageway.

[0043] Embodiment 33: The aerosol delivery device of any of embodiments 27 to 32, or any combination thereof, wherein the removable flow restrictor is configured to provide fluid communication between the first aerosol passage and the second aerosol passage.

[0044] Embodiment 34: The aerosol delivery device of any of embodiments 27 to 33, or any combination thereof, wherein the inner surface of the flow restrictor is tapered along its length.

[0045] Embodiment 35: The aerosol delivery device of any of embodiments 27 to 34, or any combination thereof, wherein the inner surface of the removable flow restrictor defines an orifice configured to provide a pressure drop between the first aerosol passage and the second aerosol passage.

[0046] Embodiment 36: An aerosol delivery device of any of embodiments 27 to 35, or any combination thereof, wherein the mouthpiece comprises a body portion configured to engage with the proximal end of the body and a hollow stem extending therethrough, the stem at least partially defining a second aerosol passage and configured to receive a flow restrictor therein.

[0047] Embodiment 37: The aerosol delivery device of any of embodiments 27 to 36, or any combination thereof, further comprising a plurality of interchangeable, removable flow restrictors. The flow restrictors may have different sizes and shapes to allow the user to customize their experience, for example, by optimizing vapor flow, pressure drop, flavor, or other sensations.

[0048] Embodiment 38: The aerosol delivery device of any one of embodiments 27 to 37, or any combination thereof, further comprising an access door assembly sealingly coupled to the body and defining a receiving chamber, the access door assembly being movable between an open configuration that provides access to the receiving chamber for loading a removable cartridge therein, and a closed configuration that secures the cartridge in fluid communication with the first aerosol passage.

[0049] Embodiment 39: The aerosol delivery device of any of embodiments 27 to 38, or any combination thereof, wherein the access door assembly is pivotally coupled to the holder.

[0050] Embodiment 40: The aerosol delivery device of any one of embodiments 1 to 39, or any combination thereof, further comprising a locking mechanism configured to secure the access door in a closed configuration.

[0051] Embodiment 41: The aerosol delivery device of any of embodiments 27 to 40, or any combination thereof, further comprising an actuator assembly configured to release the access door from the closed configuration. For example, the access door assembly is biased to the open configuration, and the actuator is a spring-loaded slide button including a locking edge that engages with an inner surface of the holder to maintain the access door in the closed configuration until slid forward.

[0052] Embodiment 42: The aerosol delivery device of any of embodiments 27 to 41, or any combination thereof, further comprising: a power source disposed within the body; and a pair of igniter contacts electrically communicating with the power source, disposed proximate the distal end of the body, and configured to engage with an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber.

[0053] Embodiment 43: An aerosol delivery device of any of embodiments 27 to 42, or any combination thereof, wherein the holder further comprises a printed circuit board disposed therein, electrically connected to a power source, and having a charging port, the printed circuit board being oriented so that the charging port is located at the distal end of the body.

[0054] Embodiment 44: The aerosol delivery device of any of embodiments 27 to 43, or any combination thereof, further comprising a button assembly configured to deliver electrical energy to an ignitable heat source upon activation.

[0055] Embodiment 45: The aerosol delivery device of any of embodiments 27 to 44, or any combination thereof, wherein the removable cartridge comprises an ignitable heat source and a substrate portion comprising a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat.

[0056] Embodiment 46: The aerosol delivery device of any of embodiments 27 to 45, or any combination thereof, wherein the access door assembly includes an insert disposed therein and configured to receive a cartridge and provide thermal insulation thereto.

[0057] Embodiment 47: A holder having a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge (comprising an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat) and a first aerosol passageway extending through at least a portion of the body; and a mouthpiece including a first end and a longitudinally opposed second end, the second aerosol passageway extending longitudinally between the first end and the second end, the first end adapted to engage the mouth of a user. an inner housing disposed within a body of the holder, the inner housing defining a first port disposed proximate the first end of the inner housing, a second port disposed proximate the second end of the inner housing, and a first channel disposed on an outer surface of the inner housing fluidly coupling the first and second ports to form a third aerosol passageway, the first port being in fluid communication with the first aerosol passageway and the second port being in fluid communication with the second aerosol passageway. The first, second, and third aerosol passageways are configured to form a continuous vapor path from the distal end of the body to the first end of the mouthpiece for passing aerosol generated from the removable cartridge to a user.

[0058] Embodiment 48: The aerosol delivery device of embodiment 47, wherein the inner housing defines a second channel disposed on its outer surface and oriented opposite the first channel.

[0059] Embodiment 49: The aerosol delivery device of either embodiment 47 or 48, or any combination thereof, wherein the first and second channels meet at the first port and the second port.

[0060] Embodiment 50: An aerosol delivery device of any of embodiments 47 to 49, or any combination thereof, wherein the inner housing is disposed within the body such that the inner surface of the holder surrounds the first and second channels.

[0061] Embodiment 51: The aerosol delivery device of any of embodiments 47 to 50, or any combination thereof, further comprising an actuator assembly coupled to the holder and configured to eject the removable cartridge therefrom.

[0062] Embodiment 52: The aerosol delivery device of any of embodiments 47 to 51, or any combination thereof, wherein the actuator assembly comprises a slider body slidably disposed within the body of the holder and configured to sealingly engage with the first end of the inner housing, the slider body defining a receptacle configured to at least partially receive a removable cartridge, and an inner stem engageable with one end of the removable cartridge and defining a fourth aerosol passage therethrough configured to pass aerosol generated from the removable cartridge, wherein the first, second, third, and fourth aerosol passages are configured to define a continuous vapor path from the distal end of the body to the first end of the mouthpiece.

[0063] Embodiment 53: The aerosol delivery device of any of embodiments 47 to 52, or any combination thereof, further comprising a collar disposed between the holder and the mouthpiece, the collar having a first end configured for sealing engagement with the proximal end of the holder and a second end configured for sealing engagement with the second end of the mouthpiece, and defining a first channel therethrough that fluidly couples the third aerosol passage and the second aerosol passage.

[0064] Embodiment 54: The aerosol delivery device of any of embodiments 47 to 53, or any combination thereof, wherein the mouthpiece is removable. Embodiment 55: The aerosol delivery device of any of embodiments 47 to 54, or any combination thereof, further comprising a power source disposed within the body and a printed circuit board in electrical communication with the power source and comprising the controller, wherein the inner housing defines a cavity configured to receive the power source and the printed circuit board therein. In some embodiments, the vapor is divided within the inner housing to move around the cavity and any electronics disposed therein.

[0065] Embodiment 56: An aerosol delivery device of any of embodiments 48 to 55, or any combination thereof, wherein the printed circuit board further comprises a charging port, and the printed circuit board is oriented within the inner housing so that the charging port is located at the proximal end of the holder.

[0066] Embodiment 57: An aerosol delivery device comprising: a holder having a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passage extending through at least a portion of the body; and a mouthpiece assembly comprising a mouthpiece including a first end configured to engage with a user's mouth and a longitudinally opposed second end configured to engage with the proximal end of the holder, the second aerosol passage extending between the first and second ends, wherein a central longitudinal axis of the second aerosol passage is offset from the central longitudinal axis of the first aerosol passage, and the first and second aerosol passages define an integral offset vapor path from the distal end of the body to the first end of the mouthpiece for passing aerosol generated from the removable cartridge to the user.

[0067] Embodiment 58: The aerosol delivery device of embodiment 57, wherein the mouthpiece assembly further comprises an insert defining a third aerosol passage at least partially disposed within a recess formed in the second end of the mouthpiece and configured to fluidly couple the first aerosol passage and the second aerosol passage.

[0068] Embodiment 59: An aerosol delivery device of either of embodiments 57 and 58, or any combination thereof, further comprising an access door assembly sealingly coupled to the body and defining a receiving chamber, the access door assembly being movable between an open configuration that allows access to the receiving chamber for loading a removable cartridge therein, and a closed configuration that secures the cartridge in fluid communication with the first aerosol passage.

[0069] Embodiment 60: The aerosol delivery device of any one of embodiments 57 to 59, or any combination thereof, wherein the access door assembly is pivotally coupled to the holder.

[0070] Embodiment 61: An aerosol delivery device comprising: a holder having a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge therein and a first aerosol passage extending through at least a portion of the body; and a removable mouthpiece comprising a hollow body including the first end and a second end longitudinally opposite the first end, an offset stem disposed within the hollow body and extending from the first end to the second end, the offset stem defining the second aerosol passage extending therethrough, the first end configured to engage with a user's mouth and the second end configured to engage with the proximal end of the holder, the offset stem in sealing engagement with the first aerosol passage in the holder to define a linear vapor path.

[0071] Embodiment 62: A holder having upper and lower body portions, each defining a proximal end and a distal end, the lower body portion further defining a receiving chamber, the receiving chamber configured to receive a removable cartridge disposed at the proximal end of the lower body portion and comprising an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon heating, the upper body portion further defining a first aerosol passage extending therethrough and comprising a sliding actuator assembly slidably disposed within the first aerosol passage, the sliding actuator connecting the removable cartridge to the lower body portion. an aerosol delivery device comprising: a holder configured to discharge aerosol from a removable cartridge, the holder having an upper body portion and a lower body portion coupled to one another so as to be movable between an open configuration and a closed configuration; and a mouthpiece including a first end and a longitudinally opposite second end, with a second aerosol passageway extending longitudinally between the first and second ends, the first end configured to engage with a user's mouth and the second end configured to engage with a proximal end of the upper body portion, the first and second aerosol passageways configured to define a linear vapor path from the distal end of the lower body portion to the first end of the mouthpiece when in the closed configuration, for passing aerosol generated from the removable cartridge to the user.

[0072] Embodiment 63: An aerosol delivery device of embodiment 62, wherein the sliding actuator assembly comprises a tubular body defining a third aerosol passage and configured to slide in a first direction and a second direction along a portion of the upper body portion, the tubular body comprising a longitudinally oriented baffle extending inward from its inner wall, the baffle dividing the aerosol moving through the third aerosol passage portion of the linear vapor path.

[0073] Embodiment 64: An aerosol delivery device of either of embodiments 62 and 63, or any combination thereof, wherein the sliding actuator assembly comprises a tubular body defining a third aerosol passage and configured to slide in a first direction and a second direction along a portion of the upper body portion, a first protrusion extending from the outer surface of the tubular body and configured to extend through an opening in the wall of the upper body portion to effect movement of the tubular body in the first and second directions, and a second protrusion extending from the distal end of the tubular body and configured to engage with a removable cartridge to advance the removable cartridge through the distal end of the lower body portion when the tubular body is moved in the first or second direction.

[0074] Embodiment 65: The aerosol delivery device of any of embodiments 62 to 64, or any combination thereof, wherein one or more portions of the first protrusion, the second protrusion, or both extend into a portion of the third aerosol passage defined by the tubular body such that the aerosol generated by the cartridge is divided into one or more portions as it travels through the tubular body.

[0075] Embodiment 66: The aerosol delivery device of any of embodiments 62 to 65, or any combination thereof, wherein the sliding actuator further comprises a sealing arrangement for sealingly engaging with the inner surface of the upper body portion.

[0076] Embodiment 67: The aerosol delivery device of any of embodiments 62 to 66, or any combination thereof, further comprising a locking mechanism disposed on at least one of the lower body portion or the upper body portion and configured to maintain the device in a closed configuration.

[0077] Embodiment 68: The aerosol delivery device of any of embodiments 62 to 67, or any combination thereof, further comprising a sealing mechanism disposed between the proximal end of the lower body portion and the distal end of the upper body portion and configured to seal the receiving chamber with the first aerosol passage to prevent leakage from the vapor path.

[0078] Embodiment 69: The aerosol delivery device of any of embodiments 62 to 68, or any combination thereof, wherein the lower body portion comprises a window disposed therein and configured to allow at least a portion of the removable cartridge to be viewed.

[0079] Embodiment 70: The aerosol delivery device of any of embodiments 62 to 69, or any combination thereof, wherein the lower body portion is rotatable relative to the upper body portion to expose the receiving chamber and load the removable cartridge therein.

[0080]

[0082] Embodiment 71: An aerosol delivery device comprising: a holder having a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; and a removable mouthpiece comprising: a first portion defined by the first end and a longitudinally opposed second end, and a second portion extending from the longitudinally opposed second end, wherein the first portion and the second portion define a second aerosol passageway extending therethrough, the first end of the first portion configured to engage with a user's mouth, the second end of the first portion configured to engage with the proximal end of the holder, and the second portion configured to extend within the holder. In some embodiments, the removable cartridge comprises an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. Embodiment 72: An aerosol delivery device of embodiment 71, wherein the second end of the first part is configured to engage with the opening at the proximal end of the holder via at least one of complementary threaded surfaces for threaded engagement, press-fit engagement, snap-fit ​​engagement, or magnetic engagement.

[0081] Embodiment 73: The aerosol delivery device of either embodiment 71 or 72, or any combination thereof, wherein the second portion of the mouthpiece is sealingly engaged with the first aerosol passage in the holder.

[0082] Embodiment 74: The aerosol delivery device of any of embodiments 71 to 73, or any combination thereof, wherein the second portion of the mouthpiece includes a sealing mechanism disposed around its outer surface.

[0083] Embodiment 75: The aerosol delivery device of any of embodiments 71 to 74, or any combination thereof, wherein the sealing mechanism comprises an O-ring disposed in a groove defined by the outer surface of the second portion of the mouthpiece.

[0084] Embodiment 76: The aerosol delivery device of any of embodiments 71 to 75, or any combination thereof, further comprising an actuator assembly disposed at least partially within the body of the holder and configured to eject the removable cartridge therefrom.

[0085] Embodiment 77: An aerosol delivery device of any of embodiments 71 to 76, or any combination thereof, wherein the actuator assembly comprises a sliding body defining at least a portion of the first aerosol passage, and the second portion of the mouthpiece is slidably disposed within the sliding body and is in fluid communication with at least a portion of the first aerosol passage within the sliding body.

[0086] Embodiment 78: The aerosol delivery device of any of embodiments 71 to 77, or any combination thereof, further comprising an inner housing disposed within the body of the holder and comprising a first retaining structure disposed at a proximal end thereof, wherein the second end of the first portion of the mouthpiece defines a mating retaining structure (e.g., a gap or groove disposed around an inner circumference of the second end) configured to engage with the retaining structure on the inner housing. In some embodiments, the inner housing may include a second retaining structure configured to mate with the holder to secure the inner housing therein, or the first retaining structure may be disposed at the proximal end of the holder.

[0087] Embodiment 79: The aerosol delivery device of any of embodiments 71 to 78, or any combination thereof, wherein the central axis of the second part of the mouthpiece is offset from the central axis of the first part of the mouthpiece.

[0088] Embodiment 80: An aerosol delivery device comprising: a holder including a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge comprising an aerosol precursor composition configured to form an aerosol upon application of heat; and a removable mouthpiece, the removable mouthpiece comprising: an elongated body portion formed by a first end and a longitudinally opposed second end and defining an aerosol passage extending therethrough; a first retention mechanism disposed about an exterior surface of the elongated body portion, the first retention mechanism configured to removably secure the second end of the mouthpiece within the holder; and a second retention mechanism disposed within a receptacle defined by the second end of the elongated body portion, the second retention mechanism configured to removably secure a portion of the cartridge therein, the second retention mechanism configured to engage a user's mouth. In some embodiments, the first retention mechanism is located proximate to the first end of the elongated body portion.

[0089] Embodiment 81: The aerosol delivery device of embodiment 80, further comprising an inner housing disposed within the body of the holder and defining a passage therethrough configured to receive a portion of the mouthpiece therein.

[0090] Embodiment 82: An aerosol delivery device of either embodiment 80 or 81, or any combination thereof, further comprising a pair of igniter contacts positioned within the holder adjacent to its distal end, the contacts configured to receive an ignitable heat source portion of the cartridge between them.

[0091] Embodiment 83: An aerosol delivery device of any of embodiments 80 to 82, or any combination thereof, wherein the inner housing comprises a stopper configured to limit insertion of the mouthpiece and operably engage the ignitable heat source with the igniter contacts.

[0092] Embodiment 84: The aerosol delivery device of any of embodiments 80 to 83, or any combination thereof, wherein the first retention mechanism is configured to sealingly engage with a passage in the inner housing.

[0093] Embodiment 85: The aerosol delivery device of any of embodiments 80 to 84, or any combination thereof, wherein the first retention mechanism includes an elastomeric seal disposed around its outer surface and configured to frictionally engage with the inner housing passage.

[0094] Embodiment 86: The aerosol delivery device of any of embodiments 80 to 85, or any combination thereof, wherein the second retention feature is configured to sealingly engage with the base portion of the cartridge.

[0095] Embodiment 87: The aerosol delivery device of any of embodiments 80 to 86, or any combination thereof, wherein the second retention mechanism includes an elastomeric seal disposed around its inner surface and configured to frictionally engage with the cartridge.

[0096] Embodiment 88: The aerosol delivery device of any of embodiments 80 to 87, or any combination thereof, further comprising an igniter push button configured to ignite the heat source when pressed by a user by actuating an igniter contact.

[0097] Embodiment 89: The aerosol delivery device of any of embodiments 80 to 88, or any combination thereof, wherein the igniter contacts are deactivated when the igniter push button is released.

[0098] Embodiment 90: The aerosol delivery device of any of embodiments 80 to 89, or any combination thereof, wherein the igniter contacts are deactivated after a set time (e.g., about 2 to 60 seconds, about 5 to 30 seconds, or about 20 seconds) either after the igniter push button is activated or after it is released.

[0099] Embodiment 91: An aerosol delivery device comprising: a holder having a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive therein a removable cartridge comprising an aerosol precursor composition configured to form an aerosol upon application of heat; and a removable mouthpiece configured to engage the proximal end of the holder. The mouthpiece comprises an elongate body formed by a first end and a longitudinally opposed second end and defining a passageway extending therethrough; a second portion defined by the first end and the longitudinally opposed second end and defining a first aerosol passageway therethrough, the first end of the second portion configured to engage a user's mouth and the second end being partially disposed within the passageway of the first portion of the mouthpiece assembly adjacent the first end of the first portion; and a slider body defined by the second end longitudinally opposed to the first end and defining a second aerosol passageway therethrough, the slider body being slidably disposed within the first portion of the mouthpiece, the first end of the slider body being coupled to the second end of the second portion of the mouthpiece, and the second end of the slider body being coupled to a removable cartridge. the second end of the inner tubular body is configured to engage a first portion of the mouthpiece proximate the second end of the first portion, the biasing mechanism configured to maintain the slider body in a loaded configuration; and an outlet guide coupled to the second end of the first portion of the mouthpiece and partially received within the second end of the inner tubular body, the outlet guide defining a cavity configured to sealingly engage the removable cartridge to removably secure the removable cartridge therein.The slider body may be configured to slide in a first direction and a second direction along the length of the first portion of the mouthpiece.

[0100] Embodiment 92: The aerosol delivery device of any of embodiments 1 to 91, or any combination thereof, further comprising a removable cartridge. The removable cartridge comprises an ignitable heat source and a substrate portion comprising a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat.

[0101] Embodiment 93: The aerosol delivery device of any one of embodiments 1 to 92, or any combination thereof, wherein the holder comprises a window disposed therein, the window being configured to allow at least a portion of the removable cartridge to be viewed.

[0102] 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. The present invention includes any combination of two, three, four, or more of the foregoing embodiments, as well as combinations of any two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure, in any of its various aspects and embodiments, is intended to be read as a whole such that any separable features or elements of the disclosed invention are intended to be combinable unless the context clearly dictates otherwise.

[0103] Having thus described the present disclosure in general terms above, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0104] [Figure 1A]1 shows a perspective view of an aerosol delivery device comprising a removable mouthpiece and a removable cartridge with an improved vapor path according to one embodiment of the present disclosure. [Figure 1B] 1 shows a cross-sectional perspective view of an aerosol delivery device comprising a removable mouthpiece and a removable cartridge with an improved vapor path according to one embodiment of the present disclosure. [Figure 2] 1B shows an exploded view of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 3A] 1B shows a cross-sectional side view of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 3B] 1B shows a pictorial perspective view of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 4A] 1B shows a series of perspective views of the mouthpiece end of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 4B] 1B shows a series of perspective views of the mouthpiece end of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 4C] 1B shows a series of perspective views of the mouthpiece end of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 5] 1B shows a partially exploded perspective view of the aerosol delivery device of FIG. 1A according to one embodiment of the present disclosure. [Figure 6A] 1B shows a side cross-sectional view of a portion of the aerosol delivery device of FIG. 1A with an alternative removable mouthpiece configuration according to one embodiment of the present disclosure. [Figure 6B] 1B shows a cross-sectional perspective view of a portion of the aerosol delivery device of FIG. 1A with an alternative removable mouthpiece configuration according to one embodiment of the present disclosure. [Figure 7A] 6B shows an exploded view of the proximal end of the aerosol delivery device of FIG. 6A according to one embodiment of the present disclosure. [Figure 7B] FIG. 6B shows a partially exploded perspective view of the aerosol delivery device of FIG. 6A according to one embodiment of the present disclosure. [Figure 8A]FIG. 1 shows a perspective view of an alternative aerosol delivery device with a removable mouthpiece and a removable cartridge according to one embodiment of the present disclosure. [Figure 8B] 1 shows a cross-sectional perspective view of an alternative aerosol delivery device with a removable mouthpiece and a removable cartridge according to one embodiment of the present disclosure. [Figure 9] 8B shows an exploded view of the aerosol delivery device of FIG. 8A according to one embodiment of the present disclosure. [Figure 10] 8B shows an enlarged perspective end view of the aerosol delivery device of FIG. 8A according to one embodiment of the present disclosure. [Figure 11A] FIG. 1 shows a perspective view of an alternative aerosol delivery device with a removable cartridge to define an improved vapor path, according to one embodiment of the present disclosure. [Figure 11B] FIG. 1 shows a cross-sectional side view of an alternative aerosol delivery device with a removable cartridge to define an improved vapor path, according to one embodiment of the present disclosure. [Figure 12] FIG. 11B shows an exploded view of the aerosol delivery device of FIG. 11A according to one embodiment of the present disclosure. [Figure 13] FIG. 11B shows an enlarged cross-sectional view of the mouthpiece end of the aerosol delivery device of FIG. 11A according to one embodiment of the present disclosure. [Figure 14A] FIG. 1 shows a perspective view of an aerosol delivery device with a removable flow restrictor according to one embodiment of the present disclosure. [Figure 14B] 1 shows a cross-sectional side view of an aerosol delivery device with a removable flow restrictor according to one embodiment of the present disclosure. [Figure 15] FIG. 14B shows an exploded perspective view of the aerosol delivery device of FIG. 14A according to one embodiment of the present disclosure. [Figure 16A] FIG. 1 shows an end view of a removable flow restrictor for use in an aerosol delivery device according to one embodiment of the present disclosure. [Figure 16B] 1 shows a cross-sectional side view of a removable flow restrictor for use in an aerosol delivery device according to one embodiment of the present disclosure. [Figure 17A] 14B shows perspective views of the aerosol delivery device of FIG. 14A in various states or operations according to one embodiment of the present disclosure. [Figure 17B] 14B shows perspective views of the aerosol delivery device of FIG. 14A in various states or operations according to one embodiment of the present disclosure. [Figure 17C] 14B shows perspective views of the aerosol delivery device of FIG. 14A in various states or operations according to one embodiment of the present disclosure. [Figure 18A] FIG. 1 shows a perspective view of another alternative aerosol delivery device with a removable cartridge to define an improved vapor path, according to an embodiment of the present disclosure. [Figure 18B] FIG. 1 shows a cross-sectional perspective view of another alternative aerosol delivery device having a removable cartridge to define an improved vapor path, according to an embodiment of the present disclosure. [Figure 19] 18B shows an exploded view of the aerosol delivery device of FIG. 18A according to one embodiment of the present disclosure. [Figure 20A] 18B shows perspective views of the aerosol delivery device of FIG. 18A at different stages of operation according to one embodiment of the present disclosure. [Figure 20B] 18B shows cross-sectional perspective views of the aerosol delivery device of FIG. 18A at different stages of operation according to one embodiment of the present disclosure. [Figure 20C] 18B shows cross-sectional perspective views of the aerosol delivery device of FIG. 18A at different stages of operation according to one embodiment of the present disclosure. [Figure 21] 1 shows a perspective view of a removable cartridge according to one embodiment of the present disclosure. [Figure 22] 1 shows a longitudinal cross-sectional view of a removable cartridge according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0105] Certain embodiments of the present disclosure are described more fully below with reference to the accompanying drawings, in which some, but not all, embodiments of the present disclosure are shown. Indeed, various embodiments of the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these exemplary 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. Like reference numerals refer to like elements throughout.

[0106] Unless otherwise specified or clear from the context, references to first, second, etc. should not be construed to imply a particular order. A feature described as being above another feature (unless otherwise specified or clear from the context) may instead be below, and vice versa; and similarly, a feature described as being to the left of another feature may instead be to the right, and vice versa. Also, while reference may be made herein to quantitative measures, values, geometric relationships, and the like, unless otherwise specified, any one or more, if not all, of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to technical tolerances, etc.

[0107] As used herein, unless otherwise specified or clear from the context, an "or" of a set of operands is an "inclusive or," whereby it is true if and only if one or more of the operands are true, as opposed to an "exclusive or," which is false if all of the operands are true. Thus, for example, "[A] or [B]" is true if [A] is true, or if [B] is true, or if both [A] and [B] are true. Furthermore, the articles "a" and "an" mean "one or more" unless otherwise specified or unless it is clear from the context that the singular form is intended. Furthermore, it should be understood that "data," "content," "digital content," "information," and similar terms may sometimes be used interchangeably unless otherwise specified. Furthermore, when multiples of the same component are listed, the multiples may be referred to individually (e.g., ##a, ##b, ##c, etc.) or collectively (##).

[0108] The present disclosure provides a description of articles (and their assembly and / or manufacture) in which materials are heated (preferably without burning the materials to any significant extent) to form an aerosol and / or inhalable substance, and such articles are most preferably compact enough to be considered "handheld" devices. In some aspects, the articles are characterized as smoking articles. As used herein, the term "smoking article" is intended to mean an article and / or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the mode of inhalation and exhalation, the type of taste or flavor, the organoleptic effect, the physical feel, the mode of use, visual cues such as those provided by a visible aerosol, etc.) without substantially burning any components of the article and / or device. As used herein, the term "smoking article" does not necessarily mean that, during operation, the article or device produces smoke in the sense of an aerosol resulting from the by-products of tobacco combustion or pyrolysis, but rather that the article or device produces vapor resulting from the volatilization or vaporization of certain components, elements, etc. of the article and / or device (including vapor within an aerosol that would be considered to be a visible aerosol that would be described as smoky). In some aspects, articles or devices characterized as smoking articles incorporate tobacco and / or tobacco-derived components.

[0109] As previously mentioned, the aerosol delivery device may provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the type of inhalation and exhalation, the type of taste or flavor, the sensory stimulating effect, the physical feel, the type of use, visual cues such as those provided by a visible aerosol, etc.) used by lighting and burning tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure may hold and use the device as a smoker would use a traditional type of smoking article, drawing on one end of the component for inhalation of the aerosol generated by the component, taking puffs at selected time intervals, etc.

[0110] The article or device of the present disclosure may also be characterized as a vapor product, an aerosol delivery article, or a drug delivery article. Thus, such an article or device may be adapted to provide one or more substances in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (e.g., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (e.g., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, regardless of whether they are visible and whether they are in a form that can be considered smoky. In some embodiments, the terms "vapor" and "aerosol" may be interchangeable. Therefore, for simplicity, the terms "vapor" and "aerosol" used to describe the present disclosure are understood to be interchangeable unless otherwise specified.

[0111] Examples of suitable vapor-producing, aerosol-delivery, or drug-delivery articles include vapor products, non-combustion heating products, hybrid products, and the like. Vapor products are commonly known as "electronic cigarettes," "e-cigarettes," or electronic nicotine delivery systems (ENDS), although the aerosol-forming material need not contain nicotine. Many vapor products are designed to heat a liquid material to generate an aerosol. Other vapor products are designed to break down an aerosol-forming material into an aerosol without heating or with only secondary heating. Non-combustion heating products include tobacco heating products and carbon-tipped tobacco heating products, and many are designed to heat a solid material to generate an aerosol without burning the solid material.

[0112] Hybrid products may use a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, semi-solid, liquid, or gel. Some hybrid products are similar to vapor products, except that the aerosol generated from the liquid or gel aerosol-generating material passes through a second material (such as tobacco) to capture additional components before reaching the user. In some exemplary embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0113] During use, smoking articles of the present disclosure are subject to many of the physical actions of an individual when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is used by lighting it with a flame and then burning and / or inhaling the burned tobacco). For example, a user of a smoking article of the present disclosure holds the article in a manner similar to a traditional type of smoking article, draws on one end of the article to inhale the aerosol produced by the article, and takes puffs for selected time intervals.

[0114] Although the systems are generally described herein with respect to embodiments relating to smoking articles, such as so-called "tobacco heating products," it should be understood that the features, components, features, and methods can be embodied in many different forms and associated with a variety of items. For example, the description provided herein can be used in conjunction with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustion heated cigarettes, and related packaging embodiments for any of the products disclosed herein. Accordingly, it should be understood that the description of the features, components, features, and methods disclosed herein are described with respect to embodiments relating to aerosol delivery devices by way of example only, and may be embodied and used in a variety of other products and methods.

[0115] The aerosol delivery device of the present disclosure generally includes several components disposed within an outer body or shell, which may be referred to as a housing. The overall design of the outer body or shell can vary, and the format or configuration of the outer body can vary, which can define the overall size and shape of the aerosol delivery device. In some exemplary embodiments, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, integral housing, or the elongated housing can be formed from two or more separable bodies. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and thus resemble the shape of a traditional cigarette or cigar. In another example, the aerosol delivery device can be substantially rectangular or have a substantially rectangular cuboid shape. In one example, all of the components of the aerosol delivery device are housed within a single housing. Alternatively, the aerosol delivery device can include two or more joined and separable housings. For example, the aerosol delivery device can have one portion with a housing that houses and is removably connectable to one or more reusable components (e.g., an accumulator such as a rechargeable battery and / or a rechargeable supercapacitor, and various electronics for controlling the operation of the item), a separate second portion (e.g., a mouthpiece), and / or a disposable component (e.g., a disposable flavor-containing cartridge containing aerosol precursor materials, flavorants, etc.). More specific formats, configurations, and arrangements of components within a single-housing type unit or a multi-piece separable-housing type unit will be apparent in light of the further disclosure provided herein. Furthermore, various aerosol delivery device designs and component arrangements can be appreciated by considering commercially available electronic aerosol delivery devices.

[0116] As described in more detail below, the holder of the aerosol delivery device of the present disclosure may comprise some combination of a power source (e.g., a power supply), at least one control component (e.g., a means for activating, controlling, regulating, and terminating power, such as by controlling the flow of current from the power source to other components of the article, such as a microprocessor, either individually or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.), a lighter portion configured to heat the heat source and / or substrate material of the cartridge, and a receiving chamber. Such a holder may be configured to receive one or more substrate cartridges containing a substrate material capable of generating an aerosol upon application of sufficient heat. In some embodiments, the holder may include a mouthpiece portion configured to allow drawing on the holder for aerosol inhalation (e.g., a predetermined airflow path through the holder so that the generated aerosol can be drawn therefrom upon inhalation).

[0117] In various aspects, the cartridge's heat source may be capable of generating heat to aerosolize the cartridge's substrate material, including, for example, an extruded structure and / or substrate, a substrate material associated with the aerosol precursor composition, tobacco and / or tobacco-related materials, such as materials naturally found in tobacco, isolated directly from tobacco or synthetically prepared, in solid or liquid form (e.g., beads, sheets, strips, wraps), etc. As described in more detail below, in some embodiments, the extruded structure may comprise a tobacco product or a composite of tobacco with other materials, such as ceramic powder. In other embodiments, a tobacco extract / slurry may be loaded into porous ceramic beads. Other embodiments may use non-tobacco products. In some embodiments, aerosol precursor composition-loaded porous beads / powder (ceramic) may be used. In other embodiments, a rod / cylinder made of an extruded slurry of ceramic powder and aerosol precursor composition may be used.

[0118] In some embodiments, the substrate material may comprise a liquid comprising an aerosol precursor composition and / or a gel comprising an aerosol precursor composition. Some examples of liquid compositions can be found in U.S. Patent Application Publication No. 2020 / 0113239 to Aller et al., which is incorporated herein by reference in its entirety. As previously mentioned, in various embodiments, one or more of the substrate materials may have an aerosol precursor composition associated therewith. For example, in some embodiments, the aerosol precursor composition may include one or more different components, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Further representative types of aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; International Publication No. WO 98 / 57556 to Biggs et al., and "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco," R.J. Reynolds Tobacco Company Monograph (1988), the disclosures of which are incorporated herein by reference. In some embodiments, the substrate material may generate a visible aerosol upon application of sufficient heat (optionally cooled with air), and the substrate material may generate a "smoky" aerosol. In other embodiments, the substrate material may generate an aerosol that is substantially invisible but whose presence is recognized by other characteristics, such as flavor or texture. Thus, the nature of the aerosol generated may vary depending on the specific components of the aerosol delivery components. The substrate material may be chemically simple relative to the chemistry of the smoke generated by burning tobacco.

[0119] In some embodiments, the aerosol precursor composition may incorporate nicotine, which may be present in various concentrations. The source of nicotine may be varied, and the nicotine incorporated in the aerosol precursor composition may be derived from a single source or a combination of two or more sources. For example, in some embodiments, the aerosol precursor composition may contain nicotine derived from tobacco. In other embodiments, the aerosol precursor composition may contain nicotine derived from other organic plant sources, such as non-tobacco plant sources, including plants of the Solanaceae family. In other embodiments, the aerosol precursor composition may contain synthetic nicotine. In some embodiments, the nicotine incorporated in the aerosol precursor composition may be derived from non-tobacco plant sources, such as other members of the Solanaceae family. The aerosol precursor composition may additionally or alternatively include other active ingredients, including, but not limited to, botanicals (e.g., lavender, peppermint, chamomile, basil, rosemary, thyme, eucalyptus, ginger, cannabis, ginseng, maca, and tisanes), stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins such as B6, B12, and C, and cannabinoids such as tetrahydrocannabinol (THC) and cannabidiol (CBD)). It is noted that the aerosol precursor composition may include any component, derivative, or combination of any of the above.

[0120] As described herein, the aerosol precursor composition may comprise or be derived from one or more plants or their components, derivatives, or extracts. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise active compounds naturally occurring in the plant that are synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibo, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, mato, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, anise, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiento, marjoram, olive, lemon balm, lemon basil, chive, short rib, verbena, tarragon, geranium, mulberry, ginseng, theanine, ciacristine, maca, schwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrate cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cardifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0121] A wide variety of flavoring agents or materials that alter the sensory or organoleptic characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some embodiments, such flavoring agents may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavoring agents may be applied to or incorporated within the substrate material and / or the region of the smoking article where the aerosol is generated. In some embodiments, such agents may be provided directly to the heating cavity or region proximate the heat source or substrate material provided. Examples of flavoring agents include, for example, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavoring agents and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups, such as high fructose corn syrup, may also be suitable for use.

[0122] As used herein, the terms "flavor," "flavoring," "flavoring agent," and the like refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.They may be any naturally occurring flavoring material, botanical substance, extract of botanical substance, synthetically derived material, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, osmanthus leaf, chamomile, fenugreek, clove, maple, macha, menthol, mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, heat, Belt fruit, papaya, rhubarb, grapes, durian, dragonfly, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascara, nutmeg, sandalwood, bergamot, geranium, hut, naswar, betel, shisha, pine, honey, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon bark, cassou, cognac, jasmine, ylang-ylang g), sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, mint oil of all species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, teas such as green and black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, blackcurrant, valerian, pimen The present invention may include other additives such as citric acid, citric acid, citric acid, citric acid derivatives (e.g., citric acid, citric acid derivatives), ...They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0123] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0124] In some embodiments, flavors can include sensations intended to achieve somatic sensations, usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of aroma or taste sensations, and these can include agents that provide heating, cooling, tingling, and numbing effects. Suitable heating agents can be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents can be, but are not limited to, eucoliptol, WS-3.

[0125] Flavoring agents may also include acidic or basic characteristics (e.g., organic acids such as levulinic acid, succinic acid, pyruvic acid, and benzoic acid). In some embodiments, flavoring agents can be combined with components of the substrate material as needed. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. Any flavoring, casing, or other material that may be useful in combination with the tobacco material to affect its sensory properties, including organoleptic properties as described herein, may be combined with the substrate material. Organic acids may be incorporated into the substrate material, particularly to affect the flavor, sensory, or organoleptic properties of pharmaceuticals, such as nicotine, that may be combined with the substrate material. For example, organic acids such as levulinic acid, lactic acid, pyruvic acid, and benzoic acid may be included in the substrate material along with nicotine in amounts up to equimolar with nicotine (based on total organic acid content). Any combination of organic acids may be suitable. For example, in some embodiments, the matrix material may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, up to a concentration where the total amount of organic acid present is equimolar to the total amount of nicotine present in the matrix material. Various additional examples of organic acids used to prepare the substrate material are described in U.S. Patent Application Publication No. 2015 / 0344456 by Dull et al., which is incorporated herein by reference in its entirety.

[0126] The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional ingredients readily apparent to one skilled in the art of tobacco and tobacco-related or tobacco-derived products. See Gutcho, Tobacco Flavoring Materials and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavorings for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties.

[0127] In other embodiments, the substrate material can include other materials with various inherent properties or characteristics. For example, the substrate material can include regenerated cellulose in the form of a plasticized material or rayon. As another example, viscose (commercially available as VISIL®), a regenerated cellulose product incorporating silica, can be suitable. Some carbon fibers may contain at least 95% carbon or more. Similarly, natural cellulose fibers such as cotton can be suitable and can be infused or otherwise treated with silica, carbon, or metal particles to enhance flame retardancy and minimize any undesirable off-gassing components that would adversely affect off-gassing, particularly flavor (especially minimizing the potential for any toxic off-gassing products). Cotton can be treated, for example, with boric acid or various organophosphate compounds to provide the desired flame retardancy by dipping, spraying, or other techniques known in the art. These fibers can also be treated (e.g., coated, infused, or both by dipping, spraying, or vapor deposition) with organic or metallic nanoparticles to impart the desired properties of flame retardancy without undesirable off-gassing or melt-type behavior.

[0128] More specific formats, configurations, and arrangements of components within the non-flammable aerosol delivery systems of the present disclosure will become apparent in light of the further disclosure provided below. Additionally, the selection and arrangement of various non-flammable aerosol delivery system components can be understood in light of commercially available electronic non-flammable aerosol delivery systems, such as the representative products referenced in the Background section of this disclosure.

[0129] According to certain aspects of the present disclosure, it may be advantageous to provide an aerosol delivery device that is easy to use and offers improved performance. Figures 1A, 1B, 2, 3A, and 3B illustrate one exemplary embodiment of such a device. In particular, Figures 1A and 1B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device 100 including an optional actuator assembly 108 and a mouthpiece 104. Specifically, the aerosol delivery device 100 comprises a holder 102 having a body defining a proximal end 102a and a distal end 102b. The holder 102 further defines a receiving chamber 110 configured to receive a removable cartridge (106 in Figure 3A) and a first aerosol passageway 150 extending through at least a portion of the body. The removable cartridge 106 comprises an ignitable heat source 120 and a substrate portion 122 including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. The mouthpiece 104 has a first end and a longitudinally opposed second end, with two aerosol passageways 154 extending longitudinally between the first and second ends. In the illustrated embodiment, the mouthpiece 104 is disposed adjacent the proximal end 102a of the holder 102, with the first end configured to engage with a user's mouth and the second end configured to engage with the proximal end of the holder 102. The device 100 also includes a power source 112 disposed within the holder 102. A slider actuator assembly 108 is coupled to the holder 102 and configured to ignite the ignitable heat source and / or eject the removable cartridge 106.

[0130] As further illustrated by the exploded view of FIG. 2 , the actuator assembly 108 includes a slider body 130 slidably disposed within the body of the holder 102 and having an upper track 132 and a lower track 134; a slider body collar 136 connecting the upper and lower tracks to define a receptacle 138 (see FIG. 1A or 3A ) configured to at least partially receive a removable cartridge; a spring-loaded push button 140 engaging the upper track 132 of the slider body 130 to move the actuator assembly 108 between the loading, writing, and ejecting positions; and a spring assembly 142 configured to engage the slider body 130 and bias the actuator assembly 108 toward the loading position or another “neutral” position. The slider body 130 is configured to be slidable in first and second directions along its length. The push button 140 is configured to engage an electrical contact 129 when in the writing position. In one embodiment, the push button 140 extends through an opening in the top surface of the upper track 132 and is slidably secured thereto. The button 140 is spring-biased to return to an off position after igniting the heat source. The holder 102 defines a slot 116 through its surface, the slot being sized and shaped to slidably receive the spring-loaded push button 140 therein. In some embodiments, the upper track 132 of the slider body 130 sealingly engages the holder about the slot 116, for example, via a gasket 117 disposed in a recess formed in the top surface of the slider body 130.

[0131] The actuator assembly 108 further comprises a pair of actuable igniter contacts 128a, 128b (collectively 128) disposed proximate the holder distal end 102a and configured to engage an ignitable heat source when the removable cartridge is secured within the receiving chamber 110 and when the actuable igniter contacts 128 are actuated by a user. The igniter contacts 128 are coupled to and disposed at the distal ends of a pair of elongated bodies 125. However, in other embodiments, the contacts 128 and the elongated bodies 125 are a single piece formed in a suitable configuration. The igniter contacts 128 are coupled to the slider body 130 via a pair of contact arms 126 disposed within a groove 135 defined by upper and lower tracks 132, 134. Specifically, first contact arm 126a is pivotally coupled to the body of holder 102 and configured to receive one of a pair of actuatable igniter contacts 128a within a retention groove 127a formed in an inner surface of contact arm 126a, and second contact arm 126b is pivotally coupled to the body of holder 102 and configured to receive the other of the pair of actuatable igniter contacts 128b within a retention groove 127b (not shown, but a mirror image of 127a) formed in an inner surface of second contact arm 126b. Contact arm 126 is further coupled to sliding body 130 (e.g., via pivot pin 180) such that sliding movement of sliding body 130 to the lighting position pivots contact arm 126 to a closed configuration in which igniter contact 128 moves into contact with ignitable heat source 120. Additionally, the contact arm 126 may be chamfered at its end that engages the slider body 130 to accommodate pivoting of the arm 126 within the holder 102 .

[0132] The receiving chamber 110 of the device 100 is further defined by an end cap 114 defining an opening 115 configured to engage with the distal end 102b of the holder to receive the removable cartridge 106, an outlet guide 144 coupled to the slider body collar 136 and slidably disposed within the body of the holder 102 via the end cap 114, and an inner slider seal body 146 disposed within and coupled to (e.g., frictionally engaged via sealing surfaces) the receptacle 138 of the slider body 130, the inner slider seal body 146 defining a cavity configured for sealing engagement with the removable cartridge 106 to removably secure the removable cartridge 106 therein. For example, the inner slider seal body 146 may include an elastomeric sleeve 148 disposed therein including a ridge or ring 176 extending radially inward from the wall of the sleeve configured to frictionally and / or sealingly engage the outer surface of the removable cartridge 106. In some embodiments, the elastomeric sleeve 148 may be integral with the inner slider seal body 146, for example, as part of an overmolded component. The inner slider seal body 146 may include a leading edge or lip 149 configured to contact or engage the spring assembly 142 by way of a ridge or ring 172 disposed around the outer surface of the seal body 146 proximate the end opposite the leading edge configured to engage the edge of the end cap 114 extending into the holder 102. Additionally, the elastomeric sleeve 148 includes a ridge or ring 170 extending radially outward from the outer wall of the sleeve 148 configured to frictionally and / or sealingly engage the inner wall of the receptacle 138.

[0133] The outlet guide 144 defines a passageway forming a portion of the receiving chamber 110 configured to pass the removable cartridge and includes a pair of opposing slots 145 through a wall of the outlet guide 144 configured to allow the igniter contacts 128 to pass through and engage the ignitable heat source 120. The outlet guide 144 can be snap-fit ​​to the slider body collar 136, for example, via mating slots and ridges. The slider body collar 136 of the slider body 130 is disposed within the receptacle 138 and includes an inner stem 133 engageable with one end of the removable cartridge and defining a passageway 139 (part of the first aerosol passageway 150) for passing aerosol generated from the removable cartridge. The end cap 114 removably engages with the holder 102, for example, via one or more of a snap fit, an interference fit, a threaded, magnetic, and / or a bayonet connection. In other embodiments, the end caps may permanently engage with the holder 102 after assembly to secure the various components therein. The end caps 114 may be translucent or transparent to allow light from an ignitable heat source to pass through when lit. Similarly, the push button 140 may be translucent or transparent to allow light from, for example, an LED to indicate the state of the device 100 to pass through.

[0134] Device 100 further comprises an inner housing 124 disposed within holder 102 and defining an inner cavity 123 configured to receive power source 112 and printed circuit board 118 therein. Printed circuit board 118 is in electrical communication with power source 112 and includes electrical contacts 129 disposed thereon for actuation by slider push button 140 when actuator assembly 108 is in the lighting position. Power source 112 is in electrical communication with igniter contacts 128 via a pair of wires 168 or other electrical connection mechanism. In one embodiment, wires 168 extend at least partially into grooves 166 defined by a pair of fingers 164 extending from a distal end of inner housing 124. The printed circuit board may further comprise a charging port 119 disposed at a proximal end of holder 102 and oriented on the printed circuit board so as to be accessible, for example, by removing mouthpiece 104.

[0135] Inner housing 124 further defines a third aerosol passageway 147. In the illustrated embodiment of Figures 3A and 3B, the third aerosol passageway consists of a first port 151a disposed at inner housing first or proximal end 124a and a second port 151b disposed at inner housing second or distal end 124b, with one or more channels 151 disposed on the outer surface of inner housing 124. As shown in Figures 4A-4C, two channels 151 are disposed on opposite sides of inner housing 124 and are surrounded by the inner surface of holder 102, thereby defining two parallel third aerosol passageways 147 (see Figure 4A) that extend around battery 112, printed circuit board 118, and associated electronics disposed within inner housing 124. Additionally, inner housing distal end 124b is in sealing engagement with slider body 130 (e.g., using a gasket or O-ring 178) when the actuator assembly is in the lighting position to provide aerosol from cartridge 106 / first aerosol passage 150 to third aerosol passage 147 further defined by inner housing 124. Generally, aerosol (vapor path 143) enters third aerosol passage 147 via second port 151b, where it splits into two vapor paths 143 extending along channels 151 disposed on each side of inner housing 124. The two vapor paths converge at inner housing proximal end 124a and exit through first port 151a, which is in fluid communication with second aerosol passage 154 in mouthpiece 104.

[0136] In some embodiments, the opening 115 in the end cap 114 allows for the introduction of ambient air into the receiving chamber 110 and the cartridge 106. However, in other embodiments not shown, the holder may include one or more openings to allow the inlet of ambient air to be directed into the receiving chamber and / or the aerosol passageway (e.g., through the substrate cartridge and / or downstream from the substrate cartridge). Thus, when a user draws on the holder (e.g., through its mouthpiece portion), air may be drawn into the receiving chamber and / or the aerosol passageway for inhalation by the user (e.g., by exiting the first end 104a of the mouthpiece through the first, second, third, and optionally fourth aerosol passageways). In some embodiments, for example, when the mouthpiece 104 is removable, the aerosol delivery device 100 includes a collar 152 that sealingly engages the proximal end 102a of the holder at one end and the mouthpiece 104 at the other end, as described in more detail below. Collar 152 defines a channel or fifth aerosol passage 153 that fluidly couples third aerosol passage 147 with second aerosol passage 154 and further defines vapor path 143 .

[0137] The removable mouthpiece 104 is described in more detail with respect to Figures 4C and 5. In the illustrated embodiment, the mouthpiece 104 is coupled to the holder 102 via a collar 152 that sealingly engages the holder's proximal end 102a at one end and the mouthpiece 104 at the other end. Specifically, the collar comprises a base portion 155 and a body portion 157, each defining an opening in fluid communication with a first channel 153 extending through the collar 152. The base portion 155 includes a first sealing mechanism 163a disposed about its exterior surface. As shown, the first sealing mechanism 163a comprises an O-ring 160 disposed within a groove 161 defined by the exterior surface of the base portion. Base portion 155 is sized and shaped to engage an opening in the proximal end of holder 102 such that base portion is disposed within the proximal end of the holder and first seal feature 163a engages an inner wall of holder 102. In some embodiments, base portion 155 may be coupled to holder 102 via at least one fastener 162. For example, inner housing 124 may be configured such that base portion 155 is secured to the inner housing via at least one fastener 162 (e.g., a screw).

[0138] Body portion 157 includes a second sealing mechanism 163b disposed around its exterior surface. As shown, second sealing mechanism 163b comprises at least one O-ring 160 disposed within one or more grooves 161 defined by the exterior surface of the body portion. Body portion 157 is sized and shaped to engage with recess 156 disposed within second end 104b of mouthpiece 104, such that body portion 157 is substantially fully disposed within recess 156 with second sealing mechanism 163b engaging the inner wall of recess 156. Second sealing mechanism 163b provides friction between mouthpiece 104 and collar 152, sufficient to secure mouthpiece 104 to holder 102 via collar 152, but minimal enough to allow a user to remove mouthpiece 104 without significant effort. The mouthpiece may be removed for cleaning and then reinstalled for continued use, or in some cases, a different mouthpiece may be attached to customize the user's experience.

[0139] 4C and 5, first channel 153 extends through collar 152 to fluidly couple third aerosol passage 147 of inner housing 124 with second aerosol passage 154 of mouthpiece 104, thereby completing vapor path 143 extending from receiving chamber 110 through first aerosol passage 150, fourth aerosol passage 139, third aerosol passage 147, fifth aerosol passage 153, and second aerosol passage 154 and exiting through opening 158 in mouthpiece portion 104. Generally, first, second, third, and fourth aerosol passages (and any fifth aerosol passage) are configured to define a continuous vapor path 143 from body distal end 102b to mouthpiece first end 104a.

[0140] In some embodiments, collar 152 includes a second channel 159 extending therethrough that is sized and shaped to at least partially receive charging port 119 (e.g., a micro USB connector) therein so that a user can access port 119 by removing mouthpiece 104. In some embodiments, second channel 159 is defined at least in part by a portion of inner housing 124 that may separate second channel 159 from first channel 153.

[0141] 6A and 6B show side cross-sectional and perspective views, respectively, of another embodiment of an aerosol delivery device 400 similar to the device 100 described with respect to FIGS. 1A and 1B. Specifically, the device 400 includes an alternative configuration for a removable mouthpiece 404. The illustration is limited to the proximal end of the device 400 for illustrative purposes only. Specifically, the illustration shows the aerosol delivery device 400 comprising a holder 402 having a body defining a proximal end 402a and a distal end (not shown), the holder further defining a receiving chamber (not shown, but similar to that described above) configured to receive a removable cartridge therein. The device further defines an aerosol passageway 450 extending through at least a portion of the body to the mouthpiece 404. The mouthpiece 404 has a first end 404a and an opposite, longitudinal second end 404b, with a second aerosol passageway 454 extending longitudinally between the first end 404a and the second end 404b. In the illustrated embodiment, the mouthpiece 404 is disposed adjacent the proximal end 402a of the holder 402, with the first end configured to engage with a user's mouth and the second end connectable to the proximal end of the holder 402. The device 400 also includes a power source 412 and associated electronics or other controls disposed within the holder 402.

[0142] 6A, 6B, 7A, and 7B, mouthpiece 404 is coupled to holder 402 via a collar 452 that engages proximal end 402a of holder 402 at one end and sealingly engages mouthpiece 404 at the other end. Specifically, collar 452 includes a base portion 455 and a body portion 457, each defining an opening in fluid communication with channel 453 extending through collar 452. Base portion 455 is sized and shaped to engage with the opening in the proximal end of holder 402 via at least one of threaded engagement, press-fit engagement, snap-fit ​​engagement, or complementary threaded surfaces for magnetic engagement, for example. In some embodiments, base portion 455 can include a sealing mechanism for sealingly engaging with holder 402. In some embodiments, base portion 455 can also be coupled to holder 402 via at least one fastener 462.

[0143] Body portion 457 includes a sealing mechanism 463 disposed about its exterior surface. As shown, sealing mechanism 463 comprises at least one O-ring 460 disposed within one or more grooves 461 defined by the exterior surface of the body portion. Body portion 457 is sized and shaped to engage a recess 456 disposed within second end 404b of mouthpiece 404, such that the body portion is substantially completely disposed within recess 456 and sealing mechanism 463 engages the inner wall of recess 456. Sealing mechanism 463 provides friction between mouthpiece 404 and collar 452 that is sufficient to removably secure mouthpiece 404 to holder 402 via collar 452, but minimal enough to allow a user to remove mouthpiece 404 without significant effort. The mouthpiece may be removed for cleaning and then reinstalled for continued use, or in some cases, a different mouthpiece may be attached to customize the user's experience.

[0144] 6A , channel 453 extends through collar 452 to fluidly couple aerosol passage 450 of inner housing 424 with aerosol passage 454 extending through mouthpiece 404, thereby completing the aerosol pathway extending from the receiving chamber through inner housing 424 and through opening 458 in mouthpiece portion 404. Collar 452 further includes a stem 473 extending distally from base portion 455 and further defining channel 453 extending through collar 452. When assembled, stem 473 extends into the holder and engages with inner housing 424. Specifically, stem 473 is at least partially inserted into aerosol passage 450 defined by inner housing 424. Stem 473 may be coupled to inner housing 424 via, for example, a press-fit or snap-fit ​​engagement.

[0145] Generally, when the actuator assembly 108 is moved to the lighting position, the lower track 134 of the slider body 130 urges the contact arms 126 toward their closed configuration (i.e., the igniter contacts 128 are in contact with the heat source 120). Specifically, the contact arms 126 engage the slider body 130 and are pivotally coupled to the holder 102, such that the exit guide 144 translates toward the proximal end 102a of the holder 102 when the actuator assembly 108 is moved to the lighting position. In this manner, the contact arms 126 are no longer supported in their open configuration by the exit guide 144 and can pivot to the closed configuration so that the igniter contacts 128 contact the heat source 120. When the push button 140 is actuated, an electrical circuit is completed and electricity is supplied to the igniter contacts 128.

[0146] In some alternative embodiments, the aerosol is generated by an electric heater configured to perform electric heating, in which electrical energy from a power source is delivered to the heater when the actuator assembly is moved to the lighting / use position. Heating the aerosol-generating material (substrate 122) releases one or more volatile substances from the aerosol-generating material to form the aerosol. Examples of suitable forms of electric heating include resistive (Joule) heating, induction heating, dielectric and microwave heating, radiant heating, arc heating, and the like. More specific examples of suitable electric heaters include resistive heating elements such as wire coils, flat plates, prongs, and microheaters.

[0147] In some examples, the cartridge 106 may include a susceptor (e.g., the susceptor may be part of the substrate 122). The susceptor is a material that can be heated by penetration with a changing magnetic field generated by a magnetic field generator, which may be separate from or part of the aerosol generator. The susceptor may be a conductive material, such that penetration by the changing magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration by the changing magnetic field causes magnetic hysteresis heating of the heating material. The susceptor in some examples may be both conductive and magnetic, such that the susceptor in these examples is heatable by both heating mechanisms.

[0148] 8A, 8B, 9, and 10 illustrate another exemplary embodiment of an aerosol delivery device 200. In particular, FIGS. 8A and 8B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device 200 including a removable mouthpiece 204. Specifically, the aerosol delivery device 200 comprises a holder 202 having a body defining a proximal end 202a and a distal end 202b. The holder 202 further defines a receiving chamber 210 configured to receive a removable cartridge (206 in FIG. 9) and an aerosol passage 250 extending through at least a portion of the body. In some embodiments, the removable cartridge 206 comprises an ignitable heat source 220 and a substrate portion 222 including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. The device 200 further comprises an optional actuator assembly 208 configured to be movable between different positions, such as a loading position and an ejection position. Mouthpiece 204 is removably secured to holder 202 as described in more detail below.

[0149] 9 , the actuator assembly 208 includes a slider body 230 having an upper track 232 and a lower track 234 coupled to one another via a generally cylindrical body that is slidably disposed within the body of the holder 202 and defines an interior space that includes a receptacle 238 configured to at least partially receive a removable cartridge, and a slider button 231 engaged with the upper track 232 of the slider body 230 to move the actuator assembly 208 between a loading position, a writing position, and an ejecting position. The slider body 230 is configured to be slidable in a first direction and a second direction along the length of the body. A positioning feature 237 (e.g., a spring-loaded ball plunger mechanism, etc.) and one or more corresponding detents may be included to temporarily position the actuator assembly 208 in one or more of the loading position, the writing position, and the ejecting position.

[0150] In one embodiment, the slider button 231 extends through and is secured to an opening in the top surface of the upper track 232, allowing a user to slide the slider body 230 relative to the holder. The holder 202 defines a slot 216 through its surface sized and shaped to slidably receive the slider button 231 therein. In some embodiments, the upper track 232 of the slider body 230 sealingly engages the holder about the slot 216.

[0151] The actuator assembly 208 further comprises a pair of static igniter contacts 228 disposed proximate the holder distal end 202a and configured to engage an ignitable heat source when the removable cartridge is secured within the receiving chamber 210. The igniter contacts 228 are coupled to the printed circuit board 218 via a pair of contact arms 226, which can bend outward upon insertion of the cartridge 206 to contact the ignitable heat source 220 of the cartridge after loading. In one embodiment, an igniter push button 240 is included that is configured, when pressed by a user, to activate the igniter contacts 228, thereby igniting the heat source 220 (i.e., an electrical circuit is completed and electricity is delivered to the igniter contacts 228). In some embodiments, the igniter contacts 228 remain activated only while the igniter push button 240 is pressed. Thus, in some embodiments, the igniter contacts 228 are deactivated when the igniter push button 240 is released, and / or the contacts may remain activated for a specified period of time.

[0152] The receiving chamber 210 of the device 200 is further defined by an end cap 214 that defines an opening 215 configured to engage with the distal end 202b of the holder and receive the removable cartridge 206 therethrough, a heat sink 286 that is disposed at the distal end of the holder 202 and secured to the end cap 214 or the holder 202, and an inner slider seal body 246 that is disposed within and coupled to (e.g., frictionally engaged via sealing surfaces with) the receptacle 238 of the slider body 230. The inner slider seal body 246 defines a cavity that is configured to sealingly engage and removably secure the removable cartridge 206. For example, the inner slider seal body 246 may include an elastomeric sleeve 248 disposed therein that includes a ridge or ring 276 extending radially inward from a wall of the sleeve that is configured to frictionally and / or sealingly engage an outer surface of the removable cartridge 206. In some embodiments, the elastomeric sleeve 248 may be integral with the inner slider seal body 246, for example, as part of an overmolded component. Additionally, the elastomeric sleeve 248 includes a ridge or ring 270 extending radially outward from the outer wall of the sleeve 248 that is configured to frictionally and / or sealingly engage the inner wall of the receptacle 238. The heat sink 286 defines a passageway that forms a portion of the receiving chamber 210 that passes the removable cartridge and receives the igniter contacts 228 disposed therein for engagement with the ignitable heat source 220. The heat sink 286 may be snap-fit ​​onto the end cap 214 or the distal end 202b of the holder.

[0153] The slider body 230 includes an inner stem 233 disposed within a receptacle 238 configured to engage one end of the removable cartridge 206 and define a passageway 250 therethrough for passing aerosol generated from the removable cartridge to the mouthpiece 204. The end cap 214 removably engages with the holder 202 via one or more of a snap fit, an interference fit, a threaded, magnetic, and / or a bayonet connection, for example. In other embodiments, the end cap can permanently engage with the holder 202 after assembly to secure various components therein. The end cap 214 may be translucent or transparent to allow light from an ignitable heat source to pass through when lit. Similarly, the slider button 231 may be translucent or transparent to allow light from, for example, an LED indicating the state of the device 200 to pass through.

[0154] In some embodiments, opening 215 in end cap 214 allows for the introduction of ambient air into receiving chamber 210 and cartridge 206. However, in other embodiments not shown, the holder may include one or more openings to allow the inlet of ambient air to be directed into the receiving chamber and / or aerosol passageway (e.g., through and / or downstream from the substrate cartridge). Thus, when a user draws on the holder (e.g., via its mouthpiece portion), air may be drawn into the receiving chamber and / or aerosol passageway for inhalation by the user.

[0155] 10 provides an enlarged view showing further details of mouthpiece 204. In the illustrated embodiment, mouthpiece 204 includes a first portion 207 having a first end 207a and a longitudinally opposed second end 207b, and a second portion 205 extending distally from the longitudinally opposed second end 207b of the first portion. The first and second portions 207, 205 define a second aerosol passageway 254 extending therethrough. The first end 207a of first portion 207 is configured to engage with a user's mouth, and the second end 207b of first portion 207 is configured to engage with a proximal end of holder 202. The second end 207b of first portion 207 may be configured to engage with an opening in the proximal end 202a of holder 202 via at least one of threaded engagement, press-fit engagement, snap-fit ​​engagement, or complementary threaded surfaces for magnetic engagement.

[0156] The second portion 205 of the mouthpiece 204 is essentially a hollow stem or tube extending from the second end 207b of the first portion 207 of the mouthpiece 204 and is configured to slidably engage with the slider body 230, which partially defines the aerosol passage 250, to provide fluid communication between the first aerosol passage 254 and the second aerosol passage 245. In some embodiments, the second portion 205 of the mouthpiece 204 passes through an opening 215' in the end cap 214'. The first portion 207 of the mouthpiece defines a first portion 254a of the second aerosol passage 254, and the second portion 205 of the mouthpiece 204 defines a second portion 254b of the second aerosol passage 254. The second portion 205 of the mouthpiece is offset from the central axis of the device 200. Specifically, second portion 205 comprises a centrally located longitudinal axis 297b that is offset from and generally parallel to centrally located longitudinal axis 297a of device 200 such that mouthpiece second portion 205 and second aerosol passage portion 254b are aligned with first aerosol passage 250 in sliding body 230 to define a direct vapor path from cartridge 206 to mouthpiece 204. As shown in FIG. 8B , second aerosol passage second portion 254b opens into second aerosol passage first portion 254a for delivery to the user. The offset configuration simplifies the vapor path to minimize and / or eliminate vapor loss (e.g., fewer joints or interfaces means fewer leak points).

[0157] The second portion 205 of the mouthpiece 204 includes a sealing mechanism 263 disposed about its exterior surface to sealingly engage the second portion 205 with a portion of the first aerosol passageway defined by the slider body 230. In some embodiments, the sealing mechanism 263 comprises an O-ring 260 disposed within a groove 261 defined by the exterior surface of the second portion of the mouthpiece. In the illustrated embodiment, the mouthpiece 204 is removably secured to the holder 202 via the sealing mechanism 263, which provides friction between the mouthpiece 204 (specifically, the second portion 205) and the slider body 230. In some embodiments, the inner housing 224 includes a retaining structure 269a disposed at its proximal end (e.g., formed on the end cap 214′), and the second end 207b of the first portion 207 of the mouthpiece 204 defines a mating retaining structure 269b configured to engage the retaining structure 269a on the inner housing 224. Retaining structure 269 may be a snap-fit ​​mechanism or other type of reversible coupling mechanism. Retaining structure 269 may further removably secure mouthpiece 204 to holder 202. Mouthpiece 204 may be removable from holder 202, for example, for cleaning or customizing device 200 (e.g., using a replaceable mouthpiece).

[0158] 11A, 11B, 12, and 13 illustrate another exemplary embodiment of an aerosol delivery device 300. In particular, FIGS. 11A and 11B illustrate a perspective view and a side cross-sectional view, respectively, of an aerosol delivery device 300 including a removable mouthpiece 304. Specifically, the aerosol delivery device 300 comprises a holder 302 having a body defining a proximal end 302a and a distal end 302b, the holder 302 further defining a receiving chamber 310 configured to receive a removable cartridge (306 in FIG. 12) and a first aerosol passageway 350 extending through at least a portion of the body. In some embodiments, the removable cartridge 306 comprises an ignitable heat source 320 and a substrate portion 322 including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. The holder 302 further comprises an access door 388 that is slidably coupled or hinged to the holder 302 and configured to be opened to load the cartridge 306 into the receiving chamber 310 via a receptacle 338 in the inner housing 324 (see FIG. 12 ). The device 300 also includes a mouthpiece 304 that is removably secured to the holder 302 and is described in more detail below.

[0159] As further shown by the exploded view of FIG. 12 , device 300 includes an inner housing 324 disposed within holder 302 and further defining receiving chamber 310, and a receptacle 338 for receiving cartridge 306. A proximal end of inner housing 324 includes a retention feature 369 configured to engage mouthpiece 304, as described below. Inner housing 324 includes a tubular structure 325 disposed therein and extending along the length of housing 324. Tubular structure 325 defines a first aerosol passageway 350, extends partially beyond the proximal end of inner housing 324, and is configured to engage at least a portion of mouthpiece 304 to provide fluid communication between first and second aerosol passageways 350, 354 and deliver aerosol to a user via opening 358 in mouthpiece 304.

[0160] The receiving chamber 310 of the device 300 is further defined by an end cap 314 that defines an opening 315 configured to engage the distal end 302b of the holder 302 and allow the removable cartridge 306 to pass therethrough during ejection. The actuator assembly 308 is slidably disposed within the body of the holder 302 and configured to eject the cartridge 306 when slid forward toward the distal end of the holder 302. In some embodiments, the actuator assembly 308 is spring loaded to return the actuator assembly 308 to a neutral position. The cartridge 306 is removably secured within the receiving chamber 310 and may be sealed (e.g., frictionally engaged via an elastomeric seal) against the first aerosol passageway 350 via any of the mechanisms or aspects disclosed herein.

[0161] Device 300 further includes a power source 312 and a printed circuit board 318 disposed within inner housing 324. Power source 312 is in electrical communication with printed circuit board 318, and a pair of static igniter contacts 328 disposed thereon can be energized via a push button 340 disposed on a side wall of holder 302. Specifically, when push button 340 is actuated, an electrical circuit is completed and electricity is delivered to igniter contacts 328. Printed circuit board 318 can further include a charging port 319 oriented on the printed circuit board to be disposed at one end of holder 302.

[0162] 13 provides an enlarged cross-sectional view showing further details of mouthpiece 304. In the illustrated embodiment, mouthpiece 304 has a first end 304a and a longitudinally opposed second end 304b, with a second aerosol passageway 354 extending longitudinally between the first and second ends. In the illustrated embodiment, mouthpiece 304 is positioned at the proximal end of holder 302, with first end 304a configured to engage with a user's mouth and second end 304b configured to engage with the proximal end of holder 302. Mouthpiece 304 is configured to sealingly engage holder 302 such that first and second aerosol passageways 350, 354 are in fluid communication for delivering aerosol generated in the receiving chamber to a user.

[0163] In the illustrated embodiment, the removable mouthpiece 304 comprises a hollow body 356 (i.e., a recess) and a stem 305 (or similar tubular structure) disposed within the hollow body 356 and extending from a first end 304a to a second end 304b. The stem 305 defines a second aerosol passage 354 extending therethrough and engages with the inner housing 324 to be fluidly coupled with an aerosol passage 350 of the inner housing 324. The stem 305 may be coupled to the inner housing 324, for example, via a press-fit or snap-fit ​​engagement with the tubular structure 325 within the inner housing 324. In some embodiments, the stem 305 is sealingly engaged with the first aerosol passage 350 within the holder 302. For example, the stem 305 may include a sealing mechanism 359 similar to any of those disclosed herein.

[0164] In some embodiments, the stem 305 of the mouthpiece 304 is offset from the central axis of the device 300. Specifically, the stem 305 comprises a centrally located longitudinal axis 397b offset from a centrally located longitudinal axis 397a of the device 300 and generally parallel to the longitudinal axis 397a, such that the stem 305 and second aerosol passageway 354 of the mouthpiece are aligned with the first aerosol passageway 350 in the inner housing 324 to define a direct vapor path from the cartridge 306 to the mouthpiece 304. As shown in FIG. 13 , the second aerosol passageway 354 opens into a recess or receptacle 367 located in the proximal end of the mouthpiece 304 for delivering the aerosol to the user. The offset configuration simplifies the vapor path to minimize and / or eliminate vapor loss (e.g., fewer joints or interfaces means fewer leak points).

[0165] 12 and 13 further illustrate the incorporation of an insert 365 into the proximal end of mouthpiece 304. Specifically, a receptacle 367 formed in proximal end 304a of mouthpiece 304 is configured to secure insert 365 therein. Insert 365 may be removably secured within receptacle 367 via at least one of threaded engagement, press-fit engagement, snap-fit ​​engagement, or complementary threaded surfaces for magnetic engagement. Insert 365 defines a cavity 371 in fluid communication with second aerosol passageway 354 and outlet 358 for delivering aerosol to a user. Generally, insert 365 allows for customization of device 300 (e.g., different sized outlets, aerosol conditioning, incorporation of flavoring, etc.) and may be easily removed for cleaning.

[0166] In some embodiments, the longitudinally opposed second end 304b is configured to engage an opening in the holder's proximal end 302a via at least one of threaded engagement, press-fit engagement, snap-fit ​​engagement, or complementary threaded surfaces for magnetic engagement. In other embodiments, the mouthpiece 304 is removably secured to the holder 302 via a sealing mechanism that provides frictional resistance between the mouthpiece 304 and the holder 302 or other components therein. In some embodiments, the inner housing 324 includes a retaining structure 369a disposed at its proximal end, and the second end 304b of the mouthpiece 304 forms a mating retaining structure 369b configured to engage with the retaining structure 369a on the inner housing 324. The retaining structure 369b may be a snap-fit ​​mechanism or other type of reversible coupling mechanism. The retaining structure 369 may further removably secure the mouthpiece 304 to the holder 302. The mouthpiece 304 can be removed from the holder 302, for example, by applying a pulling or twisting action to the mouthpiece 304 or by actuating a release, for example, for cleaning or customizing the device 300 (e.g., using a replaceable mouthpiece).

[0167] 14A, 14B, and 15 illustrate another exemplary embodiment of an aerosol delivery device 500. In particular, FIGS. 14A and 14B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device 500 including a removable mouthpiece 504 and a removable flow restrictor 565. Specifically, the aerosol delivery device 500 comprises a holder 502 having a body defining a proximal end 502a and a distal end 502b, the holder 502 further defining a receiving chamber 510 configured to receive a removable cartridge 506 and an aerosol passageway 550 extending through at least a portion of the body. The removable cartridge 506 comprises an ignitable heat source 520 and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. The mouthpiece 504 has a first end configured to engage the user's mouth and an opposed second longitudinal end, with a second aerosol passageway 554 extending longitudinally between the first and second ends. In the illustrated embodiment, the mouthpiece 504 is coupled to the proximal end 502a of the holder 502 via a body portion 555 disposed at the distal end of the mouthpiece 504. The body portion 555 is configured for releasable and / or sealing engagement with an opening in the proximal end of the holder 502.

[0168] A removable flow restrictor 565 (see FIGS. 16A and 16B ) is generally disposed between the holder 502 and the mouthpiece 504. The flow restrictor 565 includes an outer surface 565 c configured to be removably secured within the holder and an inner surface 565 d that defines a third aerosol passage 553, the flow restrictor configured to be partially disposed within the first aerosol passage 550, the second aerosol passage 554, or both. In some embodiments, the inner surface 565 d of the flow restrictor 565 is tapered along its length and defines an orifice 515 at its proximal end, which can be configured to provide a pressure drop between the first aerosol passage 550 and the second aerosol passage 554 when installed. However, the inner surface 565 d can define various profiles (e.g., cylindrical, stepped, etc.) to suit a particular application. In some embodiments, the removable flow restrictor 565 is configured to sealingly engage the first aerosol passageway, the second aerosol passageway, or both. Alternatively or additionally, the flow restrictor 565 may be removably secured to the holder 502 via at least one of threaded engagement, press-fit engagement, snap-fit ​​engagement, frictional engagement, or complementary threaded surfaces for magnetic engagement.

[0169] 16A and 16B, flow restrictor 565 includes a body portion 565a and a lip portion 565b disposed at a proximal end thereof, both defined by an outer surface 565c. As seen in FIG. 14B, body portion 565a is disposed within first aerosol passage 550, and lip portion 565b is configured to engage proximal end 502a of the body, as described in more detail below, and is disposed within second aerosol passage 554. Third aerosol passage 553 provides fluid communication between first aerosol passage 550 and second aerosol passage 554. The overall size, shape, and finish of the flow restrictor 565 are selected to suit a particular application (e.g., installation method and location, performance characteristics, etc.). For example, the outer surface 565c may have a surface finish that enhances the fit and seal between the flow restrictor 565 and the first and / or second aerosol passages 550, 554, or may include one or more grooves for retaining a sealing device (e.g., an O-ring) for sealing and / or frictional engagement with the passages 550, 554.

[0170] The mouthpiece 504 is removable so that the flow restrictor 565 can be easily removed for cleaning or replacement, e.g., to change the operating characteristics of the device. In general, the removable flow restrictor 565 allows for customization of the device 500, and specifically the user's experience with the device 500. For example, the flow restrictor 565 may have different sized outlets, aerosol passage configurations, thermal properties (e.g., to improve temperature control of the aerosol delivered to the user), or even the incorporation of flavorings.

[0171] In the illustrated embodiment, the mouthpiece 504 is coupled to the holder 502 via a body portion 555, as described above. The body portion 555 is sized and shaped to engage an opening in the proximal end of the holder 502 such that the body portion 555 is disposed within the proximal end of the holder 502, with or without a sealing mechanism, such that the body portion 555 is substantially flush with the proximal end 502a of the holder. In some embodiments, the body portion 555 may be coupled to the holder 502 via at least one fastener (e.g., a screw) and / or may physically engage an interior wall of the holder 502. The mouthpiece 504 further includes a nozzle or extension 505 that forms a first end of the mouthpiece and is configured to be engaged by a user's mouth. The nozzle 505 terminates in an opening 558 that partially defines a second aerosol passageway 554 and is configured to deliver generated aerosol to the user.

[0172] Opposite body portion 555, hollow stem 507 extends into the holder when assembled. Specifically, in some embodiments, the body of holder 502 includes a tubular structure 521 disposed therein and extending along the length of holder 502. Tubular structure 521 at least partially defines first aerosol passageway 550, extends toward the proximal end of holder 502, and is configured to engage at least a portion of mouthpiece 504 to provide fluid communication between first and second aerosol passageways 550, 554 and deliver aerosol to a user via opening 558. In the illustrated embodiment, stem 507 engages tubular structure 521, with the flow restrictor essentially being "sandwiched" therebetween. In some embodiments, the flow restrictor 565 is first inserted into the tubular structure 521 of the holder so that its lip abuts the proximal end of the tubular structure 521, and then the mouthpiece 504 is secured to the proximal end of the holder 502 so that the stem 507 passes through the flow restrictor 565 and the proximal end of the tubular structure 521, fluidly connecting the first, second, and third aerosol passages 550, 554, 553.

[0173] The mouthpiece 504 may be coupled to the holder 502 via a frictional resistance sufficient to secure the mouthpiece 504 to the holder 502, but minimal enough so that the user can remove the mouthpiece 504 without significant effort. For example, the mouthpiece may be removed from the holder by, for example, applying a pulling or twisting action to the mouthpiece 504 or by actuating a release. The mouthpiece may be removed to access the flow restrictor, and then removed for cleaning or replacement to customize the user's experience. The mouthpiece 504 may also be cleaned and / or replaced after removal.

[0174] The holder 502 further comprises an access door assembly 589 pivotally coupled to the body via a pivot assembly 584 (e.g., pivot pin 584a, receptacle 584b), although in some embodiments the door assembly 589 may be slidingly or hingedly coupled to the holder 502. As shown in FIGS. 14A and 15 , the door assembly 589 includes a door 588 configured to fit substantially flush with the exterior surface of the holder 502 in a closed configuration and sized and shaped to receive a chassis or inner housing 524 that defines a receiving chamber 510 for receiving the cartridge 506 therein. The chassis 524 may comprise multiple layers of material that provide temperature control for the device, e.g., insulation to prevent heat from the cartridge from being transferred to the holder and to prevent the user from coming into contact with a “hot” device. Assembly 589 further includes a pair of static igniter contacts 528 disposed proximate holder distal end 502b, a sealing mechanism 560 configured to sealingly engage receiving chamber 510 with first aerosol passageway, and a biasing mechanism 542 configured to bias a loaded cartridge into contact with igniter contacts 528 when in the closed configuration. Door assembly 589 is moved between its open and closed configurations via a spring-loaded slider button, as described in more detail with respect to Figures 17A-17C.

[0175] Device 500 further includes a power source 512 and a printed circuit board 518 disposed within holder 502. Power source 512 is in electrical communication with printed circuit board 518 and static igniter contacts 528. Printed circuit board 518 includes electrical contacts 529 (e.g., pogo pins) that contact igniter contacts 528 when door assembly 589 is in the closed configuration. Printed circuit board 518 may further include a charging port 519 (e.g., a micro USB connector) oriented on the printed circuit board to be disposed at one end of holder 502.

[0176] In the illustrated embodiment, an igniter push button 540 is disposed on a sidewall of the holder 502 and is configured to activate the igniter contacts 528 when pressed by a user, thereby igniting the heat source 520 of the cartridge 506 to generate an aerosol. Specifically, when the push button 540 is activated, an electrical circuit is completed and electricity is delivered to the igniter contacts 528. In some embodiments, the igniter contacts 528 remain activated only while the igniter push button 540 is pressed. Thus, in some embodiments, the igniter contacts 528 are deactivated when the igniter push button 540 is released. In some embodiments, the igniter push button 540 may be configured to activate the igniter contacts 528 for a set period of time after release. In one embodiment, the push button 540 extends through an opening 563 in the holder 502. In some embodiments, the button 540 is spring-loaded and may return to an off position after igniting the heat source. The device 500 may further include an LED ring 541 adjacent the push button 540 that may light up during ignition and / or change color to indicate the status of the device 500 .

[0177] 17A-17C illustrate the loading and unloading of a cartridge (i.e., consumable) 506 into the device 500. Specifically, FIG. 17A shows the door assembly 589 in a closed configuration, in which the door assembly 589 encloses a receiving chamber 510 within the holder 502. To move the door assembly to the open configuration, the spring-loaded slider button 508 is slid forward or distally to release the door assembly 589 from the holder 502. As shown in FIG. 17B, the door assembly 589 is biased to the open configuration, thereby exposing the chassis 524 and the receiving chamber 510 disposed therein. As further shown, the cartridge is inserted into the receiving chamber 510 with the ignitable heat source 520 end inserted first. Once cartridge 506 is loaded, door assembly 589 is pushed closed (the biasing force is small enough that a user can close the door assembly with one finger) and slide button 508 reconnects with holder 502, locking door assembly 589 in the closed configuration as shown in FIG. 17A.

[0178] In the closed configuration, the cartridge 506 is secured within the holder so as to be in fluid communication with the first aerosol passageway 550 (see FIG. 14B ). The ignitable heat source 520 is in contact with the igniter contacts 528 via the biasing mechanism 542 and can be ignited so that the cartridge can be consumed (i.e., aerosol is generated and delivered to the user via the aerosol passageway). The cartridge 506 can then be ejected from the device 500, as shown in FIG. 17C . Specifically, the slide button 508 is slid forward or distally to release the door assembly 589 and expose the cartridge 506. Once in the open configuration, the device 500 can be turned upside down to allow the cartridge to fall out of the receiving chamber 510. After ejection, the user can insert a new cartridge or simply close the door assembly 589 for later use. In some embodiments, the device 500 can include a locking mechanism (not shown) configured to further secure the access door assembly 589 in the closed configuration. In some embodiments, the locking mechanism may include a magnetic engagement, a threaded interface, a snap fit, a detent, and / or may be spring loaded into the closed configuration.

[0179] 18A, 18B, 19, and 20A-20C illustrate another exemplary embodiment of an aerosol delivery device 700. In particular, Figures 18A and 18B illustrate a perspective view and a cross-sectional perspective view, respectively, of aerosol delivery device 700 including a removable cartridge 706, a mouthpiece 704, a slider assembly 708, and an ignition push button 740. Aerosol delivery device 700 includes a two-piece holder 702 having an upper body portion 701 and a lower body portion 703 that define a linear vapor path 743 and form proximal and distal ends, respectively.

[0180] The lower body portion 703 defines a receiving chamber 710 disposed therein and configured to receive a removable cartridge 706 including an ignitable heat source 720 and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat. The lower body portion 703 includes a pair of actuable igniter contacts 728 disposed proximate a distal end thereof and coupled thereto via a pair of contact arms 726. The actuable igniter contacts 728 are configured to engage with the ignitable heat source 720 when the removable cartridge 706 is secured within the receiving chamber 710. Additionally, the lower body portion 703 includes a window 782 disposed therein and configured to provide a view of at least a portion of the receiving chamber 710 so that a user can observe the cartridge 708 and / or the electrical contacts 728. All or a portion of the window 782 may comprise a transparent or translucent material (e.g., polycarbonate, polyethylene terephthalate, acrylic, etc.). In some embodiments, a portion of lower body portion 703 may be made from a transparent or translucent material.

[0181] Upper body portion 701 defines a first aerosol passageway 750 extending therethrough and houses a power source 712, a printed circuit board 718 with associated electronics, and a sliding actuator assembly 708. The sliding actuator assembly 708 is slidably disposed within upper body portion 701, specifically within first aerosol passageway 750, and configured to eject a removable cartridge from lower body portion 703. Upper body portion 701 and lower body portion 703 are movably coupled together via one or more mechanisms 784 (e.g., swivel joints) such that lower body portion 703 can rotate relative to upper body portion 701 between an open configuration that exposes receiving chamber 710 so that a removable cartridge may be loaded therein, and a closed configuration in which receiving chamber 710 and first aerosol passageway 750 are in fluid communication and are configured to deliver aerosol generated from the cartridge to mouthpiece 704.

[0182] Additionally, device 700 may include a sealing mechanism 772 (e.g., an O-ring disposed in a groove on the face of the proximal end of lower body portion 703) disposed between the proximal end of lower body portion 703 and the distal end of upper body portion 701 and configured to seal receiving chamber 710 with first aerosol passageway 750 to prevent aerosol leakage and / or ingress of ambient air from vapor path 743. In some embodiments, aerosol delivery device 700 further includes a locking mechanism 785 disposed on at least one of lower body portion 703 or upper body portion 701, the locking mechanism configured to maintain the device in a closed orientation (i.e., the upper and lower body portions are aligned and in fluid and / or electrical communication). Locking mechanism 785 may include, for example, one or more of a magnet, friction, a snap fit, or a detent. However, in some other embodiments, the upper body portion 701 and the lower body portion 703 may be integrally formed together or fixedly coupled to one another. Other ways of movably coupling the upper body portion 701 and the lower body portion 703 include a hinge joint, a sliding track, or the like.

[0183] The mouthpiece 704 is disposed at the proximal end of the upper body portion 701 and has a first end and a longitudinally opposed second end, with a second aerosol passageway 754 extending longitudinally between the first and second ends. In the illustrated embodiment, the first end of the mouthpiece 704 is configured to engage with a user's mouth, and the second end is configured to engage with the proximal end of the upper body portion 703. The mouthpiece 704 is configured for sealing engagement with the upper body portion 701 such that the first and second aerosol passageways 750, 754 are in fluid communication to deliver aerosol generated in the receiving chamber 710 to the user via the vapor path 743. The mouthpiece 704 may be removably coupled to the upper body portion 701, for example, to provide for cleaning or customization of the device 700. However, in other embodiments, the mouthpiece 704 may be integrally formed with the upper body portion 701.

[0184] 19 , the slider actuator assembly 708 includes a generally tubular slider body 730 positionable within the upper body portion 701 for sliding movement in first and second directions along the length of the upper body portion 701. The slider body 730 defines a passageway extending therethrough that is aligned with the first aerosol passageway 750 of the upper body portion 701 to form a third aerosol passageway 738 extending therethrough. The slider body 730 includes a first protrusion 731 extending from its outer surface and extending through an opening 716 in the wall of the upper body portion 701, the first protrusion 731 configuring the slider body 730 to be in a loading position (e.g., the slider body 730 is fully disposed within the upper body portion 701) and an ejection position (e.g., the slider body 730 is moved distally within the device 700). The slider body 730 further includes a second protrusion or stem 733 extending from its distal end. The stem 733 is configured to engage the removable cartridge 706 to advance the removable cartridge through the distal end of the lower body portion 703 when the actuator assembly 708 is moved to the ejection position. Portions of the protrusions 731, 733 extend into the third aerosol passage 738 such that the vapor path 743 splits around those portions. Specifically, one or more portions of the first protrusion, the second protrusion, or both may extend into portions of the third aerosol passage 738 within the slider body 730, such that the aerosol produced by the cartridge 706 and drawn into the mouthpiece 704 is split into one or more portions as it travels through the tubular body. In some embodiments, the slider body 730 includes a longitudinally oriented baffle 739 extending inwardly from its interior wall, the baffle splitting the aerosol passage 738 extending through the slider body.

[0185] The upper body portion 701 further defines two cavities 707, 709, the first cavity 707 further defining a first aerosol passageway 750 and configured to receive the slider body 730 therein, and the second cavity configured to house the power supply 712 and printed circuit board 718. Additionally, the actuator assembly 708, and specifically the slider body 730, includes a seal arrangement for sealingly engaging the inner surface of the first cavity 707 (e.g., to prevent aerosol leakage or unwanted air ingress). In the illustrated embodiment, the seal arrangement comprises a pair of O-rings 760 disposed in grooves 761 disposed proximate the distal and proximal ends of the slider body 730. However, other configurations of the seal arrangement are contemplated and considered within the scope of the present disclosure.

[0186] The lower body portion 703 also defines two cavities 707', 709' that are generally aligned with the cavities 707, 709 of the upper body portion 701 when in the closed configuration. Specifically, the first cavity 707' at least partially defines a receiving chamber 710 and opposing openings 715, 715' and, in some embodiments, includes a bar 711 or other structure for supporting the window 782 and / or guiding the cartridge 706 during insertion. In the illustrated embodiment, the lower body portion 703 defines a cutout or other opening that exposes the receiving chamber 710 and is configured to receive the window 782 therein. The window 782 may be mounted or coupled to the lower body portion 703 via adhesive, a snap fit, or other means known in the art. The cavity 707' / receiving chamber 710 includes a groove or other structure for securing therein a retention mechanism 776 that frictionally and / or sealingly engages the exterior surface of the cartridge 706, as described below. In the illustrated embodiment, the retention mechanism 776 is an O-ring.

[0187] Second cavity 709' is generally configured to house various electronics and other mechanisms necessary to provide power to igniter contact 728 and activate igniter contact 728 to ignite heat source 720 of cartridge 706. For example, contact arm 726 is electrically coupled to a power source within second cavity 709' and extends through a wall of second cavity 709', thereby positioning igniter contact 728 within receiving chamber 710. Lower body portion 703 further defines a pair of openings 763 therethrough that are disposed on opposite sides of lower body portion 703 and configured to engage actuator button 740 and light-emitting diode (LED) 741, described below.

[0188] The overall operation of the device 700, and the specific operation of the slider actuator assembly 708, will be described with reference to Figures 20A-20C. Specifically, Figure 20A depicts the cartridge 706 being loaded into the device 700 (i.e., the actuator assembly in the loaded position), Figures PA3-11B depict the device 700 during lighting and smoking, and Figure 20C depicts the cartridge 706 being ejected from the device 700 (i.e., the actuator assembly in the ejection position).

[0189] 20A , to load cartridge 706 into receiving chamber 710, lower body portion 703 is rotated or otherwise offset (e.g., twisted) from upper body portion 701 to expose the receiving chamber through opening 715′. Prior to rotating the body portions, actuator assembly 708 is moved to a loading position (i.e., fully retracted toward mouthpiece 704) such that sliding body 730 is fully positioned within first cavity 707 of upper body portion 701. Cartridge 706 is manually inserted into receiving chamber 710 of lower body portion 703 to place cartridge 706 in a lighting and / or use position, and the cartridge is sealingly secured within chamber 710 via retention mechanism 776 such that ignitable heat source 720 is operatively aligned with igniter contact 728. After loading, the upper and lower body portions are returned to alignment so that the sealed end of cartridge 706 is in fluid communication with first aerosol passageway 750. The fit between the upper and lower body portions is such that there is no aerosol leakage or air ingress between them, with or without the use of additional sealing configurations as previously described.

[0190] 20B , in the lighting / use position, the distal end of the cartridge 706 is positioned proximate the distal end of the lower body portion 703 such that the cartridge 706 is disposed inside the receiving chamber 710. Notably, in the lighting / use position of the illustrated embodiment, the heat source 720 portion of the cartridge 706 is also positioned proximate the distal end of the lower body portion 703 and is aligned with the igniter contact 728 in the lighting position. The heat source 720 is ignited via aligned push buttons 740 located on either side of the lower body portion 703 of the aerosol delivery device 700. The buttons 740 are movably coupled to the lower body portion, with or without a sealing arrangement, so that a user can simultaneously depress both buttons (e.g., by a pinching motion) to engage and deflect the contact arm 726, thereby moving the igniter contact 728 into contact with the ignitable heat source 720. Upon release, button 740 returns to its original position at least in part via spring action from the deflected contact arm 726 and / or return bias element. In some embodiments, igniter contacts 728 remain activated only while igniter push button 740 is pressed. Thus, in some embodiments, igniter contacts 728 are deactivated when igniter push button 740 is released. In some embodiments, igniter push button 740 may be configured to activate igniter contacts 728 for a set period of time after release. Device 700 also includes a pair of LEDs 741 that may illuminate and / or change color during ignition to indicate the status of device 700. Additionally, a user may observe ignition through window 782.

[0191] In some embodiments, device 700 may include an ejection mechanism as shown in FIG. 20C . Generally, the ejection mechanism is configured to eject cartridge 706 from the distal end of lower body portion 703 through opening 715. Between loading and ejection, cartridge 706 passes through second cavity 709′. In one embodiment, the ejection mechanism is incorporated into actuator assembly 708 such that when slider protrusion 731 (and actuator assembly 708) is moved forward, the ejection mechanism engages one end of cartridge 706 and pushes the cartridge out of receiving chamber 710 and out of aerosol delivery device 700 through opening 715 in lower body portion 703. Specifically, a user can slide the actuator assembly 708 forward (i.e., away from the mouthpiece) using, for example, their thumb and protrusion 731, so that the inner stem 733 of the slider body 730 enters the cavity 707′ of the lower body portion 703, pushing the cartridge 706 forward and disengaging it from the retention mechanism 776. The cartridge 706 can then be withdrawn from the device 700 or dropped from the device 700.

[0192] In the illustrated embodiment, the outer housing or holder may comprise a rigid material. For example, the holders 102, 202, 302, 402, 502, and 702 in the illustrated embodiment may be constructed of an aluminum material. However, in other embodiments, the holder may be constructed of other materials, including other metallic materials (e.g., stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), graphite materials, ceramic materials, plastic materials, or any combination thereof. In some embodiments, at least a portion of the heat source and / or at least a portion of the substrate material may be circumscribed by a paper-foil laminate. In some embodiments, the cartridge may comprise a housing comprising a laminate including the heat source and the bead substrate material. Some examples of laminates and / or housings that may be applicable to the present disclosure may be found in U.S. Patent Application Publication No. 2020 / 0128880 to Gage et al., which is incorporated herein by reference in its entirety. Other examples of cartridges are described herein below with respect to FIGS. 21 and 22.

[0193] In some embodiments, the holder (or any component thereof, e.g., inner housing, collar, etc.) can be made of a moldable plastic material, such as polycarbonate, polyethylene, acrylonitrile butadiene styrene (ABS), polyamide (nylon), or polypropylene. In other embodiments, the holder can be made of a different material, such as a different plastic material, a metal material (e.g., but not limited to, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), a graphite material, a glass material, a ceramic material, a natural material (e.g., but not limited to, wood), a composite material, or any combination thereof. The holder can be formed by extrusion molding. As mentioned above, the mouthpiece portion in some embodiments is separable from the main body, while in other embodiments, the mouthpiece portion can be integral with the main body. In any case, the mouthpiece portion and the main body can be made of the same material or different materials. In various embodiments with a detachable mouthpiece portion, the mouthpiece portion may be coupled to the body in various ways, including, for example, one or more of a snap fit, an interference fit, a screw thread, a magnetic, and / or a bayonet connection. In other embodiments, the mouthpiece portion may be integral with the body and therefore not detachable.

[0194] In the illustrated embodiment, the holder includes substantially solid, non-porous walls. However, in other embodiments, one or more of the holder's walls can have other configurations. For example, in some embodiments, one or more of the holder's walls can be non-solid and / or substantially porous, or can include one or more non-solid and / or substantially porous portions. In some embodiments, for example, the holder can include one or more openings that can facilitate oxygen access to the heat source. Alternatively or additionally, other embodiments can include one or more openings that can mix with the aerosol generated during inhalation. In this manner, in the use position, one or more openings can be positioned proximate to the heat source, thereby providing the heat source with additional access to oxygen during combustion. In some embodiments, the holder can include one or more openings downstream of the heat source. For example, in some embodiments, the holder can include an opening extending into the holder's aerosol passageway that can mix with the aerosol generated by the cartridge's substrate material.

[0195] As previously described, the holders of various embodiments of the present disclosure include a lighting / use position. In some embodiments, the holder may also have an extinguisher position. In this manner, the extinguisher position may be configured so that the heat source of the cartridge is deprived of sufficient oxygen to sustain combustion. In some embodiments, the extinguisher position may be attained by further movement of the holder. In other embodiments, one or more additional features may be included, and the extinguisher position may be attained by activating the one or more additional features. In particular, the holder of one embodiment may include an air-impermeable cover feature disposed proximate the distal end of the holder, which may be mechanically or manually actuable (e.g., by rotating the cover feature over the end of the body and / or by sliding the cover feature across the end of the body) so that, in the extinguisher position, the cover feature substantially covers the open end of the holder and the heat source of the cartridge is deprived of sufficient oxygen to sustain combustion. In another embodiment, the holder may include a removable feature, such as an end cap, that may be used to achieve the extinguisher position. For example, in some embodiments, a separate end cap may be attachable to the distal end of the holder, such that the heat source of the cartridge is deprived of sufficient oxygen to sustain combustion. Such an end cap may also be used to cover the end of the second body portion when not in use, e.g., to prevent dirt and / or foreign matter from entering the device. Additionally or alternatively, in some embodiments, the holder of the present disclosure may include a breathable cover feature (e.g., a cover feature including multiple openings or a cover feature comprising a mesh) that protects the heat source of the cartridge in the lighting / use position. For example, the holder of one embodiment may include a breathable cover feature disposed proximate the distal end of the holder that may be mechanically or manually actuable (e.g., by rotating the cover feature over the end of the holder and / or by sliding the cover feature across the end of the holder), such that once ignited, the cover feature can be actuated to substantially cover the open end of the holder while maintaining sufficient oxygen access to the heat source.

[0196] In various embodiments, the removable cartridge may have other configurations for use with the holders of the present disclosure. For example, FIG. 21 shows a perspective view of a removable cartridge 606 according to another exemplary embodiment of the present disclosure. In the illustrated embodiment, the cartridge 606 defines a proximal end 690 and a distal end 692. The cartridge 606 of the illustrated embodiment further includes an ignitable heat source 620 comprising a fuel element 694, a substrate portion 622 comprising a substrate material 696 (see FIG. 22 ), and an outer housing 698 configured to surround at least a portion of the ignitable heat source 620 and the substrate material 622. It should be noted that, although in the illustrated embodiment, the cartridge 606 has a substantially cylindrical overall shape, in various other embodiments, the cartridge or any of its components may have different shapes. For example, in some embodiments, the cartridge (and / or any of its components) may have a substantially rectangular shape, such as a substantially rectangular cuboid shape. In other embodiments, the cartridge (and / or any of its components) may have other handheld shapes. Some examples of cartridge configurations that may be applicable to the present disclosure are found in U.S. Patent Application No. 16 / 515,637, filed July 18, 2019, entitled Aerosol Delivery Device With Consumable Cartridge, which is incorporated herein by reference in its entirety.

[0197] In some embodiments, a barrier may be present between the heat source and the substrate material. In some embodiments, such a barrier may comprise a disk that may include one or more openings. In some embodiments, the barrier may be composed of a metallic material (e.g., stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), a graphite material, a ceramic material, a plastic material, or any combination thereof. In some embodiments, a heat transfer component, which may or may not comprise a barrier, may be present between the heat source and the substrate material. Some examples of heat transfer components are described in U.S. Patent Application Publication No. 2019 / 0281891 to Hejazi et al., which is incorporated herein by reference in its entirety. In some embodiments, the barrier and / or heat transfer component may prevent or inhibit combustion gases from being drawn through the substrate material (and / or through the air passages through which aerosols are drawn).

[0198] In various embodiments, the heat source may be configured to generate heat upon ignition. In the illustrated embodiment, the ignitable heat source 620 has a generally cylindrical shape and includes a combustible fuel element 694 incorporating a combustible carbonaceous material. In other embodiments, the heat source may have a different shape, such as a prismatic shape with a cubic or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Some carbonaceous materials may be primarily composed of carbon and / or may have a carbon content, on a dry weight basis, typically greater than about 60%, generally greater than about 70%, often greater than about 80%, and often greater than about 90%.

[0199] In some cases, the heat source may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components such as powdered tobacco or tobacco extract; flavoring agents; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermostable graphite hollow cylindrical (e.g., tubing) fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; an ammonia source such as an ammonia salt; and / or binders such as guar gum, ammonium alginate, and sodium alginate). In other embodiments, the heat source may comprise a plurality of ignitable objects, such as a plurality of ignitable beads. Note that in other embodiments, the heat source may differ in composition or relative content from those described above. For example, in some embodiments, different forms of carbon, such as graphite or graphene, may be used as the heat source. In other embodiments, the heat source may have increased levels of activated carbon, different carbon porosities, different amounts of carbon, blends of any of the aforementioned components, etc. In still other embodiments, the heat source may comprise a non-carbon heat source, such as a flammable liquefied gas configured to generate heat upon ignition. For example, in some embodiments, the liquefied gas may include one or more of petroleum gas (LPG or LPG), propane, propylene, butylene, butane, isobutene, methylpropane, or n-butane. In yet other embodiments, the heat source may comprise a chemical reaction-based heat source, where ignition of the heat source involves the interaction of two or more individual components. For example, a chemical reaction-based heat source may include a metal agent and an activating solution, where contact between the metal agent and the activating solution activates the heat source. Some examples of chemical-based heat sources may be found in U.S. Patent No. 7,290,549 to Banerjee et al., which is incorporated herein by reference in its entirety. Combinations of heat sources are also possible. While the specific dimensions of applicable heat sources may vary, in the illustrated embodiment, ignitable heat source 620 has a length in the inclusive range of about 5 mm to about 20 mm, and in some embodiments may be about 12 mm, and an overall diameter in the inclusive range of about 3 mm to about 8 mm, and in some embodiments may be about 4.8 mm (and in some embodiments, about 7 mm).

[0200] In other embodiments, the heat source may be constructed in a variety of ways, but in the illustrated embodiment, the ignitable heat source 620 is extruded or composited using crushed or powdered carbonaceous material, with a dry weight of approximately 0.5 g / cm 3 often exceeding about 0.7 g / cm 3 often exceeding about 1 g / cm 3 See, for example, fuel source components, formulations and designs of the type described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are incorporated herein by reference in their entireties.

[0201] In various embodiments, the heat source can have a variety of configurations, including, for example, a substantially solid cylinder or a hollow cylinder (e.g., a tube). In other embodiments, the heat source may comprise a plurality of hollow or substantially solid spheres, which in some embodiments can comprise substantially the same size and in other embodiments can comprise two or more sizes. In various embodiments, the heat source can be fabricated by a variety of methods, including, but not limited to, extrusion, injection molding, compression molding, etc. The ignitable heat source 620 of the illustrated embodiment comprises an extruded monolithic carbonaceous material having a generally cylindrical shape including a plurality of internal passages 691 extending longitudinally from a first end of the ignitable heat source 620 to an opposing second end of the ignitable heat source 620. In the illustrated embodiment, there are approximately thirteen internal passages 691, including a single central internal passage 691a, six peripheral internal passages 680b spaced apart from the central internal passage 691a and having a size (e.g., diameter) similar to that of the central internal passage 691a, and six peripheral internal passages 691c spaced apart from the outer surface of the ignitable heat source 620 and having a diameter smaller than that of the central internal passage 691a. Note that in other embodiments, there need not be multiple internal passages, and / or the multiple internal passages can take other forms and / or sizes. For example, in some embodiments, there may be as few as two internal passages, and still other embodiments may include as few as one internal passage. Still other embodiments may not include any internal passages at all. Additional embodiments may include multiple internal passages that may be of unequal diameters and / or shapes, may be unevenly spaced apart, and / or may be disposed within the heat source.

[0202] Alternatively or additionally, some embodiments may include one or more peripheral grooves extending longitudinally from a first end of the heat source to an opposite second end, while in other embodiments, the grooves need not extend the entire length of the heat source. In some embodiments, such grooves may be substantially equal in width and depth and may be substantially evenly distributed around the circumference of the heat source. In such embodiments, there may be as few as two grooves, and still other embodiments may include as few as one groove. Still other embodiments may not include any grooves at all. Additional embodiments may include multiple grooves that may be of unequal width and / or depth and may be unevenly spaced around the circumference of the heat source. In still other embodiments, the heat source may include grooves and / or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to its opposite second end. In some embodiments, the heat source may include an expanded carbon monolith formed by an expansion process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, the entire contents of which are incorporated herein by reference. Thus, some embodiments can provide advantages in terms of reducing the time it takes to ignite the heat source. In some other embodiments, the heat source can be co-extruded with an insulating layer (not shown), thereby reducing manufacturing time and costs. Other fuel element embodiments include carbon fiber of the type described in U.S. Patent No. 4,922,901 to Brooks et al., or other heat source embodiments such as those described in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety. Further examples of heat sources, including debossed heat source systems, methods, and smoking articles containing such heat sources, are described in U.S. Patent Application Publication No. 2019 / 0254335 to Spicer et al., which is incorporated herein by reference in its entirety.

[0203] Generally, the heat source is positioned sufficiently close to the aerosol delivery component having one or more aerosolizable components (as well as any flavorings, medications, etc. similarly provided for delivery to a user) such that the aerosol formed / volatilized by the application of heat from the heat source to the aerosolizable component (e.g., substrate portion) is deliverable to a user via the mouthpiece. That is, when the heat source heats the substrate component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. Note that the foregoing terms mean that references to release, releasing, releases, or released are interchangeable to include forming or generating, forming or generating, forming or generating, and forming or generating. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof. Furthermore, the selection of various smoking article components is understood in light of commercially available electronic smoking articles, such as the representative products listed in the Background section of this disclosure.

[0204] FIG. 22 shows a longitudinal cross-sectional view of the cartridge 606 of FIG. 21. As shown, the substrate material 622 of the illustrated embodiment has opposing first and second ends, and the ignitable heat source 620 is disposed adjacent to the first end of the substrate material 622. While the dimensions and cross-sectional shape of the various components of the cartridge can vary depending on the needs of a particular application, in the illustrated embodiment, the cartridge 606 can have an overall length in the inclusive range of about 10 mm to about 50 mm and a diameter in the inclusive range of about 2 mm to about 20 mm. Further, in the illustrated embodiment, the outer housing 698 can have a thickness in the inclusive range of about 0.05 mm to 0.5 mm. Furthermore, in the illustrated embodiment, the substrate portion 622 can have a length in the inclusive range of about 5 mm to 30 mm and a diameter slightly smaller than the diameter of the overall cartridge, for example, a diameter in the inclusive range of about 2.9 mm to about 9.9 mm, to accommodate the thickness of the housing 698. In the illustrated embodiment, the substrate material 622 comprises tobacco beads, which may have a diameter size ranging from approximately 0.5 mm to 2.0 mm, although other embodiments may vary in size. In other embodiments, the substrate material may be granular tobacco material or cut filler tobacco. Although other embodiments may vary, in the illustrated embodiment, the outer housing 698 of the cartridge 606 is filled to approximately 80-90% capacity to allow for insertion of the fuel element 694.

[0205] In the illustrated embodiment, the substrate portion 622 includes a substrate material 696 having a single segment, although in other embodiments, the substrate portion may include one or more additional substrate material segments. For example, in some embodiments, the aerosol delivery device may further include a second substrate material segment (not shown) having opposing first and second ends. As previously mentioned, in various embodiments, one or more of the substrate materials may include tobacco or a tobacco-related material and have an associated aerosol precursor composition. In other embodiments, a non-tobacco material, such as a cellulose pulp material, may be used. In other embodiments, the non-tobacco substrate material may not be a plant-derived material. Other possible compositions and / or ingredients (and / or substrate materials) for use in the substrate material are described above. See also the above discussion regarding various possible shapes of the substrate material, aerosol precursor compositions, additives, flavorings, etc.

[0206] As shown in FIGS. 21 and 22 , the outer housing 698 of the cartridge 606 in the illustrated embodiment is configured to enclose at least a portion of the substrate portion 622, including the substrate material 696. In the illustrated embodiment, the outer housing 698 is also configured to enclose a portion of the ignitable heat source 620. In some embodiments, the outer housing can enclose the entire heat source. In the illustrated embodiment, the outer housing comprises a rigid material. For example, the outer housing 698 in the illustrated embodiment is constructed from an aluminum material. However, in other embodiments, the outer housing may be constructed from other materials, including other metallic materials (e.g., stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), graphite materials, ceramic materials, plastic materials, or any combination thereof. In some embodiments, at least a portion of the heat source and / or at least a portion of the substrate material may be circumscribed by a paper-foil laminate. In some embodiments, the cartridge may comprise a housing comprising a laminate including the heat source and the bead substrate material. Some examples of laminates and / or housings that may be applicable to the present disclosure may be found in U.S. Patent Application Publication No. 2020 / 0128880 to Gage et al., which is incorporated herein by reference in its entirety.

[0207] In the illustrated embodiment, the outer housing 698 is configured as a tubular structure that substantially encloses the substrate material 622. However, as previously mentioned, in other embodiments, the outer housing may have other shapes. While the shape of the outer housing may vary, in the illustrated embodiment, the outer housing 698 comprises a tubular structure having an open end and a closed end. The illustrated embodiment of the outer housing 698 also includes one or more end openings 693 located at the closed end of the outer housing 698 that are configured to allow aerosolized vapor (alternatively referred to herein as "vapor" or "aerosol") to pass therethrough. The end openings 693 in the illustrated embodiment are in the form of a pair of elongated, rounded slots. However, in other embodiments, the end openings may have any configuration that allows the passage of aerosol. Thus, it will be understood that the end openings 693 may include fewer or additional openings than those illustrated and / or openings of alternative shapes and sizes.

[0208] In various embodiments, the present disclosure may also be directed to kits providing various components as described herein. For example, a kit may include a holder with one or more cartridges. In another embodiment, a kit may include multiple holders. In a further embodiment, a kit may include multiple cartridges. In yet another embodiment, a kit may include multiple holders and multiple cartridges. Kits of the present invention may further include a case (or other packaging, transport, or storage component) for housing one or more additional kit components. The case may be a reusable rigid or flexible container. Additionally, the case may simply be a box or other packaging structure. In some embodiments, a brush or other cleaning accessory may be included in the kit. The cleaning accessory may be configured to be inserted into the cartridge-receiving chamber of the holder, or in other embodiments, may be inserted into a separate opening that allows a user to remove debris from the cartridge-receiving chamber.

[0209] Many modifications and other embodiments of the present disclosure may 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 holder comprising a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; a removable mouthpiece including a first end and a longitudinally opposed second end, with a second aerosol passageway extending longitudinally between the first and second ends, the first end configured to engage a user's mouth and the second end connectable to a proximal end of the holder; a collar disposed between the holder and the mouthpiece, the collar having a first end configured for sealing engagement with a proximal end of the holder and a second end configured for sealing engagement with a second end of the mouthpiece, the collar defining a first channel therethrough, the first channel configured to fluidly couple the first and second aerosol passageways; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the collar further defines a second channel therethrough, the second channel configured to access the charging port.

3. The color is a base portion defining an opening in fluid communication with the first channel, the base portion having a first sealing mechanism disposed about an exterior surface thereof and sized and shaped to engage the opening in the proximal end of the holder; a body portion defining an opening in fluid communication with the first channel, the body portion having a second sealing mechanism disposed about an exterior surface thereof, the body portion sized and shaped to engage a recess disposed within the second end of the mouthpiece; 10. The aerosol delivery device of claim 1, further comprising:

4. The aerosol delivery device of claim 3 , wherein the base portion is disposed within the proximal end of the holder.

5. 5. The aerosol delivery device of claim 4, wherein the base portion is coupled to the holder via at least one fastener.

6. 5. The aerosol delivery device of claim 4, further comprising an inner housing configured to secure one or more components therein, the base portion being secured to the inner housing via at least one fastener.

7. 3. The aerosol delivery device of claim 2, wherein the first sealing mechanism comprises an O-ring disposed within a groove defined by an exterior surface of the base portion.

8. 3. The aerosol delivery device of claim 2, wherein the second sealing mechanism comprises at least one O-ring disposed within one or more grooves defined by the exterior surface of the body portion.

9. 10. The aerosol delivery device of claim 1, further comprising an actuator assembly coupled to the holder and configured to eject the removable cartridge.

10. The aerosol delivery device of claim 2 , further comprising a power source disposed within the body.

11. an inner housing disposed within the body of the holder; a printed circuit board in electrical communication with the power supply and including a controller; wherein the inner housing is configured to receive a power supply and a printed circuit board.

11. The aerosol delivery device of claim 10.

12. 12. The aerosol delivery device of claim 11, wherein the printed circuit board further comprises a charging port, and the printed circuit board is oriented within the inner housing so that the charging port is located at the proximal end of the holder.

13. 13. The aerosol delivery device of claim 12, wherein the second channel is configured to at least partially accommodate the charging port so that the charging port is accessible after removal of the mouthpiece.

14. The color is a base portion defining an opening in fluid communication with the first channel, the base portion being sized and shaped to engage the opening in the proximal end of the holder; a body portion defining an opening in fluid communication with the first channel, the body portion having a sealing mechanism disposed about an exterior surface thereof and sized and shaped to engage a recess disposed within the second end of the mouthpiece; 10. The aerosol delivery device of claim 1, further comprising:

15. The aerosol delivery device of claim 14, wherein the base portion is configured to engage with the opening at the proximal end of the holder via at least one of a threaded engagement, a press-fit engagement, a snap-fit ​​engagement, or complementary thread surfaces for magnetic engagement.

16. 15. The aerosol delivery device of claim 14, wherein the sealing mechanism comprises at least one O-ring disposed within one or more grooves defined by the exterior surface of the body portion.

17. 15. The aerosol delivery device of claim 14, further comprising an inner housing disposed within the body of the holder and configured to secure one or more components therein, the inner housing further defining at least a portion of the first aerosol passage, and the base portion of the collar including a stem extending distally therefrom and configured to engage with at least a portion of the first aerosol passage in the inner housing.

18. 10. The aerosol delivery device of claim 1, further comprising a removable cartridge, the removable cartridge comprising an ignitable heat source and a substrate portion including a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat.

19. 10. The aerosol delivery device of claim 1, wherein the holder includes a window disposed therein, the window configured to allow at least a portion of the removable cartridge to be viewed.

20. 1. An aerosol delivery device comprising: a holder comprising a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; a mouthpiece including a first end and a longitudinally opposed second end, with a second aerosol passageway extending longitudinally between the first and second ends, the first end configured to engage a user's mouth and the second end configured to engage a proximal end of the holder; a removable flow restrictor having an outer surface configured to be removably secured within the holder and an inner surface defining a third aerosol passage; An aerosol delivery device comprising:

21. 21. The aerosol delivery device of claim 20, wherein the flow restrictor is configured to be at least partially disposed within the first aerosol passageway, the second aerosol passageway, or both.

22. 21. The aerosol delivery device of claim 20, wherein the removable flow restrictor is configured to sealingly engage the first aerosol passageway, the second aerosol passageway, or both.

23. 21. The aerosol delivery device of claim 20, wherein the flow restrictor comprises a body portion and a lip portion disposed at a proximal end thereof, the lip portion configured to engage the proximal end of the body.

24. 24. The aerosol delivery device of claim 23, wherein the body portion is disposed within the first aerosol passageway.

25. 21. The aerosol delivery device of claim 20, wherein the removable flow restrictor is configured to provide fluid communication between the first aerosol passageway and the second aerosol passageway.

26. 21. The aerosol delivery device of claim 20, wherein the inner surface of the flow restrictor is tapered along its length.

27. 27. The aerosol delivery device of claim 26, wherein an inner surface of the removable flow restrictor defines an orifice configured to provide a pressure drop between the first aerosol passage and the second aerosol passage.

28. 21. The aerosol delivery device of claim 20, wherein the mouthpiece comprises a body portion configured to engage with the proximal end of the body and a hollow stem extending therethrough, the stem at least partially defining the second aerosol passage and configured to receive a flow restrictor therein.

29. 21. The aerosol delivery device of claim 20, further comprising a plurality of replaceable, removable flow restrictors.

30. 1. An aerosol delivery device comprising: a holder comprising a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; a mouthpiece including a first end and a longitudinally opposed second end, with a second aerosol passageway extending longitudinally between the first and second ends, the first end configured to engage a user's mouth and the second end configured to engage a proximal end of the holder; an inner housing disposed within the body of the holder, the inner housing defining a first port disposed proximate a first end of the inner housing, a second port disposed proximate a second end of the inner housing, and a first channel disposed on an exterior surface of the inner housing fluidly coupling the first port and the second port to form a third aerosol passageway, the first port being in fluid communication with the first aerosol passageway and the second port being in fluid communication with the second aerosol passageway, the first, second, and third aerosol passageways being configured to form a continuous vapor path from the distal end of the body to the first end of the mouthpiece for passing aerosol generated from the removable cartridge to a user; An aerosol delivery device comprising:

31. 31. The aerosol delivery device of claim 30, wherein the inner housing defines a second channel disposed on an outer surface thereof and oriented opposite the first channel.

32. 32. The aerosol delivery device of claim 31, wherein the first and second channels meet at the first port and the second port.

33. 32. The aerosol delivery device of claim 31, wherein the inner housing is disposed within the body such that the inner surface of the holder surrounds the first and second channels.

34. 1. An aerosol delivery device comprising: a holder comprising a body defining a proximal end and a distal end, the body further defining a receiving chamber configured to receive a removable cartridge and a first aerosol passageway extending through at least a portion of the body; A removable mouthpiece, a first portion defined by a first end and a longitudinally opposed second end; a second portion extending from the second longitudinally opposite end; the first and second portions defining a second aerosol passageway extending therethrough, a first end of the first portion configured to engage with a user's mouth, a second end of the first portion configured to engage with a proximal end of the holder, and the second portion configured to extend within the holder. With removable mouthpiece An aerosol delivery device comprising:

35. 35. The aerosol delivery device of claim 34, wherein the second end of the first portion is configured to engage with the opening at the proximal end of the holder via at least one of a threaded engagement, a press-fit engagement, a snap-fit ​​engagement, or complementary thread surfaces for magnetic engagement.

36. 35. The aerosol delivery device of claim 34, wherein a central axis of the second portion of the mouthpiece is offset from a central axis of the first portion of the mouthpiece.

37. 35. The aerosol delivery device of claim 34, wherein the second portion of the mouthpiece is in sealing engagement with the first aerosol passageway in the holder.

38. 38. The aerosol delivery device of claim 37, wherein the second portion of the mouthpiece includes a sealing mechanism disposed around an exterior surface thereof.

39. 39. The aerosol delivery device of claim 38, wherein the sealing mechanism comprises an O-ring disposed within a groove defined by an exterior surface of the second portion of the mouthpiece.

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